Instruction Manual TF-2025NC Serial No: 541-98101 to 541-11137 541-13143 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 UNIVERSAL TILT-FRAME BAND MACHINE MODELFIRST SERIAL NO. LAST SERIAL NO. TF-2025NC541-98101541-11137 541-13143 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 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 and Tensigage. PRINTED IN U.S.A. i PB-485.6 (6-13) TABLE OF CONTENTS MACHINE DIMENSIONS LUBRICATION Floor Plan ................................................................1 Front View ...............................................................2 Side View .................................................................3 Lubrication Chart .....................................................32 Lubrication Diagram ................................................33 MAINTENANCE MACHINE FEATURES Replacing Saw Guide and Back-Up Inserts ............34 Hydraulic System ....................................................34-35 Coolant Ststem ........................................................35 Machine Cleaning ....................................................35 Machine Alignment ..................................................35 Brush Adjustments ..................................................35 Wear Plate Replacement .........................................35 Bandwheels .............................................................35-36 Cleaning Optional Chip Conveyor ...........................36 Head Angle Calibration ............................................36 Front and Side Views ..............................................4 Head Assembly .......................................................5 Proximity/Limit Switch Locations .............................6 INSTALLATION Location ...................................................................7 OSHA Notice!! .........................................................7 Unpacking ...............................................................7 Cleaning ..................................................................7 Lifting .......................................................................7 Floor Installation and Alignment ..............................7-8 Electrical Installation ................................................8 Hydraulic Installation ...............................................8-9 Coolant Installation ..................................................9 Preparation for Use .................................................9 TROUBLE SHOOTING ...................................37-39 ACCESSORIES OPERATION Safety Precautions ..................................................10 Using the Job Selector ............................................10 Cutting Capacity ......................................................11 Control Console .......................................................11-14 Operator Workstation ..............................................14-20 Programming Parts and Jobs ..................................20-24 Saw Band Preparation ............................................24-25 Post Adjustment ......................................................25 Feed Force Adjustments .........................................25-26 Saw Head Approach Rate .......................................26 Coolant System ......................................................26 Hydraulic System ....................................................26 Chip Removal ..........................................................26-27 Idler Wheel Motion Detector ....................................27 Typical Operating Procedures .................................27-31 Out of Stock .............................................................31 Roller Stock Conveyors ...........................................40 Vertical Guide Rollers (For Conveyors) ...................40 Nesting Fixture ........................................................40-42 Vertical Guide Rollers (For Nesting) ........................42 Chip Conveyor W/Coolant Reservoir ......................42 Mist Lubricator .........................................................42 Outboard Vise ..........................................................43 Lift Rollers ...............................................................43 Laser Line Option ....................................................43 Right to Left Feed ....................................................43 3º Head Cant ...........................................................43 Fixed Head (Non-Tilting) .........................................43 Material Handling Equipment ..................................43 How to read your serial number: ii MACHINE DIMENSIONS INCHES (± .03) MILLIMETERS (± 1 mm) FLOOR PLAN 1 MACHINE DIMENSIONS (Continued....) INCHES (± .03) MILLIMETERS (± 1 mm) FRONT VIEW 2 MACHINE DIMENSIONS (Continued....) INCHES (± .03) MILLIMETERS (± 1 mm) SIDE VIEW 3 MACHINE FEATURES FRONT VIEW SIDE VIEW 4 MACHINE FEATURES (Continued....) HEAD ASSEMBLY 5 MACHINE FEATURES (Continued....) PROXIMITY/LIMIT SWITCH LOCATIONS REAR VIEW HEAD TOP VIEW 6 INSTALLATION LIFTING All the “left”, “right”, “front” and “rear” designations in this manual are as viewed by the operator looking directly at the teeth of the saw band. LOCATION 1. 2. 3. The floor area required by the machine is approximately 105.00 inches (2667.0 mm) in width by 179.84 inches (4567.3 mm) in length. Machine height for the machine is 107.65 inches (2734.3 mm). Refer to pages 1, 2 and 3 for further machine dimensions. Locate the machine to provide adequate space for your sawing needs. Be sure also to provide: (a) Sufficient clearance for loading and unloading of stock; (b) Coolant tray installation and removal; (c) Head tilt; (d) Door openings; (e) Maintenance and lubrication procedures; (f) Operation of any machine accessories. 1. There is three (3) forged 3/4-10NC eye-bolts for lifting purposes. Two (2) are located on the front corners of the machine base and one (1) located in the rear center near the head pivot pillow block. 2. Using chains attached to the eyes-bolts, it is recommended that lifting and transporting of the machine be done with an overhead hoist. Net weight is approximately 7200 pounds (3265.9 kg). 3. The indexer unit should also be lifted by overhead hoist. Use chains or straps in such a manner as to provide adequate safety precautions to personnel and equipment. Net weight of the indexer unit is approximately 3250 pounds (1474.2 kg). 4. The hydraulic power unit (aproximately 600 pounds (272.2 kg) and conveyors (if supplied as optional equipment) can be lifted and transported by overhead hoist, fork lift, or by other means that provides adequate safety precautions. Provide ample space for roller conveyors and/or other material handling equipment. OSHA NOTICE!! FLOOR INSTALLATION and ALIGNMENT OSHA Regulation 1910.212 (5B). Machines designed for a fixed location shall be securely anchored to prevent walking or moving. 1. The machine base must be leveled first before the indexer unit is installed. 2. While the machine is suspended by the overhead hoist, thread the provided leveling screws into each machine base foot and attach the jam nuts. Slowly lower the saw into desired position. 3. 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. 4. Place a level on the machine vise wear plate bed. Make final adjustments to level the machine in both directions. Make sure weight bears evenly on all mounting pads. 5. Position the indexer unit to the machine base and loosely install socket cap screws and set screws and nuts to attach the indexer to the machine base. 6. Holes for locating dowel pins have been drilled through the machine base and mounting brackets. DO NOT drive dowel pins until indexer alignment is correct. UNPACKING 1. 2. The machine is fastened to and shipped on a wooden skid. Overseas shipments are also crated. Carefully remove all protective covers, strapping, hold-down brackets, crating, etc., but DO NOT remove the head support bracket until the machine is placed in desired location. Then: (a) Remove all bolts which fasten the machine to the shipping skid; (b) Check around the machine for other removable brackets, extra machine parts or supplies which might have been placed there for shipment; (c) Inspect the machine and all parts for shipping damage. Claim procedures are listed on this manual’s inside front cover. CLEANING 1. NEVER lift the machine by its sawing head. If necessary, use solvent to remove rust-preventive coating applied to exposed bare metal surfaces. 7 FLOOR INSTALLATION and ALIGNMENT (Continued....) 7. Adjust the indexer leg leveling screws to roughly level and square it to the saw. 8. Place a straightedge of known accuracy on both vise beds and level the indexer within the following dimensions: • The indexer vise bed and machine vise bed bearing surfaces are to be co-planar within 0.030 inch (0.76 mm) T.I.R., or 0.0008-inch per inch (0.02 mm per mm) mearsured from the plane of the saw band to the index vise. 9. After the machine has been leveled, drive in the dowel pins and install anchoring screws through the base pad holes next to the leveling screws. 10. Remove the protective shipping bracket installed to connect the saw head to the base frame during shipping. 11. Install optional roller stock conveyor(s) if supplied. These do not attach to the machine and should be anchored to the floor separately. 5. Turn the disconnect switch to "OFF" on the electrical enclosure. 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 (25.4 mm) diameter or larger hole into the electrical cabinet. 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. These are for installation of future accessories. Electrical Connections to Disconnect Switch. 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 cabinet 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). 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 main enclosure located the rear of the machine. 4. DO NOT start machine hydraulics until the following “Hydraulic Installation” procedures have been performed. Other than machine servicing, it is highly recommended that the electrical disconnect switch remain "ON" at all times. The following are important disconnect precautions: HYDRAULIC INSTALLATION The disconnect must be "ON" before the machine will operate. Turning "OFF" the disconnect will shut down the machine. 1. The enclosure must be closed and the appropriate securing screws must be in place before starting machine operation. 8 Position the hydraulic power unit behind and to the right of the machine so the hydraulic hoses can be connected without stress and tension. HYDRAULIC INSTALLATION (Continued....) 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. 3. Connect the hydraulic lines between the machine and power unit by matching tags on hoses to connection points on the power unit. Refer to the hydraulic schematic if necessary. 4. Remove the orange coupling guard between the hydraulic pump and motor and turn the coupling to assure free movement. 5. 6. 7. From the rear, slide the coolant tray between the deflector shields all the way in and under the saw head with the coolant pump to the rear of the machine. 3. 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 intake must be sufficiently submerged for coolant flow to reach all areas in the coolant system. PREPARATION FOR USE Prime the hydraulic pump by jogging the Hydraulic Start and Hydraulic Stop pushbuttons. Check the rotation of the hydraulic pump motor as indicated on the arrow label. 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 5 again. As soon as hydraulic pump motor rotation is correct, jog the Hydraulic Start and Hydraulic Stop pushbuttons 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. COOLANT INSTALLATION 1. 2. Install the coolant pump by attaching it to the mounting bracket inside the coolant tray with screws provided. Coolant Installation. 9 1. Check to be sure all safety guards, covers and doors are in place, closed and/or secured. 2. Remove the protective Saw Cap from the saw band by opening the upper bandwheel door and carefully pull the cap off the saw band. 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. OPERATION SAFETY PRECAUTIONS Warning Label - READ and UNDERSTAND. USING THE JOB SELECTOR 1. Refer to the Job Selector chart on the front 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 saw band break-in procedures. Job Selector recommendations are a general guide for correct cut-off sawing on a properly maintained DoALL saw and can be adjusted to meet special sawing requirements. They are based on cutting annealed, scale-free stock using a Imperial Bi-Metal saw blade. Job Selector. 10 CUTTING CAPACITY CONTROL CONSOLE 1. The standard machine's cutting capacity is: Electrical Controls • At 0° tilt: 20 inches (508.0 mm) wide by 25 inches (635.0 mm) high for rectangular stock; 20 inches (508.0 mm) diameter for round stock. 1. • At 45° tilt: 20 inches (508.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; 17 inches (431.8 mm) diameter for round stock. Head Angle. This selector switch with "-", "HOLD", and "+" settings regulate the direction of head tilt and operates ONLY when the Operation selector switch is in the "MANUAL" position. • Turn the selector to "-" or left causes the head to pivot to the left or negative direction. • At 60° tilt: 20 inches (508.0 mm) wide by 11 inches (279.4 mm) high for rectangular stock; 11 inches (279.4 mm) diameter for round stock. • Turn the selector to "+" or right causes the head to pivot to the right or positive direction. 2. Cutting capacity may vary with addition of accessories and will be noted when applicable. • Turn the selector to "HOLD" stops head movement in either direction. 2. 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. 3. Saw Head Control. Use this selector switch with "REV" (reverse), "HOLD" and "FWD/AUTO" (forward/auto) settings to regulate the direction of saw head movement. • Rotating the selector to "REV" or reverse moves the saw head back or away from the sawing area. This also will pause the auto cycle. • Turning the selector switch to "HOLD" stops all saw feed motion and stops the saw band. • Rotating the selector switch to "FWD/AUTO" or "FORWARD/AUTO" moves the saw head forward or towards the sawing area. The saw head will move at a rapid rate of speed until it reaches the feed start (2 PRS) proximity switch which then decelerate to a feed rate adjusted by hydraulic controls. • During manual operating mode: The saw head will move forward only if the F2 key on the operator work station is pushed or the saw band is on. 4. Head Angle Rapid. Used in conjunction with the Head Angle selector switch, pushing and holding this pushbutton accelerates the rate of speed the saw head moves while rotating the saw head. Vise Capacity 1. The vises maximum opening is 20.50 inches (520.7 mm) with an index stroke range from 0.50 to 40.00 inches (12.7 to 1016.0 mm). • Weight limit for the indexer is approximately 3000 pounds (1360.8 kg) evenly distributed with no impact. Saw Band Recommendations 1. 2. 3. A high-speed DoALL Imperial Bi-Metal Super Silencer saw band with protective Saw Cap is supplied with the machine. Band length is 209 inches (5308.6 mm); width is 1.25 inches (31.7 mm); recommended gage is 0.042-inch (1.1 mm); kerf is 0.085-inch (2.2 mm). A machine in correct adjustment, good operating condition and using proper cutting fluid is essential to efficient sawing. 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. Consult your DoALL sales representative for complete information about saw bands and their applications. 11 CONTROL CONSOLE (Continued....) Typical Pushbutton Panel. 5. • 7. Band/Cycle Start. Push this green pushbutton to start the band drive motor. The button will be illuminated when the band drive motor is operating. Allow the motor to accelerate to operating speed before starting a cut. • The following conditions must exist before pushing the Band/Cycle Start button: (a) The Emergency Stop pushbutton is reset (turn the button head clockwise); (b) Hydraulics must be on; (c) All doors and covers/guards must be closed or in place; (d) A saw band must be installed and the Band Tension selector must be at “ON”; (e) The inboard (fixed) vise must be clamped; (f) If in auto mode, the index vise must also be clamped. 8. Band/Cycle Stop. Push this red pushbutton to stop the band drive motor. 9. Outboard Vise (Optional). This selector switch with "OPEN", "HOLD"' and "CLAMP" settings operate the vise on the opposite side of the saw band from the feed direction of the index vise. • The "OPEN" setting opens the vise jaws; the "CLAMP" setting closes the vise jaws; and "HOLD" stops vise jaw movement. Post. This selector switch with "DOWN", "HOLD", and "UP" settings regulate post movement. (a) Rotating the selector to "DOWN" lowers the post; (b) The "UP" position raises the post; (c) The "HOLD" position stops post movement. 10. Hydraulic Start. Push this green pushbutton to start the hydraulic pump motor (the button will be illuminated when the hydraulics are operating). The hydraulic pump motor must be on to operate the machine. When the saw head is rotated, make sure the post is positioned to clear the material. Failure to do so will result in damage to the post. Make sure the vise jaw is opened wide enough when indexing material through the outboard vise. 6. Chip Conveyor (Optional). This selector switch with "REVERSE", "OFF", and "FORWARD" settings operate the optional motorized chip conveyor. • Before starting the hydraulics, the Emergency Stop pushbutton must be reset (turn the button head clockwise). • Turning the selector to the "FORWARD" position moves the chip conveyor belt to the rear of the saw and deposits the chips into a container. This is the normal operating position and recommended that it is in the "FORWARD" position during sawing procedures. 11. Hydraulic Stop. Pushing this red pushbutton turns off the hydraulic pump, coolant pump, band drive and the optional chip conveyor motor. 12. Emergency Stop. Pushing this red mushroom head pushbutton stops all machine motors (band drive, hydraulic pump, coolant pump and optional chip conveyor) simultaneously. To reactivate machine motors: • If the machine was operating in manual mode before the Emergency Stop button was pushed: (a) Reset the Emergency Stop button by turning the button head clockwise; (b) Push the Hydraulic Start and Band/Cycle Start buttons in sequence. • Turning the selector to "REVERSE" moves the chip conveyor belt towards the front of the machine. Use this setting only to clear a temporary situation. • The center position turns the chip conveyor "OFF". 12 CONTROL CONSOLE (Continued....) • If the machine was operating in automatic mode before the Emergency Stop button was pushed: (a) Reset the Emergency Stop button by turning the button head clockwise; (b) Push the Hydraulic Start button; (c) Position the stock as necessary; (d) Clamp both index and fixed vises; (e) Push the Auto (F6) button; (f) Push the Band/Cycle Start button. Hydraulic Control Panel 1. • • Turning the selector to “OFF” releases band tension and enables saw band removal or installation. • The “HOLD” setting stops band tension cylinder movement and allows the operator to position the saw band over the bandwheels. • The “ON” setting pressures the cylinder and establishes band tension required for cutting. DO NOT operate the band drive motor unless band tension is on. •The Band Tension selector must be "ON" before the saw head will traverse. Variable Vise Pressure. This control valve and gauge are 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 by loosening the lower locking knob, then turn the upper adjusting knob until the desired pressure is shown by the indicator gauge. Turn the knob clockwise to "increase" pressure; counterclockwise to "decrease" pressure. 2. Lift Roller (Optional). This selector switch operates each lift roller (left and/or right hand) in the "UP" or "DOWN" positions. This control is located on or near the control panel or a separate console. 3. Laser (Optional). This selector switch turns the lineup laser "ON" and "OFF". This control is located on or near the control panel or a separate console. To avoid eye damage, DO NOT stare into the laser beam. Optional Material Handling Controls Typical Hydraulic Control Panel. 2. 3. 4. Head Approach. This valve regulates the saw head’s forward rate. Turn the knob counterclockwise to “increase” the velocity; clockwise to “decrease” it. Coolant. 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. Feed Force. This valve and gauge are used to regulate the amount of pressure being placed by the saw band against the workpiece. Turn the knob clockwise to “increase” pressure; counterclockwise to “decrease” the force desired as shown on the gauge. The valve’s lower locking knob helps maintain the setting. Other Controls 1. 1. Conveyor Speed. This selector switch with "LOW" or "1" and "HIGH" or "2" settings regulate the speed of the conveyor(s). • When the selector is in the "LOW" or "1" position, the conveyor maximum speed is reduced to about 30%. 2. Infeed Conveyor Enable. This selector switch with "ON" and "OFF" settings allows the operator to turn the power "OFF" or "ON" to the conveyor. This is used in conjunction with the Conveyor Speed/Direction control. 3. Outfeed Conveyor Enable. This selector switch with "ON" and "OFF" settings allows the operator to turn the power "OFF" or "ON" to the conveyor. This is used in conjunction with the Conveyor Speed/Direction control. 4. Conveyor Speed/Direction. This two position joystick allows the operator to adjust the conveyor speed and direction of material flowing through the machine. •The Infeed and/or Outfeed Conveyor Enable selectors must be "ON" for this control to operate. Band Tension. This selector switch with "OFF", "HOLD" and "ON" settings is used when changing saw bands. The control is located on the rear side of the column and accessed from the left side. 13 CONTROL CONSOLE (Continued....) • Moving the joystick to the right will convey the material to the rear of the machine; moving the joystick to the left will convey the material forward on the system. • The rate of travel in either direction is controlled by how far the joystick is moved from center. The farther from center, the faster the rate of travel. Operator Workstation Function Keys. •The "F" keys have labels located above the key to indicate the function performed. OPERATOR WORKSTATION 1. The operator workstation consists of a display screen showing various controls and messages to operate the machine. On some screens there is a screen number in the upper right corner such as 1 of 4 etc. This indicates that it is the 1st of a group of 4 screens. You may move between screens by using the "RIGHT" and "LEFT" arrow keys. If there is no screen number, then there is only one screen in that group. • Most screens have instructions on the screen to assist in entering information. 2. 3. To the right of the function keys is the numeric keypadwhich is used to enter data into memory. Numeric Keypad. • Below the display are two (2) rows of function keys. These function keys (F1, F2...etc.) are assigned so that those regulating manual machine functions are in the bottom row, those concerning automatic functions and screen selection are in the top row. Operator Workstation. 14 The keypad has numbers 0 thru 9 plus the decimal point. The "CLEAR" key is used to clear existing data. The "ENTER" key is used to enter data into memory. The "HELP" key is non-functional and not used. OPERATOR WORKSTATION (Continued....) • 4. (a)Auto - When the saw is placed in this mode and the cycle initiated, the saw will automatically rotate the saw head, cut the part, reposition the material for the next cut and continue to cycle until the machine senses an "out-of-stock condition". Then the job is either complete or the cycle is interrupted. Above the numeric keypad is a set of four (4) arrow keys ("UP", "DOWN", "LEFT", "RIGHT") that will allow the operator to move around on a screen, to another screen or increase/decrease a value that is indicated on the screen. Do not push two (2) or more keys at the same time unless instructed. The standard feed direction for this band saw is left to right. Instructions are given with a left to right feed orientation. Any references that differ for the right to left feed will be given at that time. (b)Manual - This mode allow manual control of the machine using the panel keys and/or the pushbutton/ selector switches on the control panel. Function Keys 1. Operation Modes: Choices are AUTO and MANUAL. F1 - Screens. When electrical power is turned on to the machine, the following screen is displayed. This screen is a title screen that includes a listing of control screens that the operator can access at any time by pressing the F1 key. • Job Information on the selected job with various choices: (a) Job Number - This is the preprogrammed job that has been selected; this is the job that the saw will run when an automatic cycle is initiated. (b) Height - The height of the material as entered into the job. (c)Cycles - The number of times the job will be run. For example, if one (1) is displayed, the saw will cut the parts entered into the job, in sequence, one time and stop. If two (2) is displayed, the saw will cut the parts entered into the job, in sequence, two times and stop. (d)Dones - The number of cycles done. Title Screen (F1). 2. (e) Part # - The part number in the job that the saw is currently cutting. (f) No. of Parts - The number of times the current part is to be cut. (g)Dones - The number of times the current part has been cut. F2 - View. The VIEW screen displays vital information about the saw including the operating mode in which the saw is operating under, information on the selected job and other machine information. (h) Top Length - The length of the top of the current part. (i) Bottom Length - The length of the bottom of the current part. (j) #1 Cut Angle (Right)* - The leading cut angle of the current part. (k) #2 Cut Angle (Left)* - The following cut angle of the current part. View Screen (F2). 15 *For Right-to-Left Feed, the #1 and #2 cut angle orientation are switched, that is the leading cut angle would be left and the following cut angle would be right. OPERATOR WORKSTATION (Continued....) • Other machine information include: (a) Head Angle - The actual cutting angle of the saw head. (b) Index Position - The actual position of the index vise. (c) Band Speed - The actual band speed while the saw band is running. • The VIEW screen can be accessed at any time by pressing the F2 key except when editing a job. 3. F3 - Set-Up. The first of four (4) screens, these series of screens allows the operator to set certain preferences to various saw functions. Press the "UP" and "DOWN" arrow keys to the set-up parameter, then press the "+/-" key to change the item. Press the "ENTER" key to accept the selection or "CLEAR" to cancel. On screen 1 of 4: (a) Index Forward - This is preferred when using the nesting fixture and may be valuable when using variable vise pressure. It allows the use of two vises to provide extra clamping area. Operating sequence is as follows: When the cut has been completed, the index vise jaws open, the index moves to the required dimension and clamps the material. The fixed vise then unclamps, the index vise moves forward with material to the front position closest to the saw band and remains clamped during the cut. (b) Index Rear - This is the shortest cycle time and is preferred for most operations when not using the nesting fixture or variable vise pressure. Operating sequence is as follows: While a cut is being made, the index vise jaws open and moves to the rear to position itself for the next index stroke; when the cut is completed, the index vise jaws close, the fixed vise jaws open, and the index vise transfers the material into cutting position. When the last part in a job is being cut, the index will remain forward until the next job has been started. • Display Units: MILLIMETERS. (a) When the unit of measure is changed, all stored and displayed data is converted. This procedure takes a few moments to convert and a message screen will appear as this occurs. (b) Inch measurements use three places to the right of the decimal; millimeter measurements use two places to the right of the decimal. Conversions made from inches to millimeters are within .01 millimeter; conversions made from millimeters to inches are within .001 inches. • Vise Overlap: OVERLAP. Set-Up Screen (F3) (1 of 4). • Vise Control: NESTING. Choices are STANDARD or (a)Standard - This allow the operator to select "OVERLAP" or "NO OVERLAP" in the Vise Overlap option. • Choices are INCHES or Choices are OVERLAP or NO (a)Overlap - After the index has moved forward and the index vise jaws clamp, a time lapses before the fixed vise jaws open. This selection is forced if “nesting” is selected in the Vise Control option above. The greatest accuracy is obtained when “overlap” is selected because the material is always clamped by one of the vises. (b)Nesting - When using the nesting fixture option for cutting bundles of material, the selection does not allow the "NO OVERLAP" in the Vise Overlap option. The first time user is advised to select the “INDEX REAR” setting. The first time user is advised to select the “Standard” setting. (b) Home Position: Selects index vise position during the cut. Choices are INDEX FRONT or INDEX REAR. 16 No Overlap - After the index has moved forward, the index vise jaws open at the same time as the fixed vise jaws close. This selection allows slightly faster operation because both vises are cycled at the same time. This selection also allows material that has a tendency to “climb” in the vises to fall back to the vise bed. OPERATOR WORKSTATION (Continued....) 4. The first time user is advised to select the “No Overlap” setting. Press the "RIGHT" arrow key to move to the second of four (4) screens in F3 - Set-Up. Press the "0/INS" key to begin editing. Use the "UP" and "DOWN" arrow keys to move to set-up parameter. When a field is highlighted, enter the value, then press E"NTER" to accept or "CLEAR" to quit. Set-Up Screen (F3) (3 of 4); Also F16 - Creep Speed. (a) When creep speed is active (LED is lit), the index vise does not go to full speed after five (5) seconds. It will always stay at the creep speed setting. (b) Press "0/INS" key to select, enter new value with the keypad, press "ENTER" to accept. (c) If the operator pushes and quickly releases the "UP" or "DOWN" arrow key, the index speed change will be very small (about 1%). There will be a greater speed change when the key is pushed and held longer. (d) If the CREEP SPEED key is active, the operator may increase the rate of index forward travel by pushing and holding the "UP" arrow key. Pushing and holding the "DOWN" arrow key will decrease the rate of index travel. Set-Up Screen (F3) (2 of 4). • • Fixed Vise Clamped Delay - This allows the operator to set a time allotted for the fixed vise jaws to clamp before index movement is allowed (due to longer closing time resulting from variable vise pressure, etc.) and is used with the nesting fixture. Entry range is from .3 to 9.99 seconds. A Fixed Vise Clamped Delay of .3 seconds is suggested for the first time user. Index Vise Clamped Delay. This allows time allotted for the index vise jaws to clamp before index movement is allowed (due to longer closing time resulting from variable vise pressure, etc.) and is used with the nesting fixture. Entry range is from .3 to 9.99 seconds. 5. Holding the "INDEX FWD" or "INDEX REV" keys while pushing an arrow key will NOT change the Creep Speed setting. Press the "RIGHT" arrow key to move to the fourth of four (4) screens in F3 - Set-Up. This screen displays the band speed. This screen is also the same when you press the F5 - Band Speed key. An Index Vise Clamped Delay of .3 seconds is suggested for the first time user. • Kerf Width. Allows the operator to enter the dimension of the actual kerf width obtained from the saw band. The saw uses this value to compensate for the material removed by the cut. For the highest accuracy the user should measure the actual kerf width and enter the measured value. 4. Press the "RIGHT" arrow key to move to the third of four (4) screens in F3 - Set-Up. This screen is used to select the positioning speed (creep speed) of the index vise. This screen is also the same when you press the F16 - Creep Speed key. Set-Up Screen (F3) (4 of 4); Also F5 - Band Speed. 17 OPERATOR WORKSTATION (Continued....) (c) Previous - The time of the previous cut is shown. (a) Band speed may be changed by pressing the "0/INS" key to select the band speed. Then enter a new value, Press "ENTER" to accept. Use the "UP/DOWN" arrow keys to increase or decrease the band speed. • Auto System Shut-Off Delay. After the automatic cycle is complete, the hydraulic pump motor will shut off after a time entered in this field. Press the "0/INS" key and an arrow key until the field is highlighted. Then enter the desired time and press the "ENTER" key. (b) Band speed range is 50 - 400 fpm (15 - 122 m/min). The machine cannot be programmed for speeds beyond this range. • 6. F4 - Job. From this screen, the operator can select the job that the machine will run. See "Programming Parts and Jobs" later in this section for detailed instructions on how this is done. Job Data Clearing. To access the job data clearing functions, a password must be entered. Press the "0/INS" key and an arrow key until the field is highlighted. Then enter "2", "0", "2", and "5", press the "ENTER" key. The following message will appear: 7. F6 - Auto. Automatic Cycle On-Off. Pushing this key selects or deselects the automatic operating mode and lights the little LED in the upper left corner of the key. When the key is pushed again, the automatic mode is turned off and individual manual machine operations such as machine setup, positioning material, etc. are activated. Job Clearing Message Box. F7 - Cut Time. This screen will allow the operator to set the cut time limit, set the auto system shut-off delay time and job data clearing. 8. • • The top line directs the operator to choose the job clearing option by using the "UP/DOWN" arrow keys. Choose the clearing options carefully. Once the job data clearing is initiated, the effects are irreversible and data is permenantly lost. The first option is to clear data in the selected job highlighted on the Job Edit screens. When chosen, the following message in the box appears: Job Clearing Message Box (First Option). • Cut Timing/Clearing Screen (F7). • Cut Time. This field shows three (3) categories: (a) Current - This shows the current running time with the saw band on and the saw head moving forward. The cut time will remain in the field until another cut begins. (b) Press the "+/-" key to initiate clearing data in the selected job. All job data in all nine (9) parts of the selected job will be set to zero (0). Afterwards, a message in the box appears: Data Cleared Message Box. • Limit - A cut time limit can be entered in this field. By proper use of this field, it can be determined when the saw band is getting dull and may require changing. If the cut time limit expires, a message will appear informing the operator of this condition. To set the cut time limit, press the "0/INS" key and the arrow key until the field is highlighted. Then enter the desired time and press the "ENTER" key. 18 The second option is to clear job data in ALL jobs. When chosen, the following message in the box appears: Job Clearing Message Box (Second Option). OPERATOR WORKSTATION (Continued....) • Press the "+/-" key to initiate clearing data in the selected job. All job data in all nine (9) parts of the selected job will be set to zero (0). Afterwards, a message in the box appears: Manual Function Keys - Bottom Row Manual Function Keys (Bottom Row). Data Cleared Message Box. 9. F8 - Head Angle. Accessing this screen will allow the operator to automatically position the saw head to a specific angle. This could be helpful for positioning the material for the first cut in an automatic cycle or to make manual cuts. This control will operate in manual mode only. Head Angle Screen (F8). • Press the "0/INS" key to activate the data entry field, then use the numeric keys to enter the desired head angle. Press the "ENTER" key to accept the entry and the F8 key to initiate the head rotation to the programmed angle. 1. F9 - Index Open. This key controls the opening movement of the index vise jaw. Operation options: (a) Pushing and holding this key opens the index vise jaws; (b) Releasing the key stops the vise jaw movement. 2. F10 - Index Clamp. Push this key to clamp the index vise jaw. The LED in the corner of the key shines only when clamping force is applied. 3. F11 - Fixed Open. This key controls opening movement of the fixed vise jaw. It functions similarly to the INDEX OPEN button described above. 4. F12 - Fixed Clamp. Push this key to clamp the fixed vise jaw. The LED in the corner of the key shines only when clamping force is applied. When the band drive motor is running, the fixed vise jaws must be clamped before the saw head will move. 5. F13 - Index Rev (Reverse). Pushing this key causes the index vise to move away from the saw band (toward the rear of the feed conveyor). Releasing the key stops index motion. • When the "INDEX REV" key is pushed, the index creeps slowly for about five (5) seconds, then accelerates to full speed. • The index will not move if the fixed vise jaws and index vise jaws are both clamped. 6. F14 - Index Fwd (Forward). Pushing this key moves the index vise toward the saw band. Releasing the key stops index vise motion. • When the "INDEX FWD" key is pushed, the index will creep slowly for about five (5) seconds, then accelerate to full speed. • The index will not move if the fixed and index vise jaws are clamped. Head Angle Orientation. • If electrical power to the machine is lost for any reason, it will be necessary to calibrate the saw head. This procedure is described in the "Maintenance" section of this manual. When entering the head angle, keep in mind that you must enter a negative (-) value to rotate the saw head to the left. It is not necessary to enter a plus (+) sign when rotation is to the right. 19 OPERATOR WORKSTATION (Continued....) 7. F15 - Load Prep. This key is used to prepare the machine for material loading. Pushing this key starts a cycle which: (a) Moves the saw head completely back; (b) Opens the index vise jaws and fixed vise jaws fully; (c) Moves the index completely to the rear (away from the saw band). • The LED in the corner of the "LOAD PREP" key shines when the function is in process and goes out when completed. 8. F16 - Creep Speed. This screen is used to set the positioning speed (creep speed) of the index vise. This screen is also the same when you press the F16 - Creep Speed key. • This control was described preiously under "Set-Up Screen - 3 of 4". See that section for details on this control. • Press "0/INS" key to select, enter new value with the keypad, press "ENTER" to accept. • If the operator pushes and quickly releases the "UP" or "DOWN" arrow key, the index speed change will be very small (about 1%). There will be a greater speed change when the key is pushed and held longer. • If the "CREEP SPEED" key is active, the operator may increase the rate of index forward travel by pushing and holding the "UP" arrow key. Pushing and holding the "DOWN" arrow key will decrease the rate of index travel. Holding the "INDEX FWD" or "INDEX REV" keys while pushing an arrow key will NOT change the Creep Speed setting. Part Definition. 2. The top and bottom lengths are always horizontal planes but the two (2) sides can be cut at angles. The angles of the sides are created by the tilting of the saw head and cutting with the saw band. 3. The maximum cut angle for either side is ± 60°. The saw will register 0° when the saw head is in the vertical position. When the saw head is tilted to the right of this position, the angle is registered as positive (+), when tilted to the left, negative (-). 4. A part can be produced by trimming #1 Cut Angle; or the part can be produced by trimming #2 Cut Angle; or by trimming both Cut Angles. Part Cut With #1 Cut Angle. Part Cut With #2 Cut Angle. PROGRAMMING PARTS AND JOBS 1. This section will cover the definition of parts and jobs. References to "#1 Cut Angle" and "#2 Cut Angle" are reversed or in switched positions on the screens for Right To Left Feed. Part Cut With Both Cut Angles. What is a Part? 1. This machine is designed to produce parts. A part is defined by having four (4) sides; a top length, a bottom length, a leading side (referred to as #1 Cut Angle), and a following side (referred to as #2 Cut Angle). The height of the material also is an important component of the part. 20 5. As noted before, the height, the top and bottom lengths are also components of the part. • The material height, or vertical dimension, of the part is important for proper machine operation. The machine uses the height for calculations such as part lengths and maximum cut angles. PROGRAMMING PARTS AND JOBS (Continued....) • • There may be an occasion when the cycle has been interrupted and there are Dones retained in the job but it is preferred that the job be restarted from the beginning with all Dones cleared to zero (0). This is accomplished by pressing both the "ENTER" and "CLEAR" keys simultaneously while the Job Select screen is displayed. 3. When viewing the Job Select screen (F4), the operator can then access the Edit Job screens by pressing the "RIGHT" arrow key. Up to nine (9) parts can be entered into a job. There are nine (9) screens in succession representing the nine (9) parts that are potentially contained in each job. All screens are identical in content with the exception of the part number which is displayed in large characters near the top of the screen. Use the "RIGHT" arrow key to move through the part screens in succession and the "LEFT" arrow key to return to the previous screen. When programming a part, it is necessary to enter the height, #1 Cut Angle, #2 Cut Angle and the Top Length or the Bottom Length. The machine will automatically calculate the other length. What are Jobs? 1. A job is defined as a part or group of parts stored, in series, in the memory of the machine and recalled for the automatic cutting cycle. The number of parts stored in a job can be as few as one (1) and as many as nine (9). The maximum number of jobs available is 99. 2. F4 - Job. From this screen, the operator can select the job that the machine will run. The screen will display the job parameters the machine will use when running a job. These include the height of the material, the number of cycles, the number of parts, the number of parts done, the two (2) cut angles of the part, and the bottom length. Parameters can not be changed while the saw is running that particular job. Edit Job Screen. Programming a Single Part Into a Job 1. This section will walk you through the basics of entering data into a job edit screen and offer some considerations when entering the data. 2. To begin data entry, press the "0/INS" key and a data entry field will flash. Use the arrow keys to move between fields. When positioned on the desired data field, use the numeric keys to enter a value, then press the "ENTER" key. If an error is made in entering data, press the "CLEAR" key before pushing the "ENTER" key. To move to another field, press the "0/INS" key again and use the arrow keys to move between the fields. (a) Edit Job #. Use this field to select the number of the job desired for editing. There are a total of 99 jobs available for editing and running. Part #1 screen is the first screen that wil appear when a job is selected. Example: Enter "1" into the field. Job Screen (F4). • While an automatic cycle is running, the Dones are updated in the "Cycles # of Dones" box and "Parts # of Dones" column. If the cycle is interrupted for any reason (i.e. out of stock, Emergency Stop, etc.), the Dones are retained in memory. When the cycle is restarted, the job will resume with the first cut of the first part where the "# of Dones" is less than the "# of Parts". When the saw has fully completed all the parts programmed in the job, the Dones will automatically be set to zero (0). 21 PROGRAMMING PARTS AND JOBS (Continued....) (b) (c) (d) (e) Height. This is where the material height is entered. It is extremely important that the correct height is entered because many calculations are based off of this value. Incorrect height could result in undesired parts cut and/or damage to the machine. The Part #1 screen is the ONLY screen where the height value can be edited. Example: Enter "6" into the field. Cycles. To the right of the height data field is a field to enter the number of cycles. This number reflects the number of times the machine will run the selected job. Part #1 screen is the ONLY screen where the cycles value can be edited. Example: Enter "1" into the field. No. of Parts. Below the the cycles field is the data field for the number of parts. This is the number of times the machine will cut the part before advancing to the next part. If zero (0) is entered or displayed in this field, the machine will skip the part and advance to the next part. Example: Enter "1" into the field. • An important programming consideration is the maximum allowable cut angle related to the material height and the physical dimensions of the machine. Certain angles are not possible for certain material heights because of the physical limits of the machine. The machine will calculate the maximum allowable cut angle based on the programmed material height and will disallow the entry and replace it with the maximum allowable cut angle. • For example, if the material height is 20 inches (508.4 mm), the maximum allowable cut angle is at ± 34°. (g) Top and Bottom Lengths. Above and below the graphic representation are the data fields for entering part length. This allows the operator to enter either length with the other length calculated by the machine. Example: Enter "18" into the Bottom Length field. The Top Length computes to 6 inches (152.4 mm). • If the examples were followed, the part produced will look like this: Part Parameters. On the screen, there is a graphic representation of the part symbolizing the recorded part parameters. This is not a literal depiction of the part but a simple guide to general shape surrounded by the part parameters the operator has entered. The part parameters consist of the Cut Angles and Top and Bottom Lengths. Part Produced From Example. Programming More Than One Part 1. This section will help you in programming Parts #2 through #9 and programming more than one part in the "# of Parts" data field. The screens for parts #2 through #9 are identical to the Part #1 screen except the Height and Cycles fields can only be entered on the Part #1 screen. 2. The #1 Cut Angle on Parts #2 through #9 is determined by the last angle cut on the preceeding part. Therefore, the #1 Cut Angle can ONLY be edited on the Part #1 Job Edit screen. The last angle cut on a part is determined by the number of parts cut. • Example: When programming Part #1 and "1" is entered in the "# of Parts" data field, the #1 Cut Angle of Part #2 will be the same as the #2 Cut Angle of Part #1. Part Parameters Surrounding the Part Graphic. (f) Cut Angles. On either side of the graphic representation are the data fields for the cut angles. They are identified as #1 Cut Angle and #2 Cut Angle with #1 Cut Angle being the first angle of the part that is cut. Example: Enter "-45" into the #1 Cut Angle field; enter "45" into the #2 Cut Angle field. 22 PROGRAMMING PARTS AND JOBS (Continued....) Odd Number of Parts Entered in a Multiple Part Sequence. • Example of Part #1. *For Right To Left Feed, the #1 Cut Angle and #2 Cut Angle are switched in position on the screens. • If the number entered in the "# of Parts" data field is more than 1, the machine will alternate angles and index lengths, in effect, inverting the part. This minimizes material waste. • The machine computes the length that was not programmed by the operator. The reason that both top and bottom lengths are necessary is that the top length is used as the index length when inverting parts during a multiple part sequence. Example: If the number entered in the "# of Parts" data field is even, the #1 Cut Angle of Part #2 is the same as the #1 Cut Angle of Part #1. Even Number of Parts Entered in a Multiple Part Sequence. If an existing job is edited and a cut angle, material height, or "# of Parts" are changed, the cut angles on all the remaining parts may be altered. The machine will automatically update the remaining parts when the operator attempts to move to a different screen. The following message screen will appear. Alternating Index Lengths in a Multiple Part Sequence. 2. • The #1 Cut Angle on Parts #2 through #9 is determined by the last angle cut on the preceding part. When the part is inverted during a multiple part sequence, the last angle cut during the sequence is determined by the number entered in the "# of Parts" data field is odd or even. Message Box After an Update of Data. • Example: If the number entered in the "# of Parts" data field is odd, the #1 Cut Angle of Part #2 is the same as the #2 Cut Angle of Part #1. 23 After three (3) seconds, the panel will scroll through the remaining Edit Job screens updating all cut angle data on the remaining parts. If the #1 Cut Angle on Parts #2 through #9 is different than what is desired, a transition part must be programmed. PROGRAMMING PARTS AND JOBS (Continued....) 3. • Blade Guards If the number of Cycles is greater than one (1), the last angle of the last part entered in the job MUST be the same as the #1 Cut Angle of Part #1 of the job. The last angle cut is determined by whether an odd or even number is entered in the "# of Parts" data field. The machine will NOT run if these two angles are not the same. If a different angle is desired as the last angle, a transition part must be programmed. This condition is detected by the machine and a message screen will appear. 1. The machine has several guards for operator safety and protection. All guards must be in place before any sawing procedure is started. 2. Post Guard. This guard is hinged and attached to the upper saw guide and extends up towards the bandwheel. 3. Post Bellows. Mounted in the right side of the upper saw guide and also extends up towards the bandwheel. 4. Column Guard. This guard is mounted on the head column and located between the bandwheels. 5. Index Guard. This guard with a interlocked door is located in the rear of the indexer. DO NOT defeat the purpose of any guard or safety devise. They are there for YOUR PROTECTION! Saw Guides 1. Message Box If Transition Part Is Needed. SAW BAND PREPARATION 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 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 209 inches (5308.6 mm); width is 1.25 inches (31.7 mm); recommended gage is 0.042-inch (1.1 mm); kerf is 0.085-inch (2.2 mm). 2. A machine in correct adjustment, good operating condition and using proper cutting fluid is essential to efficient sawing. 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. Typical Saw Guide. Saw Guide Insert Adjustment 1. Consult your DoALL sales representative for complete information about saw bands and their applications. 24 Loosen the adjustment screw (turn counterclockwise) on each saw guide. Turn the insert adjustment screw clockwise until tight and then back off 1/4 turn. This applies to both upper and lower saw guides. SAW BAND PREPARATIONS (Continued....) POST ADJUSTMENT Saw Band Removal 1. Post and upper saw guide height is regulated by the Post selector switch on the control panel. 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. 1. 2. Always use extreme care when handling saw bands. Wear gloves. 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. Turn the Band Tension selector switch to "OFF". Then: (a) Open the upper bandwheel; (b) Open the hinged post guard; (c) Loosen the saw guide insert adjustment screws; (d) Carefully remove the old, worn or broken saw band from between the saw guide inserts and both bandwheel; (e) Carefully work the saw band out from the column guard and dispose the saw band immediately. FEED FORCE ADJUSTMENTS Saw Band Installation 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. 2. 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. Then: (a) Maneuver the saw band into the column guard; (b) Turn The Band Tension selector switch to "ON" to apply just enough tension to hold the saw band in position, then turn the selector to "HOLD". 3. 4. When the saw head has been tilted, make sure the post and saw guide will clear the material at the maximum programmed head angle. 1. Feed force is the pressure exerted by the workpiece against the saw band's cutting edge. It is controlled hydraulically and regulated with the Feed Force valve. Turn the valve clockwise to "decrease" pressure, counterclockwise to "increase" it. 2. The following are important factors to consider when setting or adjusting the Feed Force valve: • Turn the Feed Force valve to a low setting if the correct feed force 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 Feed Force valve setting. Blade damage may occur. Slip the saw band between the saw guide inserts by twisting it 90° so the blade teeth are facing the front of the machine and pointing downward. Then: (a) Turn each saw guide insert adjustment screw clockwise until tight and then back off 1/4 turn; (b) Remove the protective Saw Cap from the saw band; (c) Close the hinged post guard and then the bandwheel door; (d) Turn the Band Tension selector switch to "ON" to apply full tension to the saw band. Push the Band/Cycle Start button and run at a very low speed to check for proper band tracking against the each bandwheel rear flange. 25 • Certain work-hardening materials will require a moderately heavy initial Feed Force 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. • Generally, top performance from a sharp saw band results from relatively low Feed Force 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. • Feed force adjustments are not necessary for changing stock cross-sections. A balancing valve enables the saw band to maintain a uniform cutting rate. FEED FORCE ADJUSTMENTS (Continued....) COOLANT SYSTEM Reducing Cutting Rate & Band Speed for Pipe, Tubing and Structurals Coolant Selection 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. 1. Up to 3/16 inch (0 to 4.8 mm) 40% 3/16 to 3/8 inch (4.8 to 9.5 mm) 50% 3/8 to 5/8 inch (9.5 to 15.9 mm) 60% 5/8 to 1 inch &over (15.9 to 25 mm & over) 70% 1. Coolant is applied as follows during sawing: • To the saw band and cutting area through the saw guide inserts. Flow is regulated by a valve on the control panel. • To a flushing nozzle for washing parts or cleaning areas of the machine. 2. Coolant flow is started by: (a) Pushing the Hydraulic Start button; (b) Turning the Coolant selector to "ON" or "BAND ON"; (c) Turning the coolant valve on the control panel clockwise until fluid completely shrouds the saw band. 3. *Based on 5 inch (127.0 mm) solids. Cutting Rate to Thickness Relationship. SAW HEAD APPROACH RATE 1. After the stock has been positioned for cutting and the Saw Head Control selector is placed at the "FWD/AUTO" setting, the saw head's approach (traversing) rate is regulated by the Head Approach valve. 2. Correct head approach is important for helping: (a) Determine overall cutting accuracy and finish of cut; (b) Improve blade life by eliminating breakage and tooth strippage at the cut's start and break-out points. 3. Literature describing these and other coolant types is available from a DoALL sales representative. Coolant Application SECTION FACTOR TO APPLY THICKNESS TO MINIMUM CUTTING RATES GIVEN BY JOB SELECTOR* 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. DO NOT start cutting until coolant is flowing adequately. Dry cutting will greatly reduce blade life. Check the coolant level if flow is stopped or reduced. Drip pan capacity is 20 gallons (75.7 liters). Optional chip conveyor has a capacity of 50 gallons (189.2 liters). HYDRAULIC SYSTEM To move the saw head if the band drive motor is not running: (a) Place the saw in "MANUAL" operating mode; (b) Move the Saw Head Control selector to "FWD/AUTO"; (c) Make the desired Head Approach valve setting; (d) There must be some Feed Force setting. 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. CHIP REMOVAL 1. 26 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 REMOVAL (Continued....) Band Wiper 1. DO NOT shovel or rake chips while the saw band is running. Band Brush 1. A wiper located at approximately the ten (10) o'clock position from the lower bandwheel removes coolant residue from the moving saw band before it reaches the upper bandwheel. Carriage Brush 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. 1. A brush located on the lower front side of the saw head removes chips and depris from the head carriage bearing rails as the saw head is traversing. IDLER WHEEL MOTION DETECTOR 1. This safety devise located in front of the lower bandwheel stops the machine if the saw band should break or stall in the workpiece. Always determine the cause of the stoppage and correct it before attempting to resume operation. TYPICAL OPERATING PROCEDURES Manual Operation 1. To start the machine: (a) Make sure the main disconnect switch is turned to "ON"; (b) Turn the Emergency Stop button head clockwise to reset (if necessary); (c) Push the Hydraulic Start button. This will start the hydraulic pump motor. 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. When the machine is ready for operation, the Display will show the title screen to indicate readiness to accept manual input, or to be set-up for automatic operation. 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. 3. Push the F15 - Load Prep key. The associated LED will light up and the following actions will occur: (a) Saw head moves to the maximum retracted position; (b) The index and fixed vises open completely; (c) The index moves to its maximum rear position; (d) The associated LED goes out to indicate the completion of the Load Prep cycle. • Alternate Method. Retract the saw head by moving the Saw Head Control selector to "REV". Then: (a) Move the Saw Head Control selector to the "HOLD" setting when the saw head reaches the desired position; (b) Before starting a new job, it may be more convenient to retract the saw head to its maximum reverse position to be sure it will clear the material to be loaded; (c) Push the F9 - Index Open and F11 - Fixed Open keys. • Operating Note: The saw head must be retracted completely to accomodate a stockpiece wider than the piece previously clamped. 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. 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. 27 TYPICAL OPERATING PROCEDURES (Continued....) 4. Load the stock to be cut onto the feed conveyor rollers near the fixed vise jaws and position for a crop cut. 5. To move the stock into position for clamping by the fixed vise jaws: (a) Move the index vise to the rear or almost to the rear of its travel (if necessary); (b) Clamp the index vise jaws; (c) Push the F14 - Index Forward or F13 - Index Reverse keys to position the stock for a crop cut (1/4" (6.3 mm) or more of material must be extending beyond the path of the saw band). • 6. 10. The operator may adjust band speed, coolant flow, approach rate, and/or feed force at any time during the sawing process. 11. After the cut has been completed, the saw band will shut off with the saw head in the forward position. Next: (a) Retract the saw head by moving the Saw Head Control selector to "REV" (move the selector to "HOLD" when the desired saw head position is reached); (b) Unclamp the index and fixed vise jaws; (c) Remove the cut-off piece. Automatic Operation Preparation Operating Notes: (a) The index will move slowly for the first few seconds after the F14 - Index Forward or F13 - Index Reverse key has been pushed, then move at a rapid rate; (b) For slow positioning, use the F15 - Creep Speed key for slow positioning as needed. Push the F12 - Fixed Clamp key to clamp the fixed vise jaws around the stock. Then: (a) Move the Saw Head Control selector to "FWD/AUTO" and position the saw band just behind the stock; (b) Move the Saw Head Control selector to the "HOLD" setting; (c) Press the F8 - Head Angle key and tilt the saw head to desired setting; (d) Align for a good cut angle; (e) Adjust the post until it is just clears the material. 1. This machine has been designed for automatic operation. With very little initial set-up, this machine will automatically produce parts without operator assistance other than suppling material for the saw. 1. Programming Considerations. The creative operator will find that the machine offers a great deal of flexibility as far as how the saw can be programmed to produce parts to maximum productivity. There are several programming options that can be used that will produce parts in the order that best suits your production needs. Use the following example to help you utilize the saw's potential. 2. Example: Factory has an order for 20 frames with outside dimension of 10" by 12". The width of the parts is 1". Correct Starting Cut Angle. 7. Push the F5 - Band Speed key. Then adjust band speed by entering the band speed directly. You can also use the "UP" and "DOWN" keys to adjust band speed. 8. Using the Feed Force and Head Approach controls to make initial settings. Watch closely as the saw head moves forward and make any adjustments that may be needed. 9. Select the coolant flow desired for your application. Make sure to cover both sides of the saw band. To begin the cut: (a) Move the Saw Head Control selector to "FWD/AUTO"; (b) Push the Band/Cycle Start button. The band drive will come up to speed and the saw head will feed to begin the cut. The fixed vise must be clamped for the machine to start. Dimensions of Frame Example. 3. 28 The parts coming off the machine are provided directly to the assembly area and the parts are required to arrive in order of assembly. The saw can be programmed as follows: TYPICAL OPERATING PROCEDURES (Continued....) Part #4 Part #1 • On a saw with left to right feed, the parts would come off the machine in this order and cycle 20 times: 4. The parts coming off the machine are provided directly to the assembly area and the parts are not required to arrive in order of assembly. The saw can be programmed as follows: Part #2 Part #3 Part #1 29 TYPICAL OPERATING PROCEDURES (Continued....) Part #2 Part #2 • • Automatic Operation On a saw with left to right feed, the parts would come off the machine in this order and cycle 20 times: 1. Program the job information into the job library. Each job has a number assigned by the machine control. 2. Start the machine by following steps 1 through 8 from the preceding "Manual Operation" section. 5. In this case, the saw will cut Part #1 40 times and Part #2 40 times and then stop. The parts coming off the machine are going directly to storage bins and the parts are required to come off the saw as they would be stored. The saw can be programmed as follows: 3. Select the specific job to be run by: (a) Push the F4 - Job key and Select Job screen appears. (b) Enter the job number and then push "ENTER". 4. Edit the job if necessary. See the Control Console section referring to the "Operator Work Station" previously in the "Operation" chapter for information on this process. 5. Select the automatic cycle by pushing the F6 - Auto key. The LED in the corner of the key will shine to indicate that the automatic cycle is set-up. 6. With the material now in position for a crop cut: (a) Move the Saw Head Control selector to "FWD/ AUTO"; (b) Push the Band/Cycle Start button. 7. If the index home position is set to "FORWARD", the index vise will remain near the saw band and be clamped. After the cut has been completed: (a) The index will move back the cut length and clamp; (b) The fixed vise jaws will open; (c) The index will move the piece forward; (d) The fixed vise jaws will clamp and a cut will be started. Part #1 30 Both fixed vise and index vise jaws must be clamped before the machine will start. TYPICAL OPERATING PROCEDURES (Continued....) 8. 9. If the index home position is set to "REAR", the index vise will move back the cut length and remain open for the duration of the cut. Then: (a) The index vise jaws will clamp and the fixed vise jaws will open; (b) The index will move the workpiece forward; (c) The fixed vise jaws will clamp and a cut will be started. 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. OUT OF STOCK After all programmed jobs have been completed: (a) The saw head will retract; (b) The band drive motor will shut off; (c) Hydraulics will remain on. 1. The machine senses the material in the index vise throughout the job cycle. During a single index, if the sensor on the back of the index vise does not sense material, it marks the point where it lost detection of material and calculate the remaining length of travel. • If there is enough material to complete the index and safely clamp the material, the cycle will continue until the index is complete. Then the material is moved to the sawing zone and the cut is completed. The machine will then stop the automatic cycle. • If there is not enough material to complete the index, the machine will stop the automatic cycle. • If an out of stock condition occurs, a message is displayed indicating such. The saw will have to be set-up again and restarted. Important Automatic Cycle Operating Reminders 1. 2. 3. When the saw head has been tilted, make sure the post and saw guide will clear the material at the maximum programmed head angle. The operator may adjust band speed, coolant flow, rapid approach rate, and/or feed force at any time during the sawing process. To run jobs in automatic cycle: (a) Stock to be cut must be clamped by both vises; (b) The job to be cut must be displayed on the Select Job screen; (c) Push the F6 - Auto key; (d) Move the Saw Head Control selector to "FWD/AUTO"; (e) Push the Band/Cycle Start button. To interrupt automatic cycle: (a) Move the Saw Head Control selector to "HOLD" (this will stop saw head movement and saw band); (b) To resume cut after interuption, move the Saw Head Control selector to "FWD/AUTO" and then push the Band/Cycle Start button. If the automatic cycle is interupted by pushing the F6 Auto key or the Band/Cycle Stop pushbutton, all motion, saw band and hydraulic pump will stop. A crop cut will be required to resume operation. This method of interuption of the automatic cycle is NOT RECOMMENDED. 4. The operator can push the F4 - Job key, then to the Edit Job screens to edit or enter jobs while the automatic cycle is running. The operator CANNOT edit the job being cut while the machine is running. 5. The operator can also set all "Dones" to "0", this sets the quantity done to "0" for all of the parts for the current job. 31 LUBRICATION LUBRICATION CHART LUBRICATION POINT NO. LOCATION DESCRIPTION AND SERVICE RECOMMENDATIONS LUBRICATION INTERVAL* 1 Vise Movable Jaw Slides/Gibs. Four (4) grease fittings. 1 for each gib. Add two (2) for Optional Outboard Vise. 2 Band Tension Slide. Clean and apply grease. MONTHLY 3 Bandwheel Bearings. One (1) grease fitting each bandwheel. MONTHLY 4 Index Vise Linear Bearings. Six (6) grease fittings. MONTHLY 5 Head Carriage Linear Bearing (Older machines). Four (4) grease fittings. Current machines are sealed for life. MONTHLY 6 Head Pivot Pillow Blocks. Two (2) grease fittings. MONTHLY 7 Insert Adjustment Screws. Oil the threads. 8 Post. Clean and apply oil. 9 Miscellaneous: Vise Slides, Hinges, Pivot Points, Component Parts, Unpainted Surfaces, etc. To ensure function and maintain appearance while reducing wear, corrosion, rust, etc. Apply when and where needed in amounts required. RECOMMENDED LUBRICANT WEEKLY INSERT CHANGE MONTHLY AS REQUIRED 10 Electric/Hydraulic Motors. Hydraulic Pump, Coolant, Drive and Optional Chip Conveyor. 11 Coolant Reservoir (Drip Pan). 20 gallon (75.7 liter) capacity. Chip Conveyor (Optional). 50 gallon (189.2 liter) capacity. Drain, clean and refill whenever coolant becomes undesireable for further use. Clean the mesh strainer at the same time. 12 Band Mist Lubricator (Optional). Keep reservoir filled and hoses clear. 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. Lubricate per manufacturer's recommendations. CHECK DAILY/ 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. 13 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. 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. 32 LUBRICATION DIAGRAMS TOP VIEW HEAD VIEW 33 MAINTENANCE REPLACING SAW GUIDE AND BACK-UP INSERTS 1. These instructions can be used to replace saw guide inserts and back-up inserts on both upper and lower saw guides. 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 button; (c) Remove the reservoir drain plug; (d) Allow the reservoir to drain completely. The band drive motor must NOT be running when replacing saw guides and back-up inserts. System Pressure Loosen the insert adjustment screw on each saw guide. Then: (a) Remove the saw band; (b) Remove the adjustment screw being very careful not to drop or lose the front insert when it falls from the assembly; (c) Loosen the flat head screw and remove the rear insert. 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.) 2. Pressure is adjusted by turning the screw extending outward from the hydraulic reservoir. Consult a DoALL service representative if assistance is needed. 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. 2. Following a new pump installation: (a) Jog the Hydraulic Start and Hydraulic Stop buttons 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. Typical Saw Guide Assembly . 2. 3. 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. 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. Seals & Cups 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.). 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. 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. 34 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. HYDRAULIC SYSTEM (Continued....) BRUSH ADJUSTMENTS Band Brush DOALL hydraulic fluid with an aniline point of approximately 221° F. (106° C.) will not cause deterioration of component seals. 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. Move the brush closer to the blade as normal wear occurs. Replace the brushes when necessary. COOLANT SYSTEM 1. The machine’s coolant drip pan has a 20 gallon (75.7 liter) capacity. 2. 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 undesireable for further use. If another type of coolant is to be used, the entire coolant system must be flushed (use DoALL’s Kleen Flush). Band Wiper To thoroughly clean the drip pan section below the saw head, removal of the drip pan may be necessary. Carriage Brush 3. 1. 1. MACHINE CLEANING 1. 2. 3. Keep the machine and its parts as clean as possible to prevent excessive wear and damage. A wiper located at approximately the ten (10) o'clock position from the lower bandwheel removes coolant residue from the moving saw band before it reaches the upper bandwheel. Adjust or replace the brushes when necessary. A brush located on the lower front side of the saw head removes chips and depris from the head carriage bearing rails as the saw head is traversing. Adjust or replace the brushes when necessary. WEAR PLATE REPLACEMENT 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. 1. The removeable 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. 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. The machine has four (4) vise jaw wear plates (additional two (2) for optional outboard vise); one (1) 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 1. Combination Shovel-Rake. MACHINE ALIGNMENT 1. The index, inboard and outboard tables has three (3) vise bed wear plates each. When no rollers are supplied, there is two (2) each. All wear plates are mounted with flat head screws. BANDWHEELS Misalignment of the machine’s saw guides, slide bar, saw band, pivot points, post, etc., will cause inaccurate sawing. 1. 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. 35 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. BANDWHEELS (Continued....) 2. Replace the entire bandwheel if the rim becomes badly worn. 3. Ideally, the saw band should be tracking on both wheels so that the back edge will just lightly contact the wheel flanges, or is not more than 0.005 inch (0.127 mm) away from the flanges. Typical Bandwheel Flange and Tread. CLEANING OPTIONAL CHIP CONVEYOR 1. To clean the optional chip conveyor, turn the machine off. Then: (a) Disconnect the coolant hoses; (b) Pull the conveyor out from its cradled position in the base; (c) Clean the conveyor trough; (d) Clean out the chip box and the reservoir floor; (e) Replace the conveyor. HEAD ANGLE CALIBRATION 1. If electrical power is lost to the machine by turning off the disconnect switch or by any other means, it will be necessary to calibrate the saw head. Other than machine service, it is recommended that the electrical disconnect switch remain "ON" at all times. 2. Calibration procedures as follows: (a) Using the Head Angle selector switch, manually rotate the saw head in the positive direction until the bottom of the saw head makes contact with the physical stop at the end of travel; (b) After making contact with the physical stop, continue to hold the Head Angle switch in the direction of travel for three (3) seconds. 3. During that time, the machine controls will automatically set the saw head angle to the actual angle of the saw head at the physical stop. 4. This procedure should be repeated any time the electrical power is off to the machine for any amount of time or angles may not be correct. 36 TROUBLE SHOOTING Repair and adjustment procedures should be made only by experienced maintenance personnel, or by a DoAll service representative. Reference to the machine's electrical and hydraulic schematics will be helpful. 4. BLADE TOOTH GULLETS ARE LOADING MACHINE WILL NOT START 1. Check for pinching of saw band in the material due to crooked stock. Use wider set saw band. Check that the disconnect switch is in the “ON” position. 1. Use a coarser pitch saw band. 2. Increase the band speed setting, or decrease the feed pressure setting. 3. Check for improper coolant application. Check the positioning of the band brush. Replace the brush, if necessary. 2. Reset the Emergency Stop pushbutton (rotate the button head clockwise). 4. 3. Check the main fuses/circuit breakers and control circuit fuse/circuit breaker. SAW BAND SQUEAL 4. Make sure the bandwheel door and/or the index guard door are closed. 5. Push the motor starter overload reset buttons in the electrical cabinet. If overload tripping occurs, locate and correct the problem. 1. Coolant is not covering the saw band properly. 2. Check for worn or improperly-adjusted saw guide inserts. SAW BAND VIBRATION 6. Check the control transformer for power. 1. Check for a dull or damaged saw band. 7. Check the hydraulic motor and wiring. 2. 8. Check the starter, relay coils and contacts for faulty operation. Incorrect band speed or feed pressure setting is being used. 3. Check for incorrect saw band pitch. Have an electrical service person check the continuity of the starting circuit. 4. Coolant mixture is weak, or incorrect coolant is being used. MACHINE STARTS, BUT WON’T CONTINUE RUNNING 5. Stockpiece is not being firmly clamped by the vise jaws. 1. The saw band is broken or too long and is activating the band tension limit switch (3 LS). 6. Check for worn or improperly-adjusted saw guide inserts. 2. Check to see if the bandwheel door and/or the index guard door are closed (the band drive motor will not start unless both are closed). 7. Check for a worn saw guide back-up bearing. 8. Bandwheel bearings are badly worn or damaged. The out of stock limit switch (1 PCS) has been actuated. PREMATURE BLADE TEETH DULLING 9. 3. SAW BAND STALLS DURING A CUT 1. Decrease saw head feeding pressure. 2. Increase band speed and/or head approach rate. 3. Check for low hydraulic pressure. 37 1. Band speed and/or cutting rate is too high. 2. Check for faulty stock: Heavy scale, inclusions, hard spots, etc. 3. Stock analysis is incorrect. This can result in an incorrect cutting recommendation. 4. Coolant is not covering the saw band properly. TROUBLE SHOOTING (Continued....) 6. 5. Check for saw band vibration. 6. Check for chip welding, or a chipped blade tooth lodged in the cut. SAW BAND IS NOT RUNNING TRUE AGAINST THE SAW GUIDE BACK-UP BEARINGS (May Cause Vibration) 7. Saw band being used is incorrect. 8. Coolant mixture is too weak, or incorrect coolant is being used. 9. Check for saw band vibration. 10. Decrease feed pressure to "break in" a new saw band on its first few cuts. 1. Examine the carbide back-up bearings. Replace them if they are chipped or worn more than 0.020inch (0.5 mm). 2. Have a DoALL service representative check machine alignment. 3. Check for worn saw guide pivot bolts. 4. Saw guides are loose, or not positioned close enough to the stock. BLADE TEETH STRIPPING 1. Increase band speed or decrease feed pressure. 2. Check for chip welding, or for a chipped blade tooth lodged in the cut. Use a finer pitch saw band. INACCURATE CUT-OFF 1. Check for worn or dull blade teeth. 2. Check for a hard spot in stock being cut. 3. Faulty stock is being used: Check for heavy scale, inclusions, hard spots, etc. 3. Band brush is not properly cleaning the blade teeth. 4. Check for a worn, or improperly adjusted band brush. 4. Increase band speed being used and/or decrease feed force. 5. Check for vibration caused by loose vise jaw clamping against the stockpiece. 5. Check for dirty coolant. Replace if necessary. 6. Check for worn saw guide inserts and/or carbide back-up bearing. 6. Check for crooked stock (this can result in straight, but not square cuts). 7. Coolant is not being applied correctly. 7. Saw guides are loose, or not positioned close enough to the stock being cut. 8. Check for incorrect saw band tension being used. 8. Saw band pitch choice is incorrect. 9. Saw band pitch may be too coarse for thickness of the stock section. 9. Check for incorrect adjustment of inserts, back-up bearing, or worn pivot bolts. 10. Check machine alignment. Have a DoALL service representative check and/or adjust machine alignment. 11. Check for coolant not being supplied evenly to both sides of the saw band. SAW BAND BREAKAGE 1. The saw band is being fed into the stockpiece due to incorrect saw head feeding rate. 2. Increase band speed being used and/or decrease feed force. 3. Check for stock not being held firmly by the vise jaws. 4. Check for incorrect adjustment of the saw guide inserts and carbide back-up guides. 5. Check for insufficient coolant flow. SURFACE FINISH OF CUT-OFF PIECE IS TOO ROUGH 38 1. Check for vibration while sawing. 2. Check for a damaged saw band. 3. Use a finer pitch saw band. SAW HEAD DOESN'T TILT TROUBLE SHOOTING (Continued....) 1. Check for faulty operation of Solenoids 5 and 6. 4. Increase band speed being used and/or decrease the feed rate. 2. Check adjustment of the head clear proximity switch (2 PRS). 5. Check the saw band back-up inserts for wear. Replace them if necessary. 3. Check the index forward proximity switch (4 PRS). 6. Increase flow of coolant to the cutting area. 7. Feed force may be too high if using a new saw band. SAW HEAD WON’T TRAVERSE CUTTING RATE IS TOO SLOW 1. Use a coarser pitch saw band. 2. Increase band speed and/or feed force. STOCK FEEDS ERRATICALLY 1. Check for low hydraulic system oil level. 2. Check to see if Solenoid 15 and 16 is operating. 2. Vise(s) must be clamped. 3. Check the head clear proximity switch (2 PRS) for faulty operation. 4. Check for saw head obstruction. 5. Check Solenoids 9 and 10 for incorrect operation. Check to see if Solenoid 15 and 16 is operating. Check for faulty operation of the index forward proximity switch (4 PRS) on the index vise base. Check for faulty operation of Solenoids 15 and 16. 1. Check for mechanical obstructions. 2. Check for faulty operation of Solenoids 11 and 12 for fixed vise; Solenoid 13 and 14 for index vise; Solenoid 22 and 23 for optional outboard vise. INDEX WON’T RETURN Check fo see if Solenoid 15 and 16 is operating. 2. Check for incorrect adjustment of the index forward proximity switch (4 PRS). 1. Check for faulty operation of Solenoids 9 and 10. 2. Check adjustment of the head clear proximity switch (2 PRS). 3. Check the index forward proximity switch (4 PRS). SLUGGISH HYDRAULIC OPERATION Check control panel selector switch settings. 1. Bleed air from the saw head feed cylinder. It may be necessary to move the saw head back and forth several times to thoroughly bleed the saw head feed cylinder. SAW HEAD DOESN'T MOVE FOR REPEAT CUTS VISES WIL NOT OPEN OR CLAMP 3. 2. 1. VISES WON’T TRANSFER AFTER AN INDEX 1. The head approach rate setting is too low. SAW HEAD TRAVERSES ERRATICALLY INDEX VISE WON’T MOVE FORWARD 1. 1. 39 1. Check for low hydraulic system pressure or low reservoir level. 2. Check for air in the hydraulic system. 3. Check for a blocked or clogged hydraulic filter. 4. Check for faulty hydraulic pump operation. 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 (1524.0 mm) long by 22 inches (558.8 mm) wide with a weight capacity of 750 pounds (340.2 kg) per roller. • Stock conveyor ten (10) feet (3048.0 mm) long by 22 inches (558.8 mm) wide with a weight capacity of 750 pounds (340.2 kg) per roller. 3. For nesting fixture, an additional set of vertical rollers are mounted to the end of the indexer to provide another laterally adjustment. 4. The vertical roller is adjusted along the guide rail and clamped to the rail to laterally confine stock when indexing. Vertical Guide Roller For Conveyors. NESTING FIXTURE Roller Stock Conveyor. 2. 3. 4. To install a roller stock conveyor: (a) Position the assembled conveyor(s) behind or in front of the machine base; (b) Adjust the conveyor to the machine with the leveling screws on the conveyor legs. The top of the front conveyor roller should be inline to 0.010-inch (0.25 mm) above the vise bed wear plate. 1. This optional feature is designed for high-production, multiple sawing of stacked bars, rounds and tubing. Its jaws have the capacity to hold stock from 8 to 20 inches (203.2 to 508.0 mm) wide, and from 1.38 to 10.25 inches (34.9 to 260.3 mm) high. 2. Vertical nesting clamp cylinders are mounted to the machine’s inboard and index vise tables. The cylinders operate simultaneously with the regular vise clamping cylinders. The remaining rollers must be parallel to, and in the same plane with the vise beds to within 0.010-inch (0.25 mm) per 24 inches (609.6 mm) of travel. A negative (-) angle tilt of the saw head is NOT permitted with the Nesting Fixture. Depress the roller shafts for ease of installation of rollers. The hydraulically-operated Nesting Fixture can also be used with the Variable Vise Pressure control. The conveyor DOES NOT attach to the machine base. Anchor the conveyor to the floor after all leveling and adjustments are made. Stacking Stock 1. VERTICAL GUIDE ROLLERS (For Conveyors) 1. Vertical guide rollers are effectively used to help maintain correct positioning of long stock on the conveyor. 2. These can be installed between the interface plate and conveyor or between conveyors (if more than one is supplied). 40 Correct stock nesting is essential for proper clamping of the vises and nesting fixture. It is important that nesting vise clamping pressure be transmitted to every stacked piece. Sometimes this can be more easily accomplished by manually jogging the stack. NESTING FIXTURE (Continued....) 2. Proper stacking of round stock is important because saw band breakage may occur if round nested 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). 4. Move the the vise's rod end hose(s) to indicated position. Rod End Hose Position. Control Console Round Stock Stacking Methods. 5. Pieces should be stacked as closely together as possible. Metal chips lodged in open spaces between individual pieces will affect cutting accuracy. 1. Push the F3 - Set-Up key. 2. Push the "DOWN" arrow key to "Vise Control". Vise Adjustment 1. Stack stock to be cut between the machine’s vise jaws. Then: (a) Push the F12 - Fixed Clamp and F10 - Index Clamp keys; (b) Center the nesting fixture’s vertical clamping cylinder. Set-Up Screen (F3) (1 of 4). 3. Press the "+/-" key to change selection. 4. Use the "UP" and "DOWN" arrow keys to change other selections on the screen if required. For Best Nesting Cutting Results Nesting Fixture Vise Adjustments. 2. 3. "Vise Overlap" cannot be changed in Nesting mode. Adjust the indexer’s vertical guide rollers (if supplied) so the stock will be guided correctly toward the saw band. 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 rod end of the front and/or index vise cylinders to achieve relatively equal release. 41 1. Total stack width should be no more than five (5) to six (6) inches (127.0 to 152.4 mm). 2. Stack the same number of stockpieces in each row. 3. The stack should always be higher than it is wide. 4. Apply as much coolant as possible while cutting. NESTING FIXTURE (Continued....) CHIP CONVEYOR W/COOLANT RESERVOIR 5. Replace wear plates on the moveable vise jaw and nesting fixture’s vertical clamping jaw when they become worn. 1. This option has a conveyor belt and reservoir located under the saw head and slides in and out from the rear for cleaning or servicing. 6. Adjust the feed table’s vertical guide rollers (if supplied) to keep the stack from collapsing when the vises are unclamped. 2. 7. Generally, reduced band speed and feed force are necessary when sawing stacked materials. This results in a lower cutting rate than possible when sawing solid stock. The chip conveyor motor operates simultaneously with the hydraulic pump motor. The conveyor belt moves slowly at the bottom of the reservoir. Its movement carries metal chips to the opening at the rear of the machine where chips empty into a customer-supplied container. 3. A mesh screen filters the coolant before returning to the reservoir for reuse. 4. A sight gage mounted on the rear of the reservoir for viewing coolant level. 5. The chip conveyor has a 50 gallon (189.2 liter) capacity with a float switch to indicate low coolant level. 8. In some instances, increased production and blade life may be obtained by nesting fewer pieces than maximum vise capacity permits. VERTICAL GUIDE ROLLERS (For Nesting) 1. These are mounted to the rear of the feed table's tail block to provide two (2) laterally adjusted vertical rollers. The roller operate to the rear of the tail block's horizontal roller. 2. Each vertical roller is adjustable along the pivot rod and clamps to a flat on the rod (note that the left vertical roller can be adjusted flush with the tail block roller's left end. Chip Conveyor With Coolant Reservoir. MIST LUBRICATOR Vertical Guide Rollers For Nesting Fixture. 3. When the vertical rollers are not needed, they can be easily removed and stored for later use. 42 1. The mist lubricator has a reservoir mounted in the rear of the machine with a nozzle unit mounted above and left of the lower bandwheel near the band wiper. 2. See the literature sent with your machine on recommendations and operation of the mist lubricator unit. OUTBOARD VISE RIGHT TO LEFT FEED 1. The outboard vise is mounted on the opposite side of the saw band as the indexer and used for job requirements where more clamping or holding power is needed. 1. 2. The outboard vise is usually operates in sync with the fixed vise during automatic cycle. However, it can also operate independent of other vises if desired. 3. 3° HEAD CANT 1. The vise operates in the same fashion as the fixed vise with "OPEN", "HOLD" and "CLAMP" settings. When in "MANUAL" mode, make sure the vise jaw is opened wide enough when indexing material through the outboard vise. 2. 1. Usually mounted on the same side as the indexer, the lift roller is used to help manually feed the material along into the cutting area. This roller can be mounted on either side of the saw band. 1. A selector switch on the control panel operates the lift roller (left and/or right hand) with "UP" or "DOWN" settings. 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 is controlled by a selector switch with "ON" and "OFF" settings and is located on or near the control panel. Turn the laser "OFF" when not in use. 3. The laser is adjustable to position the laser beam where desirable. 4. When the laser is turned on, a warm-up period of 3 to 5 seconds take place before a line appears. If the line is difficult to see, darken the work area to enhance the line. 5. Remove the protective shipping cap from the laser devise before operation. See a DoALL sales representative for information on all your cutting applications. This factory installed option does not allow tilting of the sawing head. MATERIAL HANDLING EQUIPMENT LASER LINE OPTION This factory installed option tilts the saw head forward three (3) degrees from vertical for easier and faster cutting of structural and other certain materials. FIXED HEAD (NON-TILTING) LIFT ROLLERS 1. Factory installed right to left feed may be desireable because of factory constraints and other factors. Operations and all other functions are the same except some orientations on the work station screens are different but are noted. 43 Special material handling equipment can enhanced the performance of your machine. Contact your DoALL sales representative for information on any material handling needs that could increase your productivity.
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project