500DS Instruction M anual

500DS Instruction M anual
Instruction Manual
500DS
Serial No: 593-13159 to
Band Sawing Machine
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.
OPERATOR'S INSTRUCTION MANUAL
METAL CUTTING BAND SAW
MODELFIRST SERIAL NO.
LAST SERIAL NO.
500DS593-13159
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 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 1-888-362-5572
For general information, visit our web site at: www.doallsawing.com
DoALL SAWING PRODUCTS
2375B TOUHY AVENUE
ELK GROVE, ILLINOIS 60007 U.S.A.
The following registered trademarks of the DoALL Company are used in this manual:
DoALL, Imperial Bi-Metal, Kleen-Kool, and Tensigage.
PRINTED IN U.S.A.
i
PB-542.4 (5-13)
TABLE OF CONTENTS
MACHINE DIMENSIONS
LUBRICATION
Floor Plan ..................................................... 1
Top View ..................................................................2
Front View ...............................................................3
Lubrication Chart .....................................................16
Lubrication Diagrams ..............................................17
MAINTENANCE
MACHINE FEATURES
Saw Guide Insert Replacement ...............................18
Drive Belt Removal or Replacement .......................18
Band Tension Adjustment ........................................19
Flood Coolant ..........................................................19
Chip Removal ..........................................................19
Replacing Vise Bed Wear Plate ..............................19
Bandwheels .............................................................19
Counterbalance Spring ............................................20
Electric Motors .........................................................20
Mist Lubricator .........................................................20
Front View .................................................... 4
Rear View ................................................................5
INSTALLATION
Location ...................................................................6
OSHA Notice! ..........................................................6
Unpacking ...............................................................6
Cleaning ..................................................................6
Lifting .......................................................................6
Floor Installation ......................................................6-7
Electrical Installation ................................................7
Plant Air Installation (If Required) ............................7
Preparation for Use .................................................7
TROUBLE SHOOTING ...................................21-24
ACCESSORIES
Roller Stock Conveyors ...........................................25
Vertical Guide Rollers (Conveyors) .........................25
Worklight ..................................................................25
Laser Line Option ....................................................25-26
Mist Lubricator .........................................................26
Vertical Hold Down ..................................................26-27
OPERATION
Safety Precautions ..................................................8
Using the Job Selector ............................................8
Cutting Capacity ......................................................8
Machine Controls ....................................................9-10
Saw Band Preparation ............................................10-11
Saw Guide Arm Adjustment .....................................12
Work Height Adjustment ..........................................12
Saw Head Positioning for Angle Cuts ......................12
Vise jaw Adjustment ................................................ 12 Flood Coolant System .............................................13
Dry Cutting ..............................................................13
Band Brush and Chip Removal ...............................13-14
Typical Operation Procedures .................................14-15
How to read your serial number:
ii
MACHINE DIMENSIONS
INCHES: ± .03
(MILLIMETERS: ± 1 mm)
Note: Additional space will be required
for conveyors, etc.
FLOOR PLAN
1
MACHINE DIMENSIONS (Continued....)
INCHES: ± .03
(MILLIMETERS: ± 1 mm)
TOP VIEW
2
MACHINE DIMENSIONS (Continued....)
INCHES: ± .03
(MILLIMETERS: ± 1 mm)
FRONT VIEW
3
MACHINE FEATURES
FRONT VIEW
4
MACHINE FEATURES (Continued....)
REAR VIEW
5
INSTALLATION
LIFTING
All the "left", "right", "front", "rear" directions
in this manual are as viewed by the operator
when facing the machine with the drive motor
is on the left end of the head beam.
LOCATION
1.
Position the machine to allow adequate space for all
your sawing needs with maximum convenience.
2.
Locate the machine to provide sufficient clearance
for: (a) Material loading and unloading; (b) All
door openings; (c) Head elevation and head swivel;
(d) Maintenance and lubrication procedures;
(e) Operation of the any supplied machine
accessories.
3.
Approximate floor dimensions for the machine are
shown on pages 1, 2 and 3.
4.
Accessories such as roller stock conveyors will
require additional working area.
Never lift the machine by its sawing head.
1.
A fork lift truck is recommended to lift the machine to
its permanent location. Net weight is approximately
2400 pounds (1088.6 kg).
2.
Spread the forks to fit into the pockets located in the
rear of the base to provide even machine weight
distribution and to protect against frame stress.
OSHA NOTICE!
OSHA Regulation No. 1910.212 (5B).
Machines designed for a fixed location shall
be securely anchored to prevent walking or
moving.
Fork Lift Pockets (Rear View).
3.
UNPACKING
1.
2.
3.
FLOOR INSTALLATION
The machine and other parts and supplies were
fastened to a wooden skid before shipment.
1.
Before placing the machine down, install one (1)
M16 x 70 mm leveling screw and nut into each
base foot pad. Then: (a) Adjust the four (4) leveling
screws to extend an equal distance through the
mounting pad - approximately one-half inch (12.7
mm); (b) Tighten the jam nuts; (c) Just before
touching the floor, place a foot casting under each
leveling screw; (d) Now lower the machine in the
desired location.
2.
Remove the bracket or strapping holding the saw
head to the base.
3.
Place a machinist's level on the vise bed. Then
adjust the leveling screws until the vise base wear
plates are level and weight of the machine is
resting evenly on all mounting pads.
4.
Adjust the two (2) leveling screws by the electrical
box enclosure to raise the machine slightly to allow
coolant to drain towards the open end of the coolant
pan and drop into the reservoir.
DO NOT remove the red metal bracket (if
supplied) or the strapping holding the saw
head to the vise base until the machine has
been lifted and positioned at its permanent
location.
Remove all other protective covers, strapping,
crating, etc. Then: (a) Remove the bolts or screws
attaching the machine to the shipping skid.
Inspect the machine for broken or damaged parts.
Refer to this manual's inside front cover for damage
claim procedures.
CLEANING
1.
Accessory roller stock conveyors can be lifted into
position using a fork lift or other means that provides
adequate safety precautions.
If necessary, use solvent to remove the rustpreventative coating applied to the machine's
exposed bare metal surfaces before shipping.
6
FLOOR INSTALLATION (Continued....)
5.
2.
Install anchoring screws through the base pad holes
next to the leveling screw locations.
Relocation Procedures
1.
2.
Should machine relocation become necessary at a
later date, it will be extremely important to protect
the frame against undue stress. Before moving,
reinstall the shipping bracket connecting the saw
head to the base.
Follow the procedures in the "Lifting" section
previously stated for moving and lifting the machine
to its new location.
Bring the incoming line circuit leads to the
disconnect switch terminals in the electrical control
box enclosure attached to the right side of the
machine base. Refer to the furnished electrical
schematic, if necessary.
2.
Turn the electrical supply and machine disconnect
switch to "ON".
If required, fill the coolant and hydraulic reservoirs
with fluid recommended in the Lubrication Chart.
Be sure that all other points listed in the Lubrication
Chart have been checked and/or serviced.
2.
All covers and guards must be in place and all doors
must be closed.
3.
See the "OPERATION" section later in this
manual on how to operate the workstation
controls such as starting the hydraulics, etc.
3.
Start the hydraulics. Then raise the saw head. If
the hydraulic motor rotates correctly, the saw head
will now raise from the full down position.
4.
If the saw head does not raise, it means that the
hydraulic motor’s rotation is reversed (this can
be verified by observing motor rotation). Motor
rotation must be according to the arrow on the
pump body. Hydraulic system operation cannot
be maintained if the saw head is not raised.
5.
If hydraulic pump motor rotation is reversed: (a) Turn
the disconnect switch to "OFF" and remove power
at the source of electrical supply; (b) Interchange
two (2) of the L1, L2, or L3 leads to the disconnect
switch; (c) Restore power and perform Step 3
again.
PLANT AIR INSTALLATION (If Required)
1.
1.
Electrical installation must be made by
authorized electrical maintenance personnel!
1.
DO NOT exceed 90 psi (6.2 bar or 6.3 kg/
cm²).
PREPARATION FOR USE
ELECTRICAL INSTALLATION
Plant air is connected at the air filter on the lower
left side of the base. Air pressure should be in the
range of 80 to 90 psi (5.5 to 6.2 bar or 5.6 to 6.3
kg/cm²).
Plant air is required to operate the optional mist
lubricator system.
7
DO NOT defeat the purpose of any guard
or safety devise. They are there for YOUR
PROTECTION!
The operator must understand the safety rules
and operation of the machine and has read the
instruction manual BEFORE operating the machine.
OPERATION
SAFETY PRECAUTIONS
Warning Label - READ and UNDERSTAND.
USING THE SAW BAND SELECTOR
CUTTING CAPACITY
1.
1.
Your machine is designed to cut rectangular stock
up to 14 inches (355.6 mm) high and 20 inches
(508.0 mm) wide. It will also cut round stock up to
15 inches (381.0 mm) in diameter.
2.
With the saw head adjusted for 60° cutting, the
machine will saw rectangular stock up to 14 inches
(355.6 mm) high and ten (10) inches (254.0 mm)
wide. It will also cut round stock up to ten (10)
inches (254.0 mm) in diameter.
3.
With the saw head adjusted for 45° cutting, the
machine will saw rectangular stock up to 14 inches
(355.6 mm) high and 14 inches (355.6 mm) wide.
It will also cut round stock up to 15 inches (381.0
mm) in diameter.
4.
Vise bed capacity is approximately 1800 pounds
(816.5 kg) evenly distributed with NO impact.
Refer to the Saw Band Selector label, located on
the drive motor cover, for information about blade
choice and pitch, and suggested band speed for
stock type and thickness.
Saw Band Selector.
2.
For example, to cut low carbon steel which is two
(2) inches (50.8 mm) thick, you would choose a saw
band with 5-8 pitch, and set the band speed for 275
fpm (84 m/min).
8
MACHINE CONTROLS
1.
Both electrical and hydraulic controls are located on
a remote console. The console can be positioned
anywhere (within the conduit length) that gives the
operator a clear view of the cutting area.
4.
Laser (Optional). This control turns the optional
laser line generator "OFF" and "ON".
•
See the "ACCESSORIES" section for information
on the use of this option.
5.
Saw Head Control. This selector switch with "UP",
"HOLD", and "DOWN/AUTO" settings regulates the
saw head's vertical movement.
•
Saw head travel during automatic cycle can be
stopped by: (a) Moving the Saw Head Control
selector to "HOLD" (saw head fall will stop but the
hydraulic and band drive motors will continue to run);
or (b) Turning the Operation selector to "MANUAL"
(the saw head will stop if traveling downward).
6.
Head Down Rapid. Pushing and holding this button
(during manual operation only) permits the saw head
to move downward when: (a) The band drive motor
is not running; (b) The Saw Head Control selector
is at the "DOWN/AUTO" setting.
7.
Coolant. Four position selector switch with "AUX",
"OFF", "BAND ON" and "ON" settings.
•
(a) "BAND ON" allows the flood coolant system to
operate when the band drive motor is running; (b)
"ON" allows the flood coolant system to operate
without the band drive motor running; (c) "AUX" is
used for the optional cutting lubrication system; (d)
"OFF" turns off either system.
8.
Hydraulic Start/Stop. Push the upper green
portion of the button to start the hydraulic pump
motor. Push the lower red portion of the button to
stop the hydraulic pump motor.
9.
Band Speed. Band speed is infinitely variable
between 50 and 400 fpm (15 to 120 m/min.). Turn
the knob clockwise to "INCREASE" the band
speed; counterclockwise to "DECREASE" it.
Electrical Controls
Electrical Controls.
1.Vise. This selector switch with "OPEN", "HOLD"
and "CLAMP/AUTO" settings regulate opening and
closing of the vise jaw.
•
When the saw head is completely raised, moving
the Vise selector to "OPEN" causes the vise jaws
to open completely.
2.
Operation. This selector with "MANUAL" and
"AUTO" settings determines the machine's operating
mode.
•
Placing the Operation selector to "MANUAL" will
stop all machine functions at the head down position
following the completion of each cut.
•
3.
Placing the Operation selector at "AUTO" permits
a full cycle mode following the completion of cuts
-- the band drive motor stops, but the hydraulics will
continue running to permit the saw head to rise until
the head clear position is reached.
10.
Band Start/Stop. Push the upper green portion
of the button to start the band drive motor. Push
the lower red portion of the button to stop the band
drive motor.
Be sure the saw band is properly tensioned
before pushing this button.
9
Change band speeds ONLY when the band
drive motor is running. Be sure the saw band
is correctly tensioned before starting the band
drive motor.
Emergency Stop. This red mushroom head button
turns off all functions of the saw. This button latches
down when pushed and must be released or reset
before the machine can be started. Rotate the
button head clockwise to release or reset.
MACHINE CONTROLS (Continued....)
3.
Hydraulic Controls
Work Height Setting Mechanism. This mechanism
allows the head to rise only high enough to clear
the work being cut. See "Work Height Adjustment"
later in this section.
SAW BAND PREPARATION
Recommended Saw Band
1.
The machine is shipped with a saw band installed.
The saw band recommended for use with this
machine is 197 inches (5003.8 mm) long, 1-1/4 inch
(31.7 mm) wide, and has a 0.042-inch (1.67 mm)
gage thickness.
Blade Guards
1.
Hydraulic Controls.
1. 2. Feed Force. This valve regulates the amount of
pressure being placed by the saw band against
the workpiece. Turn the knob counterclockwise
to “INCREASE” the pressure; clockwise to
“DECREASE” it. The valve’s lower locking knob
helps maintain the setting.
The following blade guards are positioned to provide
operator safety while the machine is running:
(a) A top guard located above and between the
bandwheel doors; (b) A guard mounted between
the lower left saw guide arm and the left bandwheel
door; (c) A guard assembly between the lower
right saw guide arm and the right bandwheel door.
Blade guards (b) and (c) may be removed to help
facilitate saw band changing procedures.
DO NOT defeat the purpose of any guard
or safety devise. They are there for YOUR
PROTECTION!
Saw Guide Insert Adjustment
1.
Feed Rate. This valve regulates the saw head’s
descending rate. Turn the knob counterclockwise
to “INCREASE” the velocity; clockwise to
“DECREASE” it.
Adjustment screws for the saw guide inserts are
located on the lower portion of each saw guide
arm.
Other Controls
1.
2.
A power Disconnect Safety Switch is located on
the front of the electrical box enclosure.
Do not try to open the control box unless this
switch is turned off. Always disconnect power
to the machine before opening the electrical
control box.
Head Pivot Lock. Located below and to the left of
the discharge tray, this lock handle is used to secure
the saw head at the desired cutting angle. Turn the
clamping handle counterclockwise to "UNLOCK"
the saw head; turn the clamping handle clockwise
to "LOCK" the saw head in place.
Saw Guide Detail.
10
SAW BAND PREPARATION (Continued....)
2.
1.
4.
Apply correct band tension by turning the band
tension handwheel clockwise. Then: (a) Remove
the new saw band's protective cap; (b) Turn the saw
guide insert adjustment screws clockwise until tight
(do not over tighten); (c) Turn each adjustment
screw back counterclockwise a 1/4 turn.(d)
Reposition or mount the band brush and reinstall
both blade guards; (e) Close both bandwheel
doors.
Always use extreme care when handling saw
bands. Wear gloves.
Push the Band Stop button. Then: (a) Raise the
saw head to a position where there is space under
the saw guide arms and clears the vise clamp
cylinder. (b) Turn the head pivot clamping handle
clockwise to "lock" the saw head in place; (c) Turn
the band tension handwheel counterclockwise
(this moves the idler bandwheel to the right and
loosens band tension).
2.
Open the right and left bandwheel doors. Then: (a)
Remove or reposition the band brush, if necessary;
(b) Loosen and remove the right and left blade
guards; (c) Loosen the saw guide inserts by turning
both adjustment screws counterclockwise.
3.
Place your gloved hand on the non-cutting edge of
the saw band between the saw guide arms. Then:
(a) Push the saw band downward to free it from the
saw guide inserts; (b) Grasp the saw band near the
idler bandwheel and remove it, then remove the saw
band from around the drive bandwheel; (c) Work the
saw band's upper strand through the upper blade
guard above the saw guide arms; (d) Move the saw
band down and under both saw guide arms.
Twist the saw band 90° so that its teeth between the
saw guide arms point down and to the right. Then:
(a) Insert the saw band into the saw guide inserts
and pull up against the back-up bearing; (b) Check
the saw band's position around the bandwheels (its
back edge must rest against each bandwheel's rear
flange).
Follow these adjustment procedures: (a) Turn the
adjustment screw clockwise until the fixed and the
movable inserts are tight against the saw band (do
not tighten further); (b) Turn the adjustment screw
back counterclockwise a 1/4 turn.
Saw Band Removal
3.
Band Tension Handwheel
1.
Turn Handle to Set Band Tension.
2.
Immediately dispose of the old or broken saw
band. If possible, recoil the saw band into the
original holder before scrapping it.
Saw Band Installation
1.
2.
Band tension is applied by turning the handle which
protrudes from the saw head's right side. Turn the
handwheel clockwise to "increase" band tension;
counterclockwise to "decrease" it.
Always use extreme care when handling saw
bands. Wear gloves.
Remove the old or broken saw band as described in
the previous section. Clean metal chips and other
foreign materials and debris from around the saw
guides and both bandwheels.
3.
Form the saw band into one large loop. Then:
(a) Slip the saw band under the saw guide arms
and into approximate position for placement; (b)
Work the saw band into the upper blade guard. (c)
With the saw band's teeth facing towards you, slip
the looped saw band around the drive and idler
bandwheels.
11
Correct band tension for the machine's standard 11/4 inch (31.7 mm) wide by 0.042-inch (1.067 mm)
gage saw band is 4.0 units or 30,000 psi (2115 kg/
cm²) measured by a DoALL Tensigage. This tension
setting is established when the factory preset stop
bolt contacts the large washer. An escutcheon near
the band tension handwheel describes the washer
to stop bolt relationship in a setting of 30,000 psi
(2115 kg/cm²).
DO NOT start the band drive motor unless the
saw band has been properly tensioned.
Important factors which influence band tension
settings are the size of stock to be cut and desired
band life. General rules-of-thumb are: (a) Lower
tensions will increase saw band life; (b) Greater
tension is required as spacing is increased between
the saw guide arms; (c) Higher band speeds require
greater tension.
SAW GUIDE ARM ADJUSTMENT
SAW HEAD POSITIONING FOR ANGLE CUTS
1.
1.
2.
From the rear of the machine, the right saw guide
arm is fixed. The left saw guide arm can be adjusted
as follows to accommodate varying stock widths: (a)
Loosen the left saw guide insert adjustment screw
by turning counterclockwise; (b) Loosen the left
arm's locking knob by turning it counterclockwise;
(c) Move the arm along the slide bar until it is as
close as possible to the stock without making
contact with the stock when the head is raised or
lowered; (d) Turn the locking knob clockwise to
tighten; (e) Tighten the insert adjustment screw as
previously instructed.
2.
DO NOT move the left saw guide arm while
the saw band is running.
The best cutting results are generally obtained
when the saw guide arms are positioned as close
as possible to the stock.
The capacities of the machine are reduced
when angle cutting.
The 0°, 45° and 60° angle positions have been
preset at the factory. If adjustment becomes
necessary, it can be made with the screws and
jam nuts located on the front and back of the pivot
weldment.
VISE JAW ADJUSTMENT
WORK HEIGHT ADJUSTMENT
1.
To position the saw head for angle cutting from
0° to 60°: (a) Loosen the head swivel clamping
handle, located next to the electrical box enclosure
by turning it counterclockwise; (b) Pivot the saw
head to the desired angle as indicated by the pointer
located below the handle; (c) Turn the handle
clockwise to "LOCK" the saw head in place.
The work height mechanism works in conjunction
with the head clear proximity switch (1 PRS) to
assure that the saw head has raised sufficiently
above the stock so manual stock positioning can
be accomplished safely.
1.
The movable vise jaw is mounted on a bearing rail
so it can be adjusted to the "inboard" side (the jaw
is in front of the saw band) or the "outboard" side
(the jaw is behind the saw band) depending on the
location of the saw head.
2.
The vise jaw must be on the opposite side of the
saw band to the saw head angle position. The vise
jaw can be used on either side of the saw band
when cutting at 0º ("Inboard" side is preferred
because it is closest to the saw band).
The saw head must be raised high enough
to clear the movable vise jaw when clamped
and vise selector switch should be in "OPEN"
setting before positioning is permitted.
Vise Jaw Adjustment.
Work Height Adjustment.
2.
To adjust, lower the saw head all the way. Then:
(a) Loosen the lock knob; (b) Rotate the adjustment
flag to the desired work height indicated with the
pointer; (c) Tighten the lock knob.
3.
There is a convenient metric equivalent chart for
converting the work height to millimeters.
3.
12
To adjust the vise jaw to either position: (a) Pull out
the T-pin located under the vise clamp cylinder until
disengaged from the vise base; (b) Slide the vise
jaw to either position until the pin engages into the
preset hole in the vise base.
FLOOD COOLANT SYSTEM
1.
The flood coolant system applies coolant through
the saw guide insert area to deliver coolant at the
point of cut. A selector switch is also provided on
the remote control panel so the operator can select
between the flood coolant system and the optional
mist lubrication system.
2.
Used coolant flows back to the reservoir through
the open end of the coolant pan. The reservoir has
a lift-off top access the filtering screen that strains
the coolant to remove metal particles and other
impurities.
3.
Coolant reservoir capacity is nine (9) gallons (34 0
liters). The pump will not operate correctly unless
the filter element is completely submerged in
coolant.
Coolant Selection
1.
2.
When making a coolant choice, the operator may
want to consider the following points:
•
Excessive heat build-up is the main cause of blade
tooth failure during band machining. Coolant
has both lubricating and cooling properties. Its
application does the following: (a) Helps reduce
the heat generated during sawing; (b) Helps prolong
blade life; (c) Generally promotes more efficient
cutting rates.
•
Flushing Hose
Choosing and using the proper cutting fluid is
important to most cutting procedures. An operator's
coolant choice will depend on such factors as: (a)
The type of material being cut; (b) The material's
machinability rating; (c) Band speed and feed rate
to be used; (d) Saw band type to be used and its
expected life; (e) The overall sawing operation.
1.
DRY CUTTING
1.
The operator may find it desirable to cut some
materials (such as cast iron, aluminum, magnesium,
etc.) without coolant. When dry cutting these
materials, follow the same operating procedures
used when cutting with coolant. However, dry
cutting will reduce saw band life.
BAND BRUSH AND CHIP REMOVAL
Band Brush
Using more than one coolant variety may provide
maximum sawing results and economy. Always
follow the coolant manufacturer's instructions.
1.
A band brush removes metal particles from the
saw blade teeth. The band brush is located
inside the right bandwheel door and powered by
the bandwheel. It is attached to a bracket that is
mounted to the saw head frame.
2.
The brush must be properly adjusted to clean blade
tooth gullets if satisfactory sawing performance is to
be obtained. As bristles wear down, adjust brush
position by: (a) Loosening the bolts holding the
brush assembly to the bracket on the saw head; (b)
Move the brush to clean chips from the blade teeth
gullets, but do not contact the bottom of the gullets;
(c) Retightening the bracket bolts.
Coolant Application
1.
Part of the Flood Coolant System, the flushing hose
is attached to the coolant pump and delivers cutting
fluid through a hand nozzle. It is used primarily for
machine cleaning purposes.
Coolant is supplied by means of a reservoir and
pump to the cutting area through the saw guide
inserts on the saw guide arm. A valve on each saw
guide arm regulates the flow to the saw guides.
Turn the valve counterclockwise until coolant
completely covers both sides of the saw band.
NEVER adjust the band brush while the
saw band is running or allow metal chips to
accumulate on the brush.
Chip Removal
1.
Coolant Pump and Reservoir.
13
Metal fragments removed from the band brush and
from the stockpiece drop onto the coolant pan. Chip
collections should be removed from the coolant pan
when necessary.
BAND BRUSH and CHIP REMOVAL
(Continued....)
2.
Loading Material
1.
In addition, the operator should check often for
chip accumulations around such machine areas
as: saw guides, vise bed, vise jaws, head feed
cylinder, etc. These accumulations may affect
machine performance if not removed. Remove chip
accumulations at least twice per eight (8) hour shift
and more often with heavier use.
Be sure the band drive motor and the saw band
are STOPPED completely before cleaning the
machine.
Manual Operation
VARIABLE VISE PRESSURE
1. The Variable Vise Pressure control valve (located on
the valve manifold) is used to adjust vise clamping
force against materials which cannot tolerate full
vise clamping pressure (examples are thin-walled
tubing, pipe, light structurals, etc.).
•
Clamping pressure is set with the knob until the
desired pressure is shown by the indicator gauge.
Turn the knob clockwise to "increase" pressure;
counterclockwise to "decrease" pressure.
Push the Hydraulic Start button. Then: (a) Turn the
Feed Rate control clockwise to the "OFF" position;
(b) Raise the saw head until it clears the stock to
be cut; (c) Adjust the movable saw guide arm for
stock width; (d) Adjust the movable vise jaw to the
opposite side of the angle being cut if necessary; (e)
Adjust the saw head for angle cutting if necessary;
(f) Load the material into cutting position; (g) Clamp
the vise to secure the material.
1.
Place the Saw Head Control selector to "HOLD"
and move the Operation selector to "MANUAL"or
"AUTO".
2.
Push the Band Start button. Then: (a) Turn the
band speed adjustment knob at the desired velocity;
(b) Turn the Saw Head control selector to "DOWN/
AUTO"; (c) Adjust the Coolant valves on each saw
guide arm so the coolant covers both sides of the
saw band.
3.
Start the saw head movement downward by turning
the Feed Rate knob until the desired cutting rate
is achieved (counterclockwise to "increase" feed
rate, clockwise to "decrease" it). This setting can
be adjusted as the cut progresses.
•
The operator may want to use the Head Down
Rapid control to lower the saw head at a faster feed
rate until reaching near the stock.
4.
Adjust band speed, feed rate, feed force and coolant
volume as necessary during the sawing process.
After a Cut is Completed - If "MANUAL" Selected
1.
Variable Vise Pressure.
TYPICAL SAWING PROCEDURES
Preparation
1.
These operations assume that the machine is
prepared as follows: (a) The band drive motor is
"OFF"; (b) The saw band is properly installed and
tensioned; (c) Both bandwheel doors are closed;
(d) All guards are in place and/or secured; (e) The
coolant reservoir or the optional mist lubricator
reservoir is full and all lubrication points are properly
serviced and if necessary, place the Coolant
selector switch at the desired delivery mode; (f)
The band brush is properly positioned; (g) Adjust
the work height for material size.
The drive motor will shut off with the saw head down
following the completion of a cut. The operator
should then: (a) Remove the cut-off piece; (b) Use
the Saw Head control and raise the saw head
until it clears the stock; (c) Prepare for another
cut following the above procedure or; (d) Clean
the machine if it is to remain idle for any period of
time.
After a Cut is Completed - If "AUTO" Selected
1.
14
The drive motor will shut off and the saw head
will raise to the position determined by the work
height mechanism. The operator should then: (a)
Remove the cut-off piece; (b) Prepare for another
cut by repeating the above procedure or; (d) Clean
the machine if it is to remain idle for any period of
time.
TYPICAL SAWING PROCEDURES
(Continued....)
For future reference, keep a record of band
speed, coolant application, feed rate, etc. and
other settings for successful jobs.
15
LUBRICATION
LUBRICATION CHART
LUBRICATION
POINT NO.
LOCATION DESCRIPTION and
SERVICE RECOMMENDATIONS
LUBRICATION
INTERVAL*
RECOMMENDED
LUBRICANT
1
2
Band Tension Screw. Clean and apply grease.
MONTHLY
Bandwheel Bearings. One (1) grease fitting each bandweel.
MONTHLY
3
Vise Guide Rail. Clean and apply grease.
MONTHLY
4
Head Swivel Lock Linkage. Clean and apply lubricant.
MONTHLY
5
6
7
Saw Guide Arm Slide. Clean and apply oil.
MONTHLY
Head Pivot Shaft Bearing Surfaces. Apply oil.
MONTHLY
8
Miscellaneous: Vise Slide, Hinges, Pivot Points, etc.
Clean and apply oil.
3 MONTHS
9
Electric Motor. Drive, Hydraulic Pump.
Lubricate (if any) per manufacturer's recommendations.
10
11
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,
anti-seize compound.
LPS Copper Anti-Seize, or equivalent.
Saw Guide Adjustment Screws. Clean and apply oil.
INSERT CHANGE
Coolant Reservoir. Nine (9) gallon (34.0 liter) capacity.
Drain, clean and refill as necessary.
CHECK DAILY
AS REQUIRED
Band Mist Lubricator (Optional). Sixteen (16) ounces (0.95
liter) capacity. Keep filled and hoses clear.
CHECK DAILY/
AS REQUIRED
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.
Premium quality, saw band coolant and
lubricant.
DoALL cutting fluids and/or oils (Kool
All).
Contact your DoALL sales
representative for the best oils or fluids
for your application.
DoALL cutting fluids or oils (AL-2000).
12
Hydraulic Reservoir. Three (3) gallon (11.3 liter) capacity. Check fluid level daily and keep the reservoir full. Drain,
change the filter element and refill after the 1st month; every
six (6) months thereafter.
CHECK DAILY/
AS REQUIRED
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.
16
LUBRICATION DIAGRAM
FRONT VIEW
REAR VIEW
17
MAINTENANCE
SAW GUIDE INSERT REPLACEMENT
DRIVE BELT REMOVAL OR REPLACEMENT
1.
1.
Remove the adjusting screw holding the spring
washer housing and movable insert. Then: (a)
Insert a screwdriver through the adjusting screw
hole until it engages the fixed insert screw slot; (b)
Remove the fixed insert; (c) Remove the shoulder
screw located above the adjusting screw on the rear
side of saw guide arm; (d) Remove the back-up
bearing from their seat.
To install or remove the band drive belt, turn the
machine off. Then remove the drive cover by
removing the screws holding it to the mounting
plate.
Replacing Drive Belt.
2.
Loosen the screws that hold the drive motor to the
mounting bracket and slide to the left to relax the
tension the drive belt.
3.
Stretch the old belt and remove it from the motor
pulley and then the driven pulley. Next: (a) Carefully
place a new drive belt into the motor pulley groove;
(b) Stretch and pull the belt around and into the
driven pulley groove.
4.
Slide the drive motor to the right towards the center
of the machine to tension the drive belt. Tighten the
screws to hold in place. For correct tension, there
should be little or no deflection at the center span
of the belt.
5.
Also check the new belt's tracking in the pulley
grooves by turning the driven pulley slowly
clockwise.
6.
If tracking and belt tension is correct, tighten the
screws holding the motor mounting bracket and
then reinstall the drive cover.
Saw Guide Detail.
2.
Thoroughly clean the saw guide body and insert
areas.
3.
Inspect the back-up bearing's useable wear
surfaces. If the surface last used is worn: (a)
Reinsert the bearing into the saw guide with the
unworn surface exposed to the back of the saw
band; (b) Reinstall the back-up bearings; (c)
Reinsert the shoulder screw.
4.
Install new fixed and movable inserts if worn.
5.
To reassemble: (a) Install the fixed and movable
inserts, plus spring washer housing; (b) Place
the saw band between the inserts; (c) Turn the
adjusting screws clockwise until tight (do not
overtighten); (d) Turn each adjusting screw back
counterclockwise a 1/4 turn.
6.
Replacing the saw guide inserts should be done to
both saw guide arms at the same time.
18
BAND TENSION ADJUSTMENT
Chip Collection
1.
1.
2.
Tension adjustment of the saw band will be
necessary from time to time. Adjustment is made
by turning the upper handwheel extending from the
machine's left side.
Machine Cleaning
Correct band tension will stress a high-speed steel
saw band to 30,000 psi (2115 kg/cm²). This is
comparable to a Tensigage reading of 4.0 units or
30,000 psi (2115 kg/cm²) measured by a DoALL
Tensigage. Refer also to the band tensioning portion
in the "OPERATION" section of this manual.
1.
FLOOD COOLANT
1.
Most metal chips removed from the saw band
and from the stock drop onto the coolant pan.
Periodically remove the chips.
During the sawing process, the operator should
check often for chip accumulations around such
machine areas as: saw guides, vise bed, vise
jaws, head feed cylinder, bandwheels, etc. These
accumulations can affect machine performance
and accuracy and should be removed from these
areas as often as possible. Removing chips
at least twice per each eight (8) hour shift is
recommended; more often with heavier use.
Check the coolant often for signs of contamination
or breakdown. Drain the entire system and clean
it thoroughly when coolant becomes unsuitable for
further use.
2.
Empty the reservoir periodically and clean the
coolant screens.
REPLACING VISE BED WEAR PLATE
3.
Flush the entire coolant system with DoALL's "Kleen
Flush" when changing to a different coolant type.
1.
The machine's vise bed is covered by one (1) steel
plate which must be replaced before their mounting
screw heads become worn and damaged (making
removal difficult). It can be removed when the vise
jaw is at the maximum open position.
2.
Follow these vise bed replacement directions: (a)
Move the vise jaw to its maximum open position;
(b) Remove all wear plate mounting screws; (b)
Slide the vise jaw to the other side to access the
other mounting screws; (c) Install new wear plate
and mounting screws.
CHIP REMOVAL
Band Brush
1.
The band chip brush should be positioned so that its
bristles remove all metal chips from the blade tooth
gullets, but do not touch the bottom of the gullets.
Replace the brush if its bristles become too worn
for proper blade cleaning.
2.
To replace the brush or adjust it to a new position:
(a) Loosen the carriage bolts that hold the band
brush to the mounting bracket; (b) Remove the
nut to replace the brush; (c) Place new brushes
and reinstall the nut; (d) Adjust the band brush into
position as described above.
Be sure the band drive motor and the saw band
are STOPPED completely before cleaning the
machine.
BANDWHEELS
1.
Remove the bandwheels every six (6) months to
clean them and the surrounding machine areas.
Bandwheel Flange and Tread.
2.
Band Brush.
19
Occasionally check each bandwheel's back-up
flange and wheel tread for wear. Saw bands will not
track properly if the wheel tread's taper is worn.
COUNTERBALANCE SPRING
1.
After a period of time, the saw head may not cut
through the stock or cuts too far into the vise bed
wear plates. To adjust, follow these procedures:
•
There is no need to remove the counterbalance
spring from the machine. (a) Loosen the threaded
collar from the lower hex nut; (b) Adjust the lower
hex nut up or down until the saw band teeth are
approximately 0.06 inch (1.52 mm) below the work
surface; (c) Turn the threaded collar down tightly
on top of the hex nut and secure it.
Be sure the saw head falls only enough to
cut completely through the work. TOO MUCH
head fall could result in cutting the vise bed
wear plates too deeply or completely off. TOO
LITTLE head fall will result in an incomplete
cut through the workpiece.
Counterbalance Spring.
ELECTRIC MOTORS
1.
Follow the manufacturer's maintenance instructions
for each electric motor. These instructions are
located in the pocket inside the main electrical
enclosure.
MIST LUBRICATOR
1.
See the instructions sent with the unit for information
on maintenance and adjustments. They are located
in the pocket inside the main electrical enclosure.
20
TROUBLE SHOOTING
Repair and adjustment procedures should
be made only by experienced maintenance
personnel. Reference to the machine's
electrical and hydraulic schematics will be
helpful.
MACHINE WON'T START
1.
Make sure the disconnect switch is turned to
"ON".
4.
Lubricant is not being supplied evenly to both sides
of the saw band.
5.
Stock is crooked. This usually results in straight,
but not square cuts.
6.
Decrease the distance between the saw guide arms.
Move the left arm as close as possible to the stock
being cut.
7.
Check for incorrect blade pitch being used.
2.
Hydraulics must operating before the saw band
motor can be turned on.
8.
Band tension is incorrect.
3.
Make sure both bandwheel doors are closed.
9.
Stock is not held firmly between the vise jaws or
vise T-pin not engaged into the vise base.
4.
Make sure the Emergency Stop pushbutton is reset
(turn the button head clockwise).
10.
Check for incorrectly adjusted saw guide inserts
and back-up bearing.
5.
Circuit breakers have tripped. Wait several minutes
for them to cool, then reset.
11.
6.
The optional band tension proximity switch may
have been tripped.
Check for machine misalignment (have a service
representative check and/or adjust machine
alignment).
7.
Check for broken belts and/or mechanical
jamming.
8.
Raise the saw head off the head down proximity
switch (2 PRS).
9.
Check for a burned out band drive motor.
10.
Check the incoming leads, wiring and control circuits
for possible malfunction.
VERTICAL CUT INACCURACY (Cut pieces are
thicker at the top or bottom)
MACHINE STARTS, BUT WON'T CONTINUE
RUNNING
1.
Check for loose or worn saw guide inserts. Tighten
the inserts if loose, replace inserts if worn.
2.
Reduce the feed rate being used.
3.
Check for crooked stock and/or incorrect stock
positioning between the vise jaws.
4.
Move the left saw guide arm closer to the stock.
5.
Check for incorrect band tension adjustment.
1.
Check for defective band drive contactor in the
electrical control box.
6.
Stock is not held firmly between the vise jaws or
vise T-pin not engaged into the vise base.
2.
The saw head has not cleared the head down
proximity switch (2 PRS). Move the saw head up.
7.
Check for a worn saw band.
8.
Check for saw head vertical misalignment. Have
a service representative check and/or adjust saw
head alignment.
INACCURATE CUT-OFF
1.
Saw band teeth are dull or worn.
2.
The band brush needs adjustment or
replacement.
3.
Increase the band speed or decrease the feed
rate.
HORIZONTAL CUT INACCURACY (Cut pieces
are thicker on one side)
21
1.
Check for loose or worn saw guide inserts. Tighten
the inserts if loose, replace inserts if worn.
2.
Check for crooked stock and/or incorrect stock
positioning between the vise jaws.
TROUBLE SHOOTING (Continued....)
BAND TOOTH GULLETS LOADING
3.
Stock is not held firmly between the vise jaws or
vise T-pin not engaged into the vise base.
1.
Use a courser pitch saw band.
2.
4.
Check for machine misalignment. Have a
representative check and/or adjust machine
alignment.
Increase the band speed or decrease the feed
rate.
3.
Band brush needs adjustment or replacement.
BAND TEETH STRIPPING
4.
Check for inadequate lubricant application.
1.
5.
Check for incorrect band tension adjustment.
Increase the band speed or decrease the feed
rate.
2.
Check for chip welding, or for a chipped blade tooth
lodged in the cut.
3.
PREMATURE BAND TEETH DULLING
1.
Band speed and/or cutting rate is too high.
Check for faulty stock: heavy scale, inclusions, hard
spots, etc.
2.
Check for faulty stock: heavy scale, inclusions, hard
spots,etc.
4.
Band brush needs adjustment or replacement.
3.
Stock analysis is incorrect. This can result in the
wrong initial cutting recommendations.
5.
Blade pitch is too course if a thin stock section is
being cut.
4.
Check for lubricant not covering the saw band
completely.
6.
Check for vibration caused by stock not being held
firmly between the vise jaws.
5.
Check for saw band vibration or chip welding.
7.
Check for worn saw guide inserts and/or back-up
bearing.
6.
Check for a chipped blade tooth lodged in the cut.
7.
Incorrect saw band is being used.
8.
Lubricant is not adequately covering both sides of
the saw band.
8.
Check for incorrect band tension adjustment.
9.
Check for incorrect band tension.
9.
Decrease the feed rate during the first few cuts to
break-in the saw band if new.
PREMATURE SAW BAND BREAKAGE
1.
Check for a poor weld in the saw band, or for
incorrect band tension.
2.
Saw band is being dropped into the stock. Make
an adjustment with the Feed Rate control.
3.
Increase the band speed and/or decrease the feed
rate.
4.
Stock is not held firmly between the vise jaws or
vise T-pin not engaged into the vise base.
5.
SAW BAND RUNS IN WRONG DIRECTION
1.
Switch the incoming electrical lines.
SAW BAND STALLS DURING A CUT
1.
Decrease the feed rate or increase the band
speed.
2.
Check for incorrect band tension adjustment.
3.
Check for improper adjustment of the saw guide
inserts and back-up bearing.
Use a finer pitch blade; at least three (3) teeth should
be in the stock at all times.
4.
Check for a worn or slipping drive motor belt.
6.
Install a finer pitch saw band.
5.
7.
Increase the lubricant volume being supplied.
Excessive lubricant is making the bandwheels
slippery.
22
TROUBLE SHOOTING (Continued....)
3.
Use a finer pitch saw blade.
SAW BAND VIBRATION
4.
Check for worn saw guide back-up bearings.
Replace if necessary.
5.
Band tension setting is incorrect.
6.
Increase the band speed or decrease the feed
rate.
1.
Check for incorrect blade pitch choice.
2.
Band speed being used is incorrect.
3.
Make a saw head feed rate adjustment.
4.
Stock is not held firmly between the vise jaws or
vise T-pin not engaged into the vise base.
1.
Use a courser pitch saw blade.
5.
Check for worn or improperly adjusted saw guide
inserts.
2.
Increase the band speed or feed rate.
6.
Check for a worn saw guide back-up bearing.
NO LUBRICANT FLOW
7.
Check for a dull or damaged saw band.
1.
Check for low lubricant level in the reservoir.
8.
Check for incorrect band tension adjustment.
2.
Clean or replace the air intake filter.
3.
Check for a faulty solenoid valve.
4.
Check incoming air supply. Must be at least 80 psi
(5.62 kg/cm² or 5.5 bar).
CUTTING RATE IS TOO SLOW
SAW BAND NOT RUNNING TRUE AGAINST
SAW GUIDE BACK-UP BEARINGS (Vibration may result)
1.
Check for chipped or worn back-up bearings.
Replace if chipped or worn more than 0.020-inch
(0.5 mm).
2.
Check for loose saw guide arms, or arms are not
located close enough to the stock.
3.
Check machine alignment (Calling a service
representative is recommended).
SAW HEAD WILL NOT RAISE, OR RAISES
SLOWLY
Increase the feed rate (rate being used is not
compatible with th size or type of material being
cut).
2.
Increase the lubricant volume.
3.
Use a courser pitch saw band.
4.
Reduce or vary the band speed.
5.
Check the band tension setting.
Check for mechanical obstructions.
2.
Check for low hydraulic system pressure. Pressure
should be approximately 450 psi (31.6 kg/cm² or
31.0 bar).
SAW HEAD WON'T LOWER
HIGH FREQUENCY SQUEAL DEVELOPS
WHILE SAWING
1.
1.
1.
The feed rate is too low.
2.
Check for saw head obstructions.
SAW HEAD LOWERS ERRATICALLY
1.
Check for mechanical obstruction or binding.
2.
Check for worn or damaged head feed cylinder or
head feed valve.
3.
Check for air in the head feed cylinder.
CUT-OFF PIECE SURFACE FINISH IS TOO
ROUGH
SAW HEAD DROPS SLOWLY WHEN MACHINE
IS SHUT OFF
1.
Check for machine or saw band vibration.
1.
Check for a worn head feed cylinder.
2.
Check for a dull or damaged saw band.
2.
Check for hydraulic system leaks.
23
TROUBLE SHOOTING (Continued....)
INCOMPLETE CUT
1.
Clear away build-up of chips or other debris on the
vise bed (check also for build-up below the saw
guides).
2.
Adjust the head-down limit switch.
3.
Check the counterbalance spring adjustment.
VISE WON'T CLAMP OR MOVE
1.
Saw head not raised high enough.
2.
Check for a worn vise clamp cylinder.
3.
Check for vise obstructions.
24
ACCESSORIES
ROLLER STOCK CONVEYORS
1.
Your machine may be equipped with one of the
following roller stock conveyors for moving long
stock into cutting position (or as an unloading
adjunct). The following conveyors are available:
•
Stock conveyor five (5) feet (1525.0 mm) long by
22 inches (558.8 mm) wide rollers with a weight
capacity of 750 pounds (340.2 kg) per roller.
•
Stock conveyor ten (10) feet (3050.0 mm) long by
22 inches (558.8 mm) wide rollers with a weight
capacity of 750 pounds (340.2 kg) per roller.
2.
These can be installed between the discharge tray
and conveyor or between conveyors (if more than
one is supplied) or between interface plate and
conveyor when vertical hold down clamp cylinder
is supplied.
Vertical Guide Roller.
Roller Stock Conveyor.
2.
To install a stock conveyor: (a) Position conveyor
up to the discharge tray that is mounted on the
base of the machine; (b) Bolt the conveyor to the
discharge tray with hardware provided. Do not
tighten hardware at this time.
3.
Adjust the conveyor to the machine with the
leveling screws on the conveyor legs. The top of
the conveyor rollers should be inline to 0.010-inch
(0.25 mm) above the vise bed wear plate.
4.
Tighten all hardware once adjustments have been
made.
5.
Depress the roller shafts for ease of installation or
removal of rollers.
3.
WORKLIGHT
1.
The worklight illuminates the cutting area for better
visibility and safety. It has its own "ON-OFF" switch
mounted on the light.
LASER LINE OPTION
Anchor the conveyor to the floor after all
leveling and adjustments are made.
Vertical guide rollers are effectively used to help
maintain correct positioning of long stock on the
conveyor.
25
To avoid eye damage, DO NOT stare into the
laser beam.
1.
A laser devise is used to emit a line on the material
to be cut. This line shows the approximate spot
where the cut will take place.
2.
The devise is controlled by a selector switch with
"ON" and "OFF" settings and is located on the
electrical control panel. Turn the laser "OFF" when
not in use.
3.
The laser is adjustable to position the laser beam
where desirable.
VERTICAL GUIDE ROLLERS
1.
The left vertical roller is adjustable and can be
clamped in any position using the clamping handle.
The right fixed vertical roller is in the same plane
as the fixed vise jaws.
LASER LINE GENERATOR (Continued....)
4.
5.
2.
When the laser is turned on, a warm-up period of 3
to 5 seconds takes place before a line appears. If
the line is difficult to see, darken the work area to
enhance the line.
Mounting
1.
Match the hole pattern on the discharge tray and
mount the interface plate to the tray with the provided
hardware. Do not tighten yet.
2.
See the instructions sent with the unit for information
on operation and adjustments. They are located in
the pocket inside the main electrical enclosure.
Level the interface plate to the same plane or within
.030 inch (.75 mm) below the discharge tray. When
leveling is satisfactory, tighten the hardware.
3.
Plant air supply is connected to the air filter under
the coolant pan on the left side of the machine. Plant
air supply should be 80 to 90 psi (5.5 to 6.2 bar or
5.6 to 6.3 kg/cm²) to operate this option.
An alternate mounting position is to remove the
discharge tray and install the interface plate directly
to the machine base.
Remove the protective shipping cap from the laser
devise before operation and replace the cap when
not in use.
MIST LUBRICATOR
1.
2.
Vertical nesting clamp assembly is mounted ONLY
to the 45° side of the machine base. The cylinder
operates simultaneously with the regular vise
clamping cylinder.
DO NOT exceed 90 psi (6.2 bar or 6.3 kg/cm²)
air pressure.
4.
Mount the vertical hold down assembly to the
interface plate with the provided hardware. The hole
pattern on the interface plate allows the cylinder to
be installed in five (5) different positions.
5.
The vertical hold down assembly may come with
an optional set of vertical guide rollers. They may
be mounted at the end of the interface plate or at
the end of the conveyor.
VERTICAL HOLD DOWN
1.
This optional feature is designed for high-production,
multiple sawing of stacked bars, rounds and tubing.
The capacity is the same as standard with the
exception of minimum bundle height is at least 1.00
inch (25.4 mm).
•
A five (5) foot or ten (10) foot conveyor must be
ordered with this option. An optional set of vertical
guide rollers can also be used.
The alternate mounting position will restrict
the cutting angle to approximately 25° to 32°
depending on the position of the vertical hold
down clamp cylinder.
Vise Adjustment
1.
Adjust the vertical hold down clamp cylinder by
sliding it along the horizontal support so the clamp
bar will rest at the center of the bundle being cut.
Vertical Hold Down Clamp Adjustments.
Vertical Hold Down.
26
VERTICAL HOLD DOWN (Continued....)
2.
Adjust the vertical guide rollers (if supplied) so
the stock will be guided correctly toward the saw
band.
3.
If the horizontal clamping vises and the vertical
nesting clamp do not release at approximately the
same time: (a) Adjust the hydraulic restrictor valve
at the top of the vertical hold down clamp cylinder
to achieve relatively equal release.
Stacking Stock
1.
Correct stock stacking is essential for proper
clamping of the vises and hold down bar. It is
important that vise clamping pressure be transmitted
to every stacked piece. Sometimes this can be
more easily accomplished by manually jogging the
stack.
2.
Proper stacking of round stock is important because
saw band breakage may occur if round pieces slip
or spin during sawing.
3.
Two (2) workable round stock stacking methods
are shown in the next illustration. Using the same
number of rounds in each row usually provides
the best sawing results, although the alternate
method can be used if the material is not stacked
too high.
Round Stock Stacking Methods.
4.
Pieces should be stacked as closely together
as possible. Metal chips lodged in open spaces
between individual pieces will affect cutting
accuracy.
27
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