Jet Tools Welder CS 275 User Manual

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Operating Instructions and Parts Manual

Manual Cold Saws

Models CS-275, CS-315

model CS-315 shown

WALTER MEIER (Manufacturing), Inc.

427 New Sanford Road

LaVergne, Tennessee 37086

Ph.: 800-274-6848

Part No. M-414226

Revision C 12/2013

www.jettools.com

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2.0 Table of contents

Section

Page

1.0 Warranty and Service.....................................................................................................................................2

2.0 Table of contents............................................................................................................................................3

3.0 Safety warnings..............................................................................................................................................4

4.0 Introduction ....................................................................................................................................................5

5.0 Cold saw features ..........................................................................................................................................6

6.0 Specifications.................................................................................................................................................7

7.0 Unpacking ......................................................................................................................................................9

7.1 Contents of shipping container...................................................................................................................9

8.0 Installation and assembly ...................................................................................................................................9

8.1 Operating lever...........................................................................................................................................9

8.2 Handle ........................................................................................................................................................9

8.3 Exension roller............................................................................................................................................9

8.4 Coolant tank ...............................................................................................................................................9

8.5 Splash plates..............................................................................................................................................9

8.6 Length stop...............................................................................................................................................10

9.0 Electrical connections ..................................................................................................................................10

9.1 Three-phase models ................................................................................................................................10

9.2 Single-phase models................................................................................................................................10

9.3 Voltage conversion (model CS-275-1 only)..............................................................................................10

9.4 Grounding instructions .............................................................................................................................11

10.0 Adjustments ...............................................................................................................................................11

10.1 Miter adjustment.....................................................................................................................................11

10.2 Vise ........................................................................................................................................................11

10.3 Stops ......................................................................................................................................................11

10.4 Blade replacement .................................................................................................................................12

11.0 Controls......................................................................................................................................................12

12.0 Operation ...................................................................................................................................................12

13.0 Maintenance...............................................................................................................................................13

13.1 Maintenance requirements.....................................................................................................................13

13.2 Periodic maintenance.............................................................................................................................13

13.3 Coolant system......................................................................................................................................13

13.4 Lubrication..............................................................................................................................................13

14.0 Blade selection...........................................................................................................................................13

14.1 General characteristics...........................................................................................................................13

14.2 Determining proper tooth pitch...............................................................................................................14

14.3 Cutting and feeding speed .....................................................................................................................14

14.4 Coolant ...................................................................................................................................................14

14.5 Blade structure .......................................................................................................................................14

14.6 Types of blades......................................................................................................................................14

14.7 Teeth shape ...........................................................................................................................................15

15.0 Troubleshooting .........................................................................................................................................16

15.1 Blade and cutting problems....................................................................................................................16

15.2 Machine fault and operating problems ...................................................................................................17

16.0 Parts...........................................................................................................................................................17

16.1.1 CS-275 Cold Saw (Machine Assembly) – Exploded View ..................................................................18

16.1.2 CS-275 Cold Saw (Machine Assembly) – Parts List ...........................................................................19

16.2.1 CS-315 Cold Saw (Machine Assembly) – Exploded View ..................................................................22

16.2.2 CS-315 Cold Saw (Machine Assembly) – Parts List ...........................................................................23

16.3.1 CS-275 and CS-315 Cold Saws (Stand Assembly) – Exploded View.................................................26

16.3.2 CS-275 and CS-315 Cold Saws (Stand Assembly) – Parts List .........................................................26

17.0 Electrical connections ................................................................................................................................27

17.1 Models CS-275 and CS-315 (3 Phase)..................................................................................................27

17.2 Model CS-275 (1 Phase)........................................................................................................................28

17.3 Model CS-315 (1 Phase)........................................................................................................................29

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10. Do not operate this machine while tired or

under the influence of drugs, alcohol or any

medication.

11. Make certain the switch is in the OFF position

before connecting the machine to the power

supply.

3.0 Safety warnings

1. Read and understand the entire owner’s

manual before attempting assembly or

operation.

12. Make certain the machine is properly

grounded.

13. Make all machine adjustments or maintenance

with the machine unplugged from the power

source.

2. Read and understand the warnings posted on

the machine and in this manual. Failure to

comply with all of these warnings may cause

serious injury.

14. Remove adjusting keys and wrenches. Form a

habit of checking to see that keys and

adjusting wrenches are removed from the

machine before turning it on.

3. Replace the warning labels if they become

obscured or removed.

4. This cold saw is designed and intended for use

by properly trained and experienced personnel

only. If you are not familiar with the proper and

safe operation of a cold saw, do not use until

proper training and knowledge have been

obtained.

15. Keep safety guards in place at all times when

the machine is in use. If removed for

maintenance purposes, use extreme caution

and replace the guards immediately after

maintenance is complete.

16. Make sure the cold saw is firmly positioned on

a secure foundation.

5. Do not use this cold saw for other than its

intended use. If used for other purposes, JET

disclaims any real or implied warranty and

holds itself harmless from any injury that may

result from that use.

17. Check damaged parts. Before further use of

the machine, a guard or other part that is

damaged should be carefully checked to

determine that it will operate properly and

perform its intended function. Check for

alignment of moving parts, binding of moving

parts, breakage of parts, mounting and any

other conditions that may affect its operation.

A guard or other part that is damaged should

be properly repaired or replaced.

6. Always wear approved safety glasses/face

shields while using this cold saw. Everyday

eyeglasses only have impact resistant lenses;

they are not safety glasses.

7. Before operating this cold saw, remove tie,

rings, watches and other jewelry, and roll

sleeves up past the elbows. Remove all loose

clothing and confine long hair. Non-slip

footwear or anti-skid floor strips are

recommended.

18. Provide for adequate space surrounding work

area and non-glare, overhead lighting.

19. Keep the floor around the machine clean and

free of scrap material, oil and grease.

8. Wear ear protectors (plugs or muffs) during

extended periods of operation.

20. Keep visitors a safe distance from the work

area. Keep children away.

9. Some dust created by power sanding, sawing,

grinding, drilling and other construction

activities contains chemicals known to cause

cancer, birth defects or other reproductive

harm. Some examples of these chemicals are:

21. Make your workshop child proof with padlocks,

master switches or by removing starter keys.

22. Give your work undivided attention. Looking

around, carrying on a conversation and “horse-

play” are careless acts that can result in

serious injury.

•

Lead from lead based paint.

Crystalline silica from bricks, cement and

other masonry products.

23. Maintain a balanced stance at all times so that

you do not fall or lean against the blade or

other moving parts. Do not overreach or use

excessive force to perform any machine

operation.

•

Arsenic and chromium from chemically

treated lumber.

Your risk of exposure varies, depending on

how often you do this type of work. To reduce

your exposure to these chemicals, work in a

well-ventilated area and work with approved

safety equipment, such as face or dust masks

that are specifically designed to filter out

microscopic particles.

24. Use the right tool at the correct speed and

feed rate. Do not force a tool or attachment to

do a job for which it was not designed. The

right tool will do the job better and more safely.

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25. Do not make a cut which exceeds the

capacities of the cold saw as shown in the

specifications section of this manual.

29. Turn off the machine and disconnect from

power before cleaning. Use a cloth or brush to

remove chips or debris — do not use your

hands.

26. Use recommended accessories; improper

accessories may be hazardous.

30. Do not stand on the machine. Serious injury

could occur if the machine tips over.

27. Maintain tools with care. Keep blades sharp

and clean for the best and safest performance.

Follow instructions for lubricating and changing

accessories.

31. Never leave the machine running unattended.

Turn the power off and do not leave the

machine until it comes to a complete stop.

28. Make sure the work piece is securely attached

or clamped to the table. Never use your hand

to hold the work piece.

32. Remove loose items and unnecessary work

pieces from the area before starting the

machine.

Familiarize yourself with the following safety notices used in this manual:

This means that if precautions are not heeded, it may result in minor injury and/or

possible machine damage.

This means that if precautions are not heeded, it may result in serious injury or possibly

even death.

- - SAVE THESE INSTRUCTIONS - -

4.0 Introduction

The JET CS-275 and CS-315 Cold Saws are designed to provide a reliable solution to the needs of machine

shops and production environments that work with steel or iron. The saws are manually operated. After

clamping the material in the vise, the operator presses the trigger starting the blade, and brings the operating

lever downward to cut the material. The saws can perform miter cuts up to 45º to the right or left.

This manual is provided by JET covering the safe operation and maintenance procedures for the JET Cold

Saw. This manual contains instructions on installation, safety precautions, general operating procedures,

maintenance instructions and parts breakdown. Your machine has been designed and constructed to provide

years of trouble-free operation if used in accordance with the instructions as set forth in this document.

If there are questions or comments, please contact your local supplier or JET. JET can also be reached at our

web site: www.jettools.com.

Retain this manual for future reference. If the machine transfers ownership, the manual should accompany it

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5.0 Cold saw features

Figure 1

rotated for fast clamping. An anti-burr attachment is

included, as well as a stop assembly for repetitive

cuts of the same length.

Miter cutting head

The miter cutting head is the unit that performs the

cut, and is pivoted downward manually by means

of the operating lever. The head is mounted to a

cast iron base, and consists of a blade support unit

with guard, transmission unit, and motor. The

depth of cut is set by adjusting the depth stop. The

miter cutting head swivels and locks into any

position within a 135º range.

Control panel

The panel features independent ON and OFF

buttons with indicator light, a mushroom style red

emergency OFF switch, coolant flow switch, and a

switch for speed selection.

Flood coolant system

Miter position lock

The miter position lock secures the miter cutting

head from movement. The miter is secured when

the lever is moved to the right and is released

when the lever is moved to the left.

The coolant pump must be

submerged before operating to prevent damage

to the pump.

Coolant is dispensed directly onto the saw blade

from a coolant fitting on the upper blade guard.

Coolant is provided through tubing from the coolant

pump which rests inside the machine base. See

under Maintenance for further information about

proper coolants.

Self-centering vise

The self-centering vise holds the work piece in

place during cutting. The handwheel brings the

vise toward the work piece, then the cam lever is

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6.0 Specifications

Model numbers......................................................................... CS-275.....................................................CS-275-1

Stock numbers...........................................................................414226........................................................414228

Blade diameter ................................................................. 11” (275mm) ................................................11” (275mm)

Blade thickness ................................................................. 0.08” (2mm).................................................0.08” (2mm)

Arbor diameter................................................................ 1-1/4” (32mm) ............................................. 1-1/4” (32mm)

Blade speed (RPM)..............................................................54 and 108............................................................... 54

Vise type ................................................... adjustable jaws, cam handle........................ adjustable jaws, cam handle

Maximum vise opening ......................................................................4” ................................................................ 4”

Miter angle range (deg.).................................................................... 90 ............................................................... 90

Miter stops (deg.).................................................................. 45 L, 45 R................................................... 45 L, 45 R

Slotting capability.............................................................................yes ..............................................................yes

Material length stop.........................................................30”, graduated .............................................30”, graduated

Vise platform height from floor............................................38” (96.5cm) ................................................38” (96.5cm)

Saw motor....................................TEFC, 1-1/2HP, 3PH, 230VAC, 60Hz.... TEFC, 1-1/2HP, 1PH, 115/230VAC, 60Hz

(prewired 115V)

Plug provided ................................................................................... no ...................................................yes (115V)

Coolant pump..................................TEFC, 1/8HP, 1PH, 230VAC, 60Hz....... TEFC, 1/8HP, 1PH, 115/230VAC, 60Hz

Coolant tank capacity........................................................1.5 gal (5.7L) ...............................................1.5 gal (5.7L)

Overall dimensions (LxWxH)..........40” x 39” x 72” (1016x991x1829mm)............40” x 39” x 72” (1016x991x1829mm)

Base footprint ..................................................23” x 24” (584 x 610mm) ..............................23” x 24” (584 x 610mm)

Net weight with stand...................................................... 330 lb (150kg) ............................................. 330 lb (150kg)

Shipping weight .............................................................. 360 lb (163kg) ............................................. 360 lb (163kg)

Model numbers......................................................................... CS-315.....................................................CS-315-1

Stock numbers...........................................................................414227........................................................414229

Blade diameter ................................................................. 12” (315mm) ................................................12” (315mm)

Blade thickness ................................................................. 0.08” (2mm).................................................0.08” (2mm)

Arbor diameter................................................................ 1-1/4” (32mm) ............................................. 1-1/4” (32mm)

Blade speed (RPM)..............................................................52 and 104............................................................... 52

Vise type ................................................... adjustable jaws, cam handle........................ adjustable jaws, cam handle

Maximum vise opening ...................................................................4.7” ............................................................. 4.7”

Miter angle range (deg.).................................................................... 90 ............................................................... 90

Miter stops (deg.).................................................................. 45 L, 45 R................................................... 45 L, 45 R

Slotting capability.............................................................................yes ..............................................................yes

Material length stop.........................................................30”, graduated .............................................30”, graduated

Vise platform height from floor............................................38” (96.5cm) ................................................38” (96.5cm)

Saw motor..........................................TEFC, 2HP, 3PH, 230VAC, 60Hz.................TEFC, 2HP, 1PH, 230VAC, 60Hz

Plug provided ................................................................................... no ............................................................... no

Coolant pump..................................TEFC, 1/8HP, 1PH, 230VAC, 60Hz..............TEFC, 1/8HP, 1PH, 230VAC, 60Hz

Coolant tank capacity........................................................1.5 gal (5.7L) ...............................................1.5 gal (5.7L)

Overall dimensions (LxWxH)..........40” x 39” x 72” (1016x991x1829mm)............40” x 39” x 72” (1016x991x1829mm)

Base footprint ..................................................23” x 24” (584 x 610mm) ..............................23” x 24” (584 x 610mm)

Net weight with stand...................................................... 390 lb (177kg) ............................................. 390 lb (177kg)

Shipping weight ...............................................................420 (190.5kg) .............................................. 420 (190.5kg)

Cutting Capacities:

Solid Bars

Tubing

Model

Angle

90°

45°

90°

45°

3.3”

3.5”

2.5” x 2.5”

2.2” x 2.2”

3.2” x 3.2”

2.6” x 2.6”

3.1” x 2.0”

2.2” x 2.0”

4” x 3.2”

3.3”

3.5”

2.5” x 2.5”

2.2” x 2.2”

3.2” x 3.2”

2.6” x 2.6”

3.1” x 2.0”

2.2” x 2.0”

4” x 3.2”

CS-275

CS-315

3.2” x 2.6”

Table 1

The specifications in this manual were current at time of publication, but because of our policy of continuous

improvement, JET reserves the right to change specifications at any time and without prior notice, without incurring

obligations.

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7.1 Contents of shipping container

7.0 Unpacking

Cold Saw

Operating Lever

Open shipping container, and any secondary

boxes. Check for shipping damage; report any

damage immediately to your distributor and

shipping agent. Do not discard any shipping

material until the Cold Saw is assembled and

running properly.

Work Stop Assembly

Hex Cap Screws with Nuts

Handle

Roller Assembly

Compare the contents of your container with the

following parts list to make sure all parts are intact.

Missing parts, if any, should be reported to your

distributor. Read the instruction manual thoroughly

for assembly, maintenance and safety instructions.

Splash Plates

Coolant Tank w/ Pump (inside base)

Operating Instructions and Parts Manual

(not shown)

Warranty Card (not shown)

Figure 2

8.0 Installation and assembly

Tools required for assembly (not provided):

The base of the machine must be anchored to the

floor by two lag bolts or studs properly anchored

into concrete.

6mm hex key (Allen wrench)

12mm and 19mm open-end wrenches

After positioning the machine, remove any cords

that were used to secure the head in lowered

position during shipping.

Remove all packing material from around the

machine. Remove screws holding the saw to the

skid. Lift the machine off the skid using straps

around the cast iron portions of the head (keep

straps away from blade, levers, etc.).

Exposed metal surfaces have been coated with a

rust-protectant from the factory. Remove this using

soft cloth dampened with

good

cleaner/degreaser. Do not use gasoline, paint

thinner, acetone, or other highly flammable

substances, and avoid using an abrasive pad as it

may scratch metal surfaces.

The location should have sufficient lighting to

prevent shadows around the work area. Leave

enough room on all sides of the machine for

movement of stock and for general maintenance

work.

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8.1 Operating lever

Refer to Figure 3.

1. Remove the hex nut and screw from the hole

at the front of the saw head (Figure 4). These

fasteners will not be used again unless the

machine needs to be transported in the future.

2. Insert the operating lever into the threaded fill

hole. Rotate it a good distance into the hole,

and make sure the final orientation of the

handle grip is in a comfortable position for the

operator, as shown in Figure 3.

3. Secure the operating lever by tightening the

hex nut against the saw head.

Figure 4

4. Push the two-pin cable connector into the

receptacle sleeve on the junction box of the

motor, and tighten the knurled ring to secure.

8.4 Coolant tank

Refer to Figure 5.

Direct the lower end of the drain hose into the

basket of the coolant tank, as shown.

Fill the tank with coolant

before operating the coolant pump. Failure to

do so may damage the pump.

Adjust the valve on the coolant fitting atop the

blade housing, to achieve desired flow. When the

coolant switch is in the ON position, flow starts

when the drive motor is started. Turning off the

coolant switch stops coolant flow.

Figure 3

8.2 Handle

Refer to Figure 4.

Figure 5

Screw the handle into the handwheel and tighten

with the nut, using a 12mm wrench.

8.5 Splash plates

8.3 Exension roller

Refer to Figure 6.

Refer to Figure 4.

The plates deflect expended coolant and swarf

coming off the blade, into the encircling channel of

the base. The coolant drains back into the tank,

while the swarf is easily cleaned from the channel.

Mount the extension roller to the side with the

existing socket head cap screws, using a 6mm hex

key.

Mount the two plates to the front and rear of the

base, using the existing screws in the base and a

6mm hex key. Slots allow height adjustment.

Slots make the roller assembly adjustable for

height. Place a straight edge across the clamp

table and the extension roller to achieve alignment.

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the fuse holder or circuit breaker to prevent it being

turned on while the machine is being wired.

See table 2 for recommended circuit sizes for your

particular model. NOTE: Local codes take

precedence over recommendations.

Recommended circuit size

CS-275

CS-275-1 (1PH,115/230V)

CS-315 (3PH 230V)

CS-315-1 (1PH, 230V)

Table 2

(3PH 230V)

10A

20A

15A

20A

9.1 Three-phase models

Figure 6

The CS-275 (3-phase) and CS-315 (3-phase) are

rated for 230-volt only power. They are not

supplied with a plug. You may either install a

proper 230V UL/CSA listed plug, or “hardwire” the

machine directly to a service panel.

8.6 Length stop

Refer to Figure 7.

1. Screw the lower rod into the threaded hole in

the base. Orient the rod so that the graduated

scale is visible, and tighten the hex nut with a

19mm wrench to secure.

After wiring, make sure that the blade rotates in the

proper direction. If it does not, reverse two of the 3-

phase wires on the supply input.

2. Calibrate the length stop: Lower the blade, and

loosen the knobs on the rod holder. Then slide

the upper rod into contact with the blade, and

adjust the rod holder so that its left edge aligns

with the zero. Re-tighten the top knob to

secure the zero setting.

9.2 Single-phase models

The CS-315-1 (single phase) is rated for 230-volt

only power. It is not supplied with a plug. You may

either install a proper 230V UL/CSA listed plug, or

“hardwire” the machine directly to a service panel.

The CS-275-1 (single phase) is rated for

115/230V, prewired for 115V and supplied with a

120-volt rated plug. It may be converted to 230V.

See section 9.3.

9.3 Voltage conversion (model CS-

275-1 only)

To convert from 115V to 230V:

1. Remove the panel from the control box.

2. On the transformer, reconnect the L11 line

from the 120V terminal to the 230V terminal

(A, Figure 8).

Figure 7

9.0 Electrical connections

Electrical connections must

be made by

qualified

electrician in compliance with all relevant

codes. This machine must be properly

grounded to help prevent electrical shock and

possible fatal injury.

On all models, if a machine is being hard-wired to a

panel, make sure a disconnect is available for the

operator. During hard-wiring of the machine, make

sure the fuses have been removed or the breakers

have been tripped in the circuit to which the cold

saw will be connected. Place a warning placard on

Figure 8

3. Replace the 20 amp fuses with 10 amp fuses

in the first two fuse holders (B, Figure 8).

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4. Switch the leads in the coolant pump junction

box, according to the diagram in Figure 9. (A

diagram is also included on the coolant pump.)

10.2 Vise

Refer to Figure 10.

The vise is self-centering and has a cam action

lever for fast clamping. Use the handwheel to move

the vise jaw about 1/16-inch away from the work

piece, then rotate the cam lever to tighten.

The adjustable anti-burr arm keeps the off-cut end

from flexing, which can cause burring. Use a 10mm

hex key to loosen the arm for adjusting.

Figure 9

5. The saw is now ready for 230V operation.

9.4 Grounding instructions

This machine must be grounded. In the event of a

malfunction or breakdown, grounding provides a

path of least resistance for electric current to

reduce the risk of electric shock.

Improper connection of the equipment-grounding

conductor can result in a risk of electric shock. The

conductor with insulation having an outer surface

that is green with or without yellow stripes, is the

equipment-grounding conductor.

If repair or

replacement of the electric cord or plug is

necessary, do not connect the equipment-

grounding conductor to a live terminal.

Figure 10

10.3 Stops

Check with a qualified electrician or service

personnel if the grounding instructions are not

completely understood, or if in doubt as to whether

the tool is properly grounded. Repair or replace a

damaged or worn cord immediately.

Refer to Figure 11.

The front stop limits the blade depth of cut. The rear

stop limits return motion of the head.

To adjust depth of cut:

10.0 Adjustments

1. Disconnect machine from power source.

2. Using two 3/4” (19mm) wrenches, loosen lock

nut (A) while holding screw (B) stationary.

10.1 Miter adjustment

Refer to Figure 10.

3. With the saw in the fully lowered position, turn

screw (B) until the saw blade bottoms out at

the desired level.

The cold saw head has a rotational range of 135°.

To adjust the miter position, follow the steps below:

4. Tighten lock nut (A).

1. Move the miter position lock lever to the left to

release.

2. Adjust the head to the desired angle by

pushing on the back of the motor to the right or

left. The miter position is shown on the scale.

3. Loosen the cap screw (A) atop the vise, and

slide the jaw as needed to accommodate the

angle of the blade. Re-tighten the cap screw

securely.

4. When the desired cutting angle is set, move

miter position lock lever firmly to the right to

secure the setting.

Two adjustable miter stops are provided for +45

and -45 degrees. Use an angle measuring device

against blade and jaws, or make test cuts to verify

the initial setting of these stops.

Figure 11

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10.4 Blade replacement

Disconnect machine from the

power source before changing saw blades.

Failure to comply may result in serious injury!

To change the saw blade (Figure 12):

1. Disconnect machine from power.

2. Clamp a piece of wood in the vise, and lower

the blade upon it to prevent rotation.

3. Release the linkage from the blade guard at

(A) with a 5mm hex key, and rotate the guard

out of the way.

4. Remove the screw (B) with a 10mm hex key.

NOTE: Left-hand threads; turn clock-wise to

loosen.

5. Remove the blade (use gloves).

Figure 13

6. Secure a new blade by reversing the above

steps. Make sure the direction of the teeth is

correct.

Coolant Flow – The green ON button must be

active to start coolant flow.

Low/Off/High Switch – Selects the blade speed.

For the blade to operate, the On switch must be

pressed, blade speed switch must be set to Low or

High (3-phase models only), and the trigger on the

operating lever pressed.

IMPORTANT: A new blade requires a break-in

period. Use half the normal feed speed for the

operation; operate for a cutting surface of about

300 cm²for hard materials; about 1000 cm²for soft

materials. Then resume normal speed.

Trigger – (shown in Figure 3). When pressed, it

activates a micro-switch in the operating lever grip.

12.0 Operation

Before using the machine:

‰

Check that safety devices (e.g. blade guards)

are in position and work perfectly and that

personal safety requirements are complied

with.

‰

Check the sharpness of the blade and verify

proper coolant flow.

Operating

1. Position work piece and close the vise; rotate

the cam lever at the handwheel to secure the

setting of the vise. NOTE: A long work piece

must have proper support on both ends.

Figure 12

11.0 Controls

2. If mitering, adjust the head accordingly and

lock it in position. If making a mitered cut,

verify that the blade will not contact the rear

vise jaw. If it will, loosen the screw on the rear

vise jaw and slide the jaw so that it clears the

path of the blade, then retighten screw.

The Control Panel (Figure 13) has the following

functions.

Power On and Off.

Pressing the On button activates power to the

machine. The On button has a green indicator

lamp when electrical power is active.

3. Turn the power on.

Pressing the red Off button stops blade movement.

4. Select the blade speed.

5. Turn on coolant flow switch.

Emergency Stop – Press to shut down all

machine functions. To restart machine, rotate

button clockwise to disengage E-stop.

6. Start the blade by pressing the trigger on the

handle grip. The trigger also activates the

coolant flow.

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7. Pull the operating lever to bring down the

blade into the work piece. You will manually

control the speed of the downstroke.

13.4 Lubrication

For long life and trouble free operation, it is

essential that this machine is kept well lubricated.

The vise and leadscrew should be oiled daily. Pivot

joints and bearings should be greased weekly.

Check the gearbox oil level weekly, full level is top

of sight glass with head in full up position.

8. When the cut is complete, release the trigger

and raise the head. The spring will help return

the head to upward position.

9. Release the vise using the handwheel, and

remove the work piece.

The gearbox oil should be changed out after the

first 100 hours of operation, then after every 2,000

working hours. Drain the gearbox by unscrewing

the plug on the side of the head (Figure 14). To re-

fill the head, remove the operating lever and pour

oil into the hole. The plug also serves as the oil

level sight glass. Full level is top of sight glass with

head in full up position.

NOTE: When operations are complete, always

return the head to upward position to relieve stress

on the return spring.

13.0 Maintenance

13.1 Maintenance requirements

Follow local regulations for proper disposal of used

lubricants.

All maintenance and cleaning

procedures must be performed with the power

switched OFF. Failure to comply may result in

serious injury!

Recommended Lubricants:

Gearbox

Use Texaco Meropa® 460 or equivalent.

On completion of maintenance, ensure that

replaced parts and/or any tools used have been

removed from the machine before starting it up.

Grease fittings

Texaco Starplex® 2 or equivalent

Vise and Leadscrew

Regal® R & O 68

13.2 Periodic maintenance

‰

Remove all swarf from the machine,

preferably with a cloth.

‰

Remove chips from the coolant tank and

change coolant regularly.

‰

Top off the coolant level.

Check the wear of the blade and change if

necessary (see Blade Replacement).

Empty the chips out of the base.

Clean the vise and lubricate all the joints

and sliding surfaces, using good quality oil.

Attend to daily, weekly and annual

lubrication recommendations (see the

Lubrication section).

‰

Figure 14

13.3 Coolant system

Check coolant level in the tank periodically and top

off if necessary. Coolant can also be added by

pouring directly on the table, which will drain into

the tank through the filter plate.

14.0 Blade selection

When using the cold saw, it is important to select

the correct type of blade for the material to be cut.

This section explains the limitations and specific

applications of the different types of blades.

This coolant system can operate with either a

soluble oil base coolant or water-soluble synthetic

coolant. Coolant should be changed regularly.

Some recommended brands are DoAll and Lenox.

These coolants are available at your local industrial

distributor.

14.1 General characteristics

Fine Tooth Pitch – used for thin wall materials such

as sheet steel, tubes and profiles.

Periodically remove excess chips from the coolant

tank, and clean the filter on the coolant pump.

Coarse Tooth Pitch – used for large cross-sections,

and for soft materials (aluminum alloys and soft

alloys in general).

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speed depends on the cross-section of the

material. Solid or thick-walled materials

14.2 Determining proper tooth pitch

(thickness>5mm) can therefore be cut at high

speed providing there is sufficient swarf removal by

the blade, while thin-walled materials such as

tubes or thin profiles must be cut with a low feeding

speed.

Proper tooth pitch depends on:

a) the size of the section;

b) the hardness of the material;

c) wall thickness.

Solid sections call for

blades with a coarse

tooth pitch, while small

cross-sections require

A new blade requires a break-

in period, during which time about half the

normal feeding speed should be used.

blades with finer teeth.

This is because when

cutting walls of small

14.4 Coolant

The cooling fluid ensures that the blade teeth and

material in the area of the cut do not overheat. The

fluid must be an excellent lubricant so as to prevent

abrasion of the teeth and welding of the chips to

the teeth (seizing).

cross-section (1–7mm)

profiles, it is important

that the number of teeth actually making the cut

should not be too few, otherwise the effect

obtained will be one of tearing rather than of chip

removal, leading to a large increase in shearing

stress. On the other hand, when cutting thick

materials or solid sections using an excessively

fine tooth pitch, the chip collects as a spiral inside

the gullet, and since fine tooth pitches have small

gullets, the accumulated chip will exceed the gullet

capacity and press against the walls of the

workpieces, resulting in poor cutting (same

situation with soft materials), greater shearing

stress and hence breakage of the blade.

14.5 Blade structure

For non-ferrous metals, it is common to use

circular saws with a brazed hard metal HM cutting

edge, consisting of a disc made of alloy tool steel

(71Cr1) on which the shape of the teeth and the

seats for the cutting edges are made of Widia K10.

These saws have shown excellent wear resistance

but low resistance to impact, which is in any case a

minor problem with non-ferrous materials.

Table 4

14.6 Types of blades

The blade required for the cold saw is of HM hard

steel type since the machine is to be used for

cutting non-ferrous materials. In addition to the size

and pitch of the teeth, however, the blades also

have different geometric characteristics in

accordance with their particular use:

Table 3

A larger pitch should be chosen when, as a result

of the shape of the piece to be cut, the cross-

section at any given point exceeds the average

cross-section given above.

tooth cutting angle – may be negative or positive

tooth sharpening – may be BW with an alternate

raked tooth or C with a roughing tooth raked on

both sides and a non-raked finishing tooth

14.3 Cutting and feeding speed

The cutting speed and the head feeding speed are

limited by the amount of heat generated near to the

points of the teeth. If the head feeding speed is too

high, the cut will not be straight in either the vertical

or the horizontal plane. As we have already said,

the cutting speed depends on the strength

(kg/mm2) and hardness (HRC) of the material and

the dimensions of the thickest section. The feeding

tooth pitch – the distance between the crest of

one tooth and the crest of the next tooth (tooth

pitch = T)

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14.7 Teeth shape

“

C” TYPE SHARPENING (HZ)

Coarse toothing with roughing tooth raked on both

sides and non-raked finishing tooth. The roughing

tooth is about 0.3 mm higher.

Coarse toothing with roughing tooth and finishing

tooth. Used in saws with pitch greater than or equal

to 5 mm for cutting ferrous and non-ferrous

materials with solid or solid-profiled sections.

Figure 17

Short swarf material such as brass, bronze,

aluminum and hard cast iron require smaller cutting

angles because the swarf becomes crushed

immediately and the rake angle has little effect

during the cutting stage.

The cold saws use discs with positive cutting

angles for cutting solid materials and with negative

cutting angles for cutting hollow profiles. This is

because, as a result of the high cutting speeds,

even with non-ferrous materials the tool ”strikes”

against the wall of the profile to be cut several

times, thus requiring a cutting edge with a larger

resistant section.

Figure 15

“

BW” TYPE SHARPENING DIN 1838--UNI 4014

Coarse toothing with teeth alternately raked to the

right and left.

Toothing generally used on cut-off machines for

cutting ferrous and alloy materials with tubular and

profiled sections.

Figure 18

Circular saws can also be characterized by other

parameters such as the whine reduction feature,

which cuts down noise at high speeds, or

expansion, which compensates for the pushing of

chips inside the cutting edge, thus reducing the

thrust on the walls of the material to be cut.

Figure 16

POSITIVE AND NEGATIVE CUTTING ANGLES

The cutting angle may vary from positive to

negative depending on the cutting speed, the

profile and the type of material to be cut.

A positive angle determines better penetration of

the tool and hence lower shear stress and greater

ease of sliding for the swarf over the cutting edge.

On the other hand, the cutting edge has lower

mechanical resistance, so that as the breaking load

of the material to be cut increases, the cutting

angle decreases from positive until it becomes

negative, thus offering a cutting edge with a larger

resistant section.

Figure 19

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15.0 Troubleshooting

15.1 Blade and cutting problems

Problem

Probable Cause

Solution

Ensure proper coolant flow; hoses unclogged; nozzles

pointed correctly, etc. Make sure coolant type is

suitable for the machine.

Coolant flow problem

Material too hard

Check the blade speed and the type of blade you are

using. Also be aware of feed pressure.

With a new blade it is necessary to start cutting at half

feeding speed. After the wearing-in period (a cutting

surface of about 300 cm²for hard materials and about

1000 cm²for soft materials) the blade and feed speeds

can be brought up to normal values.

Blade not worn-in correctly

Teeth breaking

The swarf wedges into the bottom of the teeth causing

excessive pressure on the teeth themselves. Use a

blade with coarser tooth pitch.

Blade with excessively fine

tooth pitch

The surface of the cut may have undergone work

hardening. When starting work again, use a lower

blade speed and reduced feed pressure. A tooth from

the old blade may be left in the cut: check and remove

before starting work again.

New blade inserted in a

partially completed cut

Any movement of the work piece during cutting can

cause broken teeth: check the vise, jaws and clamping

pressure.

Work piece not clamped firmly

in place

The blade runs over the material without removing it:

increase feed speed.

Feed speed too slow

Blade speed too high

The teeth slide over the material without cutting it:

reduce the blade speed.

Check the coolant level and clean coolant lines and

nozzles.

Insufficient coolant

Rapid tooth wear

Incorrect fluid concentration

Check and use the correct concentration.

The materials may present altered zones either on the

surface, such as oxides or sand, or in section, such as

under-cooled inclusions. These zones, which are

much harder than the blade, cause the teeth to break:

Discard or clean these materials.

Material defective

Blade speed too high

Reduce blade speed.

Teeth in contact with material

before starting the cut

Always check the position of the blade before starting

a new job.

Broken blade

Check the coolant level and clean coolant lines and

nozzles.

Insufficient coolant

Cuts not straight

Feed speed too strong

Reduce feed speed.

Blade not perpendicular to

workpiece.

Contact Walter Meier technical support.

Table 5

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15.2 Machine fault and operating problems

Problem

Probable Cause

No incoming power

Solution

Check connections at machine and power source.

Replace fuse/bulb.

Green pilot lamp not lit

when ON button pressed

Lamp fuse or bulb is out

Emergency Stop engaged

Rotate Emergency Stop button to disengage.

Check: the phases; the cables; the plug; the socket.

Also check that the motor connections are in place.

Electrical power supply

Trigger switch not activating

Transformer

Check that socket/plug connection from handle to

motor is inserted correctly; check micro-switch in

trigger.

Check that the voltages are present both on the input

and output. Otherwise replace.

Check that the phases in it are present both on the

input and output, that it is not jammed, that it closes

when powered and that it is not causing short circuits.

Change if any of these problems are found.

Magnetic Contactor

Thermal relay

Motor

Motor will not turn

Make sure it is closed, i.e. check that the phases are

present in input and output, that it is not causing short

circuits and responds when the reset coil is closed. If it

has tripped to protect the motor, check the amperage

setting, re-set, and check the motor. Change if

necessary.

Check that it has not burned out, that it turns freely

and that there is no moisture in the connection

terminal board box. The winding can be rewound or

replaced by experienced motor repair personnel.

Table 6

16.0 Parts

Ordering replacement parts

Replacement parts are listed on the following pages. To order parts or reach our service department, call 1-

800-274-6848, Monday through Friday (see our website for business hours, www.waltermeier.com). Having the

Model Number and Serial Number of your machine available when you call will allow us to serve you quickly

and accurately.

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16.1.1 CS-275 Cold Saw (Machine Assembly) – Exploded View

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16.1.2 CS-275 Cold Saw (Machine Assembly) – Parts List

Index No. Part No.

Description

Size

Qty

1 ................CS275-1.................... Lock Handle............................................................. ......................................1

2 ................CS275-2.................... Lock Nut................................................................... ......................................1

3 ................CS275-3.................... Shaft ........................................................................ ......................................1

4 ................CS275-4.................... Machine Base.......................................................... ......................................1

5 ................CS275-5.................... Roller Bracket .......................................................... ......................................1

6-1.............TS-1492021 .............. Hex Cap Screw........................................................ M12x30 .........................2

7 ................CS275-7.................... Roller ....................................................................... ......................................1

9 ................TS-1504041 .............. Socket Head Cap Screw.......................................... M8x20 ...........................3

10 ..............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................1

11 ..............CS275-11.................. Hand Wheel............................................................. ......................................1

12 ..............CS275-12.................. Pin............................................................................ ......................................1

13 ..............CS275-13.................. Bearing Bushing ...................................................... ......................................1

14 ..............CS275-14.................. Bearing .................................................................... ......................................1

15 ..............CS275-15.................. Bushing.................................................................... ......................................1

16 ..............CS275-16.................. Lead Screw.............................................................. ......................................1

17 ..............CS275-17.................. Lock Handle............................................................. ......................................1

18 ..............CS275-18.................. Vise, Moveable ........................................................ ......................................1

19 ..............CS275-19.................. Washer .................................................................... ......................................1

20 ..............CS275-20.................. Spring ...................................................................... ......................................1

21 ..............CS275-21.................. Plate......................................................................... ......................................1

22 ..............TS-1506021 .............. Socket Head Cap Screw.......................................... M12x25 .........................3

23 ..............CS275-23.................. Hex Screw ............................................................... M10x30.........................1

24 ..............CS275-24.................. Spring ...................................................................... ......................................1

25 ..............TS-1550061 .............. Flat Washer ............................................................. M8.................................1

26 ..............TS-1504041 .............. Socket Head Cap Screw.......................................... M8x20 ...........................1

27 ..............CS275-27.................. Pin............................................................................ 5x12 ..............................1

28 ..............CS275-28.................. Switching Plate ........................................................ ......................................1

29 ..............TS-1540061 .............. Hex Nut.................................................................... M8.................................1

30 ..............TS-1550061 .............. Flat Washer ............................................................. M8.................................3

31 ..............TS-1504051 .............. Socket Head Cap Screw.......................................... M8x25 ...........................1

32 ..............CS275-32.................. Switching Handle..................................................... ......................................1

33 ..............TS-1503021 .............. Socket Head Cap Screw.......................................... M6x10 ...........................1

34 ..............CS275-34.................. Retaining Ring ......................................................... S-60 ..............................1

35 ..............CS275-35.................. Blade Shield............................................................. ......................................1

36 ..............TS-2245102 .............. Button Head Socket Screw...................................... M5x10 .........................14

37 ..............CS275-37.................. Plate......................................................................... ......................................2

38 ..............CS275-38.................. Blade Cover............................................................. ......................................1

39 ..............CS275-39.................. Socket Head Cap Screw (left hand thread) ............. M12x35LH.....................1

40 ..............CS275-40.................. Flange...................................................................... ......................................1

41 ..............CS275-41.................. Saw Blade................................................................ ......................................1

42 ..............CS275-42.................. Spindle..................................................................... ......................................1

43 ..............CS275-43.................. Worm Gear.............................................................. ......................................1

44 ..............CS275-44.................. Lock Nut................................................................... ......................................1

45 ..............CS275-45.................. Stop ......................................................................... ......................................1

46 ..............CS275-46.................. Vise, Stationary........................................................ ......................................1

47 ..............TS-1502061 .............. Socket Head Cap Screw.......................................... M5x25 ...........................3

48 ..............CS275-48.................. Base Swing Arm ...................................................... ......................................1

49 ..............CS275-49.................. Support Rod............................................................. ......................................1

50 ..............CS275-50.................. Vise Jaw Insert ........................................................ ......................................1

51 ..............CS275-51.................. Serrated Jaw Insert.................................................. ......................................1

52 ..............CS275-52.................. Small Serrated Jaw Insert........................................ ......................................1

53 ..............CS275-53.................. Handle Grip with Trigger Switch .............................. ......................................1

..................CS275-53N ............... Handle Grip with Trigger Switch (s/n 1312XXXX and higher) ........................1

55 ..............CS275-55.................. Handle ..................................................................... ......................................1

..................CS275-55N ............... Handle (s/n 1312XXXX and higher)......................... ......................................1

56 ..............CS275-56.................. Nut ........................................................................... ......................................1

57 ..............TS-2310201 .............. Hex Nut.................................................................... M20...............................1

58 ..............CS275-58.................. Machine Head.......................................................... ......................................1

59 ..............BB-6301ZZ................ Ball Bearing ............................................................. 6301ZZ..........................1

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Index No. Part No.

Description

Size

Qty

60 ..............BB-6205ZZ................ Ball Bearing ............................................................. 6205ZZ..........................2

61 ..............CS275-61.................. Rubber Gasket......................................................... ......................................1

62 ..............TS-1490031 .............. Hex Cap Screw........................................................ M8x20 ...........................4

63 ..............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................4

64 ..............CS275-64.................. Flange...................................................................... ......................................1

65 ..............CS275-65.................. Oil Seal.................................................................... 25x45x10 ......................1

66 ..............CS275-66.................. Worm Shaft.............................................................. ......................................1

67 ..............CS275-67.................. Coupling................................................................... ......................................1

68 ..............CS275-68.................. Motor........................................................................ 1.5HP, 220V, 3PH.........1

..................CS275-68-1............... Motor........................................................................ 1.5HP, 115/230V, 1PH..1

69 ..............CS275-69.................. Wire Terminal Clamp............................................... ......................................4

70 ..............CS275-70.................. Control Wire............................................................. ......................................1

71 ..............TS-1490031 .............. Hex Cap Screw........................................................ M8x20 ...........................4

72 ..............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................4

73 ..............CS275-73.................. Oil Plug .................................................................... 1/2” PT..........................1

74 ..............TS-0271031 .............. Socket Set Screw .................................................... 3/8”-16x3/8....................2

75 ..............CS275-75.................. Shaft ........................................................................ ......................................1

76 ..............CS275-76.................. Bushing.................................................................... ......................................1

77 ..............CS275-77.................. Cover ....................................................................... ......................................1

78 ..............TS-1504031 .............. Socket Head Cap Screw.......................................... M8x16 ...........................2

79 ..............CS275-79.................. Locking Knob........................................................... M8x20 ...........................1

80 ..............CS275-80.................. Length Setting Rod Bracket..................................... ......................................1

81 ..............CS275-81.................. Upper Length Setting Rod ....................................... ......................................1

82 ..............CS275-82.................. Lower Length Setting Rod ....................................... ......................................1

83 ..............TS-1540081 .............. Hex Nut.................................................................... M12...............................1

84 ..............CS275-84.................. Locking Knob........................................................... M8x18 ...........................1

85 ..............CS275-85.................. Filter......................................................................... ......................................1

86 ..............TS-1491031 .............. Hex Cap Screw........................................................ M10x25 .........................1

86-1...........TS-1540071 .............. Hex Nut.................................................................... M10...............................1

87 ..............CS275-87.................. Drain Cover.............................................................. ......................................1

88 ..............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................2

89 ..............TS-1504051 .............. Socket Head Cap Screw.......................................... M8x25 ...........................2

90 ..............TS-1504071 .............. Socket Head Cap Screw.......................................... M8x35 ...........................1

91 ..............CS275-91.................. Support .................................................................... ......................................1

92 ..............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................2

93 ..............TS-1504041 .............. Socket Head Cap Screw.......................................... M8x20 ...........................2

94 ..............TS-1533032 .............. Pan Head Machine Screw....................................... M5x10 ...........................4

95 ..............CS275-95.................. Stop Push Button..................................................... ......................................1

96 ..............CS275-96.................. Start Push Button..................................................... ......................................1

97 ..............CS275-97.................. Emergency Stop ...................................................... ......................................1

98 ..............CS275-98.................. 2/4P Selection Switch.............................................. (3ph only)......................1

99 ..............CS275-99.................. Pump Selection Switch............................................ ......................................1

100 ............CS275-100................ Control Box Panel.................................................... (3ph)..............................1

..................CS275-100-1............. Control Box Panel.................................................... (1ph)..............................1

101 ............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................2

102 ............TS-1490021 .............. Hex Cap Screw........................................................ M8x16 ...........................2

103 ............CS275-103................ Electrical Control Box .............................................. ......................................1

104 ............CS275-104................ Control Box Bottom Plate ........................................ ......................................1

105 ............CS275-105................ Magnetic Contactor.................................................. 12D (3ph)......................1

..................CS275-105-1............. Magnetic Contactor.................................................. 18D (1ph)......................1

106 ............CS275-106................ Fuse Set .................................................................. (3ph)..............................4

..................CS275-106-1............. Fuse Set .................................................................. (1ph)..............................4

..................CS275-106-2............. Fuse (not shown)..................................................... 10A (3ph) ......................3

..................CS275-106-3............. Fuse (not shown ).................................................... 2A (3ph/1ph) .................1

..................CS275-106-4............. Fuse (not shown)..................................................... 20A (1ph) ......................3

107 ............CS275-107................ Cover Plate.............................................................. (3ph)..............................1

..................CS275-107-1............. Cover Plate.............................................................. (1ph)..............................1

108 ............CS275-108................ Transformer............................................................. (3ph)..............................1

..................CS275-108-1............. Transformer............................................................. (1ph)..............................1

109 ............CS275-109................ Relay........................................................................ ......................................1

110 ............CS275-110................ Plate......................................................................... ......................................1

111 ............CS275-111................ Support Plate........................................................... ......................................1

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Index No. Part No.

Description

Size

Qty

112 ............TS-0680031 .............. Flat Washer ............................................................. 5/16”..............................2

113 ............TS-1504031 .............. Socket Head Cap Screw.......................................... M8x16 ...........................2

114 ............CS275-114................ Screw....................................................................... M5x6.............................2

119 ............CS275-119................ Oil Seal.................................................................... 35x47x8 ........................1

120 ............CS275-120................ Rubber Gasket......................................................... ......................................1

121 ............CS275-121................ Rubber Sheet........................................................... ......................................2

122 ............CS275-122................ Holder Plate............................................................. ......................................1

123 ............CS275-123................ Anti-Dust Plate......................................................... ......................................1

125 ............CS275-125................ Stopper.................................................................... ......................................2

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16.2.1 CS-315 Cold Saw (Machine Assembly) – Exploded View

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16.2.2 CS-315 Cold Saw (Machine Assembly) – Parts List