Operator’s Manual Text

Section I

Model LE-10A

Dake/Johnson Horizontal Band saw

Fully Automatic

DAKE Division of JSJ

724 Robbins Road

Grand Haven, MI 49417

Phone: 1-800-937-3253 616-842-7110

Fax: 1-800-846-3253 616-842-0859

E-mail: [email protected]

[email protected]

Web: www.dakecorp.com

12/10/07 Model LE10A Text 1

FOREWORD

This manual has been prepared to acquaint you with the operation, maintenance, and serviceable components of your Dake/Johnson machine.

We urge that you read it carefully before operating your machine. Please refer to the manual when contacting the factory regarding parts, schematic or when you have other questions.

As Dake’s policy is one of continuous development for each range of machine, the contents of this manual, though completely up to date when issued, are subject to change without notice.

For your information and future reference, data concerning your machine may be inserted in the space provided below.

Machine Model LE 10A_____________________

Serial Number ___________________________

Date Received

Voltage

___________________________

220 Volt _________________________

Phase 3______ Cycle 60_____ Motor H.P.3_____

Please give the machine model and serial number in correspondence and include the part numbers on part orders.

DAKE Division of JSJ

724 Robbins Road

Grand Haven, MI 49417

Phone: 1-800-937-3253 616-842-7110

Fax: 1-800-846-3253 616-842-0859

E-mail: [email protected]

[email protected]

Web: www.dakecorp.com

NOTE:

Use only genuine Dake/Johnson replacement parts and optional equipment. Use of substitutes or imitations may cause damage to the machine. This may void the warranty, and may cause injury.

12/10/07 Model LE10A Text 2

CONTENTS

SECTION 1 – Safety

1.1 General Safety Instructions

1.2 Location of Safety Labels

SECTION 2 – Description

2.1 General Product Specifications

2.2 Machine Life

2.3 Intended Use

2.4 Noise Level

SECTION 3 – Transportation & Installation

3.1 Transportation

3.2 Preparation for Installation

3.3 Inspection

3.4 Environment requirement

3.5 Dismantling

SECTION 4 – Machine operation

4.1 Control Panel Description

4.2 Blade Change

4.3 Manual operation Instructions

4.4 Blade speed change

4.5 Automatic operation instructions

4.6 Part length set part length

4.7 Bundle attachment installation

4.8 Cutting data

4.9 Lubrication and maintenance

4.95 Trouble shooting

12/10/07 Model LE10A Text 3

Machine Type

Capacity

Bundled

Drop Length

Possible

Blade Size

Blade Speeds

Feed Stroke

(Single)

Multiple

Stroke

Feed Type

Length Set Up

Horse Power

Blade Motor

Hydraulic

Pump HP

Coolant Pump

Type & HP

Hydraulic Oil

Capacity

Coolant

Capacity

Vises (Quick set ratchet type)

Vise

Clamping

Pressure

Vise Ways

Work Table

Hitch Feed

Capacity

2.1 General Product Specifications

Horizontal scissors type

Rapid Head

Approach

4-½ “ – 7” wide, 5-½ “ high

Blade Tensioning

Less than 2 inches

138 inches x 1 inch

88 / 130 / 177 / 223 / 262

F.P.M.

3/8 inch minimum - 16 inch maximum

9 times (142 inches maximum)

Hydraulic hitch feed with vertical rollers, feed speed 16 inches in

6 seconds

Front mounted hand wheel, and

DRO with large numeral digits.

3 H.P.

1 H.P.

Gear type 1/8 H.P.

Electrical

System Control

Warning Light

Auto Shut Off

Chip Brush

Foot Print

Roller Support w/ vertical roller dimensions

Work Height

Weight

Tool Kit

1.2 gallons

10 gallons

Hydraulic with blade forward clamping for minimized burr and with 1” throw

600 pounds

Precision ground and hardened

Machined with chip clearance inserts

2790 pounds with use of roller table

Spare Parts

Work Light

Machine Support

Pads

Collective Hour

Timer

Auger Style Chip

Removal System

Guarding

Lubricant

Hydraulic

Pump

Hydraulics on demand (HOD) with minimum pressure start up

Voltage

Head Feed

Piece Counter

Hydraulic regulation with RPM compensation feed back

9,999 piece with auto shut off

12/10/07 Model LE10A Text

AMP

Operating

Temperature

Sure stop hydraulically controlled

Mechanical with preset locking ring

CE approved / Thermo overload, low voltage protection, 110 control voltage

PLC

Yes

Pieces reached, out of stock, blade slippage/breakage

Speed synchronized

76 inches x 69 inches (145 inches deep without roller support)

72 inches long x 16 inches wide

21-½ inches

2700 pounds

Standard – Includes screw drivers, wrenches and Allan keys

Standard – Includes chip brushes and guide bearing replacements

Standard

Standard

Standard

Standard

Full hinged

Flood type unit built into the machine (Electric)

•

Available 230-volt three phase

• Available 460-volt three phase

(external transformer)

Machine should be wired to main service by a qualified

Electrician.

• 20-amp service for 230-volt machine

•

16-amp service for 460-volt machine

No special operating temperature level

4

SECTION 1

1.1 General Safety Instruction

Read and understand the instruction manual and warning signs before operating this machine. Failure to follow these instructions and warnings can result in serious injury or death.

1. Always wear eye protection.

2. Do not wear gloves, neckties, loose clothing or jewelry while operating machine.

3. Keep fingers out of path of the blade.

4. Do not remove jammed or cut-off pieces until blade had completely stopped.

5. Check blade tension and adjust blade guide before starting.

6. Always clamp stock firmly in place before cutting and use auxiliary support for long material.

7. Disconnect machine power from source before making repairs or adjustments.

8. Guards should be in place and used at all times.

9. Keep machine and chip collections system clean.

10. Never operate the machine when guarding is removed.

11. Do not touch the blade or place any body part into the vice area when machine is in operation.

12/10/07 Model LE10A Text 5

4

5

Location of Safety Labels 1.2

1

3

6

SAFETY

you see this symbol on your saw, be alert to the potential personal injury.

Follow recommended precautions and safe operating practices. Carefully read all safety messages in these instructions and on your saw safety signs. Keep safety labels in good condition.

Label 1 – DANGER – KEEP THE COVERS CLOSED WHEN SAW BLADE IS IN

MOTION

Label 2 – DANGER – KEEPS HANDS OFF DURING SAWBLADE OPERATION

Label 3 – DANGER – KEEP BODY PARTS AWAY FROM MOVING PARTS

DURING MACHINE OPERATION

Label 4 – DANGER – DO NOT STEP ON THE ROLLERS ON FEED TRACK

Label 5 – DANGER – THIS MACHINE ELECTRICITY MUST BE LOCKED OUT

BEFORE SERVICING.

Label 6 – DANGER – STEEL TOE SAFETY SHOES MUST BE WORN WHEN

OPERATING THIS MACHINE

2

1

7

12/10/07 Model LE10A Text 6

2.2 Machine Life

The intended life limit of this machine is ten years under normal operating conditions and with good maintenance. The intended life of this machine is calculated by: 8 hours x 5 days x 52 weeks x 10 years = 20,800 hours.

2.3 Intended Use

The LE10A is an automatic hydraulic band saw machine. It is designed and constructed for metal sawing only. It is not intended to cut other materials for example: meat, wood, stone, plastic, Mg and analogous materials.

For safety, it is designed with safety guarding to protect from the moving elements while operating.

The interlock devices of the wheel guards are hardwired to stop the spindle revolution of the drive and drive wheel.

This machine has three operation modes:

(1) Automatic Mode

(2) Single Cycle Mode

(3) Manual Mode

It is designed for a trained and skilled person to operate this machine; they must be trained until they know how to operate it safety.

It is designed that this machine can not be used in a potential explosive environment.

2.4 Noise Level

The LE10A have a noise level below 75dB (For detailed information, please refer to the TECHNICAL Section)

Use a forklift to move the crated machine.

When moving the machine with a forklift, be sure the load is safely balanced

SECTION 3

3.1 Transportation

personal injury or damage to the machine can result. Below is the requirements for lifting:

12/10/07 Model LE10A Text 7

LE10A

Item Metric English

Machine

Weight W

Capacity, T

Length of the

Fork, L1

Distance between fork,

L2

1200

Kg

2 ton

1.5 meters

1.2 meters

2,646 lbs

2 ton

59.06“

47.24”

3.2 Preparation for installation

1. LEVELING:

It is important to install the machine so that the rear most portion of the main body table, feed table and roller bed is slightly raised. This prevents cutting fluid from flowing backward along the material to be cut, especially long material, and draining on the floor.

See Figure 3.3

Shim section B thicker than section A by 6mm. Shim section D thicker than section

E by 14mm. Horizontally, the table should be level or a little lower on the right.

FIGURE 3.3

If the table is higher on the right, recovery of the cutting oil will be slowed. The height of the roller table, which is factory-adjusted, need not be re-adjusted. Be sure the roller table is on the same level as the upper face of the feed table. Use a straight edge to determine this. The roller face should be level with the feed table or up to 0.12mm higher.

After the leveling is complete, check to make sure none of the steel sheets fail to touch the floor due to overload.

REMOVING BRACKET FOR TRANSPORTATION:

This bracket must be removed before operating machine. Keep the bracket for use in moving the machine in the future.

12/10/07 Model LE10A Text 8

This red bracket must be removed before the electrical is connected.

Figure 3.4

Warning!!!!

Failure to remove this bracket could cause damage to the machine and void the warranty.

INITIAL OILING:

Clean the machine thoroughly. Be sure anti-corrosion additives applied to sliding parts are removed with cleaning oil. When making a test run refer to the instructions on 8-1 for proper oiling.

Be sure the cutting fluid is full before operating, since it is usually drained before packing.

Use the oil gauge to check oil and cutting fluid level in the machine.

Warning!!!!!

Do not start the motor without oil; damage to the pump will result

.

OIL FILL

OIL GAUGE

WARNING!!!!

Only a licensed electrician who follows local and state laws is authorized to connect power to this machine.

The power supply cord will need to come out of the electric box located on the left side of the machine. Connect power source to the terminals on this cord. Once connected, turn the main power on (on the left side of machine). The green lamp should now be on.

Attach grounding terminal located beside the power cord to the factory ground line.

12/10/07 Model LE10A Text 9

CAUTION!!!!!

THE GROUND WIRE MUST BE CONNECTED; FAILURE TO CONNECT THE

GROUND WIRE CAN DAMAGE THE MACHINE AND VOID THE WARRANTY.

Next, make sure the emergency stop button is not activated and that item 4 on page 11 is to the right. Now press the LIFT button (see picture item 6 on page 11); lifting starts in one or two seconds after the emergency button is released, the head continues in the up direction as long as the button is held down.

If the head does not go up, immediately turn the power off, consult your electrician.

3.3 Inspections for Trial Run

After the saw has been installed, this inspection should be performed. The following checklist will locate any items that may need further attention.

Connect the power (only a qualified electrician)

Coolant fluid is full (only water based coolant)

Hydraulic oil level is full

Check for loose components, guards or panels

Tools and other materials left on saw, remove all tools that are not part of the machine.

3.4 Environment Requirement

1. Keep the machine on a dry, shaded place to prevent damage to the electrical components.

2. Storage condition:

Temperature: -20

°

C

75°

C

Humidity: 10% 90%

3. Operation condition:

Temperature: 0

°

C

55°

C

Humidity: 10% 90%

3.5 Dismantle

1.

2.

3.

4.

Turn the power OFF.

Disconnect the power supply.

Drain the hydraulic oil and coolant.

Reverse the procedure of installation for this machine.

12/10/07 Model LE10A Text 10

12

SECTION 4

4.1 Control Panel Description

13 14

15

1

2

3 4

5

6 7 8

9

1. POWER LIGHT

This light will come on when the circuit breaker is ON.

2. EMERGENCY STOP BUTTON

When this button is depressed, all machine operations will stop.

3. BLADE DRIVE BUTTON

When this button is depressed, the saw blade motor, cutting fluid pump and the chip removal system will begin to operate and the saw head begins to descend.

The saw head descends quickly until the quick approach arm makes contact with the work and thereafter, it will descend at the designated cutting speed.

NOTE: a. On the manual operation, if the front vise is not closed, the saw blade motor will not operate and saw head will not descend even if the button is depressed. b. With the rear vise stop position switch set at depressing this button will not operate the saw blade motor unless the rear vise is at the forward limit position. (Manual Operation)

10

11

12/10/07 Model LE10A Text 11

4. AUTO-MANUAL SELECTOR

For Continuous cutting, turn this selector to

(AUTO)

.

To individually operate each function, turn this selector to the hand picture

(MANUAL)

.

5. QUICK APPROACH BUTTON

When this button is pressed the head will move in the downward position until the quick approach arm touches the material.

6. RAISE BUTTON

When this button is pressed the blade motor stops and the saw head moves in the upward position. When the button is released the head will stop moving.

7. VISE CLAMP BUTTON

When this button is pressed and held, one vise will open and the other vise will close

8. VISE CLAMP SELECTION

When this selector is turned to the left (see picture to the right) with the automanual selector (4) turned to MANUAL the front vise opens and the rear vise closes; when the selector is turned to the picture (on the lower left of this paragraph) the rear vise opens and the front vise closes.

Rear vise opens

NOTE:

On the manual operation, if this selector is

Not turned to the “Rear vice open” the saw blade motor will not operate even if the drive button (3) is depressed.

9 & 10 REAR VISE FORWARD AND BACKWARD BUTTONS

When the forward button (9) is depressed with the auto-manual selector turned to

“MANUAL” the rear vise moves forward; when the backward button (10) is depressed, the rear vise moves backward. The rear vise stops moving when the button is released.

11. CUTTING FLUID PUMP SWITCH

When this switch is set at “|” the cutting fluid pump operates and the cutting fluid will be on even though the saw blade motor is not in operation. Use this switch when removing saw chips with the cutting fluid (without the blade operation).

12. CUTTING PIECE COUNTER

This counter is used to press the number of cuts required on the automatic operation. When the counter reaches the preset number, the machine automatically stops. To activate the counter, set the counter ON/OFF witch at “| “

13. REAR VISE STOP POSITION SWITCH

Front vise opens

12/10/07 Model LE10A Text 12

For bundle cutting, set this switch to the multiple picture, so that the rear vise remains at the forward limit position. For single cutting, set this switch to the single picture, so that the rear vise stays at the backward limit position.

NOTE: When the switch is set for bundle cutting, the blade will not start unless the rear vise is at the forward limit position.

14. FEEDING-TIMES PRESET COUNTER

When a cutting length of more than 23” (600mm) is required, preset the required number of feeds on this counter. The counter is capable of being set to the maximum of nine feeds. 9*15.74=141.66 (9 x 400mm = 3600mm)

15. WORKING LIGHT

Turn this knob to the left to have the work light on, turn the knob to the right to have the work light off.

16. BLADE SPEED ADJUSTING BUTTON (Not Shown)

The saw blade speed suited for the work piece to be cut can easily be founded by depressing these buttons. Use the speed indication as a guide for selecting the saw blade speed.

12. CUTTING PRESSURE CONTROL & FLOW CONTROL (Not Shown used on

LE13A only))

When this control is turned clockwise, the cutting force of the saw blade increases; when it is turned counterclockwise, the cutting force decreases. Align the pressure control with the zone which corresponds to the material on the work piece to be cut.

4.2 Blade change

1. Select the saw blade best suited for the work piece to be cut. Size and shape of the work piece and type of material should all be considered when selecting the saw blade to be used.

2.

Saw blade change

.

Warning!!!!!

Always wear gloves, safety glasses and other protective equipment to prevent injury when changing the saw blade. The power must be locked out before changing the saw blade.

a. Turn on the main power on the left side of the machine. b. Press the hydraulic ON button to start the hydraulic pump motor.(item

6 page 11) c. Turn the auto-manual selector to manual position (the hand item 4 page 11) d. Press the raise button (item 6 pages 11) to raise the saw head until it is above the vise. e. Push the emergency stop button and turn off the main power on the machine.

12/10/07 Model LE10A Text 13

Warning!!!!!

Never change the blade with the power on.

f. Remove the blade safety cover. g. Open both the drive wheel and idle wheel covers. h. Turn both the left and right insert lock levers counter clockwise to loosen the inserts. i. Turn the blade tension selector to “

LOOSEN

” to move the driven wheel toward the idle wheel, this will loosen the blade. j. Remove the band saw blade. k. Place the saw blade onto both the drive and idle wheels. l. Insert the saw blade into both the left and right inserts so that the back edge of the saw blade touches the back-up tip of each insert. m. To properly position the saw blade on the drive wheel, insert so that the back edge of the saw blade makes contact with the flange of the drive wheel. n. Turn the blade tension handle clock wise to tighten the blade (about ten clicks)

3. Adjust the position of the wire brush. a. Loosen the lock lever for the wire brush case. b. Manually move the brush case so that the wire brush contacts the saw blade properly.

4. Properly position the blade guide according to the diameter (or the width) of the work piece to be cut. a. Pull the left insert lock lever down to loosen the insert. b. Loosen the lock lever of the blade guide, and manually move the blade guide and align the indicator of the blade guide with the scale of the guide bar, depending upon the size of the work piece. c. After adjusting the blade guide position tighten the lock lever of the blade guide. d. Push the insert lock lever up to tighten the insert.

MANUAL OPERATION

4.3 Manual Operation Instructions

1. Properly place the work piece on the work feed table. e. Depress the raise button to raise the saw head until it is at the highest position. f. Manually disengage the pawls from both the front and rear vise racks, and open the front and rear vise completely. g. Loosen the lock handles of the vertical roller guides to completely open the vertical roller guides. h. Set the rear vise stop position switch so that the rear vise stays at the backward limit position.

12/10/07 Model LE10A Text 14

i. Carefully place the work piece onto the work feed table so that is extends approximately 2.5” (60mm) beyond the rear vise.

2. Determine the proper position of the work piece for cutting. j. Turn the vise clamp selector to “rear vise open”. k. Manually move the rear vise until it pushes against the work piece.

Then engage the pawl with the rack. l. Turn the vise clamp selector to “front vise open”, so that the work piece is securely clamped with the rear vise. m. Push the vertical roller guides against the work piece and tighten the guides with the lock handles. n. Depress the rear vise forward button until the rear vise moves to the forward limit position. o. Manually move the front vise until it pushes against the work piece then engage the pawl with the rack. p. Turn the vise clamp selector to “rear vise open” so that the work piece is securely clamped with the front. q. Depress the rear vise backward button until the rear vise moves to the backward limit position. r. Turn the vise clamp selector to “front vise open”. s. Lower the saw blade by depressing the quick approach button, until the quick approach feeler is just above the work piece. t. Depress the rear vise forward button to move the work piece forward until the cutting position of the work piece is aligned with the saw blade. If necessary, press the rear vise backward button so that the work piece is accurately positioned. u. After properly adjusting the position of the work piece, turn the vise clamp selector to “back vise open”, so that the work piece is securely clamped with the front vise.

Warning!!!!!

Always turn the machine power off before changing the blade speed. The power must be locked out before changing the blade speed.

4.4 Blade speed change

3. Adjust the saw blade speed. v. There is a handle just to the right of the motor, when loosened the motor can be moved up and down. Move the motor up and move the belt to the desired speed. w. It is necessary to properly adjust the saw blade speed, depending upon the material and shape of the work piece to be cut. x. The blade drive uses a V-Belt: A-47 (60 Hz) and A-48 (50 Hz).

Blade speeds are 27, 40, 54, 68 and 80m/min

12/10/07 Model LE10A Text 15

When the blade drive button is pressed, the cutting fluid pump begins to operate causing the cutting fluid to flow out the coolant lines. Adjust the cutting fluid flow with the fluid controls so that the proper amount of fluid will flow from the blade inserts, the quick approach and the wire brush case.

The flow of cutting fluid should be adjusted, depending upon the material.

Saw chips which are fine and curve require an increase in the amount of cutting fluid.

Saw chips which are fine and grained require a reduction in the amount of cutting fluid.

5. Adjust both the cutting force and the descending speed of the saw blade and begin cutting the work piece. a. Turn the cutting pressure control to the zone corresponding to the material (or shape) of the work piece to be cut. When the work piece is large (or difficult to cut), turn the control to the right end of the corresponding zone. When the work piece is small (or easy to cut), turn the control to the left end of the corresponding zone. Always turn the cutting pressure control to the point most suitable for the work piece to be cut. b. Slowly turn the flow control clockwise from zero to the point just before the blade begins to vibrate. As the flow control is turned, the saw blade begins to descend and the actual cutting of the work piece begins. After completion of the cutting, the saw blade stops at the lower limit position (only LE13A).

12/10/07 Model LE10A Text 16

AUTOMATIC OPERATION

4.5 Automatic operation instructions

1. Cut the edge of the work piece by using the same procedures as those described under the Manual Operation Section above.

2. Press the raise button to raise the saw blade until the quick approach feeler is approximately 10mm (0.4 in) above the work piece.

3. Turn the vise clamp selector to open the front vise.

4. Press the rear vise forward button until the work piece moves forward to the required cutting position.

5. Turn the vise clamp selector to clamp the work piece with the front vise.

6. Press the rear vise forward button until the rear vise moves to the forward position.

4.6 Part length set up

How to set the required cutting length on the cutting length counter

.

WARNING!!!!!

Do not change the numerals (number of feeds) on the feeding times preset counter during operation.

a. Loosen the hand-wheel lock screw. b. Turn the hand-wheel to set the required cutting length on the cutting length counter.

NOTE

:

1. When setting the cutting length, be sure to turn the hand wheel clockwise past the desired length, then turn it counter clock wise to the desired length to prevent error due to the backlash. c. Tighten the hand-wheel lock screw

7. If the required cutting length exceeds the maximum cutting length of 23.6 inches

(600mm), feed the work piece as many times as necessary, using the feed times preset counter (item 14 page 11). For example: if a cutting length of 31.5 inches (800mm) is required. a. Divide 31.5 by 2 =15.75 b. This will be the length of cut needed to make 31.5 inches.

12/10/07 Model LE10A Text 17

c. Set the feed times counter at 2. d. Now the material will be pushed forward two times, each time moving the material forward 15.75 inches.

NOTE:

1. The cutting length preset device is factory adjusted to compensate for the set width of the saw blade.

2. When the feeding times preset counter is not in use, set it a

1.

3. The feeding times preset counter is capable of feeding the work piece nine times, up to a maximum cutting length of

212.5 inches (5400mm).

8.

How to set the number of required cuts on the cutting piece counter

.

Warning!!!!!

Do not change the number of cuts during cutting operation.

a. Set the cutting piece counter switch (item 12 page 11) at “o” (OFF). b. Press the reset button (on the bottom of the readout) to reset all white numerals to zero. c. On the top of this read out there are five black buttons, each button is a different digit. Push these buttons to desired amount of pieces to be cut. d. After the number of cuts has been set. e. Set the counter ON/OFF switch at “| “(ON).

9. Turn the auto-manual selector to AUTO and press the blade drive button. The blade will run and the automatic operation will begin.

10. After the required number of cuts have been completed, the saw blade will stop in the lower position and all machine operations will stop.

NOTE:

1. During automatic operation, shifting the auto-manual selector to MANUAL will cause the saw blade to stop in the lower position, after completion of the cutting operation on which the selector was shifted.

4.7 How to install bundle attachments

How to use the bundle cutting attachments

WARINING!!!!!

Never install the bundle attachments while the machine is in operation. This machine electricity must be locked out before installing bundle attachments.

12/10/07 Model LE10A Text 18

WARNING!!!!!

Keep fingers clear of vise, personal injury could occur.

This multi-vise is used when bundle cutting is performed. To perform bundle cutting, proceed as follows:

1. Install the stud bolts on the front and rear vises and position the multi-vise on the front and rear vises.

2. Connect the multi-vise hoses to their quick connectors at the front and rear vise cylinders.

3. Attach the bundle cutting fence to the work tray. The fence is designed to prevent the cut pieces from spreading out across the work tray. Adjust the width of the fence so that it equals the width of the bundle.

4. Set the switch to bundle cutting (item 13 pages 11).

5. Position the work piece for bundle cutting.

Allowable clamping width: 7 inches (180mm)

6. Roughly align the center of the multi-vise cylinders with the center of the work pieces to be cut and tighten the lock nuts.

7. Turn the multi-vise handles so that there is 1/4” of clearance between the work retaining plate and the material.

8. For subsequent operations, refer to the instructions for manual operation and automatic operation, and perform the bundle cutting.

EXAMPLE:

CORRECT

INCORRECT

12/10/07 Model LE10A Text 19

BLADE BREAK IN OPERATION

When a new saw blade is used, be sure to first break in the blade before using it for actual extended operation. Failure to break in the blade will shorten the life of the blade and result in less than optimum efficiency. To break in the blade, proceed as follows:

1. Lengthen the time required for cutting 2-3 times that of normal.

2. The break-in operation can be considered sufficient if all unusual noises or metallic sounds have been eliminated. (For instance, to completely break in the blade, a minimum of five complete cuts of a 200mm (7.9 in) diameter work piece will be required.)

3. After the break-in operation has been completed, return the blades speed and descending speed to their normal settings

12/10/07 Model LE10A Text 20

12/10/07 Model LE10A Text

4.8 Cutting Data

21

Description

Hydraulic Oil

Gearbox Oil

Drive wheel

Idle Wheel

Blade Tension Device

Worm Shaft

Cutting Fluid

6.2 Lubrication

Lubricant

DTE 24 Hydraulic oil

80/90 Synthetic gear lube

Shell Alvania EP Grease 2 or Mobilplex 48

Shell Alvania EP Grease 2 or Mobilplex 48

Shell Alvania EP Grease 2 or Mobilplex 48

Shell Alvania EP Grease 2 or Mobilplex 48

Water based coolant

Section 7 – MAINTENANCE

7.1 Periodic Maintenance

After use for the day, clean out saw chips that have accumulated in the machine. To do this, set the cutting fluid pumps switch at “|”and wash saw chips away with the discharging cutting fluid.

Before beginning operation for the day, perform the following maintenance operations:

1. Check the hydraulic oil level, adding oil if necessary.

Grease Fittings

2. Check the cutting fluid level, adding fluid as necessary. If the fluid appears contaminated or deteriorated, drain and replace it.

3. Check the saw blade to ensure that it is properly positioned on both the drive, idle wheels and in the left and right inserts.

4. Check the wire brush for proper contact with the saw blade. If it is worn, replace.

5. Check the urethane rope (used on the idle wheel) for wear. If they are broken, replace.

6. Lubricate the following points: a. Front vise slide plates b. Rear vise slide plates c. Feed cylinder guide shaft.

7.2 Six Month Maintenance

Check the following once every six months:

1. Clean the filters in the cutting fluid tank.

2. Replace the transmission oil (recommended oil: 80/90 synthetic) after the first three months or 600 hours of operation and every six months or 1200 hours of operation (whichever occurs first) thereafter.

3. Replace the hydraulic oil.

12/10/07 Model LE10A Text 22

Machine has power but will not start cut in Semi-Auto mode

Vibration during cutting or excessive noise

Yellow warning light flashes

Material will not feed

Blade cuts crooked or unsure

Hydraulic pump runs when head button pushed but machine will not run

Will not cut in automatic mode

Will not cut to length set on digital readout

Blade Stalls in cut

SECTION 8 – TROUBLE SHOOTING CHART 8.1

Use of blade with incorrect pitch.

Failure to break in blade.

Excessive blade speed.

Insufficient blade speed.

Call blade supplier.

Perform break-in (first 12 cuts 1/3 slower than normal cut rate).

Reduce speed.

Increase blade speed.

Excessive chip load (blade loads up with chips, too fine).

Wire chip brush worn/improperly adjusted.

Blade improperly held by insert.

Carbide pads too loose.

Reduce load cut slower or coarser blade, adjust chip brush for cleaning blade.

Readjust or replace (just touch blade).

Roller table in true alignment with feeder unit.

Belt slipping stalling blade.

Guide arms set too far apart.

Limit switches on doors and pulley

(open).

Fuse blown in machine or wall service.

Insufficient blade tension.

Tighten the 2 knurled knobs on guide arms as tight as possible to reduce pad clearance, or replace.

Not set straight to machine feed system.

Sits too high or low to the feed roller.

Adjust

Belt is loose on pulley. Loosen motor lock handle, push down on motor and tighten. Replace belt is worn.

Move guide arms closer together. Use indicator marks on guide arm rail for proper spacing.

Check all doors are closed. Check limit adjustment, make sure cotter pin is not interfering with limit activation.

Check and replace fuses as needed.

Out of stock or end of program Estop pushed in.

Blade too narrow/too wide (out of capacity) too long.

Coolant mixed incorrect, or no coolant used.

Front vise not closed.

Zero parts entered in piece counter or zero strokes.

Not in automatic mode. Reset piece counter bottom button.

Part moved during cut.

Movement detector on idle wheel out of adjustment.

Length set up wheel backed up during set up.

Tighten blade a half to a full turn beyond when tensioner lock ring clicks.

Press reset button on counter. Make sure you have stock. Reset number of pieces in counter check E-stop.

Use only blade within cap. .035-.045 thickness. Use blade or correct length & width.

Mix coolant to manufactures specs. (10-

1) Increase coolant flow.

Jog the vise selector switch and bump vise close button. This will close vises.

Reset # in piece counter. Must have at least 1 stroke entered. Out of stock limit tripped. Feed limit failure.

Reset piece counter. Check that machine is in automatic cycle. Vises are closed.

Check clamping of part. Use bundle cutting option for multiple piece cutting.

Adjust red LED illuminates as wheel passes by it.

Set to length without going beyond length, and backing up. Backlash is screw will cause

12/10/07 Model LE10A Text 23

8.1 Minor trouble shooting

Symptom

Hydraulic pump motor does not run even though hydraulic on button is depressed.

Saw blade motor does not run even when blade drive button is depressed.

Probable Cause

a. Power line disconnected b. Circuit protector OFF c. Thermal relay activated d. Loose terminal retaining screw e. Out-of-stock limit switch activated a. Terminal relay activated b. Vise clamp selector set at c. Rear vice stop position switch set at

Corrective Action

a. Connect b. Turn ON c. Push reset button d. Tighten e. Set vise clamp selector at a. Push reset button b. Set vice clamp selector at c. Move rear vise to its forward limit position

(when performing bundle cutting) d. Set rear vise stop position

Rear vice does not move forward or backward even when its forward or backward button is depressed.

Front or rear vise does not open or close even a. Auto-Manual selector set at b. Saw head not at its UP position a. Auto-Manual selector set at switch at (when performing single cutting) a. Set auto-manual selector b. Raise saw head to its UP position a. Change auto-Manual selector setting. though vise clamp selector is manipulated

For problems not indicated on the above chart, refer to the electrical circuit and hydraulic circuit diagrams (provided inside the electrical enclosure).

For original Dake replacement parts contact us at:

DAKE Division of JSJ

724 Robbins Road

Grand Haven, MI 49417

Phone: 1-800-937-3253 616-842-7110

Fax: 1-800-846-3253 616-842-0859

E-mail: [email protected]

[email protected]

Web: www.dakecorp.com

12/10/07 Model LE10A Text 24