Instruction Manual TF Band Sawing Machine

Transcription

1 Instruction Manual TF-2525 Serial No: to Band Sawing Machine

2 DAMAGE CLAIM PROCEDURES VISIBLE DAMAGE AT THE TIME OF DELIVERY: 1. Note damage on carrier s delivery receipt. Accept the shipment. It can be returned later if repairs are not possible in the field. 2. Request a damage inspection from the delivery carrier: a. The carrier will send his own people or contract an independent agency to make the inspection. b. The inspector will request a signature on the report and leave a copy. c. The carrier damage inspection report is not final. If additional damage is found when repairs are started, contact the carrier for another inspection; or at least give them the details of the damage. 3. Do not move the equipment from the receiving area and keep all shipping materials until carrier damage inspection report is complete. 4. If possible, take photographs of the damage and keep them for your files. Photos could possibly prove a claim at a later time. 5. Keep a record of all expenses and be sure they are documented. 6. Repair damage in the field whenever possible. Carriers encourage this to keep expenses down. 7. You have nine (9) months to file a claim. CONCEALED DAMAGE: 1. You have fourteen (14) days to report damage not noted at time of delivery. a. Report damage as soon as possible. This makes it easier to prove that it did not happen at cosignee s plant. b. Inspect machine(s) carefully before moving from the receiving area. Again, if machine is not moved, it is easier to prove your case. 2. Request a damage inspection from the delivery carrier: a. The carrier will send his own people or contract an independent agency to make the inspection. b. The inspector will request a signature on the report and leave a copy. c. The carrier damage inspection report is not final. If additional damage is found when repairs are started, contact the carrier for another inspection; or at least give them the details of the damage. 3. Do not move the equipment from the receiving area and keep all shipping materials until carrier damage inspection report is complete. 4. If possible, take photographs of the damage and keep them for your files. Photos could possibly prove a claim at a later time. 5. Keep a record of all expenses and be sure they are documented. 6. Repair damage in the field whenever possible. Carriers encourage this to keep expenses down. 7. You have nine (9) months to file a claim.

3 OPERATOR'S INSTRUCTION MANUAL UNIVERSAL TILT-FRAME BAND MACHINE MODEL FIRST SERIAL NO. LAST SERIAL NO. TF For your information and future reference, pertinent data concerning your machine should be written in the spaces provided above. This information is printed on a label or stamped on a plate attached to your machine. Be sure to provide machine model and serial numbers with any correspondence or parts orders. Specifications contained herein were in effect at the time this manual was approved for printing. The DoALL Company, whose policy is one of continuous improvement, reserves the right, however, to change specifications or design at any time without notice and without incurring obligations. PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATING THE MACHINE! For Sales, Parts and Service, call DoALL SAWING PRODUCTS 2375B TOUHY AVENUE ELK GROVE, ILLINOIS U.S.A. The following registered trademarks of the DoALL Company are used in this manual: DoALL, Imperial Bi-Metal, Polypac and Tensigage. PRINTED IN U.S.A. PB (2-10)

4 TABLE OF CONTENTS MACHINE DIMENSIONS Floor Plan... 1 Front View... 2 Side View... 3 MACHINE FEATURES Front and Rear Views... 4 Side View... 5 Head Assembly... 6 INSTALLATION Location... 7 OSHA Notice!!... 7 Unpacking... 7 Cleaning... 7 Lifting... 7 Floor Installation and Alignment... 7 Electrical Installation... 8 Hydraulic Installation... 8 Coolant Installation... 9 Preparation for Use... 9 OPERATION Safety Precautions Using the Job Selector Cutting Capacity Control Console Operator Workstation Saw Band Preparation Post Adjustment Head Reverse Rate Head Tilt Adjustments Miter Meter Roller Table Vise Adjustments Band Feed Adjustments Coolant System Hydraulic System Chip Removal Typical Operating Procedures LUBRICATION Lubrication Chart Lubrication Diagrams MAINTENANCE Replacing Saw Guide/Back-Up Inserts Hydraulic System Coolant System Machine Cleaning Machine Alignment Brush Adjustments Wear Plate Replacement Bandwheels Chip Conveyor Miter Meter TROUBLE SHOOTING ACCESSORIES Variable Vise Pressure Filler Plates Nesting Fixture Roller Stock Conveyors Vertical Guide Rollers Mist Lubricator Right Hand Vise Laser Line Option How to read your serial number: ii

5 MACHINE DIMENSIONS INCHES (±.03) MILLIMETERS (± 1 mm) FLOOR PLAN 1

6 MACHINE DIMENSIONS (Continued...) INCHES (±.03) MILLIMETERS (± 1 mm) FRONT VIEW 2

7 MACHINE DIMENSIONS (Continued...) INCHES (±.03) MILLIMETERS (± 1 mm) SIDE VIEW 3

8 MACHINE FEATURES REAR VIEW FRONT VIEW

9 MACHINE FEATURES (Continued...) SIDE VIEW 5

10 MACHINE FEATURES (Continued...) HEAD ASSEMBLY 6

11 INSTALLATION LOCATION All the left, right, front and rear designations in this manual are as viewed by the operator facing the machine's control console. 1. The floor area required by the machine with allowance for 45 left and right head tilt is approximately inches ( mm) in width by inches ( mm) in length. Standard machine height is inches ( mm). Refer to pages 1, 2 and 3 for further machine dimensions. 2. Locate the machine to provide adequate space for your sawing needs. Be sure to provide sufficient clearance for: (a) Loading and unloading of stock; (b) Door openings; (c) Head tilting; (d) Power unit placement; (e) Maintenance and lubrication procedures; (f) Operation of any machine accessories, if applicable. 3. Provide ample space for roller conveyors and/or other material handling equipment. OSHA NOTICE!! UNPACKING OSHA Regulation (5B). Machines designed for a fixed location shall be securely anchored to prevent walking or moving. 1. The machine is fastened to and shipped on a wooden skid. Overseas shipments are also crated. 2. Carefully remove all protective covers, strapping, hold-down brackets, crating, etc. Then: (a) Remove all bolts which fasten the machine to the shipping skid; (b) DO NOT remove the head support bracket until the machine is placed in desired position; (c) Check around the machine for other removable brackets, extra machine parts or supplies which might have been placed there for shipment; (d) Inspect the machine and all parts for shipping damage. Claim procedures are listed on this manual s inside front cover. CLEANING 1. If necessary, use solvent to remove rust-preventive coating applied to exposed bare metal surfaces before shipment. LIFTING DO NOT use compressed air for cleaning purposes as this may force dirt and debris into the machine's working parts. NEVER lift the machine by its sawing head. 1. An overhead hoist with chain hooks is recommended to lift and transport the machine into its final position. Net weight is approximately 6200 pounds ( kg). 2. Place the chain hooks into the base openings (there is three (3) openings on each side). Be sure to pad areas where the chains may rub and damage machine surfaces. 3. The hydraulic power unit, conveyors and/or material handling equipment (if supplied) can be lifted and transported by overhead hoist, fork lift, or by other means that provides adequate safety precautions. FLOOR INSTALLATION and ALIGNMENT 1. While the machine is suspended above the floor, thread the provided leveling screws into each machine base foot and attach the jam nuts. Slowly lower the saw into desired position. 2. Just prior to touching the ground, place a cast iron foot pad under each of the leveling bolts. Lower the saw completely onto the foot pads. 3. Place the machine in desired position and then remove the head support bracket that connects the saw head to the machine frame. Remove the two (2) carriage brackets located in the rear of the machine behind the electrical control box enclosure. 4. Place a level on the machine roller table bed. Insert the 3/4-10NC leveling screws into the mounting pads and make final adjustments to level the machine in both directions. Make sure weight bears evenly on all mounting pads. 5. Position the roller conveyors and/or material handling equipment and attach if necessary to the machine frame. Adjust the leveling screws so that the conveyor rollers are in the same plane as the table rollers and weight bears evenly on all legs. 7

12 ELECTRICAL INSTALLATION (Continued...) ELECTRICAL INSTALLATION Electrical installation must be made by authorized electrical maintenance personnel only. 1. Refer to the machine specifications plate on the saw head frame to verify that the electrical supply circuit will meet the voltage/phase/frequency/amperage requirements listed. A basic data plate is reproduced on this manual s introductory page. 2. The electrical supply to this machine must be a dedicated circuit. 3. Power is connected to the electrical enclosure located in the rear of the machine. 4. The following are important disconnect precautions: The disconnect must be "ON" before the machine will operate. Turning off the disconnect will shut down the machine. The enclosure door must be closed and the appropriate securing screws must be in place before starting machine operation. 5. Turn the disconnect switch on the electrical enclosure to "OFF". Then: (a) Loosen the screws at the right door edge and open the door; (b) Familiarize yourself with operation of the disconnect switch operating handle, door interlock function, switch drive dog and shaft/clamp operating positions. 6. Punch a one (1) inch (25 mm) diameter or larger hole into the electrical enclosure. Then: (a) Bring power wiring (L1, L2, L3 and ground) through the hole (the cable and connector are to be supplied by the customer). DO NOT bring the power cable through any holes in the back wall. 7. Bring the power cable leads up to the disconnect switch. Then: (a) Connect L1, L2 and L3 to their respective terminals; (b) Connect the ground wire to the ground terminal (refer to the electrical schematic if necessary). 8. Place the operating shaft and operating handle of the disconnect switch in the "OFF" position. Then: (a) Close the electrical enclosure door and secure its screws; (b) Now turn the electrical supply and the disconnect switch to "ON" (no action will occur until the Hydraulic Start button on the control console has been pushed). DO NOT start machine hydraulics until the following Hydraulic Installation procedures have been performed. HYDRAULIC INSTALLATION 1. Position the hydraulic power unit behind and to the right of the machine. 2. Check the hydraulic reservoir fluid level in the power unit. Capacity is 20 gallons (75.7 liters). If the reservoir level is low (or empty): (a) Check to see that the reservoir s drain plug is installed tightly; (b) Fill with multi-purpose automatic transmission fluid or other fluid recommended on the Lubrication Chart. 3. Connect the hydraulic lines between the machine and power unit by matching tags on hoses to connection points on the machine. Refer to the hydraulic schematic if necessary. 4. Push the Hydraulic Start and Vise Clamp keys on the operator workstation and then the Band/Cycle Start key. The saw band should be running in a downward direction between the saw guides. 5. If the saw band direction is incorrect: (a) Turn the disconnect switch to "OFF" and remove power at the source of electrical supply; (b) Interchange any two (2) of the L1, L2, or L3 leads to the disconnect switch; (c) Restore power and perform Step 4 again. 6. As soon as the saw band movement is correct, jog the Hydraulic Start and Stop keys several times to make sure the hydraulic pump is primed. Then allow the machine to run for several minutes to remove entrapped air. Also check for any hydraulic leaks at this time. Electrical Connections to Disconnect Switch. 8

13 COOLANT INSTALLATION 1. Fill the coolant reservoir with 20 gallons (75.7 liters) of oil or cutting fluid recommended by the Lubrication Chart. DO NOT let coolant spill over the tray and onto the floor. The coolant pump strainer/screen must be sufficiently submerged for coolant flow to reach all areas in the coolant system. 2. Check for coolant leaks and tighten any fittings if necessary. PREPARATION FOR USE 1. Check to be sure all safety guards, covers and doors are in place or closed. 2. Remove the protective Saw Cap (if necessary) from the saw band by opening the upper bandwheel door and carefully pull the cap off the saw band. If desired, rotate the bandwheel to help in removal of the Saw Cap and then closed the bandwheel door. 3. Check to see that all other points listed by the Lubrication Chart have been properly checked and/or serviced. 9

14 OPERATION SAFETY PRECAUTIONS Warning Label - READ and UNDERSTAND. USING THE JOB SELECTOR 1. Refer to the Job Selector chart on the top panel of the control console for information about the recommended blade pitch, band speed, and cutting rate. This information is listed according to type of material to be cut and its thickness. The Job Selector also has a checklist for proper machine operation and reference notes about band speed, feed force, etc. Job Selector recommendations can be adjusted to meet special sawing requirements and are a general guide for correct cut-off sawing on a properly maintained DoALL saw. They are based on cutting annealed, scale-free, solid material using a Imperial Bi-Metal saw blade. Typical Job Selector. 10

15 CUTTING CAPACITY 1. The standard machine's cutting capacity is: At 0 tilt: 25 inches (635.0 mm) wide by 25 inches (635.0 mm) high for rectangular/square stock; 25 inches (635.0 mm) diameter for round stock. At 45 left tilt: 25 inches (635.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; inches (444.5 mm) diameter for round stock. At 45 right tilt: 25 inches (635.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; 17 inches (431.8 mm) diameter for round stock. 2. Cutting capacity may vary with addition of accessories and will be noted when applicable. Vise Capacity 1. The vise maximum opening is inches (647.7 mm). 2. Vise bed roller capacity is 6000 pounds ( kg) evenly distributed with NO impact. 2. Head Reverse Rate. Also located on the left side of the control console, this valve is used to regulate the reversing speed of the saw head. Turn the knob counterclockwise to increase the reversing velocity; clockwise to decrease it. The valve s lower locking set screw helps maintain the setting. 3. Miter Meter. The unit, mounted below the Feed Rate and Head Reversing Rate controls, has a LCD window displaying the direction and degree of head tilt. Push the "POWER" button to turn the unit on. Electrical Control Panel 1. Emergency Stop. Pushing this red mushroom head pushbutton stops all machine motors (band drive, hydraulic pump and coolant pump) simultaneously. Before the machine can resume operation, the Emergency Stop pushbutton must be reset (turn the button head clockwise until it pops up). CONTROL CONSOLE Left Side of Console 1. Feed Rate. This valve is used to regulate the linear travel of the sawing head towards the workpiece and is located on a bracket attached to the left side of the control console. Turn the knob counterclockwise to increase feed rate; clockwise to decrease the rate. The valve s lower locking set screw helps maintain the setting. Control Console. 11

16 CONTROL CONSOLE (Continued...) Operator Workstation 1. Most saw controls can be operated from the touch screens of the workstation and are described later in this section. Hydraulic Control Panel 1. Band Speed. This keylock adjustment valve allows the operator to set and maintain infinitely variable band speed between 60 and 300 fpm (18 and 90 m/min.). Refer to the data plate to the left of the valve for equivalent band speeds which can be reached with different valve settings. Turn the knob clockwise to increase the band speed, counterclockwise to decrease it. When setting band speed, the operator should try to obtain a vibration free speed level. Vibration while cutting generally indicates a need for a lower speed. If the vibration is severe, retract the saw head slightly from the stock, then adjust the band speed and resume cutting. Other Controls 1. Disconnect Switch. This switch supplies incoming power to the machine. 2. Band Tension. This selector valve with "TENSION", "RELEASE" settings and a center position for "HOLD" is used when changing saw bands. The control is located on the rear side of the column and accessed from the left side. Turning the selector to RELEASE lowers the upper bandwheel and enables saw band removal or installation. The center position or HOLD setting stops bandwheel movement and allows the operator to position the saw band over the bandwheels. The TENSION setting raises the upper bandwheel and automatically provides correct band tension. DO NOT operate the band drive motor unless band tension is on. 3. Coolant. Located to the left and below the control console, this valve regulates coolant flow to the upper saw guide and flushing hose. Turn the valve counterclockwise to increase coolant flow; clockwise to decrease the flow. 4. See the "Accessories" section of this manual on controls for the Variable Vise Pressure and Nesting Fixture options. OPERATOR WORKSTATION Typical Hydraulic Panel. 2. Feed Rate (or Band Feed). This control valve is used to adjust the saw band's feed force against the workpiece. Feed force is servo-maintained and infinitely adjustable between 0 and 22 ipm (0 and mm/min.). Turn the knob clockwise to increase the band feed, counterclockwise to decrease it. The valve s lower locking set screw helps maintain the setting. 3. Feed Rate (or Band Feed) Gauge. This indicator gauge located directly above the Band Feed valve registers the amount of pressure being directed against the workpiece. If a key does not respond, press and hold the key until a message in the upper left corner of the screen appears and then follow the prompts. 1. After the power is turned on, the Operations screen appears showing a collection of keys to operate the machine. 2. System, F1 thru F5. These keys are not used and requires NO interaction from the operator. Operations Screen For the saw head and vise functions to operate, the hydraulics MUST be on and the operation in the MANUAL MODE. 12

17 OPERATOR WORKSTATION (Continued...) 6. Hydraulic Start-Stop. Pressing these keys starts and stops the hydraulic pump and coolant pump motors. 7. Saw Head Forward-Reverse. Press and hold these keys will feed or retract the saw head from the cutting area. Release the key to stop saw head movement. 8. Band/Cycle Start-Stop. Pressing these keys starts and stops the band drive motor. For the band drive motor to start: (a) The hydraulics must be "ON"; (b) The vise is clamped; (c) Bandwheel door must be closed. Operations Screen. 1. In the upper left corner is a Display area for prompts and error messages. 2. Head Tilt Left-Right. Press and hold this key to tilt the saw head. Release the key stops the saw head movement. A quick press and release of the left or right tilt key will "pulse" the saw head according to the pulse setting on the Set-Up Screen. The pulse setting allows a short movement of the saw head to more accurately set the cut angle. Press and hold this key after the "pulsing" will move the saw head at a standard speed. 9. Mode. This key shows the current operating mode of the saw. Pressing the key will toggle between "MANUAL" and "FULL CYCLE". 10. Vise. This key toggles between "OPEN" and "CLAMP" to control vise operation. In "MANUAL" mode, the saw head must be retracted to operate this key. Make sure the vise jaw is opened wide enough when moving material through the vise jaws. 11. Along the bottom of the screen, there is three (3) keys that will take the operator to other screens: Setup, Instructions and Diagnostics. Set-Up Screen When the saw head is tilted, make sure the post is positioned to clear the material. Failure to do so will result in damage to the post. 3. Approach. This key toggles between "NORMAL" and "HEAVY DUTY" settings allows a choice of head approach rate toward the material to be cut. The "HEAVY DUTY" setting is a slower than "NORMAL" travel rate and used when cutting large, tough material. 4. Guide Post Up-Down. Press and hold these keys will raise or lower the guide post. Release the key to stop guide post movement. 5. Laser Start (Optional). This key starts or turns "ON" the optional laser line generator. After three (3) minutes the laser will automatically turn off. Set-Up Screen. 13

18 OPERATOR WORKSTATION (Continued...) 1. Coolant. A set of four (4) keys gives the operator a choice of coolant delivery options. "COOLANT ON W/BAND" allows the coolant system to operate when the band drive motor is running. "COOLANT ON" allows the coolant system to operate without the band drive motor running and is used mainly with the flushing hose. Along the bottom of the screen, there is three (3) keys that will take the operator to other screens: Operations, Setup and Instructions. Instructions Screen 1. This screen shows instructions on how to run a very basic and typical operation procedure. "COOLANT AUX MIST" is used for an optional cutting lubrication system. This key activates the mist coolant solenoid. "OFF" turns off either system. 2. Head Tilt Pulse Time. When setting a cutting angle using the Head Tilt keys, the pulse setting allows a short movement of the saw head to more accurately set the cut angle. The farther away from vertical, the lower the value should be. The value range is between 1 and Hydraulics Hour Meter. This display shows a running time the hydraulic pump motor has been operating. 4. Along the bottom of the screen, there is three (3) keys that will take the operator to other screens: Operations, Instructions and Diagnostics. Diagnostics Screen Instructions Screen. 2. Follow the steps on the screen to run a typical operation procedure either in manual or full cycle. 3. Along the bottom of the screen, there is three (3) keys that will take the operator to other screens that have been previously described. SAW BAND PREPARATION Saw Band Recommendations 1. A high-speed DoALL Imperial Bi-Metal Super Silencer saw band with protective Saw Cap is supplied with the machine. Band length is inches ( mm); width is 1-1/2 inches (38.1 mm); recommended gage is inch (1.3 mm). 2. A machine in correct adjustment, good operating condition and using proper cutting fluid is essential to efficient sawing. Diagnostics Screen. 1. Press the Diagnostics key will take the operator to a screen which shows different PLC input modules and their status. These modules are for diagnostics and service only and needs NO interaction from the operator. 3. Proper blade care should include: (a) Pushing uncut stock away from the saw band; (b) Using correct band speed, feed force and cutting fluids during operation; (c) Removing scale from stock before sawing; (d) Keeping the protective Saw Cap over blade teeth until installation time. For complete information about saw bands and their applications, go to 14

19 SAW BAND PREPARATION (Continued...) Blade Guards 1. The machine has several guards for operator safety and protection. All guards must be in place before any sawing procedure is started. Post Guard. This guard is attached to the bandwheel door and extends up towards the bandwheel. Column Guard. This guard is mounted on the head column and located between the bandwheels. Saw Guides DO NOT defeat their purpose by operating the machine without these guards. THEY ARE THERE FOR YOUR PROTECTION! 1. The upper and lower saw guides both have zeroclearance, carbide-faced, spring-loaded inserts. The inserts provide support necessary to help maintain sawing accuracy. Back support is provided by the pivoting carbide back-up inserts. Saw Guide Insert Components. 2. This applies to both upper and lower saw guides. Saw Band Removal Always use extreme care when handling saw bands. Wear gloves if necessary. 1. Before removing the saw band, set the machine to the following conditions: (a) Hydraulics are "ON"; (b) Band drive motor is "OFF"; (c) Coolant is completely shut off; (d) Saw head is vertical and completely retracted; (e) Position the post at the midrange height. 2. Move the Band Tension selector switch to "RELEASE". Then: (a) Open the upper bandwheel door; (b) Loosen the band brush bracket screw and move the brush aside; (c) Loosen the saw guide insert adjustment screws two (2) full turns counterclockwise; (d) Carefully remove the old, worn or broken saw band from between the saw guide inserts and both bandwheels ; (e) Carefully work the saw band out from the column guard and dispose the saw band immediately. Saw Band Installation Typical Saw Guide. Saw Guide Insert Adjustment 1. Loosen the adjustment screw at least two (2) turns counterclockwise on each saw guide. Then: (a) Remove the saw band (see below); (b) Turn the insert adjustment screw clockwise until it touches the fixed insert and then back two (2) full turns; (c) Replace the saw band (see below); (d) Turn the adjustment screw two (2) full turns clockwise to provide correct pressure against the saw band. Always use extreme care when handling saw bands. DO NOT attempt to change saw bands while the band drive motor is running. 1. Carefully follow all "Saw Band Removal" procedures. Then: (a) Use the Flushing Hose to clean areas around the saw guides and inserts, plus the drive and idler bandwheels; (b) Wiper with clean rag. 2. Maneuver the saw band into the column guard. Then: (a) Carefully position the saw band around the drive and idler bandwheels with the saw band's back edge resting against each bandwheel's rear flange; (b) Move the Band Tension selector switch to "TENSION" to apply just enough tension to hold the saw band in position, then move the selector to the center position to "HOLD". 15

20 SAW BAND PREPARATION (Continued...) 3. Slip the saw band between the saw guide inserts by twisting it 90 using the supplied saw band twist tool so the blade teeth are facing the front of the machine and pointing downward. Then: (a) Turn the adjustment screw two (2) full turns clockwise to provide correct pressure against the saw band; (b) Remove the protective Saw Cap from the saw band; (c) Close the upper bandwheel door; (d) Move the Band Tension selector switch to "TENSION" to apply full tension to the saw band. 4. Press the Band/Cycle Start key. Operate at a very low speed to check for proper band tracking against the each bandwheel rear flange. Band Tension Adjustment 1. Located on the rear side of the column and accessed from the left side, band tension is hydraulically applied and maintained. DO NOT operate the band drive motor unless band tension selector is in the "TENSION" position. POST ADJUSTMENT 1. Post and upper saw guide height is regulated by the Guide Post key on the operator workstation. 2. Sawing results will generally be more satisfactory if the post and upper saw guide are kept as close as possible to the material being cut. Doing so helps reduce saw band vibration and contributes to more accurate sawing. The post can be lowered only when the saw head is fully retracted. When the saw head has been tilted, make sure the post and saw guide will clear the material and/or the vise jaws. HEAD REVERSE RATE 1. Located on the left side of the control console, this valve is used to regulate the reversing speed of the saw head. Turn the knob counterclockwise to increase the reversing velocity; clockwise to decrease it. The valve s lower locking set screw helps maintain the setting. 2. It can also be used to withdraw the saw band from its kerf during a binding or jamming situation To do so: (a) Press the Band/Cycle Stop key; (b) Switch to "MANUAL" mode if not so already; (c) Turn the Head Reverse Rate knob clockwise to the minimum rate and press the Saw Head Reverse key. 3. Very gradually increase the head reversing rate by turning the control knob counterclockwise to allow the carriage to slowly retract and withdraw from its kerf. HEAD TILT ADJUSTMENTS 1. The saw head can be tilted up to 45 left or right for angular sawing and controlled by a Head Tilt keys on the operator workstation Tilt angle is indicated by the Miter Meter on the left side of the control console. 2. The sawing head must be in the fully retracted position in order to tilt the head. (a) Switch to "MANUAL" mode if necessary; (b) Press the Saw Head Reverse key to fully retract the head; (c) Press the Head Tilt Left or Right as desired and then release the key when desired angle is achieved as indicated on the Miter Meter; (d) Press and release the Head Tilt key to pulse the saw head to more accurately set the cut angle. 3. Set the Head Tilt Pulse Time in the Set-Up Screen. MITER METER When the saw head is tilted, make sure the post and upper saw guide is positioned to clear the material and/or vise jaws. Failure to do so will result in damage to the post. 1. This angle measuring devise is mounted to a bracket on the left side of the control console. The battery operated unit has a "POWER ON" button and a LCD readout window to display the tilt angle of the saw head. 2. When tilting the head to the left, the LCD will display the angle with a minus (-) sign in front of the value. When tilting to the right, there will be no sign in front of the value. Eliminate any electromagnetic radiation from such things as radio transmitters, walkietalkies, etc. which may affect the angle data shown on the display. 16

21 ROLLER TABLE 1. Material is supported on the table by four (4) rollers on each side of the saw band. Rollers have sprockets and are chained together for ease of moving material into cutting position. Material movement is done by means of a hand crank (hand crank is also used for chip conveyor) that fits onto a fitting on the far right or far left roller. Movable Vise Jaw With Vise Lock. When the saw head is tilted, make sure the post and upper saw guide is positioned to clear the material and/or vise jaws. Failure to do so will result in damage to the post. Roller Table. 2. Maximum table support weight is 6000 pounds ( kg) evenly distributed with NO impact. VISE ADJUSTMENTS 1. The inch high (317.5 mm) vise jaws are mounted on the left side of the saw band and controlled by a Vise Open/Clamp key on the operator workstation. 2. To adjust the movable jaw: (a) Lift up and hold the locking lever; (b) Slide both the vise jaw and vise lock toward the workpiece; (c) Locate the pin into the nearest hole in the vise slide bar by releasing the locking lever; (d) Press the Vise Clamp key. 3. The fixed vise jaw distance from the saw band can be adjusted by: (a) Loosening the lock screw; (b) Slide the fixed vise to desired position; (c) Tighten the lock screw. BAND FEED ADJUSTMENTS 1. Band feed is the pressure exerted by the workpiece against the saw band's cutting edge. It is controlled hydraulically and regulated with the Band Feed valve and shown on the Band Feed Gauge above the control. Turn the valve clockwise to "increase" pressure, counterclockwise to "decrease" it. The valve s lower locking set screw helps maintain the setting. 2. The following are important factors to consider when setting or adjusting the Band Feed valve: Turn the Band Feed valve to a low setting if the correct band feed is not known. The operator can then increase or decrease pressure during operation to obtain the best cutting rate consistent with desired blade life and stock cut finish. Always be sure to take a good chip. Never start a cut with the maximum Band Feed valve setting. Blade damage may occur. Certain work-hardening materials will require a moderately heavy initial Band Feed valve setting to assure immediate penetration of blade teeth. Light feeds on these materials may cause the blade to slide over the stock resulting in saw band damage. 17

22 BAND FEED ADJUSTMENTS (Continued...) Generally, top performance from a sharp saw band results from relatively low Band Feed valve settings. It will be necessary to increase the setting as the saw band becomes duller. This will help keep the cutting rate constant throughout the life of the saw band. Band feed adjustments are not necessary for changing stock cross-sections. A servo valve enables the saw band to maintain a uniform cutting rate. Reducing Cutting Rate & Band Speed for Pipe, Tubing and Structurals 1. Increasing loading per tooth occurs when sawing thin stock sections. Although the blade teeth can bear some overloading, a cutting rate reduction must be made. 2. Proceed as follows when it becomes necessary to modify solid section sawing recommendations: (a) Measure the thinnest stock section to be cut; (b) Apply the corresponding percentage factor from the chart below; (c) Use a high band speed, but never exceed the maximum speed recommended for stock sections of the same size. SECTION THICKNESS FACTOR TO APPLY TO MINIMUM CUTTING RATES GIVEN BY JOB SELECTOR* Up to 3/16 inch 40% (0 to 4.8 mm) 3/16 to 3/8 inch 50% (4.8 to 9.5 mm) 3/8 to 5/8 inch 60% (9.5 to 15.9 mm) 5/8 to 1 inch &over 70% (15.9 to 25 mm & over) Cutting Rate to Thickness Relationship. *Based on 5 inch (127.0 mm) solids. COOLANT SYSTEM Coolant Selection 1. The main cause of tooth failure during band machining is excessive heat build-up. Using the proper cutting fluid reduces the heat generated during operation. It also helps the machine take full advantage of its high-speed steel saw bands. Information describing the use, application and types of coolant is available from your DoALL sales representative. Coolant Application 1. Coolant is applied as follows during sawing: A valve located below and left of the control panel regulates: (a) The flow to the saw band and cutting area through the saw guide inserts; (b) To a flushing nozzle for washing parts or cleaning areas of the machine. A valve located under the step on the left side of the machine base near the coolant pump regulates: (a) A nozzle for removing chips and cooling the band drive motor located below and to the right of the lower bandwheel; (b) A flushing nozzle to keep chips moving off the pan onto the chip conveyor. 2. Coolant flow is started by: (a) Pressing the Hydraulic Start key; (b) Select Coolant On or Coolant On W/Band key; (c) Turning the coolant valve next to the control console counterclockwise until fluid completely shrouds the saw band. DO NOT start cutting until coolant is flowing adequately. Dry cutting will greatly reduce blade life. 3. Drip pan capacity is 20 gallons (75.7 liters). HYDRAULIC SYSTEM 1. The hydraulic and band drive systems operate independently. This allows the operator to perform the following tasks while the band drive motor is not running: (a) Change saw bands; (b) Traverse the sawing head; (c) Clamp or unclamp the vises; (d) Position stock manually. 2. The machine's hydraulic reservoir has a 20 gallon (75.7 liter) capacity. Refer to the Lubrication section of this manual for recommended oils. 18

23 HYDRAULIC SYSTEM (Continued...) 3. The machine will function through a wide range of hydraulic fluid temperatures, although ideal temperature range is between 90 and 130 F. (32 and 55 C.). Machine functions may be sluggish if operated with fluid temperature below 70 F. (21 C.). 4. The operator should check the cutting rate closely as fluid temperature rises. Feed force changes will be necessary as the fluid warms. For example: If Feed Force is set to obtain a given cutting rate with fluid temperature at 50 F. (10 C.), the rate will increase substantially when fluid warms up to 100 F. (38 C.). CHIP REMOVAL 1. Metal chips should be removed from the work area as soon as possible. They can be washed or scraped into the right front pan opening, or scooped out with the supplied shovel-rake. Chip Conveyor DO NOT shovel or rake chips while the saw band is running. 1. Metal chips removed from the saw band during operation fall into the machine's coolant reservoir. They are gathered and removed by a hand operated conveyor which carries the chips up a chute and deposits them in a container placed under the chip opening. 2. The furnished hand crank is used to operate the chip conveyor by fitting it over the extended shaft located at the front right side of the machine base. Turn the crank counterclockwise to remove the chips. The hand crank is also used for table rollers. Band Brush 1. A band brush powered by the lower bandwheel and removes metal chips from the saw band. During machine operation, the brush bristles should be positioned so that the tips clean chips from the blade teeth gullets, but do not contact the bottom of the gullets. DO NOT allow metal chips to accumulate on the brush. 2. Metal chips removed by the band brush fall into the coolant reservoir. These should be removed frequently by turning the hand crank operated chip conveyor (hand crank is also used for roller table). Chip Removal Points. Flushing Hose 1. Metal chips and other debris may accumulate over time around such machine areas as: saw guides, drive and idler bandwheels, vises, slides, feed and discharge areas, etc. 2. The operator should check often for metal chip collections which can adversely affect machine performance. They should be removed with the Flushing Hose as soon as possible. Band Wipers The DoALL Company recommends using the Flushing Hose to remove chips at least twice per each eight (8) hour shift, and more often with heavier use. 1. A wiper located at approximately the two (2) and ten (10) o'clock position from the lower bandwheel removes coolant residue from the moving saw band before it reaches the lower and upper bandwheels. 2. A set of wipers are also used to wipe the saw band before entering the cutting area. These wipers are located on top of the saw guide inserts on the upper saw guide block. Shovel-Rake 1. Accumulations of metal chips can be removed from the machine with the shovel-rake. DO NOT use the shovel-rake while the saw band is running. Combination Shovel-Rake. 19

24 TYPICAL OPERATING PROCEDURES 1. These procedures assume that the following machine conditions exist: (a) The machine has been properly installed and aligned; (b) The band drive motor is off; (c) The proper saw band has been installed, is correctly tracked and tensioned; (d) All lubrication procedures have been carried out. DO NOT remove any cut-off pieces until they are away from the saw band or the saw band has stopped completely. For future reference, keep a record of band speed, feed rate, feed force and coolant application settings for successful jobs. 2. Press the Hydraulic Start key. Then: (a) Retract the sawing head completely by pressing and holding the Saw Head Reverse key; (b) Press the Vise Open key; (c) Raise the post and saw guide by pressing the Guide Post Up key and then release the key when the saw guide has been raised enough to clear the stock and/or vise. If the saw head is to be tilted, raise the guide post to the maximum up position. 3. Load and position the material to be cut onto the roller table. 4. Press the Head Tilt Left or Right as desired and then release the key when desired angle is achieved as indicated on the Miter Meter; (d) Press and release the Head Tilt key to pulse the saw head to more accurately set the cut angle. 5. Press the Guide Post Down key to lower the saw guide/post and release the key when the post and saw guide are at a position just above material and/or vise. 6. Press the Coolant On W/Band key. 7. Select Manual or Full Cycle operating mode. Then: (a) Turn the Band Speed and Band Feed valves to initial settings; (b) Turn the Coolant valve on and adjust so that the saw band is shrouded with coolant. 8. Select Normal or Heavy Duty approach rate. 9. Press the Band/Cycle Start key. Watch closely as the saw head moves forward and make any adjustments to band speed, band feed, coolant volume, head approach and/or feed rate settings as needed. 9. After the cut has been completed: (a) The saw band will shut off with the saw head in the forward position when in the "MANUAL" mode, or (b) The saw head will fully retract and the saw band will shut off when in the "FULL CYCLE" mode. 10. If in "MANUAL" mode, retract the saw head fully. Then: (a) Open the vise; (b) Remove the cut-off piece; (c) Repeat the process for another cut if desired. 20

25 LUBRICATION Next 2 Pages 21

26 LUBRICATION LUBRICATION CHART LUBRICATION POINT NO. LOCATION DESCRIPTION AND SERVICE RECOMMENDATIONS LUBRICATION INTERVAL* 1 Rear Drive Shaft Bearing. One (1) grease fitting. MONTHLY 2 Upper Bandwheel Bearing. One (1) grease fitting. MONTHLY 3 Drive Pinion Shaft Bearings. Two (2) grease fitting. MONTHLY 4 Carriage Support Guide Bearings. Eight (8) grease fittings. MONTHLY 5 Rear Head Pivot Pillow Block. One (1) grease fitting. 3 MONTHS 6 Work Stop (Optional). Five (5) grease fittings. AS REQUIRED 7 Movable Vise Jaw Slides). Clean and apply oil. WEEKLY Saw Guide Insert Adjustment Screws. Oil the 8 INSERT CHANGE threads. 9 Post. Clean and apply oil. MONTHLY Miscellaneous: Slides, Hinges, Pivot Points, Component Parts, Unpainted Surfaces, Optional Equipment as Supplied, etc. Keep clean and apply oil as required to maintain proper function, reduce wear, and corrosion, etc. Transmission gallon (12.3 liter) capacity. Keep full. Drain and refill every 6 months or when required. CHECK MONTHLY CHECK MONTHLY RECOMMENDED LUBRICANT Premium quality, multi-purpose lithiumbase, EP (extreme pressure) grease. NLGI No. 2. Union 76, UNOBA EP 2, or equivalent. High quality, rust and oxidation-inhibited, medium hydraulic and general purpose industrial oil. ISO-VG Grade 68 (Formerly ASTM Grade No. 315). Union 76, UNAX RX 68, or equivalent. High quality, EP (extreme pressure) multi-purpose gear oil. ISO Grade No Electric/Hydraulic Motors. Hydraulic Pump, Coolant Pump, Band Drive. Coolant Reservoir (Drip Pan). 20 gallon (75.7 liter) capacity. Drain, clean and refill whenever coolant becomes undesirable for further use. Clean the mesh strainer at the same time. Band Mist Lubricator (Optional). Keep reservoir filled and hoses clear. Hydraulic Reservoir. 20 gallon (75.7 liter) capacity. Check oil level daily and keep the reservoir full. Drain, change the filter element and refill after the 1st month; every six (6) months thereafter. DoALL 150 Gear Oil, or equivalent. Lubricate (if any) per manufacturer s recommendations. CHECK DAILY/ AS REQUIRED CHECK WEEKLY/ AS REQUIRED CHECK DAILY/ AS REQUIRED Premium quality, saw band coolant and lubricant. DoALL cutting fluids and/or oils (Power- Cut). Contact your DoALL sales representative for the best oils and/or fluids for your application. DoALL cutting fluids and/or oils (AL- 2000). Multi-purpose automatic transmission fluid. General Motors Dexron III, or equivalent. * Lubrication intervals are based on a 8-hour day, 40-hour week. Lubricate more often with heavier use. 22

27 LUBRICATION DIAGRAM REAR VIEW LOWER HEAD - REAR VIEW POWER UNIT 23

28 MAINTENANCE It is strongly recommended that repair procedures be performed by experienced maintenance personnel, or a DoALL service representative who is trained to repair and service your machine. REPLACING SAW GUIDE/BACK-UP INSERTS These instructions can be used to replace saw guide inserts and back-up inserts on both upper and lower saw guides. Note that the upper and lower saw guide inserts are NOT interchangeable and care must be taken when ordering new ones. The band drive motor must NOT be running when replacing saw guides and back-up inserts. 1. Loosen the insert adjustment screw on each saw guide. Then: (a) Remove the saw band; (b) Remove the adjustment screw be very careful not to drop or lose the front insert when it falls from the assembly; (c) Loosen the screw and remove the rear insert. HYDRAULIC SYSTEM 1. Keep the reservoir filled at all times. Capacity is 20 gallons (75.7 liters). Check the reservoir oil level daily by referring to the sight gauge. 2. Drain, clean, refill the reservoir and change the oil filter after the first month of operation; every six (6) months thereafter. Clean the suction strainer and filler opening screen when necessary. Automatic transmission fluid is the recommended product. 3. Before changing the hydraulic fluid: (a) Retract the saw head completely; (b) Push the Hydraulic Stop key; (c) Remove the reservoir drain plug; (d) Allow the reservoir to drain completely. System Pressure 1. Hydraulic system pressure is correctly set at the factory and should not require adjustment for a considerable period of time. Correct system pressure is 1000 ±25 psi (68.9 ±1.7 bar or 70.3 kg/cm².) 2. Pressure is adjusted by turning the screw extending outward from the hydraulic pump. Pump Repair & Replacement 1. DO NOT attempt to repair the hydraulic pump. Return it to the factory for repair or replacement. Be sure to specify the correct pump model and serial numbers when returning the unit. Typical Saw Guide Assembly. 2. Thoroughly clean the saw guide and inserts area. Then: (a) Reverse the carbide back-up insert (if worn); (b) Replace the rubber back-up insert if it has deteriorated (this will help prevent coolant leakage) (c) Check the condition of the belleville washers on the adjustment screws, replace if flattened. 3. Install the new inserts. Then: (a) Thread the adjusting screw inward part way; (b) Reinstall the saw band between the inserts; (c) Tighten the adjustment screw; (d) Back off the adjustment screw 1/4 turn. 2. Following a new pump installation: (a) Jog the Hydraulic Start and Stop keys several times; on for two (2) seconds, off for three (3) seconds until the pump is primed; (b) Check for proper pump rotation while jogging; (c) Review wiring connections if the pump rotates in the wrong direction. Seals & Cups After the pump has been primed, run it for several minutes while operating the machine s controls to purge entrapped air from the pump and system. Check for oil leaks while the system is being operated. 1. Seals and cups used in DoALL hydraulic systems are compatible ONLY with hydraulic oils having an aniline point between 215 and 230 F. (102 and 111 C.). 24

29 HYDRAULIC SYSTEM (Continued...) 2. If hydraulic oil having an aniline point not falling within the above range is used, the seals may either swell or shrink and harden. This causes machine malfunction and leakage. DoALL hydraulic fluid with an aniline point of approximately 221 F. (106 C.) will not cause deterioration of component seals. COOLANT SYSTEM 1. The machine s coolant drip pan has a 20 gallon (75.7 liter) capacity. 2. Check the coolant often for signs of contamination or breakdown. The drip pan and coolant system should be drained and cleaned thoroughly when the cutting fluid becomes undesirable for further use. If another type of coolant is to be used, the entire coolant system must be flushed (use DoALL s Kleen Flush). Information describing the use, application and types of coolant is available from your DoALL sales representative. MACHINE CLEANING 1. Keep the machine and its parts as clean as possible to prevent excessive wear and damage. 2. Use the Flushing Hose as soon as possible to remove metal chips and other waste materials which may collect around the saw guides, bandwheels, vises, slides, etc. The hose has a hand-operated valve and attaches to the coolant pump. The DoALL Company recommends using the Flushing Hose to remove chips at least twice per each eight (8) hour shift, and more often with heavier use. 3. Use the supplied shovel-rake to remove accumulated metal chips or other waste materials from machine areas. Be sure the band drive motor is stopped before opening machine doors or covers. MACHINE ALIGNMENT 1. Misalignment of the machine s saw guides, slide bar, saw band, pivot points, post, etc., will cause inaccurate sawing. DO NOT attempt any alignment procedures not covered by this manual. Contact a DoALL service representative in such cases because special fixtures and techniques may be required. BRUSH ADJUSTMENTS Band Brush 1. The band brush will wear and lose steel bristles over time. Check often to be sure the bristles are removing metal chips from the blade tooth gullets, but are not touching the bottom of the gullets. 2. Move the brush closer to the blade as normal wear occurs. Replace the brushes when necessary. Band Wipers 1. Band wipers, located at approximately the ten (10) and two (2) o'clock positions from the lower bandwheel, remove coolant residue from the moving saw band before it reaches the upper and lower bandwheel. Adjust or replace the wipers when necessary. WEAR PLATE REPLACEMENT 1. The removable vise jaw and vise bed wear plates must be replaced before excessive wear causes the mounting screw heads to become damaged and makes removal difficult. Vise Jaw Plates 1. The machine has one (1) vise jaw wear plate on each jaw. All wear plates are mounted with low-head screws. Be sure the vise jaws are separated and the machine turned off before trying to replace the wear plates. Vise Bed Combination Shovel-Rake. 1. There is one (1) vise bed wear plate on each side of the saw band. All wear plates are mounted with low-head screws. 25

30 BANDWHEELS 1. Occasionally check each bandwheel s back-up flange and wheel tread for wear. Saw bands will not track properly if the taper is worn from the wheel tread. 2. Replace the entire bandwheel if the rim becomes badly worn. 3. Remove the bandwheels every six (6) months to clean them and surrounding areas. At the same time, clean the drive wheel ring gear and pinion before applying lubricant. Typical Bandwheel Flange and Tread. CHIP CONVEYOR 1. Metal chips removed from the saw band during operation fall into the machine's coolant reservoir. They are gathered and removed by a hand operated conveyor which carries the chips up a chute and deposits them in a container placed under the chip opening. 2. The furnished roller table hand crank can also be used to operate the chip conveyor by fitting it over the extended shaft located at the front right side of the machine base. Turn the crank counterclockwise to remove the chips. MITER METER 1. A message "LOBAT" may appear in the LCD display's upper left corner. This indicates that battery voltage has dropped below the level required for accurate readings. Carefully pry the top cover off and replace with a fresh battery. 26