TF-2025NC Instruction M anual

TF-2025NC Instruction M anual
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.
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