Model SAR 440
USE AND MAINTENANCE MANUAL
SAR 440 SA GDS
01/2006
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34
Registro Imprese n. 4272//VI116 REA n. 93906/Vicenza
SAR440SAGDS
Contents
Contents ........................................................................... "
Ordering spare parts ........................................................ "
Guarantee ........................................................................ "
Machine certification and identification marking ............. "
CHAPTER 1
Reference to accident-prevention regulations .................. "
1.1 - Advice for the operator ............................................. "
1.2 - Location of shields against accidental contact with
the tool ..................................................................... "
1.3 - Electrical equipment according to European
Standard "CENELEC EN 60 204-1" ............................ "
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1" .......................................... "
2
2
2
3
4
4
4
4
4
CHAPTER 2
Recommendations and advice for use .............................. "
2.1 - Recommendations and advice for using the machine ........ "
4
4
CHAPTER 3
Technical characteristics ................................................. "
3.1 - Table of cutting capacity and technical details ............ "
5
5
CHAPTER 4
Machine dimensions - Transport - Installation
Dismantling ...................................................................... "
4.1 - Machine dimensions ................................................. "
4.2 - Transport and handling of the machine ..................... "
4.3 - Minimum requirements for the premises
housing the machine ................................................. "
4.4 - Anchorage of standard machine ............................... "
4.5 - Instructions for electrical connection ......................... "
4.6 - Instructions for assembly of the loose parts and
accessories .............................................................. "
4.7 - Disactivating the machine ......................................... "
4.8 - Dismantling .............................................................. "
5
5
6
6
6
6
6
6
6
CHAPTER 5
Machine functional parts .................................................. "
5.1 - Operating head or saw frame .................................... "
5.2 - Vice .......................................................................... "
5.3 - Bed .......................................................................... "
7
7
7
7
CHAPTER 6
Description of the operating cycle .................................... "
6.1 - Starting up and cutting cycle ..................................... "
8
8
CHAPTER 7
Regulating the machine .................................................... "
9
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 -
Blade tension assembly ........................................... “
Blade guide blocks .................................................. “
Vice ......................................................................... “
Regulating the cutting angle ..................................... “
Blade-cleaning brush ............................................... “
Regulating the height of the cut ................................ “
Regulating the cutting speed .................................... "
Changing the blade .................................................. "
10
10
11
11
11
11
11
12
CHAPTER 8
Routine and special maintenance ................................. "
8.1 - Daily maintenance ................................................... "
8.2 - Weekly maintenance ............................................... "
8.3 - Monthly maintenance ............................................... "
8.4 - Six-monthly maintenance ......................................... "
8.5 - Oils for lubricating coolant ........................................ "
8.6 -Oil disposal ................................................................ "
8.7 - Special maintenance ................................................ "
12
12
12
12
12
12
12
12
CHAPTER 9
Material classification and choice of tool ..................... "
9.1 - Definition of materials ............................................... "
9.2 - Selecting blade ........................................................ "
9.3 - Teeth pitch ............................................................... "
9.4 - Cutting and advance speed ..................................... "
9.5 - Blade running-in ....................................................... "
9.6 - Blade structure ........................................................ "
9.7 - Blade type ............................................................... "
Teeth shape and angle ............................................. "
Set ........................................................................... "
13
13
13
13
14
14
14
14
14
15
9.7.1 - Table of recommended cutting parameters ................... "
15
CHAPTER 10
Machine components .................................................... " 16
10.1- List of spare parts .................................................... " 16
CHAPTER 11
Wiring diagrams ............................................................ " 21
Schema elettrico idraulico ............................................ " 23
CHAPTER 12
Troubleshooting ............................................................ " 24
12.1- Blade and cutting diagnosis ..................................... " 24
12.2- Electrical components diagnosis .............................. " 28
CHAPTER 13
Noise tests ..................................................................... " 28
Plates and labels ............................................................ " 29
Ordering spare parts
- When ordering spare parts you must state:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER
Without these references WE WILL NOT SUPPLY the spares. See point 10.1 - list of spare parts -
Guarantee
- The Company guarantees that the machine to which this manual refers has been designed and built to comply with safety regulations and
that it has been tested for functionality in the factory.
- The machine is guaranteed for 12 months: the guarantee does not cover the electric motors, electric components, pneumatic components
or any damage due to dropping or to bad machine management, the failure to observe maintenance standards or bad handling by the
operator.
- The buyer has only the right to replacement of the faulty parts, while transport and packing costs are at his expense.
- The serial number on the machine is a primary reference for the guarantee, for after-sales assistance and for identifying the machine for any
necessity.
2
SAR440SAGDS
Machine certification and identification marking
MACHINE LABEL
via Pasubio, 32 36033 ISOLA VIC. - ITALIA
MODEL
TYP
SAR
440 SA GDS
SERIAL NUMBER
YEAR OF MANUFACTURE
(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)
3
SAR440SAGDS
1 REFERENCE TO ACCIDENT - PREVENTION REGULATIONS
This machine has been built to comply with the national and community accident-prevention regulations in force. Improper use
and/or tampering with the safety devices will relieve the manufacturer of all responsibility.
1.1 - Advice for the operator
- Check that the voltage indicated on the plate, normally fixed to the machine motor, is the same as the line voltage.
- Check the efficiency of your electric supply and earthing system; connect the power cable of the machine to the socket and the earth
lead yellow-green in colour) to the earthing system.
- When the saw frame is in suspend mode (up) the toothed blade must not move.
- Only the blade section used for cutting must be kept unprotected. Remove guarding by operating on the adjustable head.
- It is forbidden to work on the machine without its shields (these are all blue or grey in colour).
- Always disconnect the machine from the power socket before blade change or carrying out any maintenance job, even in the case
of abnormal machine operation.
- Always wear suitable eye protection.
- Never put your hands or arms into the cutting area while the machine is operating.
- Do not wear loose clothing with sleeves that are too long, gloves that are too big, bracelets, chains or any other object that could get
caught in the machine during operation; tie back long hair.
- Keep the area free of equipment, tools or any other object.
- Perform only one operation at a time and never have several objects in your hands at the same time. Keep your hands as clean as
possible.
- All internal and/or internal operations, maintenance or repairs, must be performed in a well-lit area or where there is sufficient light
from extra sources so as to avoid the risk of even slight accidents.
1.2 - Location of shields against accidental contact with the tool
- Blue or grey metal shield fixed frontally with screws to the fixed blade-guiding block ( Ref. A ).
- Blue or grey metal shield fastened on the front with screws onto the blade guide adjustable head to ensure maximum covering of
blade and piece to be cut ( Ref. B ).
- Grey metal guards fastened to the saw frame with knobs, protecting the blade driving flywheels ( Ref. C ).
B
C
4
A
C
SAR440SAGDS
1.3 - Electrical equipment according to European Standard "CENELEC EN 60 204-1" which assimilates,
with some integrating modifications, the publication "IEC 204-1"
- The electrical equipment ensures protection against electric shock as a result of direct or indirect contact. The active parts of this
equipment are housed in a box to which access is limited by screws that can only be removed with a special tool; the parts are fed
with alternating current at low voltage (24 V). The equipment is protected against splashes of water and dust.
- Protection of the system against short circuits is ensured by means of rapid fuses and earthing; in the event of motor overload,
protection is provided by a thermal relay.
- In the event of a power cut, the specific start-up button must be reset.
- The machine has been tested in conformity with point 20 of EN 60204.
1.4 - Emergencies according to European Standard "CENELEC EN 60 204-1"
- In the event of incorrect operation or of danger conditions, the machine may be stopped immediately by pressing the red mushroom button.
- The casual or voluntary removal of the protection shield of the flywheels causes the stepping-in of a microswitch that automatically
stops all machine functions.
- In case blade breaks, the band tightening microswitch/pressure switch disconnects all machine.
NOTE: Resetting of machine operation after each emergency stop is achieved by reactivating the specific restart button.
2
RECOMMENDATIONS AND ADVICE FOR USE
2.1 - Recommendations and advice for using the machine
- The machine has been designed to cut metal building materials, with different shapes and profiles, used in workshops, turner’s
shops and general mechanical structural work.
- Only one operator is needed to use the machine, that must stand as shown in the picture.
- Before starting each cutting operation, ensure that the part is firmly gripped in the vice and that the end is suitably supported.
These figures show examples of suitable clamping of different section bars, bearing in mind the cutting capacities of the machine in
order to achieve a good efficiency and blade durability.
- Do not use blades of a different size from those stated in the machine specifications.
- If the blade gets stuck in the cut, release the running button immediately, switch off the machine, open the vice slowly, remove the
part and check that the blade or its teeth are not broken. If they are broken, change the tool.
- Check saw frame return spring to ensure proper balancing.
- Before carrying out any repairs on the machine, consult the dealer or apply to THOMAS.
5
SAR440SAGDS
3
TECHNICAL
CHARACTERISTICS
3.1 - Table of cutting capacity and technical details
4
MACHINE DIMENSIONS
TRANSPORT
INSTALLATION
DISMANTLING
0°
440
440
610 x 440
45° DX
440
440
500 x 230
45° SX
440
440
500 x 230
60° DX
320
300
320 x 245
60° SX
340
320
340 x 250
2500
4.1 - Machine dimensions
3000
TECHNICAL DATA
ELECTRIC MOTOR - 3-PHASE
kW
2,2
HYDRAULIC PUMP MOTOR
kW
1,1
COOLANT PUMP MOTOR
kW
0,18
FLYWHEEL Ø
mm
455
BLADE DIMENSIONS
mm
5200 x 34 x 1,1
VARIABLE BLADE SPEED
m/min
28 ÷ 140
VICE OPENING
mm
615
SAWFRAME INCLINATION
°
0
WORKING TABLE HEIGHT
mm
750
MACHINE DIMENSIONS
mm
2500x3000x2500
MACHINE WEIGHT
Kg
1570
2400
6
4.2 - Transport and handling of the machine
In case of transportation in its own packing, use a fork-lift truck.
Sling the machine with special straps as illustrated making
sure that the control panel has been securely placed on the
machine base
SAR440SAGDS
- Position the machine on a firm cement floor, maintaining, at the
rear, a minimum distance of 1000 mm from the wall; anchor it to
the ground as shown in the diagram, using screws and expansion
plugs or tie rods sunk in cement, ensuring that it is sitting level.
4.5 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the customer
must fit a suitable one for his own working conditions:
1 - WIRING DIAGRAM FOR 4-WIRE SYSTEM FOR THREEPHASE MACHINE - SOCKET FOR A 16A PLUG
R = L1
S = L2
T = L3
PE = GND
QUADRO ELETTRICO
4.3 - Minimum requirements for the premises
housing the machine
- Mains voltage and frequency complying with the machine motor
characteristics.
- Environment temperature from -10 °C to +50 °C.
- Relative humidity not over 90%.
4.6 - Instructions for assembly of the loose parts and
accessories
Fit the components supplied as indicated in the photo:
- Mount the stock stop.
- Mount the coolant liquid holder.
4.7 - Disactivating the machine
4.4 - Anchorage of standard machine
INGOMBRO OPERATIVO = mm 3000
INGOMBRO OPERATIVO = mm 2400
- If the sawing machine is to be out of use for a long period, it is
advisable to proceed as follows:
1) detach the plug from the electric supply panel
2) loosen blade
3) empty the coolant tank
4) carefully clean and grease the machine
5) if necessary, cover the machine.
4.8 - Dismantling
(because of deterioration and/or obsolescence)
General rules
If the machine is to be permanently demolished and/or scrapped,
divide the material to be disposed of according to type and composition, as follows:
1) Cast iron or ferrous materials, composed of metal alone, are secondary raw materials, so they may be taken to an iron foundry
for re-smelting after having removed the contents (classified in
point 3);
2) electrical components, including the cable and electronic ma-terial
(magnetic cards, etc.), fall within the category of material classified as being assimilable to urban waste according to the laws of
the European community, so they may be set aside for collection
by the public waste disposal service;
3) old mineral and synthetic and/or mixed oils, emulsified oils and
greases are special refuse, so they must be collected, transported
and subsequently disposed of by the old oil disposal service.
NOTE: since standards and legislation concerning refuse in gen-
7
SAR440SAGDS
eral is in a state of continuous evolution and therefore
subject to changes and variations, the user must keep
informed of the regulations in force at the time of disposing
of the machine tool, as these may differ from those
described above, which are to be considered as a general
guide line.
5
MACHINE FUNCTIONAL
PARTS
5.1 - Operating head or saw frame
- Machine part consisting of the members that transfer the motion
(gearmotor, flywheels), the tightening/guiding (blade guide arms,
blade tightening slide) and the tool lowering control.
5.2 - Vice
- Hydrailic locking system for cutting material. This device allows
for the quick shifting of the vice and the possibility to cut
inclinations to the left and right.
8
5.3 - Bed
- Structure supporting the HEAD OR SAW FRAME, the VICE, the
SWIVEL DEVICE with relative locking system, the ELECTRICALS,
the BAR STOP and housing the coolant TANK for cut and pump.
SAR440SAGDS
6
160 BAR
DESCRIPTION OF THE
OPERATING CYCLE
Before operating, all the main organs of the machine must be
set in optimum conditions (see the chapter on “Regulating the
machine”).
6.1 -
Getting started
DESCRIPTION OF THE CUTTING PROCESS:
-
Start the cutting cycle
Automatic closure of the vice;
Lowering of the sawframe ( blade );
Lifting of the sawframe ( using selector );
Opening of the vice.
8
PRELIMINARY OPERATIONS:
- Ensure that the machine is not on emergency stop; in which case
free the red, mushroom shaped, button ( 1 ) on the panel of commands.
- Rotate the blade tension handwheel ( 8 ) until the blade tension
pressure reaches 160 Bars.
- Rotate the main switch ( 2 ) in position 1.
- Press the illuminated button ( 3 ) and ensure that the relative
light is lit.
- Rotate the selector ( 5 ) to activate the lifting of the sawframe.
N.B.: if the lifting process does not occur, invert the electric
alimentation phase ( this operation is only to be done during installation ).
Service pressure of the hydraulic unit should be approx. 50
BAR.
WARNING: always ensure that the vice is positioned to the
extreme left or right of the counter vice to avoid accidental
contact with the structure of the sawframe.
- Turn selector ( 9 ) to open the vice.
- Position the vice according to the dimension of the material to
cut.
- Put the material to be cut in the vice, and approach the vice
jaw up to 3 - 4 mm with the handwheel.
- Ensuring that the latch is in place on the rack.
- Load the material to cut at the required cutting length and turn
the selector ( 9 ) to lock the material in the vice.
- Bring the mobile blade guiding arm as close as possible to
the object to be cut.
- Activate the hand wheel of the gear and set the speed control
to suit the characteristics of the material to be cut. ( do not
regulate when the motor is off ).
To regulate the desired speed refer to the plaque .
- In case of a wrong manoeuvre or to stop the cutting cycle,
press the STOP button ( 10 ).
- At the end of the cutting cycle, the sawframe will stop in the
inferior position. Rotate the selector ( 5 ) to activate the lifting of
the sawframe.
- Turn selector ( 9 ) to open the vice.
ATTENTION:
- The cutting cycle can be executed even if the selector ( 9 ) has
been switched for the open vice.
In fact, as you press START ( 3 ) the vice will close automatically.
To open the vice again you will have to turn the selector ( 9 )
first to close the vice and then to open the vice.
- Once the cut has been executed the hydraulic pump will keep
running for 20 seconds.
ATTENTION: Soon after the automatic shut off of the hydraulic
pump, press the button ( 4 ) to open the vice automatically if
the selector ( 9 ) was switched to vice open during the cutting
phase.
Note: It is recommend not to use the saw to its maximum
capacity for the first 50 working hours.
- Ensure that the cutting index correspond with the inclination
desired and that the device is blocked.
- Before starting the cutting process, it is advisable to advance
the blade to more or less 10 mm from the object to be cut,
pressing, if necessary, selector ( 5 ).
- Press regulator ( 6 ) to the ideal cutting speed to suit the
characteristics of the material. It is recommend that one always
start off slowly, increasing the speed if necessary.
It is absolutely forbidden to approach the hands to
the cutting area.
Note: for a proper lubrication and cooling during the cut, we
recommend to use a mixture of 9 parts of water and one of oil.
- Press button ( 4 ) to initiate the cutting cycle: control that the
blade turns in the correct direction and that the cooling liquid
flows sufficiently.
9
SAR440SAGDS
2
3
9
1
4
10
5
6
1
F
VOLANTINO VARIATORE
VARIATOR - HAND
WHEEL
8
9
27.5
32
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
46
51
56
61
66.5
72
77.5
83
89
95
101
107
113
120
127
133
140
POS. N°
VELOCITA' DI TAGLIO
CUTTING SPEED
m/min
10
36.5 41.5
SAR440SAGDS
- the CUTTING SPEED and the TYPE of BLADE - combined
with a suitable lowering of saw frame - are of decisive importance for cutting quality and for machine performance (for
further details on this topic, see below in the chapter on “Material classification and blade selection”).
- When starting to cut with a new blade, in order to safeguard its
life and efficiency, the first two or three cuts must be made
while exerting a slight pressure on the part, so that the time
taken to cut is about double the normal time (see below in the
chapter on “Material classification and blade selection” in the
section on Blade running-in).
- Press the red emergency button ( 1 ) when there are conditions of
danger or malfunctions in general, so as to stop machine operation immediately.
7.2 - Blade-guide head
Blade guiding is obtained by means of plates which are regulated
during the testing phase according to blade thickness.
CUTTING DIRECTION
A
7
B
REGULATING
THE MACHINE
B
A
A
7.1 - Blade tension assembly
C
The ideal blade tension is obtained by rotating the hand wheel belt
tensioner until the blade tension pressure reaches 160 Bars
otherwise the saw will not operate.
N.B.: when the saw is not in use it is recommend to loosen the
blade tension.
It is always recommend to use the blade sizes suggested in
this manual.
160 BAR
When replacing a blade, ensure that the belts are 1,1 mm thick as
the guiding blade pads have been adjusted to this size. If using
different size toothed belts, it will be necessary to proceed with a
new registration as follows:
- Loosen the screws ( B ) and loosen dowels (A ) widening the
passage between the plates.
- Loosen the dowels ( C ) and rotate the pins to widen the passage
between the bearings.
- Mount the new blade and rotate the hand wheel belt tensioner
until the relative dip-switch is activated.
- Tighten the dowels ( A ) and then loosen them to allow a play of
0,04 mm to ensure the smooth running of the blade and fasten
the screws ( B ).
- Rotate the pins until the bearings rest on the blade and block the
screws ( C ).
- Ensure that between the blade and the superior bearings there
are 0,2 - 0,3 mm of play; if necessary, loosen the screws ( D )
that block the heads and execute the necessary registration.
8
11
SAR440SAGDS
7.5 -
7.3 - Vice
-- The rapid advancement of the vice to the object to be cut is
obtained by manually moving the vice and lifting the latch ( F ).
Before blocking the object to be cut with the hand wheel check
that the latch is gripped to the rack.
- The vice unit can be positioned to the left or right of the blade.
Ensure that this positioning has been executed correctly in order
to avoid irreparable damage to the saw.
- It is recommended to keep the vice guide and ribbon clean and
oiled at all times.
Blade-cleaning brush
Ideal for the cleaning of the blade during its cutting cycle.
Periodically check the integrity of the brush and if necessary
proceed to an ulterior regulation to guarantee cleansing of
the blade.
7.6 -
Regulating the height of the cut
It is an accessory that permits the execution of lifting and/or nearing of the arch.
- Operate the selector button ( H ) to move the arch up and
down to the desired position.
F
1
H
7.7 7.4 - Regulating the cutting angle
- Lift the sawframe.
- Operate the Lever ( G ) to release the rotation of the device.
- Rotate the sawframe to the desired angle referring to the
graduated sector.
- Tighten the lever ( G ) to block the device from rotating.
6
Regulating the cutting speed
Regulation of the cutting speed can only be done with the motorbelt in motion.
To change the running speed, adjust with hand wheel and refer to
the plaque.
V
TABELLA LUBRIFICANTI
COMPONENTE
PART.
G
INDICE
12
LUBRIFICANTE QUANTITA'
OIL TYPE
KG
RIDUTTORE
REDUCTOR
SHELL
TIVELA S320
1,6
VARIATORE
VARIATOR
SHELL
DO NAX TA
1,2
SAR440SAGDS
BEFORE PERFORMING THE FOLLOWING OPERATIONS,
THE ELECTRIC POWER SUPPLY AND THE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.
7.8 – Replacing the blade
- Lift the sawframe in upright position.
- Loosen the blade with the hand wheel, remove the shield of the
mobile blade guide and the shield of the belt cleaning brush.
- Open the posterior and anterior carter flywheels and extract the
old blade from the flywheels and from the blade guide blocks.
- Insert the new blade inserting it between the plaques and then
on the flywheel holder, taking note of the direction of the teeth in
respect to the direction of the cut (refer to diagram below).
- Replace the tension of the blade checking that it is housed
perfectly within the flywheels.
- Re-assemble the shields of the mobile guide blade and of the
belt cleaning brush and close the carter flywheels cover, checking
that the safety dip-switch is activated otherwise the machine will
not operate when it is switched on.
WARNING: always use blades having dimensions spcified
in this manual and for which the blade guide heads have
been set: otherwise, see chapter on "Description of the
operating cycle" in the section Starting-up..
CUTTING DIRECTION
8.2 - Weekly maintenance
- More accurate general cleaning of the machine to remove shavings, especially from the lubricant fluid tank.
- Removal of pump from its housing, cleaning of the suction filter
and suction zone.
- Clean the filter of the pump suction head and the suction
area.
- Cleaning with compressed air of blade guide arms (guide bearings, pads and drain hole of the lubricating cooling).
- Cleaning flywheel housings and blade sliding surfaces on flywheels.
- Check condition of the blade cleaning brushes.
- Greasing of motor flywheel bearings.
8.3 - Monthly maintenance
- Check the tightening of the motor flywheel screws.
- Check that the blade guide bearings on arms are perfect running
condition.
- Check the tightening of the screws of the gearmotor, pump and
accident protection guarding.
8.4 - Six-monthly maintenance
REDUCTION UNIT
- we suggest to make the first oil replacement after about 300
working hours and wash internal par ts carefully.
Use synthetic oil SHELL TIVELA OIL 320 type or equivalent.
- The following oil replacement should be made after about 2000
working hours.
VARIATOR UNIT
- Make the oil replacement after about 2000 working hours using
the SHELL DONAX TA type or equivalent.
WARNING : absolutely do not mix synthetic oil and mineral oil.
PROBABLE REPLACEMENT OF OTHER PARTS –
REDUCTION GEAR OR SPEED CONTROL, MOTOR PUMP
AND ELECTRICAL COMPONENTS – TO BE EXECUTED BY
SPECIALISED AND COMPETENT PERSONNEL.
8
ROUTINE
AND SPECIAL
MAINTENANCE
THE MAINTENANCE JOBS ARE LISTED BELOW, DIVIDED INTO
DAILY, WEEKLY, MONTHLY AND SIX-MONTHLY INTERVALS. IF
THE FOLLOWING OPERATIONS ARE NEGLECTED, THE RESULT
WILL BE PREMATURE WEAR OF THE MACHINE AND POOR
PERFORMANCE.
8.1 - Daily maintenance
-
General cleaning of the machine to remove accumulated shavings.
Clean the lubricating coolant drain hole to avoid excess fluid.
Top up the level of lubricating coolant.
Check blade for wear.
Rise of saw frame to top position and partial slackening of the
blade to avoid useless yield stress.
- Check functionality of the shields and emergency stops.
Replace the oil in the hydraulic unit ad least once a year using
SHELL HYDRAULIC OIL 32 type or equivalent.
- The saw with the ascending arch device, a complete oil change
is advisable once a year using SHELL HYDRAULIC OIL 32 or
similar.
- Continuity test of the equipotential protection circuit.
8.5 - Oils for lubricating coolant
Considering the vast range of products on the market, the user
can choose the one most suited to his own requirements, using as
reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER IS
8 - 10 %.
8.6 - Oil disposal
The disposal of these products is controlled by strict regulations.
Please see the Chapter on “Machine dimensions - Transport - Installation” in the section on Dismantling.
8.7 - Special maintenance
Special maintenance operations must be carried out by skilled personnel.
However, we advise contacting THOMAS or their dealer and/or importer. Also the reset of protective and safety equipment and devices, of the reducer, the motor, the motor pump and electric components is to be considered extraordinary maintenance.
13
SAR440SAGDS
9
MATERIAL
CLASSIFICATION AND
CHOICE OF TOOL
Since the aim is to obtain excellent cutting quality, the various
parameters such as hardness of the material, shape and thickness, transverse cutting section of the part to be cut, selection of the type of cutting blade, cutting speed and control of
saw frame lowering.These specifications must therefore be harmoniously combined in a single operating condition according to
practical considerations and common sense, so as to achieve
an optimum condition that does not require countless operations to prepare the machine when there are many variations in
the job to be performed.The various problems that crop up from
time to time will be solved more easily if the operator has a good
knoledge of these specifications.
WE THEREFORE RECOMMEND YOU TO ALWAYS USE
GENUINE SPARE BLADES THAT GUARANTEE SUPERIOR
QUALITY AND PERFORMANCE.
9.1 - Definition of materials
The table at the foot of the page lists the characteristics of the materials to be cut, so as to choose the right tool to use.
be cut, according to these criteria:
- parts with a thin and/or variable section such as profiles, pipes
and plate, need close toothing, so that the number of teeth used
simultaneously in cutting is from 3 to 6;
- parts with large transverse sections and solid sections need widely
spaced toothing to allow for the greater volume of the shavings
and better tooth penetration;
- parts made of soft material or plastic (light alloys, mild bronze,
teflon, wood, etc.) also require widely spaced toothing;
- pieces cut in bundles require combo tooth design.
9.3 - Teeth pitch
As already stated, this depends on the following factors:
- hardness of the material
- dimensions of the section
- thickness of the wall.
BLADE TEETH SELECTION TABLE
THICKNESS MM
Z CONTINUOUS
TOOTH DESIGN
Z COMBO
TOOTH DESIGN
TILL 1.5
14
10/14
FROM 1 TO 2
8
8/12
FROM 2 TO 3
6
6/10
FROM 3 TO 5
6
5/8
FROM 4 TO 6
6
4/6
MORE THAN 6
4
4/6
9.2 - Selecting blade
First of all the pitch of the teeth must be chosen, in the other words,
the number of teeth per inch (25,4 mm) suitable for thematerial to
S = THICKNESS
TYPES OF STEEL
CHARACTERISTICS
Hardness Hardness
GB
USA
BRINELL ROCKWELL
SB
AISI-SAE
HB
HRB
------116
67
43
---148
80
50
---180
88
060 A 20
1020
198
93
060 A 40
1040
198
93
---1050
202
94
060 A 62
1060
202
94
735 A 50
6150
207
95
---9262
224
98
360÷480
430÷560
510÷660
540÷690
700÷840
760÷900
830÷980
1140÷1330
1220÷1400
35CD4
39NCD4
40CADG12
708 A 37
---905 M 39
4135
9840
----
220
228
232
98
99
100
780÷930
880÷1080
930÷1130
----
20NCD7
En 325
4320
232
100
760÷1030
20NiCrMo2
21NiCrMo2
20NCD2
805 H 20
4315
224
98
690÷980
100Cr6
100Cr6
100C6
534 A 99
52100
207
95
690÷980
---S-1
D6-D3
S5
410
304
---316
244
212
252
244
202
202
202
202
220
140
120
100
212
232
222
102
96
103
102
94
94
94
94
98
77
69
56,5
96
100
98
800÷1030
710÷980
820÷1060
800÷1030
670÷885
590÷685
540÷685
490÷685
620÷685
375÷440
320÷410
265÷314
245
600
420
Spring
steels
I
UNI
Fe360
Fe430
Fe510
C20
C40
C50
C60
50CrV4
60SiCr8
D
DIN
St37
St44
St52
CK20
CK40
CK50
CK60
50CrV4
60SiCr7
F
AF NOR
E24
E28
E36
XC20
XC42H1
---XC55
50CV4
----
Alloyed steels for
hardening and
tempering and for
nitriding
35CrMo4
39NiCrMo4
41CrAlMo7
34CrMo4
36CrNiMo4
41CrAlMo7
Alloyed
casehardening
steels
18NiCrMo7
USE
Construction
steels
Carbon
steels
Alloyed for
bearings
52NiCrMoKU 56NiCrMoV7C100K
------C100KU
C100W1
---BS 1
X210Cr13KU
X210Cr12
Z200C12 BD2-BD3
58SiMo8KU
---Y60SC7
---X12Cr13
4001
------Stainless
X5CrNi1810
4301
Z5CN18.09 304 C 12
X8CrNi1910
---------steels
X8CrNiMo1713
4401
Z6CDN17.12 316 S 16
Copper alloys Aluminium copper alloy G-CuAl11Fe4Ni4 UNI 5275
Special manganese/silicon brass G-CuZn36Si1Pb1 UNI5038
Special brass
Manganese bronze SAE43 - SAE430
Bronze
Phosphor bronze G-CuSn12 UNI 7013/2a
Gray pig iron
G25
Cast iron
Spheroidal graphite cast iron GS600
Malleable cast iron
W40-05
Tool steel
14
R=N/mm²
SAR440SAGDS
SOLID Ø OR L MM
Z CONTINUOUS
TOOTH DESIGN
Z COMBO
TOOTH DESIGN
TILL 30
8
5/8
FROM 30 TO 60
6
4/6
FROM 40 TO 80
4
4/6
MORE THAN 90
3
3/4
9.7 - Blade type
They differ essentially in their constructive characteristics, such as:
- shape and cutting angle of tooth
- pitch
- set
Shape and angle of tooth
Ø = DIAMETER
L = WIDTH
REGULAR TOOTH: 0° rake and constant pitch.
9.4 - Cutting and advance speed
The cutting speed (m/min) and the advance speed (cm2/min = area
travelled by the disk teeth when removing shavings) are limited by
the development of heat close to the tips of the teeth.
- The cutting speed is subordinate to the resistance of the material
(R = N/mm2), to its hardness (HRC) and to the dimensions of the
widest section.
- Too high an advance speed (= lowering of the saw frame) tends to
cause the disk to deviate from the ideal cutting path, producing
non rectilinear cuts on both the vertical and the horizontal plane.
Most common form for transversal or inclined cutting of solid small
and average cross-sections or pipes, in laminated mild steel and
grey iron or general metal.
POSITIVE RAKE TOOTH: 9° - 10° positive rake and constant pitch.
positive
The best combination of these two parameters can be seen directly
examining the chips.
Long spiral-shaped chips indicate ideal cutting.
Particular use for crosswise or inclined cuts in solid sections or large
pipes, but above all harder materials (highly alloyed and stainless
steels, special bronze and forge pig).
Very fine or pulverized chips indicate lack of
feed and/or cutting pressure.
COMBO TOOTH: pitch varies between teeth and consequently varying teeth size and varying gullet depths. Pitch varies between teeth
which ensures a smoother, quieter cut and longer blade life owing to
the lack of vibration.
Another advantage offered in the use of this type of blade in the fact
that with an only blade it is possible to cut a wide range of different
Thick and/or blue chips indicate overload of
the blade.
distance between teeth
9.5 - Blade running-in
materials in size and type.
When cutting for the first time, it is good practice to run in the
tool making a series of cuts at a low advance speed
(= 30-35 cm2/min on material of average dimensions with respect
to the cutting capacity and solid section of normal steel with R =
410-510 N/mm2), generously spraying the cutting area with lubricating coolant.
COMBO TOOTH: 9° - 10° positive rake.
positive
9.6 - Blade structure
Bi-metal blades are the most commonly used. They consist in a silicon-steel blade backing with electron beam or laser welded high speed
steel (HHS) cutting edge. The type of stocks are classified in M2,
M42, M51 and differ from each other because of their major hardness due to the increasing percentage of Cobalt (Co) and molybdenum (Mo) contained in the metal alloy.
This type of blade is the most suitable for the cutting of section bars
and large and thick pipes as well as for the cutting of solid bars at
maximum machine capacity. Available pitches: 3-4/4-6.
15
SAR440SAGDS
the cutting of pipes and thin section bars (from 1 to 3 mm).
Set
Saw teeth bent out of the plane of the saw body, resulting in a wide
cut in the workpiece.
REGULAR OR RAKER SET: Cutting teeth right and left, alternated
by a straight tooth.
Of general use for materials with dimensions superior to 5 mm. Used
for the cutting of steel, castings and hard nonferrous materials.
WAVY SET: Set in smooth waves.
ALTERNATE SET (IN GROUPS): Groups of cutting teeth right and
left, alternated by a straight tooth.
This set is associated with very fine teeth and it is used for extremely
thin materials (less than 1 mm).
ALTERNATE SET (INDIVIDUAL TEETH): Cutting teeth right and left.
This set is used for the cutting of nonferrous soft materials, plastics
and wood.
This set is associated with very fine teeth and it is mainly used for
9.7.1 - RECOMMENDED CUTTING PARAMETERS
STEEL
16
CUTTING SPEED
LUBRICATION
CONSTRUCTION
60/80
EMULSIFIABLE OIL
CEMENTATION
40/50
EMULSIFIABLE OIL
CARBON STEEL
40/60
EMULSIFIABLE OIL
HARDENING AND TEMPERING
40/50
EMULSIFIABLE OIL
BEARINGS
40/60
EMULSIFIABLE OIL
SPRINGS
40/60
EMULSIFIABLE OIL
FOR TOOLS
30/40
EMULSIFIABLE OIL
FOR VALVES
35/50
EMULSIFIABLE OIL
STAINLESS STEEL
30/40
EMULSIFIABLE OIL
SPHEROIDAL GRAPHITE
20/40
EMULSIFIABLE OIL
CAST IRON
40/60
EMULSIFIABLE OIL
ALUMINIUM
80/600
KEROSENE
BRONZE
70/120
EMULSIFIABLE OIL
HARD BRONZE
30/60
EMULSIFIABLE OIL
BRASS
70/350
EMULSIFIABLE OIL
COPPER
50/720
EMULSIFIABLE OIL
SAR440SAGDS
10
MACHINE COMPONENTS
10.1 - List of spare parts
REFERENCE N°
DENOMINATION
REFERENCE N°
DENOMINATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Bedframe
Electric box
Electric parts housing guard
Revolving arm lock lever
Arm lock bush
Machine hoisting hook
Lateral guard
Stroke-end stop
Adjustable bracket
Refrigeranting liquid tank
Electropump
Bar stop body
Bar stop push rod
Bar stop rod
Revolving arm pin
Countervice pin
Revolving arm
Bearing 32008 X
Bushing
Screw
Hinge pin protection
Bearing 32008 X
Hinge pin spacer
Hinge pin
Ring nut guk M 40x1,5
Countervice r.h. jaw
Countervice l.h. jaw
Interchangeable plate
Countervice
Countervice anterior guard
Pieces support
44
45
46
47
Bearing fork
Bearing SKF NATV 17 PPI
Pin
Bearing protection
48
49
50
51
52
53
54
Hydraulic vice cilinder
Hinge pin support
Sheath
Saw frame cylinder support
Bush
Pin
Handle
Vice support
Rack
Rack support
Vice
Vice screw
Handwheel
Pin
Pawl
Vice jaw
Crucible
Ring NILOS 32008 XAV
17
SAR440SAGDS
REFERENCE N°
DENOMINATION
REFERENCE N°
DENOMINATION
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
Sawframe
Electric motor
Speed variator
Speed variator handwheel
Ring nut guk M 40x1,5
Speed reducer
Spacer
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
Spacer
Bearing 51204
Spring washer
Manometer
Pressure switch
Rear crucible
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
18
Cylinder joint
Cylinder superior pin
Microswitch
Plate
Plate
Sawframe cylinder
Adjustable screw
transmission flywheel pin
Ring nut guk M 45x1,5
Blade tightening slide
Handle
Blade tightening handwheel
pin
Pin
Blade tightening Cylinder
Bracket
Ring NILOS 32209 XAV
Bearing 32209 XAV
Transmission flywheel
Ring nut guk M 45 x 1,5
Bearing 3309 2RS
Ring NILOS 3309 AV
Bearing protection
Motor flywheel shaft
Motor flywheel
Cone clamping
EUROCONIC
Blade guide protection
Microswitch
R.h Flywheel protection
L.h. Flywheel protection
Blade guide arm guide
L.h. adjustable blade guide
arm
R.h. adjustable blade guide
arm
Hand lever
Additional protection
130
131
132
133
134
135
Blade guide bearing pin
Bearing 6200 2RS
Ring seeger Ø 10
Upper blade guide pad
Lateral blade guide pad
Hinge
Middle protection
Brush
Brush support
Bearing 626 2RS
Brush ring
Blade protection
Auxiliary blade protection
Distributor block
Coupling
Cooling liquid cock
Flexible tube
Handgripp
38
39
36
48
41
3
37
33
2
35
34
30
31
54
29
28
27
50
1
9
26
20
4
8
17
24
22
51
16
19 43
21
52
5
15
46
44
53
6
14
18
8
45
13
47
43 23
49
7
12
11
25
6
10
42
SAR440SAGDS
19
20
132
134
ZOOM - 2
133
131
131
130
61
70
63
71
64
68
77
112
73
78
109
108
82
69
98
65
91
107
92
93
94
95
96
85
81
66
76
75
110
60
62
72
84
111
86
101
87
98
83
89
87
86
120
90
100
SAR440SAGDS
135
SAR440SAGDS
104
103
104
102
124
126
125
106
123 122
121
114
97
117
115
114
117
116
118
ZOOM 2
115
118
116
ZOOM 1
21
SAR440SAGDS
406
401
408
405
402
403
KEY:
401
402
403
404
405
406
407
408
Main switch
Arch movement selector
Emergency switch
STOP button
Regulator arch descent
On-line button
Start button
Vice selector
1
404
407
KEY:
410
411
412
413
414
415
416
417
Transformer
Fuse cartridge
Relay ( Kb )
Remote switch
Thermal motor
Remote switch
Timer
Thermal motor
411 413
417 414
415
410
KEY:
421
422
423
424
Motor gear case id.
Vice electrovalve-solenoid
Gear case tank id.
Sawframe electrovalve-solenoid
421
22
424
422
423
412
416
SAR440SAGDS
11
ELECTRIC DIAGRAM
THOMAS
THOMAS
11.1 - Three-phase electric diagram
QS1
FU1
KM1
KM2
FR2
Main switch
Fuse cartridge
Central motor control switch id.
Motor belt control switch
Thermal motor belt
M1
M2
M3
FU2
TC1
Motor gear case id.
Belt motor
Motor pump
Fuse cartridge
Transformer
23
THO MAS
THOMAS
SAR440SAGDS
24
SAR440SAGDS
11.2 - Hydraulic electric diagram
01 Sawframe downfeed regulator
02
Sawframe lifting speed
regulator
04 Electric valve
05 Valve
06 Valve
E L E N C O C O M P O N E N T I E L E T T R IC I
M O D .:
R IF .
QS1
P -F U 1
FU1
P FU2
FU2
P -F U 3
FU3
P -F U 4
FU4
TC 1
KM1
KM2
FR1
FR2
M1
M2
M3
KA1
KA2
HL
SB1
SB2
SB3
SB4
SA1
SA2
Y V I----4
SQ2
SQ3
SQ1
P
X 1
X2
X3
K TC
K M 1 -C
K M 2 -C
S A R 440 S A G D S
D E S C R IZ IO N E
O P T IO N A L :
C A R A T T E R IS T IC H E
IN T E R U T T O R E G E N E R A L E
P O R T . X M O T O R I C E N T R A L IN A ID R A U L .
F U S IB . P R O T M O T O R E ID R A U L IC O
P O R T X P R O T M O T. N A S TR O E P O M P A
F U S .P R O T M O T. N A S TR O E P O M P A
P O R T. X P R O T TR A S F .
F U S IB IL IP R O T E Z , T R A S F O R M A T O R E
P O R T. X P R O T S E C O N D .
F U S . P R O T C IR . A U S IL IA R IO
TR A S F O R M A TO R E A U S ,
T E L E R U T T O R E C E N T R . ID R A U L IC A
TE L E R U TTO R E M O TO R E N A S TR O
T E R M IC O P R O T . M O T . C E N T R A L . ID R .
T E R M IC O P R O T . M O T O R E N A S T R O
M O T O R E C E N T R A L IN A ID R A U L IC A
M O TO R E N A S TR O
PO M PA ACQUA
R E L E A U S IL IA R IO + Z O C C O L O
R E L E A U S IL IA R IO + Z O C C O L O
S P IA L IN E A
P U L S A N TE E M E R G E N ZA
P U L S A N T E L IN E A
P U L S A N T E IN IZ IO C IC L O
P U L S A N T E S T O P C IC L O
S E L E TTO R E M P V . A R C O
S E L E TTO R E M O R S A
V A L V O L E ID R A U L IC H E
M IC R O R IP A R O N A S T R O
M IC R O R IP A R O N A S T R O
M IC R O A R C O B A S S O
P R E S S O S TA TO TE N S . L A M A
S C A T O L A D E R IV A Z IO N E
M O R S E T T I C O N N E S S IO N E
M O R S E T T I C O N N E S S IO N E
T E M P O R IZ Z A T O R E + Z O C C O L O
C O N T A T T O A U S . C E N T R A L IN A
C O N TA TTO A U S . N A S TR O
20 A 600 V , T R IF A S E
32 A 600 V 3 F A S I
10 A 600 V 10 X 38
32 A 600 V 3 F A S I
16 A 600 V 10 X 38
32 A 600 V 2 F A S I
1A 600 V 10 X 38
32 A 600 V 1 F A S I
4A 600 V
10 X 38
7 5 V A U S C IT A 2 4 V O L T
25A 600V 24V
25A 600V 24V
1 0 A 7 5 0 V N . C . 2 , 5 -4 A
1 0 A 7 5 0 V N . C . 4 -6 A
K W 1 , 1 1 4 0 0 G IR I
K W 2 , 2 1 4 0 0 G IR I
K W 0 , 1 1 2 8 0 0 G IR I H 1 2 0
7 A 2 5 0 V . 2 C O N T . S C A M B IO
5 A 2 5 0 V . 4 C O N T . S C A M B IO
2 4 V . N E O N F A S TO M V .
3 A 250 V N .C .
10A 690 V N .O .
10A 690 V N .O .
10A 690 V N .C .
1 0 A 6 9 0 V + 2 N .O
10A 690 V + 2N .O .+ 2 N .C
S U C E N T R A L IN A
3 A 2 5 0 V C O N C H IA V E
3 A 2 5 0 V C O N C H IA V E
3A 400 V N C+ N O
0.5 A 250 V
300 B A R N .O
6 V IE
2,5 M M 800 V
T E R M IN A L I
2 C . S C A M B IO
300 S E C
1 NC+ 1 N O 10A 750 V .
1 NC + NO
10 A 750 V .
Q U A N T IT A F O R N IT O R E
1
1
3
1
3
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
47
2
1
1
1
G IO V E N Z A N A
W EBER
W EBER
W EBER
W EBER
W EBER
W EBER
W EBER
W EBER
F . M . T.
C .G .E .
C .G .E .
C .G .E .
C .G .E .
TE S S A R O
TE S S A R O
S A C E M I T R IF A S E
F IN D E R
F IN D E R
S IG N A L U X
T E L E M E C A N IQ U E
LO V A TO
LO V A TO
LO V A TO
LO V A TO
LO V A TO
L -C R E IT E R
R E IT E R
P IZ Z A T O
E L E TTR O TE C
P A L A ZZO L I
S IE M E N S
W E ID M U L L E R
C R O U ZE T
C .G .E .
C .G .E .
DATA:
2 0 /0 1 /0 6
SCH.
1
ART.
P 20 0003 R1
P C H 3 X 38
CH 10 X 30 10 A
P C H 3 X 38
CH 10 X 38 16 A
P C H 2 X 38
CH 10 X 38 1A M
P C H 1 X 38
CH 10 X 38 4A
75 V A 24 V . S E C
C L 00 A 3 10 T1
C L 00 A 3 10 T1
R T1 K
R T1 L
55.32 024 + 9472
55.34 024 + 9474
TB F S C 1 V E 2 4 V .
ZB 4 B S 8 4 4 + B Z1 0 2
8L M 2 TB 1 08
8L M 2 TB 1 03
8LM 2 ?
8L M 2 TS 2 31
8L M 2 TS 2 20
21,5 V D C R A C 24 V
RS 2 10 11 D
RS 2 10 11 D
F R 4501
P M N 14K T 90D
T A IS 1 0 1 0 6 1
8W A 11 011 DF 11
E W 35
TO P 3 6 2 4 V + 9 0 2 6
B C LF 10+ B CLF01
B C LF 10+ B CLF 01
25
SAR440SAGDS
12 TROUBLESHOOTING
This chapter lists the probable faults and malfunctions that could occur while the machine is being used and suggests possible remedies for
solving them.
The first paragraph provides diagnosis for TOOLS and CUTS, the second for ELECTRICAL COMPONENTS.
12.1 - Blade and cut diagnosis
FAULT
PROBABLE CAUSE
REMEDY
TOOTH BREAKAGE
Too fast advance
Decrease advance, exerting less cutting
pressure. Adjust the braking device if
mounted on the machine.
Change speed and/or type of blade.
See chapter on “Material classification and
blade selection”, in the section Blade selection table according to cutting and feed
speed.
Wrong cutting speed
Wrong tooth pitch
Choose a suitable blade. See Chapter “Material classification and blade selection”.
Chips sticking onto teeth and in the gullets or material that gums
Check for clogging of cooling liquid drain
holes on the blade-guide pads and that flow
is plentiful in order to facilitate the removal
of chips from the blade.
Defects on the material or material too
hard
Material surfaces can be oxidised or covered
with impurities making them, at the beginning of the cut, harder that the blade itself,
or have hardened areas or inclusions inside
the section due to productive agents used
such as casting sand, welding wastes, etc.
Avoid cutting these materials or in any case
perform cutting with extreme care, cleaning and removing such impurities as quickly
as possible.
Check the gripping of the part.
Ineffective gripping of the part in the vice
The blade gets stuck in the material
Starting cut on sharp or irregular section bars
Poor quality blade
Previously broken tooth left in the cut
Cutting resumed on a groove made previously
Vibrations
Pay more attention when you start cutting.
Use a superior quality blade.
Accurately remove all the parts left in.
Make the cut elsewhere, turning the part.
Check gripping of the part.
Wrong tooth pitch or shape
Replace blade with a more suitable one.
See “Material classification and blade
selection” in the Blade Types section.
Adjust blade guide pads.
Insufficient lubricating refrigerant or
wrong emulsion
Check level of liquid in the tank. Increase the
flow of lubricating refrigerant, checking that
the hole and the liquid outlet pipe are not
blocked.
Check the emulsion percentage.
Turn teeth in correct direction.
Teeth positioned in the direction opposite the cutting direction
26
Reduce feed and exert less cutting pressure.
SAR440SAGDS
FAULT
PROBABLE CAUSE
REMEDY
PREMATURE BLADE WEAR
Faulty running-in of blade
See “Material classification and blade selection” in the Blade running-in section.
Turn teeth in correct direction.
Teeth positioned in the direction opposite the cutting direction
Poor quality blade
Too fast advance
Wrong cutting speed
Defects on the material or material too
hard
Insufficient lubricating refrigerant or
wrong emulsion
Faulty welding of blade
BLADE BREAKAGE
Too fast advance
Wrong cutting speed
Wrong tooth pitch
Ineffective gripping of the part in the vice
Blade touching material at beginning of
cut
Use a superior quality blade.
Decrease advance, exerting less cutting
pressure. Adjust the braking device if
mounted on the machine.
Change speed and/or type of blade.
See chapter on “Material classification and
blade selection”, in the section Blade selection table according to cutting and feed
speed.
Material surfaces can be oxidised or covered
with impurities making them, at the beginning of the cut, harder that the blade itself,
or have hardened areas or inclusions inside
the section due to productive agents used
such as casting sand, welding wastes, etc.
Avoid cutting these materials or in any case
perform cutting with extreme care, cleaning and removing such impurities as quickly
as possible.
Check level of liquid in the tank. Increase the
flow of lubricating refrigerant, checking that
the hole and the liquid outlet pipe are not
blocked.
Check the emulsion percentage.
The welding of the blade is of utmost importance. The meeting surfaces must perfectly
match and once they are welded they must
have no inclusions or bubbles; the welded
part must be perfectly smooth and even.
They must be evenly thick and have no bulges
that can cause dents or instant breakage
when sliding between the blade guide pads.
Decrease advance, exerting less cutting
pressure. Adjust the braking device if
mounted on the machine.
Change speed and/or type of blade.
See chapter on “Material classification and
blade selection”, in the section Blade selection table according to cutting and feed
speed.
Choose a suitable blade. See Chapter “Material classification and blade selection”.
Check the gripping of the part.
At the beginning of the cutting process,
never lower the saw frame before starting
the blade motor.
27
SAR440SAGDS
FAULT
PROBABLE CAUSE
REMEDY
Blade guide pads not regulated or dirty
because of lack of maintenance
Check distance between blocks (see “Machine adjustments” in the Blade Guide
Blocks section): extremely accurate guiding
may cause cracks and breakage of the tooth.
Clean carefully.
Blade guide block too far from material
to be cut
Approach head as near as possible to material to be cut so that only the blade section
employed in the cut is free, this will prevent
deflections that would excessively stress the
blade.
The back of blade rubs against the support
due to deformed or poorly welded bands (tapered), causing cracks and swelling of the
back contour.
Check level of liquid in the tank. Increase the
flow of lubricating refrigerant, checking that
the hole and the liquid outlet pipe are not
blocked. Check the emulsion percentage.
Improper position of blade on flywheels
Insufficient lubricating refrigerant or
wrong emulsion
STREAKED OR ETCHED BANDS
Damaged or chipped blade guide
pad
Tight or slackened blade guide bearing
CUTS OFF THE STRAIGHT
Blade not parallel as to the counter-vice
Blade not perpendicular due to the excessive play between the guide pads
and maladjustment of the blocks
Too fast advance
Blade guide block too far from material
to be cut
Worn out blade
Wrong tooth pitch
28
Replace it.
Adjust it (see Chapter “Machine adjustments” in Blade guide section).
Check fastenings of the blade guide blocks
as to the counter-vice so that they are not
too loose and adjust blocks vertically; bring
into line the position of the degrees and if
necessary adjust the stop screws of the
degree cuts.
Check and vertically re-adjust the blade guide
blocks; reset proper side guide play (see
Chapter “Machine adjustments” in Blade
guide section).
Decrease advance, exerting less cutting
pressure. Adjust the braking device if
mounted on the machine.
Approach it as near as possible to material
to be cut so that only the blade section employed in the cut is free, this will prevent deflections that would excessively stress the
blade.
Replace it.
Blade with major density of teeth is being
used, try using one with less teeth (see Chapter “Material classification and blade selection” in the Blade Types section).
SAR440SAGDS
FAULT
PROBABLE CAUSE
REMEDY
Broken teeth
Irregular work of the blade due to the lack of
teeth can cause deflection in the cut; check
blade and if necessary replace it.
Check level of liquid in the tank. Increase the
flow of lubricating refrigerant, checking that
the hole and the liquid outlet pipe are not
blocked.
Check the emulsion percentage.
Insufficient lubricating refrigerant or
wrong emulsion
FAULTY CUT
Worn out flywheels
Flywheel housing full of chips
STREAKED CUTTING SURFACE
Too fast advance
Poor quality blade
Worn out blade or with chipped and/or
broken teeth
Wrong tooth pitch
Blade guide block too far from material
to be cut
NOISE ON GUIDE BLOCKS
The support and guide flange of the band
are so worn out that they cannot ensure
the alignment of the blade, causing faulty
cutting; blade rolling and drawing tracks can
have become tapered. Replace them.
Clean with compressed air.
Decrease advance, exerting less cutting
pressure. Adjust the braking device if
mounted on the machine.
Use a superior quality blade.
Replace it.
Blade used probably has too large teeth; use
one with more teeth (see “Material classification and blade selection” in the Blade
Types section).
Approach it as near as possible to material
to be cut so that only the blade section employed in the cut is free, this will prevent deflections that would excessively stress the
blade.
Insufficient lubricating refrigerant or
wrong emulsion
Check level of liquid in the tank. Increase the
flow of lubricating refrigerant, checking that
the hole and the liquid outlet pipe are not
blocked.
Check the emulsion percentage.
Chipped bearings
Dirt and/or chips between blade and guide
bearings. Replace them.
Replace them.
Worn out or damaged pads
29
SAR440SAGDS
12.2 - Electrical components diagnosis
FAULT
PROBABLE CAUSE
REMEDY
MACHINE DOES NOT WORK
Power supply
Check:
Main disconnect switch
Fuses " FU 1 "
" SQ 1 " safety microswitch
Blade tightening microswitch
Emergency button " SB 1 " on
Cycle reset or line button " SB 2 "
Thermal relay of main motor
Transformer " TC 1 "
Fuse " FU 2 - FU 3 "
MOTOR STOPPED WITH PILOT LIGHT
“HL” LIT
Check that the supply voltage is the same
as the line voltage and that it gives a value of
24 V at output.
Check fuse efficiency and ensure there are
no short circuits causing the protection on
the control side of the circuit.
Microswitch " SQ 2 "
After having raised the saw frame, check
that the microswitch is not engaged and if
necessary check operating efficiency.
Remote-control switch " KM "
Check that phases are present at both input and output; ensure that it is not blocked,
that it closes when fed, that it does not cause
short circuits; otherwise change it.
Check that it is not burnt and that it turns
freely.
It may be rewound or changed.
Motor " M 1 "
13
- phases
- cables
- socket
- plug
Voltage must arrive upstream from the fuses
(terminal board).
It must be turned to ON position.
Check electrical efficiency. Check power line
connections and relative terminals.
Check electrical efficiency and check for
shorts that trigger these protections on the
power side of the circuit.
Check closing of the flywheel guard. Check
the efficiency of the device; replace it if damaged.
Make sure to have tightened the blade with
the relevant handwheel and to have actuated
the microswitch.
Ensure that it is off and that its contacts are
unbroken.
Check mechanical efficiency; replace if damaged.
Check that thermal relay protecting main
motor is correctly connected.
NOISE TESTS
In accordance with point 1.7.4.f of the Machines Directive EEC 98/37
2 measurements with the machine operating unloaded.
- The microphone was been located close to the operator's head, at medium height.
- The weighted equivalent continuous acoustic pressure level was 65,4 dB (A).
- The maximum level of the WEIGHTED instantaneous acoustic pressure C was always less than 130 dB.
NOTE: with the machine operating, the noise level will vary according to the different materials being processed. The user must there-fore
assess the intensity and if necessary provide the operators with the necessary personal protection, as required by Law 277/1991.
30
SAR440SAGDS
PLATES AND LABELS
31
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34
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