C-650M Instruction M Anual

C-650M

Serial No: 509-94101 to Instruction Manual

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.

3. Do not move the equipment from the receiving area and keep all shipping materials until carrier “damage inspection” report is complete.

4. If possible, take photographs of the damage and keep them for your files. Photos could possibly prove a claim at a later time.

5. Keep a record of all expenses and be sure they are documented.

6. Repair damage in the field whenever possible. Carriers encourage this to keep expenses down.

7. You have nine (9) months to file a claim. OPERATOR'S INSTRUCTION MANUAL METAL CUTTING BAND SAW

MODEL FIRST SERIAL NO. LAST SERIAL NO.

C-650M 509-06103

For your information and future reference, pertinent data concerning your machine should be written in the spaces provided above. This information is 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 continu- ous 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

DoALL SAWING PRODUCTS 2375B TOUHY AVENUE ELK GROVE, ILLINOIS 60007 U.S.A.

The following registered trademarks of the DoALL Company are used in this manual: DoALL, Imperial Bi-Metal, Kleen-Kool, Polypac, Power-Cut and Tensigage.

PRINTED IN U.S.A. PB-459.2 (7-06) i TABLE OF CONTENTS

MACHINE DIMENSIONS MAINTENANCE

Floor Plan ...... 1 Replacing Saw Guide Inserts ...... 20 Front View ...... 2 Band Drive Belt Replacement ...... 20-21 Hydraulic System ...... 21 MACHINE FEATURES Coolant System ...... 21 Band Brush ...... 21 Front and Top Views ...... 3 Machine Cleaning ...... 22 Limit Switch Locations ...... 4 Machine Alignment ...... 22 Band Tension Measurement ...... 22 Wear Plate Replacement ...... 22 INSTALLATION Transmission ...... 22 Bandwheels ...... 22 Location ...... 5 Cleaning Optional Chip Conveyor ...... 23 OSHA Notice!! ...... 5 Unpacking ...... 5 Cleaning ...... 5 TROUBLE SHOOTING ...... 24-26 Lifting ...... 5 Floor Installation ...... 5-6 ACCESSORIES Electrical Installation ...... 6 Preparation for Use ...... 7 Roller Stock Conveyors ...... 27 Vertical Guide Rollers (Conveyors) ...... 27 OPERATION Variable Vise Pressure ...... 27 Vertical Hold-Down Fixture ...... 27-28 Safety Precautions ...... 8 Chip Conveyor ...... 28-29 Using the Job Selector ...... 8 Band Lubricator ...... 29 Control Console ...... 9-12 Band Twist Monitor ...... 29-30 Saw Band Preparation ...... 12-14 Front (Outboard) Vise ...... 30 Feed Force Adjustments ...... 14 Discharge Table ...... 30 Positioning the Saw Guide Arm ...... 14-15 Laser Line Option ...... 30 Positioning the Inboard Vise ...... 15 Idler Wheel Motion Detector ...... 30 Hydraulic System ...... 15 Coolant System ...... 15 Chip Removal ...... 15-16 Idler Wheel Motion Detector ...... 16 Typical Operating Procedures ...... 16-17

LUBRICATION

Lubrication Chart...... 18 Lubrication Diagram...... 19

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 FEATURES

FRONT VIEW

TOP VIEW

3 MACHINE FEATURES (Continued....)

LIMIT SWITCH LOCATIONS

FRONT VIEW

REAR VIEW

4 INSTALLATION

All “left”, “right”, “front” and “rear” des- 2. Using chains attached to the lifting eyes, it is recom- igna- tions in this manual are as viewed by mended that lifting and transporting of the machine the operator facing the control panel. be done with an overhead hoist. Shorten the chains to allow the machine to tip back. This will allow the LOCATION chains to clear the saw head and not damage the saw's surfaces. Net weight is approximately 10,500 1. Position the machine to allow adequate space for pounds (4762.8 kg). stock feeding and removal with maximum conve- nience. 3. Roller stock tables or conveyors (if supplied as accessory equipment) can be lifted and transported 2. Allow sufficient space for saw head elevation, by overhead hoist, fork lift, or by other means that bandwheel door opening, plus lubrication and provides adequate safety precautions. maintenance procedures. FLOOR INSTALLATION 3. Approximate floor dimensions are shown on pages 1 and 2. 1. Remove the shipping blocks except for those blocks holding the saw head. 3. Accessories such as roller stock tables or conveyors will require additional work area. 2. Connect the electric power (refer to the "Electrical Installation" instructions later in this section). OSHA NOTICE!! DO NOT START THE HYDRAULICS YET. OSHA Regulation 1910.212 (5B). 3. Obtain the head lift cylinder and mounting brackets Machines designed for a fixed location shall from the box of extra parts shipped with the ma- be securely anchored to prevent walking or chine. moving. 4. Install the head lift cylinder on top of the traverse UNPACKING weldment.

1. The machine is fastened to and shipped on a wooden When installing the head lift cylinder, safety skid. Overseas shipments are also crated. of the installer must be a consideration during this procedure. 2. Remove all protective covers, strapping, crating, etc. Then: (a) If necessary, remove all bolts which fasten the machine to the shipping skid; (b) Inspect the machine and all parts for shipping damage. Claim procedures are listed on this manual’s inside front cover.

CLEANING

1. Use solvent to remove rust-preventive coating applied to exposed bare metal surfaces for shipping purposes.

LIFTING Head Lift Cylinder Installation.

NEVER lift the machine by its sawing head. 5. Connect the two (2) hydraulic lines to the head lift cylinder. 1. Four (4) permanent eye holes, located at each corner of the saw base, are provided for machine 6. Activate electrical power to the machine and start lifting purposes: the hydraulics (refer to the "Hydraulic Power Unit Installation" instructions later in this section). Check for correct rotation of the hydraulic pump motor.

5 FLOOR INSTALLATION (Continued....) 2. The following are important disconnect precautions: 7. Lower the head lift cylinder and connect it to the saw head. It may be necessary to bleed these lines. The disconnect must be on before the machine will operate. Turning off the disconnect will 8. Raise the saw head and remove the remaining shut down the machine. shipping blocks. The enclosure must be closed and the ap- Leveling the Machine propriate securing screws must be in place before starting machine operation. 1. There are four (4) machine leveling points: One at each corner of the base. 3. Turn the disconnect switch on the electrical enclosure to OFF. Then: (a) Loosen the screws at the 2. Place a machinist’s level on the vise bed and rollers right door edge and open the door; (b) Familiarize next to the vise bed. Adjust the leveling screws until yourself with operation of the disconnect switch the machine is level and weight bears evenly on all operating handle, door interlock function, switch leveling pads. drive dog and shaft/clamp operating positions. 4. Punch a one (1) inch (25.4 mm) diameter or larger 3. The following are important dimensions to be ob- hole in the side of the electrical enclosure. Then: (a) tained during leveling: Bring power wiring (L1, L2, L3 and ground) through the hole (the cable and connector are to be supplied • The roller and vise bed bearing surfaces are to be by the customer). DO NOT bring the power cable co-planar within 0.015 inch (0.38 mm) T.I.R., or through any holes in the back wall. These are 0.0004 inch per inch (0.01 mm per mm) mearsured for installation of future accessories. from the plane of the saw band to the outboard roller.

4. After the machine has been leveled, install anchoring screws next to the leveling screws at each corner of the base.

6. Install roller stock table(s) or conveyor(s) if supplied as accessory equipment. These do not attach to the machine and should be anchored to the floor separately. Electrical Connection to Disconnect Switch.

ELECTRICAL INSTALLATION 5. Bring the power cable leads up to the disconnect switch. Then: (a) Connect L1, L2 and L3 to their Electrical installation must be made by au- respective terminals; (b) Connect the ground wire to tho-rized electrical maintenance personnel the ground terminal (refer to the electrical schematic only! if necessary).

1. Refer to the machine specifications plate on the 6. Place the operating shaft and operating handle of saw head frame to verify that the electrical supply the disconnect switch in the “off” position. Then: circuit will meet the voltage/phase/frequency/am- (a) Close the electrical enclosure door and secure perage requirements listed. A basic data plate is its screws; (b) Now turn on the electrical supply reproduced on this manual’s introductory page. and the disconnect switch (no action will occur until the Hydraulic Start key on the workstation touch 2. The electrical supply to this machine must be a screen has been pushed). dedicated circuit. DO NOT start machine hydraulics until the Electrical Enclosure following “Preparation for Use” procedures have been performed. 1. It is important that you familarize yourself with the electrical enclosure on this machine.

• The main enclosure is combined with the operator’s control panel on the front of the machine. Power is connected to this enclosure. 6 PREPARATION FOR USE 3. Check the band drive transmission reservoir level while the saw head is down. Capacity is approxi- Hydraulic Start-Up mately nine (9) quarts (8.5 liters).

1. Check the hydraulic reservoir fluid level. Capacity is 4. Check to see that all other points listed by the Lu- 20 gallons (75.7 liters). If the reservoir level is low (or brication Chart have been properly serviced. empty): (a) Check to see that the reservoir’s drain plug is installed tightly; (b) Fill with multi-purpose Machine Start-Up automatic transmission fluid. Always use extreme care when handling saw 2. All motors were installed and operated at the factory bands. DO NOT attempt to remove the saw during assembly. If the first motor to be checked band while the band drive motor is running. (hydraulic power unit) rotates correctly, all other motors will run correctly. 1. Remove the protective Saw Cap from the shipped- in-place saw band. This will require the following 3. If the hydraulic power unit motor rotates in reverse preparatory operations: (a) Press the Hydraulic (refer to the rotation arrow on the motor): (a) Turn Start key; (b) Press the Head Up key , then to the machine off immediately; (b) Disconnect power Head Hold after the saw band has cleared the front to the machine; (c) Interchange any two (2) of the vise; (c) Turn the Band Tension selector to “off”; three (3) phase incoming electrical supply leads at (d) Open both bandwheel covers. The Saw Cap the disconnect switch. If any of the three (3) phase can now be removed. motors run in reverse (as may occur when replacing a motor), corrective action is to interchange any two 2. With the hydraulics still running: (a) Turn the Band (2) motor leads. Tension selector to “on”; (b) Close the band wheel covers; (c) Clamp the fixed vise; (d) Press the 4. The hydraulic pump motor and coolant pump motor Band/Cycle Start key. operate from individual motor starters. The band drive motor operates from an inverter. The drive 3. Press the Band Speed key. A keypad will appear. and coolant pump motors cannot operate unless Enter the band speed by pressing the "4" and "0" the hydraulic pump motor is operating. keys and then press ENTER.

5. If the hydraulic or coolant pump motor overload The band drive motor will not start unless: (a) opens, the band will shut down. Both wheel cover doors are closed; (b) The saw band has been tensioned; (c) Hydraulics The motor overload for the band drive motor are running; (d) Vises are clamped. is included in the function of the band drive inverter.

6. As soon as hydraulic motor rotation is correct, set the coolant mode to "on", then jog the Hydraulic Start and Hydraulic Stop keys several times to make sure the hydraulic and coolant pumps are primed. Then allow the machine to run for several minutes to remove entrapped air.

Flood Coolant Start-Up

1. Install the coolant reservoir on the right side of the machine. Install the coolant pump which was shipped in the extra parts box.

2. Fill the coolant reservoir with 30 gallons (113.5 liters) of oil or cutting fluid recommended by the Lubrication Chart (remove the splash guard and pour coolant slowly into the coolant trough). DO NOT let coolant spill over the trough end and onto the floor.

7 OPERATION SAFETY PRECAUTIONS

SUPERVISOR, MAKE SURE THAT THE OPERATOR UNDERSTANDS THE FOLLOWING:

THESE PRECAUTIONS MUST BE FOLLOWED WHEN OPERATING OR SERVICING THIS MACHINE. NEVER WEAR GLOVES WHILE OPERATING THIS MACHINE. NEVER OPERATE MACHINE WITHOUT SAFETY GLASSES. NEVER OPERATE MACHINE WITHOUT SAW BLADE GUARDS IN PLACE. NEVER OPERATE MACHINE BEFORE CLOSING BAND WHEEL DOOR COVERS. NEVER OPERATE MACHINE FROM REAR. NEVER REMOVE CUT-OFF PIECES WHILE MACHINE IS RUNNING. • READ INSTRUCTION MANUALS BEFORE OPERATING THIS MACHINE. • AVOID CONTACT WITH COOLANT, ESPECIALLY GUARD YOUR EYES. • BRING ADJUSTABLE SAW GUIDE AND GUARD AS CLOSE TO WORK AS POSSIBLE. • DISCONNECT ALL ELECTRICAL POWER BEFORE SERVICING. • DO NOT SERVICE, REPAIR OR ADJUST MACHINE WITHOUT PROPER INSTRUCTION FROM YOUR SUPERVISOR AND WITHOUT READING AND FULLY UNDERSTANDING THE INSTRUCTION MANUAL. • SECURE BAND WHEEL COVER DOOR BEFORE CHANGING SAW BLADES OR REPAIRING MACHINE. • CLOSE AND SECURE BAND WHEEL COVERS BEFORE TENSIONING BAND OR STARTING MACHINE. • KEEP HANDS AWAY FROM MOVING SAW BLADES AND VISE AREA. • USE EXTREME CARE IN HANDLING BLADES. • DO NOT MEASURE, POSITION OR FEED MATERIAL WITH THE SAW BLADE RUNNING. MAKE SAFETY THE RULE AND FOLLOW SAFE SHOP PRACTICES.

DO NOT REMOVE OR DEFACE THIS SIGN. 404478

USING THE JOB SELECTOR Job Selector recommendations are a general guide for correct power sawing on a properly- 1. Refer to the Job Selector chart on the left bandwheel maintained DoALL saw. door 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.

2. For example: If the material to be cut is low carbon steel which is two (2) inches (50.8 mm) thick, the Job Selector recommends using: (a) An Imperial Bi-Metal saw blade with a blade pitch of 6; (b) Band speed of 315 fpm (96 m/min); and (c) A cutting rate of 21 square inches per minute (135 cm²/min.).

Typical Job Selector.

8 SYSTEM

F5 FF

TES

Typical Control Panel. CONTROL CONSOLE Keypad

1. Emergency Stop. Pushing this red mushroom 1. When the operator presses a key where data may head button stops all machine motors (hydraulic, be entered, one of two keypads will be displayed. coolant, band drive and optional chip conveyor) simultaneously.

• Reset the Emergency Stop button by turning it clockwise. The machine will not start unless the Emergency Stop button is reset.

2. Band Tension. This selector switch with "off", "hold" and "on" settings is used when changing saw bands. (a) "Off" releases saw band tension and enables saw band removal and installation; (b) "Hold" stops the movement of the band tension cylinder in any position; (c) "On" applies force to the band tension cylinder.

The Band Tension selector must be at "on" before the band drive motor will start or the saw head will lower.

Operator Workstation

1. Most saw controls can be operated from the touch screen of the workstation. Keypad.

2. One keypad is used only for data that has whole numbers, and the other is used when a decimal point is needed.

3 . Depending on the type of data (whole numbers or decimal) entered, some keys are not present when you press a key that requires data entry. Features of either keypad include:

4. Display Window. Located along the top of the workstation, the display shows the values entered.

Operator Workstation.

9 CONTROL CONSOLE (Continued....)

5. 0 - 9, Decimal Point, + / -. These keys are used to enter values for that function. Enter them in order including the decimal point if required.

6. Left, Right, Up, Down Arrows. These keys are used to change the data entered or correct an error in entering data.

• After entering a value (before pressing the ENTER key), use the "left" or "right" arrow key to change the position of the curser in the display window.

• After entering a value (before pressing the ENTER key), use the "up" or "down" arrow key to change the highlighted number in the display window. Use Operation Screen. the "up" arrow key to increase the value, "down" arrow key to decrease the value. 1. In the upper left corner is a Display area for prompts and error messages. 7. Enter. Pressing this key will enter the data into memory and then will return to the previous 2. COOLANT OFF. This key turns off any coolant screen. system.

8. Esc (Escape). Pressing this key will bring you back 3. COOLANT ON. This key operates the coolant to the previous screen. No data will be entered. without the band drive motor being on and is used mainly with the flushing hose. Operator Workstation 4. COOLANT ON WITH BAND. Press this key for If a key does not respond, press and hold the coolant to flow through the entire system. key until a message in the upper left corner of the screen appears and then follow the 5. MIST COOLANT ON W/BAND (Optional). Pressing prompts. this key activiates the mist coolant solenoid.

1. After the power is turned on, the Operations screen 6. UNITS. This key allows the operator to select appears shows a collection of keys to operate the between U.S. STD or METRIC for measurement machine. data. When switching from one to another, the data is converted to the new measurement mode. 2. The Diagnostics key in the lower right corner of the screen will take the operator to the next screen. 7. HEAD UP. This key raises the saw head up until the SAW HEAD HOLD key is pressed. 3. System. This key is not used and requires NO interaction from the operator. 8. HEAD HOLD. This key stops all saw head movement. 4. F1. Pressing this key will allow the operator to change the full cycle band shutoff position. See 9. HEAD DOWN. Press and hold this key to lower the the "Setup Instructions" screen for procedure. saw head.

5. F2 thru F5. These keys are used to enable or dis- • Pressing this key for more than three (3) seconds able certain options. See the "Setup Instructions" will allow the saw head to move into "rapid travel" screen for their use. mode until the operator releases the key.

Operations Screen DO NOT allow the saw head to "slam" into the material while in "rapid travel" mode as For the saw head and vise functions to oper- damage to the machine will occur. ate, the hydraulics MUST be on and the operation in the MANUAL MODE. • When in FULL CYCLE, pressing the HEAD UP key will raises the saw head, stop the saw band and will switch the saw to MANUAL.

10 CONTROL CONSOLE (Continued....) 21. FRONT (OUTBOARD) VISE CLAMP (Optional). Press this key will close the front vise. 10. SAW HEAD RAISE HEIGHT. Press this key and the keypad will appear. Enter the desired height 22. CHIP REMOVAL. Press the key to turn the chip conveyor off and on. The key will highlight when it's for the saw head to stop and then press ENTER. on. The chip conveyor should always be "on" 11. BAND SPEED. Press this key and the keypad will when sawing. appear. Enter the desired band speed and then • The hydraulics must be on before the chip conveyor press ENTER. The band speed can be changed at any time. The band speed can be changed at any can be used. time. 23. DIAGNOSTICS. This key in the lower right corner 12. BAND/CYCLE START. This key will start the band of the screen will take the operator to the next drive motor. screen.

For the band drive motor to start, the following Diagnostics Screen MUST be: (a) The hydraulics are on; (b) The 1. Press the key will take the operator to inboard vise is clamped. Diagnostics a screen which shows different PLC input modules 13. BAND STOP. This key will stop the band drive mo- and their status. These modules are for diagnostics tor. and service only and needs NO interaction from the operator. 14. INBOARD VISE OPEN. Press and hold this key will open the inboard vise. Release the key to stop • Along the bottom of the screen, there is three (3) vise jaw movement. In manual mode, the saw head keys that will take the operator to other screens: must be up to open the vise. Operations, Setup Instructions and Operator Instructions. 15. INBOARD VISE CLAMP. Press this key will close the inboard vise.

16. MANUAL/FULL CYCLE. This key shows the cur- rent operating mode of the saw. Press the key will switch between MANUAL and FULL CYCLE.

• In manual mode, the saw band will stop and saw head will remain in the down position at the end of the cycle.

• In auto mode, the saw band will stop and saw head will raise to the up position at the end of the cycle.

17. SAW HEAD FEED RATE. This displays the feed rate of the saw head as it is make a cut. Diagnostics Screen. 18. HYDRAULIC START. Pressing this key starts the hydraulic pump motor, chip conveyor motor, coolant 2. OPERATIONS. This key will take the operator to a pump motor and the band brush motor. screen which shows a collection of keys to operate the machine. The keys are described in the previ- 19. HYDRAULIC STOP. This key stops the hydraulic ous section. pump motor, chip conveyor motor and the band 3. SETUP INSTRUCTIONS. This key will take the brush motor. operator to a screen that shows instructions on how enable or disable certain options. 20. FRONT (OUTBOARD) VISE OPEN (Optional). Press and hold this key will open the front vise. 4. OPERATOR INSTRUCTIONS. This key will take Release the key to stop vise jaw movement. In the operator to a screen that shows instructions on manual mode, the saw head must be up to open how to run a basic manual or full cycle operation. the vise.

11 CONTROL CONSOLE (Continued....) Hydraulic Controls

Setup Instructions Screen 1. Feed Force. This valve, located above the left hand saw guide, regulates the amount of pressure be- 1. This screen shows instructions on how change, ing placed by the saw band against the workpiece. enable or disable certain options. Turn the knob clockwise to “decrease” pressure; counterclockwise to “increase” it. The valve’s lower locking knob helps maintain the setting. See the "Feed Force Adjustment" section later in this manual for more detailed information.

2. Feed Force Indicator. This gauge shows the amount of pressure being placed by the saw band against the workpiece.

Other Controls

1. Coolant. Three (3) valves, one (1) each located above each saw guide and one (1) attached to the outboard fence, regulates the flow of coolant to the saw guide arms and to the flushing hose. Turn the knob counterclockwise to "increase" the coolant Setup Instructions Screen. flow;clockwise to "decrease" it. See "Coolant Sys- tem" section later in this manual for more detailed 2. Follow the steps on the screen to change the full information. cycle band shutoff position or enabling/disabling the optional front vise. 2. Variable Vise Pressure. These optional control valve(s), located to the right of the operator worksta- 3. Along the bottom of the screen, there is three (3) tion, are used to adjust vise clamping force against keys that will take the operator to other screens that materials which cannot tolerate full vise clamping have been previously described. pressure (examples are thin-walled tubing, pipe, light structurals, etc.). See the "Accessories" sec- Operator Instructions Screen tion for use of this option.

1. This screen shows instructions on how to run a SAW BAND PREPARATION typical operation procedure. Cutting Capacity and Saw Band Recommendations

1. The machine’s standard cutting capacity for rect- angular stock is 25.6 inches (650 mm) high by 25.6 inches (650 mm) wide. It will also cut round stock (solids, tubing, pipe, etc.) up to 26.3 inches (670 mm) in diameter. Cutting capacity may vary with the addition of accessories. Any variation will be noted when applicable.

2. A high-speed DoALL Imperial Bi-Metal 100 saw band with protective Saw Cap is supplied with the machine. Band length is 300 inches (7620 mm); width is 2.12 inches (54 mm) with a recommended gage of 0.063 inch (1.6 mm). Operator Instructions Screen. 3. A machine in correct adjustment, good operating condition and using proper cutting fluid is essential 2. Follow the steps on the screen to run a typical op- to efficient sawing. eration procedure either in manual or full cycle.

3. Along the bottom of the screen, there is three (3) keys that will take the operator to other screens that have been previously described. 12 SAW BAND PREPARATION (Continued....) 5. Maneuver the drive wheel end loop of the saw band outward and to the left while maneuvering the idler 4. Proper blade care should include: (a) Pushing uncut wheel end loop between the idler wheel and right stock away from the saw band and lowering the saw blade guard. Then: (a) Recoil the saw band and head if the machine is to remain idle for a period of dispose of it immediately. time; (b) Using correct band speed, feed force and cutting fluids during operation;(c) Removing scale Saw Band Installation from stock before sawing; (d) Keeping the protective Saw Cap over blade teeth until installation time. Always use extreme care when handling saw bands. Wear gloves. DO NOT attempt to Blade Guards change saw bands while the band drive motor is running. 1. Themachine has three (3) blade-covering guards for operator safety. All guards must be in place 1. Carefully follow all "Band Removal" procedures before any sawing procedure is started. They above. Then: (a) Use the Flushing Hose to clean are there for YOUR PROTECTION. areas around the saw guides, plus the drive and idler bandwheels. 1. Left Guard. This guard is attached to the left saw guide arm and extends toward the idler band- 2. Slip the loop of the saw band under both saw guide wheel. by following the reverse procedure of (4) in the "Saw Band Removal" section. Then: (a) Position the 2. Right Guard. This guard extends between the right saw band around the drive and idler bandwheels; saw guide arm and the drive bandwheel. (b) Remove the Saw Cap from the saw band.

3. Top Channel Guards. This guard is part of the 3. Slip the top portion of the saw band loop into the head beam and located between the bandwheels top channel guard. Then: (a) Turn the Band Ten- doors. sion selector to "on" until the lower portion of the saw band loop is one (1) inch (25.4 mm) below the Saw Band Removal saw guides; (b) Turn the Band Tension selector to "hold". Always use extreme care when handling saw bands. 4. Grasp the saw band portion between the saw guides and twist it so the blade teeth are pointing 1. Push the Hydraulic Start key and press the Head downward; (a) Slip the twisted saw band portion up Up key. Then: (a) Raise the saw head to allow between the saw guide rollers and inserts. both bandwheel doors to be opened; (b) Press the Head Hold key to stop head movement. (c) Close 5. Check the saw band's position around both band- the inboard vise and press the Band/Cycle Start wheels (its back edge must rest against each key (this moves the left saw guide to the center of wheel's rear flange). When satisified that saw the saw). band positioning is correct: (a) Close both bandwheel doors; (b) Turn the Band Tension selector 2. Press the Band/Cyle Stop key. Next: (a) Turn to "on". the Band Tension selector to "off" (this moves the idler bandwheel to the right and releases the 6. Reposition the band brush (if necessary) and tighten saw guides); (b) Open both bandwheel doors; (c) the two (2) clamp screws (brush bristles should Loosen the clamping handle on the powered band clean the teeth gullets, but not contact the bottom brush assembly; (d) Swing the band brush away of the gullets). Then: (a) Jog the band drive motor; from the blade teeth. (b) Open each bandwheel door to make certain that the saw band is against the bandwheel flanges. 3. Place a gloved hand on the back of the saw band portion between the saw guides; (b) Push the saw Band Tension band down and out to disengage it from the saw guides (you will want to grip the saw band firmly 1. Band tension is applied by the selector switch which as you manipulate it); (c) Remove the saw band is located on the left side of the control panel. from around the drive and idler bandwheels, then its top channel guide. 2. Correct band tension for the machine's standard saw band is 3.8 to 4.0 units measured by a DoALL 4. Grasp the upper and lower portions of the saw band Tensigage. loop at approximately the center. 13 SAW BAND PREPARATION (Continued....) • Generally, top performance from a sharp saw band results from relatively low Feed Force valve set- 3. Important factors which influence band tension tings. It will be necessary to increase the setting as settings are the size of stock to be cut and desired the saw band becomes duller. This will help keep band life. General rules-of-thumb are: (a) Lower the cutting rate constant throughout the life of the tensions will increase saw band life; (b) Greater saw band. tension is required as spacing is increased between the saw guide arms; (c) Higher band speeds require • Feed force adjustments are not necessary for greater tension. changing stock cross-sections. A balancing valve enables the saw band to maintain a uniform cutting DO NOT start the band drive motor unless rate. the saw band has been properly tensioned. Reducing Cutting Rate & Band Speed for Pipe, Tubing and Structurals FEED FORCE ADJUSTMENT 1. Increasing loading per tooth occurs when sawing 1. Feed force is the pressure exerted by the workpiece thin stock sections. Although the blade teeth can against the saw band's cutting edge. It is controlled bear some overloading, a cutting rate reduction hydraulically and regulated with the Feed Force must be made. valve. Turn the valve clockwise to "increase" pressure, counterclockwise to "decrease" it. 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.

SECTION FACTOR TO APPLY THICKNESS TO MINIMUM CUTTING RATES GIVEN BY JOB SELECTOR*

Up to 3/16 inch 40% (0 to 4.8 mm)

3/16 to 3/8 inch 50% Feed Force Valve and Gauge. (4.8 to 9.5 mm)

2. The following are important factors to consider when 3/8 to 5/8 inch 60% setting or adjusting the Feed Force valve: (9.5 to 15.9 mm)

• Turn the Feed Force valve to a low setting if the 5/8 to 1 inch &over 70% correct feed force is not known. The operator can (15.9 to 25 mm & over) then increase or decrease pressure during operation to obtain the best cutting rate consistent with *Based on 5 inch (125 mm) solids. desired blade life and stock cut finish. Always be sure to take a good chip. Cutting Rate to Thickness Relationship.

• Never start a cut with the maximum Feed Force POSITIONING THE SAW GUIDE ARM valve setting. Blade damage may occur. Extend • Certain work-hardening materials will require a moderately heavy initial Feed Force valve setting 1. When the Band/Cycle Start key is pressed to begin to assure immediate penetration of blade teeth. a cut cycle, the following actions take place: (a) The Light feeds on these materials may cause the blade saw guide arm extends until the saw guide interfer- to slide over the stock resulting in saw band dam- ence limit switch (13 LS) is activated; (b) The saw age. guide arm then begins to retract; (c) The saw guide arm stops after the limit switch is deactivated.

14 POSITIONING THE SAW GUIDE ARM (Continued....)

Retract

1. When the inboard vise (or optional outboard vise) is requested to open, the following actions take place: (a) The saw guide arm begins to retract; (b) After a short delay, the vise(s) requested begin to open.

2. When the saw guide interference limit switch (13 LS) is activated, all head and vise movement stops, the saw guide arm opens and movement continues after a short delay.

POSITIONING THE INBOARD VISE

1. The vise will open to its full open position when the operator presses and holds the Inboard Vise Open key. This applies to the optional front or outboard vise also.

HYDRAULIC SYSTEM

1. The hydraulic and band drive systems operate in- Coolant Application Points. dependently. This allows the operator to perform the following tasks while the band drive motor is • To the cutting area through a flexible hose and not running: (a) Change saw bands; (b) Raise or nozzle. Flow from this point is controlled by a lower the sawing head; (c) Clamp or unclamp the needle valve and should cover the cutting area vises; (d) Position stock manually. completely. 2. The machine's hydraulic reservoir has a 20 gallon 2. Coolant flow is started by: (a) Pushing the Hydrau- (76 liter) capacity. Refer to the Lubrication section lic Start button; (b) Turning the Coolant selector of this manual for recommended oils. to "on"; (c) Turning the coolant valve on each saw guide arm counterclockwise until fluid completely COOLANT SYSTEM shrouds the saw band.

Coolant Selection DO NOT start cutting until coolant is flowing adequately. Dry cutting will greatly reduce 1. The main cause of tooth failure during band machin- blade life. ing is excessive heat build-up. Using the proper cutting fluid reduces the heat generated during 3. Check the coolant reservoir level if flow is stopped operation. It also helps the machine take full ad- or reduced. Reservoir capacity is 30 gallons (113.5 vantage of its high-speed steel saw bands.. liters).

Literature describing these and other coolant CHIP REMOVAL types is available from a DoALL Industrial Supply Center representative. 1. Metal chips should be removed from the work area as soon as possible. They can be washed, scraped, Coolant Application or scooped out with the supplied shovel-rake. 1. Coolant is applied as follows during sawing: DO NOT shovel or rake chips while the saw band is running. • To the saw band and cutting area through the saw guide inserts. Flow is regulated by a valve on each saw guide arm.

15 CHIP REMOVAL (Continued....) Shovel-Rake

Band Brush 1. Accumulations of metal chips can be removed from the machine with the shovel-rake. 1. A covered, hydraulic motor driven band brush is located near the drive bandwheel. During DO NOT use the shovel-rake while the saw machine operation, the brush bristles should be band is running. 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. Combination Shovel-Rake. 2. As the bristles wear, move the brush closer to the blade. To do so: (a) Open the right bandwheel Optional Chip Conveyor door; (b) Loosen the clamping handle; (c) Position the brush for correct blade cleaning; (d) Tighten the 1. During operation, metal chips and used coolant clamping handle and close the bandwheel door. drop directly into a sloped trough, or flow into it from the machine's run-off surfaces. Coolant then flows down the trough and through a filtering screen before returning to the reservoir.

Band Brush.

Flushing Hose

1. Metal chips and other debris may accumulate over Chip Conveyor - Top View. time around such machine areas as: saw guides, drive and idler bandwheels, vises, slides, brush 2. The chip conveyor motor operates simultaneously housing, head lift ram, feed and discharge areas, with the hydraulic pump motor. The conveyor apron etc. moves slowly at the bottom of the trough. Its movement carries metal chips to the opening at 2. The operator should check often for metal chip the machine's right side where chips empty into a collections which can adversely affect machine customer-supplied container. performance. They should be removed with the Flushing Hose as soon as possible. TYPICAL OPERATING PROCEDURES

The DoALL Company recommends using the Flushing Hose to remove chips at least twice Preparation per each eight (8) hour shift, and more often when necessary. 1. Before starting the machine: (a) Make sure the main disconnect switch is turned on; (b) Turn the Emergency Stop button clockwise to reset; (c) Press the Hydraulic Start key. This will start the hydraulic pump. The Display will also light up, flash all of the LEDs and run a short test program.

16 TYPICAL OPERATING PROCEDURES (Continued....) 2. Press the Operators Instructions key and follow the step by step instructions for a "manual" or "full cycle" cut.

3. The operator may adjust band speed, coolant flow, and/or feed force at any time during the sawing process.

4. After the cut has been completed, the saw band will shut off with the saw head in the down position. Next: (a) Raise the saw head by moving the Head Up key and the the Head Hold key to stop head movement; (b) Unclamp the inboard vise; (c) Remove the cut-off piece.

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 and coolant application settings for successful jobs.

17 LUBRICATION LUBRICATION CHART

LUBRICATION LOCATION DESCRIPTION AND LUBRICATION RECOMMENDED POINT NO. SERVICE RECOMMENDATIONS INTERVAL* LUBRICANT Premium quality, multi-purpose lithium- 1 Idler Bandwheel Bearings. One (1) grease fitting. WEEKLY base, EP (extreme pressure) grease.

NLGI No. 2. Idler bandwheel Slide. Two (2) grease fittings. MONTHLY 2 Union 76, UNOBA EP 2, or equivalent. 3 Saw Guide Arm Slide. Clean and apply oil. High quality, rust and oxidation-inhibited, Micellaneous: Vise Slides, Hinges, Pivot Points, medium hydraulic and general purpose 4 Component Parts, Unpainted Surfaces, etc. to ensure industrial oil. function and maintain appearance while reducing wear, AS REQUIRED corrosion, rust, etc. Apply when and where needed in ISO-VG Grade 68 (Formerly ASTM Grade amounts required. No. 315). Column Tube Bearings. 20 ounce (.59 liter) capacity (if WEEKLY 5 changed). Located above sight glass. AS REQUIRED Union 76, UNAX RX 68, or equivalent. 6 Saw Guide Insert Screws. Apply oil to the threads. INSERT CHANGE High quality, 4EP (extreme pressure) multi- purpose gear oil. Transmission. 9 quarts (8.5 liter) capacity. Drain and refill 6 MONTHS 7 every six (6) months. Do not overfill. Mobil Gear (629-YC1F4), Union Extra- Duty NL Gear Lube.

A.S.T.M. Std. No. 250.04.

Electric Motors. Band Drive, Hydraulic, Coolant and Lubricate (if any) per manufacturer's recommendations. 8 Optional Chip Conveyor.

Premium quality, saw band coolant and Coolant Reservoir. 20 gallons (75.7 liter) capacity. Drain, lubricant. 9 clean and refill whenever coolant becomes undesireable for CHECK DAILY/ further use. Clean the mesh screen at the same time.. AS REQUIRED DoALL cutting fluids and/or oils. 10 Mist Lubricator (Optional). Lubricate (if any) per manufacturer's recommendations. Hydraulic System. Ten (10) gallon (37.8 liter) capacity. Check fluid level daily and keep the reservoir full. Drain, CHECK DAILY/ Multi-purpose automatic transmission 11 change the filter element and refill after the 1st month; AS REQUIRED fluid. every six (6) months thereafter. * Lubrication intervals are based on a 8-hour day, 40-hour week. Lubricate more often with heavier use.

18 LUBRICATION DIAGRAMS

FRONT VIEW

TOP VIEW

19 MAINTENANCE REPLACING SAW GUIDE INSERTS 4. Slide the rear carbide insert block over the guide pins. Replace the M6 screws and belleville spring To Replace Left Saw Guide Carbide Inserts washers. DO NOT tighten fully.

Be sure the band drive motor is not running 5. Replace the front carbide insert block. when replacing saw guide inserts and back- ups. 6. Place the saw band or a piece of saw band between the carbides. 1. Remove the two (2) M10 socket head screws from the front of the saw guide block. DO NOT allow the 7. Press the Hydraulic Start Key and turn the Band insert block to fall when the screws are removed. Tension selector switch to "on". This clamps the Three (3) carbide inserts are mounted to the front carbide inserts to the saw band. block. Each is held in place by flat head screws. Remove and replace the carbides if worn. 8. Tighten the rear M6 socket head screws fully on the belleville spring washers. Then loosen the screws 2. The rear carbide insert block may be removed after by 1 to 2 turns. The loose screws tensioned by the front block removal. To do so: (a) Remove the two belleville washers allow the moving carbide insert (2) M6 socket head screws from the rear of the block to open when the Band Tension selector is guide block. DO NOT lose the belleville spring switched to "off". washers used with the M6 screws (16 per screw); (b) Slide the rear carbide insert block off the two (2) To Replace Right Saw Guide Carbide Inserts guide pins; (c) Remove and replace the carbides if worn. 1. Remove the sensing arm and the left saw band guard.

2. Follow the same procedure described for the left saw guide.

3. Replace the sensing arm and right saw band guard.

BAND DRIVE BELT REPLACEMENT

1. Turn the machine and disconnect switch off. Then: (a) Remove the band drive assembly cover; (b) Loosen the hex. nuts on the threaded pivot rod (the band drive motor will lower as you loosen the lower hex. nut); (c) Remove the broken drive belt.

Left Saw Guide Assembly.

3. The back-up carbide insert has four (4) wear surfaces. To change the carbide from a worn to unworn surface: (a) Remove the pipe plug from the front of the guide block; (b) Loosen the slotted head shoulder screw with a large straight blade screwdriver; (c) Remove the shoulder screw with a split-holding screwdriver. DO NOT allow the insert to fall when the shoulder screw is removed; (d) Rotate the back-up insert to an unworn side; (e) Replace the shoulder screw; (f) Tighten screws in reverse order and replace the pipe plug. Belt Replacement.

20 BAND DRIVE BELT REPLACEMENT After the pump has been primed, run it (Continued....) for several minutes while operating the machine’s controls to purge entrapped air 2. Position the new drive belt over the drive pulley from the pump and system. Check for oil sheaves. Then: (a) Using a bar. move the motor leaks while the system is being operated. support plate up until the correct tension is achieved (belt should have very little movement at the center Seals & Cups span of the belt); (b) Tighten the lower hex. nut first, then the upper hex. nut. 1. Seals and cups used in DoALL hydraulic systems are compatible ONLY with hydraulic oils having an 3. Turn the machine and disconnect switch on. Then; aniline point between 215° and 230° F. (102° and (a) Press the Hydraulic Start and Band/Cycle 111° C.). Start keys on; (b) Check the operation of the new drive belt ; (c) If the operation is satisfactory, turn 2. If hydraulic oil having an aniline point not falling the band drive motor off; (c) Replace the assembly within the above range is used, the seals may either cover. swell or shrink and harden. This causes machine malfunction and leakage. HYDRAULIC SYSTEM DoALL hydraulic fluid -- with an aniline point 1. Keep the reservoir filled at all times. Capacity is 20 of approximately 221° F. (106° C.) -- will not gallons (75.7 liters). Check the reservoir oil level cause deterioration of component seals. daily by referring to the sight gauge. COOLANT SYSTEM 2. Before changing the hydraulic oil: (a) Lower the saw head completely; (b) Press the Hydraulic Stop key; 1. The machine’s coolant reservoir has a 30 gallon (c) Remove the reservoir drain plug; (d) Allow the (113.5 liter) capacity. A reservoir level sight gauge reservoir to drain completely. is located at the machine’s right front side.

3. Clean, refill the reservoir, and change the oil filter 2. Check the coolant often for signs of contamination after the first month of operation; every six (6) or breakdown. The reservoir and coolant system months thereafter. Clean the suction strainer and should be drained and cleaned thoroughly when the filler opening screen when necessary. Automatic cutting fluid becomes undesireable for further use. transmission fluid is the recommended product. If another type of coolant is to be used, the entire coolant system must be flushed (use DoALL’s Kleen System Pressure Flush).

1. Hydraulic system pressure is correctly set at the 3. To thoroughly clean the reservoir section below factory and should not require adjustment for a the conveyor trough, removal of the trough will be considerable period of time. Correct system pres- necessary. sure is 1000 psi (69 bar). BAND BRUSH 2. Pressure is adjusted by turning the external screw extending outward from the hydraulic reservoir. 1. The band brush will wear and lose steel bristles Consult a DoALL Industrial Supply Center service over time. Check often to be sure the bristles are representative if assistance is needed. removing metal chips from the blade tooth gullets, but are not touching the bottom of the gullets. Pump Repair & Replacement 2. Move the brush closer to the blade as normal wear 1. DO NOT attempt to repair the hydraulic pump. occurs. Replace the brushes when necessary. Return it to the factory for repair or replacement. Be sure to specify the correct pump model and serial DO NOT adjust the band brush while the saw numbers when returning the unit. band is running. 2. Following a new pump installation: (a) Jog the Hydraulic Start and Hydraulic Stop keys 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 the buttons; (c) Review wiring connections if the pump rotates in the wrong direction. 21 MACHINE CLEANING 2. Tension may be checked "reading up" or "reading down". To "read up": (a) Fix the Tensigage to a 1. Keep the machine and its parts as clean as possible slack saw band; (b) Apply tension. To "read down": to prevent excessive wear and damage. (a) Fix the Tensigage to a tensioned saw band; (b) Relax tension. 2. Use the Flushing Hose to remove metal chips and other waste materials which may collect around 3. A DoALL Tensigage reading of 3.8 to 4.0 indicates the saw guides, bandwheels, vises, slides, sensing correct saw band tension. arm, etc. The hose has a hand-operated valve and attaches to the coolant pump. The DoALL Com- WEAR PLATE REPLACEMENT pany recommends using the Flushing Hose to remove chips at least twice per each eight (8) 1. The removeable vise jaw and vise bed wear plates hour shift, and more often when necessary. must be replaced before excessive wear causes the mounting screw heads to become damaged and 3. Use the supplied shovel-rake to remove accumulated makes removal difficult. metal chips or other waste materials from machine areas. Vise Jaw Plates

1. The machine has four (4) vise jaw wear plates on the inboard vise jaws and four (4) vise jaw wear plates on the optional front or outboard vise jaws. Combination Shovel-Rake. All wear plates are mounted with low-head screws. Be sure the vise jaws are separated and the Be sure the band drive motor is stopped before machine turned off before trying to replace the raking or removing chips. wear plates.

MACHINE ALIGNMENT TRANSMISSION

1. Misalignment of the machine’s saw guide arms, slide 1. Transmission replacement, repair, adjustment or bar, saw band, pivot points, transmissions, etc., will alignment should be performed only by a DoALL cause inaccurate sawing. Industrial Supply Center service representative.

DO NOT attempt any alignment procedures BANDWHEELS not covered by this manual. Contact a DoALL Industrial Supply Center service representa- 1. Occasionally check each wheel’s back-up flange tive in such cases because special fixtures and wheel tread for wear. Saw bands will not track and techniques may be required. properly if the taper is worn from the wheel tread.

BAND TENSION MEASUREMENT

1. Band tension measurement must be made with the machine’s hydraulics running and the Band Tension selector at "on".

Bandwheel Flange and Tread.

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 Using a Tensigage to Measure Band Tension. (0.127 mm) away from the flanges.

22 CLEANING OPTIONAL CHIP CONVEYOR

Follow these steps to clean the chip conveyor:

1. Turn the machine off. Then: (a) Disconnect the hydraulic hoses; (b) Pull the chip conveyor out from its cradled position in the base; (c) Clean the chip conveyor trough; (d) Clean the reservoir floor; (e) Replace the conveyor and cover.

23 TROUBLE SHOOTING

Repair and adjustment procedures should be 3. Use a Tensigage to check for proper saw band ten- made only by experienced maintenance per- sion. sonnel, or by a DoAll Indusrtial Supply Center representative. Reference to the machine's 4. Check for proper operation of the Band Tension electrical and hydraulic schematics will be selector. helpful. 5. Check for a worn, or improperly adjusted band brush. MACHINE WILL NOT START

1. Check to see if disconnect switch are “on”. BLADE TOOTH GULLETS ARE LOADING

2. Check the condition of the main circuit breakers, 1. Use a coarser pitch saw band. fuses and/or control circuit fuse. 2. Increase the band speed setting, or decrease the 3. Push the motor starter overload reset buttons located feed pressure setting. in the electrical enclosure. If overload tripping re- occurs, locate and correct the problem. 3. Check for improper coolant application.

4. Be sure the bandwheel doors are closed. 4. Check the positioning of the band brush. Adjust or replace the brush, if necessary. 5. Check to be sure that the Band Tension selector switch is in the "on" position. SAW BAND SQUEAL

6. Check the control transformer for power. 1. The lead-in/exit rollers are: (a) Not contacting the saw band; or (b) Positioned too tightly against the 7. Check the hydraulic motor or wiring. saw band.

8. Check the starter, relay coils and contacts for faulty 2. Check for defective lead-in/exit roller bearings. operation. SAW BAND VIBRATION 9. Have an electrical service person check the continu- ity of the starting circuit. 1. Check for a dull or damaged saw band.

MACHINE STARTS, BUT WON’T CONTINUE 2. Incorrect band speed or feed pressure setting is RUNNING being used.

1. The saw band is broken or too long and is tripping 3. Check for incorrect saw band pitch. the band tension limit switch (1 LS). 4. Coolant mixture is weak, or incorrect coolant is be- 2. Check to see if the bandwheel doors are closed (the ing used. band drive motor will not start unless both covers are closed). 5. Stockpiece is not being firmly clamped by the vise jaws. 3. The saw head has not cleared the head-down limit switch (2 LS). Press the Head Up key. 6. Check for worn or improperly-adjusted saw guide inserts.

SAW BAND STALLS DURING A CUT 7. Check for a worn saw guide back-up carbide or lead in/exit rollers. 1. Decrease saw head feeding pressure. 8. Check for incorrect saw band tension. 2. Check to see if drive belt tension is adequate to resist "cogging" underload. PREMATURE BLADE TEETH DULLING

1. Band speed and/or cutting rate is too high.

24 TROUBLE SHOOTING (Continued....) 3. Check for stock not being held firmly by the vise jaws. 2. Check for faulty stock: Heavy scale, inclusions, hard spots, etc. 4. Check for incorrect adjustment of the saw guide inserts and carbide back-up guides. 3. Stock analysis is incorrect. This can result in an incorrect cutting recommendation. 5. Check for insufficient coolant flow.

4. Coolant is not covering the saw band properly. 6. Use a finer pitch saw band.

5. Check for saw band vibration. 7. Check for incorrect saw band tension.

6. Check for chip welding, or a chipped blade tooth SAW BAND IS NOT RUNNING TRUE AGAINST lodged in the cut. THE SAW GUIDE BACK-UP BEARINGS (May 7. Saw band being used is incorrect. Cause Vibration) 1. Examine the carbide back-up bearings. Replace 8. Coolant mixture is too weak, or incorrect cool- them if they are chipped or worn more than 0.020- ant is being used. inch (0.5 mm). 9. The saw band is not properly tensioned. 2. Check machine alignment (by a DoALL Industrial Supply Center service representative). 10. Decrease feed pressure to "break in" a new saw band on its first few cuts. 3. Check for a worn lead in/exit roller.

BLADE TEETH STRIPPING 4. Saw guides are loose.

1. Increase band speed or decrease feed pressure. INACCURATE CUT-OFF 2. Check for chip welding, or for a chipped blade tooth 1. Check for worn or dull blade teeth. lodged in the cut. 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 6. Check for crooked stock (this can result in straight, back-up bearing. but not square cuts). 7. Coolant is not being applied correctly. 7. Check for loose saw guides. 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 9. Check for incorrect saw band tension. the stock section. 10. Check for incorrect adjustment of inserts or back-up SAW BAND BREAKAGE bearing.

1. The saw band is being dropped into the stockpiece 11. Check for coolant not being supplied evenly to both due to incorrect saw head feeding rate. sides of the saw band.

2. Increase band speed being used and/or decrease 12. Check machine alignment. Have a DoALL Industrial feed force. Supply Center service representative check and/or adjust machine alignment. 25 TROUBLE SHOOTING (Continued....) 2. Check for low hydraulic system pressure caused by blockage, clogged oil filter cartridge, or pinched SURFACE FINISH OF CUT-OFF PIECE IS hose. TOO ROUGH SAW HEAD LOWERS ERRATICALLY 1. Check for vibration while sawing. 1. Bleed air from the head lift cylinder. It may be necessary to raise and lower the saw head several 2. Check for a damaged saw band. times to thoroughly bleed the head lift cylinder. 3. Use a finer pitch saw band. SAW HEAD WON'T STOP AT THE CORRECT 4. Increase band speed being used and/or decrease STOCK HEIGHT the feed rate. 1. Check for faulty Solenoid 2 operation. 5. Check the saw band back-up carbides for wear. Replace them if necessary. VISES WON’T TRANSFER & SAW HEAD 6. Check for incorrect saw band tension. STAYS DOWN 1. Check for faulty operation of the head-down limit CUTTING RATE IS TOO SLOW. switch (2 LS).

1. Use a coarser pitch saw band. 2. Check to see if Solenoid 3 is operating.

2. Increase band speed and/or feed force. SLUGGISH HYDRAULIC COMPONENTS OP- NO COOLANT FLOW ERATION 1. Check for low hydraulic system pressure or low 1. Check for low coolant level in the reservoir. reservoir level. 2. Remove the coolant valves and hoses. Then use 2. Check for air in the hydraulic system. an air hose to clean out both units. 3. Check for a blocked or clogged hydraulic filter. 3. Clean the coolant pump intake screen. 4. Check for faulty hydraulic pump operation. 4. Check for coolant pump failure.

5. Check for a faulty coolant pump fuse. BAND DRIVE TRANSMISSION GETS HOT

1. Check for low transmission fluid level. STOCK FEEDS ERRATICALLY 2. Check for lubricant leakage. 1. Check for low hydraulic system oil level. NUISANCE OVERLOAD TRIPPING SAW HEAD WON’T LOWER 1. Check to see if the overload relays are set too low. 1. The feed rate setting is too low. Increase the setting if necessary.

2. Check the head-clear limit switch (3 LS) for faulty operation.

3. Check Solenoids 1 & 2 for incorrect operation.

4. Check for saw head obstruction.

SAW HEAD WON’T RAISE, OR RAISES SLOWLY

1. Check for faulty Solenoid 2 operation. 26 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 30 inches (762.0 mm) wide with a weight capacity of 2250 pounds (1020.6 kg) per roller.

• Stock conveyor ten (10) feet (3048.0 mm) long by 30 inches (762.0 mm) wide with a weight capacity of 2250 pounds (1020.6 kg) per roller.

Vertical Guide Roller.

VARIABLE VISE PRESSURE

1. The Variable Vise Pressure control valve, located to the right of the operator workstation, is used to Roller Stock Conveyor. adjust vise clamping force against materials which cannot tolerate full vise clamping pressure (examples 2. To install a roller stock conveyor: (a) Position the are thin-walled tubing, pipe,light structurals, etc.). assembled conveyor(s) behind or in front of the machine base; (b) Adjust the conveyor to the ma- • This control can be used with or without the optional chine with the leveling screws on the conveyor legs. Vertical Hold-Down Fixture. The top of the front conveyor roller should be inline to 0.010-inch (0.25 mm) above the vise bed wear 2. Clamping pressure is set by loosening the locknut plate. and turn the adjustment knob until the desired pressure is shown by the indicator gauge. The lower the 3. The remaining rollers must be parallel to, and in the number, the lighter the pressure and vice versa. same plane with the vise beds to within 0.010-inch (0.25 mm) per 24 inches (609.6 mm) of travel. VERTICAL HOLD-DOWN FIXTURE

4. Depress the roller shafts for ease of installation of 1. This feature is designed for high-production, multiple rollers. sawing of stacked bars, rounds and tubing. Its jaws have the capacity to hold stock from 10.25 to 25.5 The conveyor DOES NOT attach to the machine inches (260.3 to 650 mm) wide, and from 6.50 to base. Anchor the conveyor to the floor after 25.5 inches (165.1 to 650 mm) high. all leveling and adjustments are made. 2. Vertical nesting clamp cylinder is mounted to the VERTICAL GUIDE ROLLERS (Conveyors) machine’s inboard vise. It can also be mounted to the optional front or outboard vise if desired. The 1. Vertical guide rollers are effectively used to help cylinder operate simultaneously with the regular maintain correct positioning of long stock on the vise clamping cylinders. conveyor. The Vertical Hold-Down Fixture can also be 2. These can be installed between the interface plate used with the Variable Vise Pressure con- and conveyor or between conveyors (if more than trol. one is supplied).

27 VERTICAL HOLD-DOWN FIXTURE 5. Pieces should be stacked as closely together as pos- (Continued...) sible. Metal chips lodged in open spaces between individual pieces will affect cutting accuracy.

Vise Adjustment

1. Stack stock to be cut between the machine’s vise jaws. Then: (a) Center the nesting fixture’s vertical clamping cylinder; (b) Press the Inboard Vise Clamp key.

2. Adjust the horizontal clamp bars commensurate with the size of the nested stock.

3. If the horizontal clamping vises and the vertical nesting clamp do not release at approximately the same time: (a) Adjust the hydraulic restrictor valve at the rod end of the front and/or index vise cylinders to achieve relatively equal release.

For Best Nesting Cutting Results

Vertical Hold-Down Fixture. 1. Stack the same number of stockpieces in each row. Stacking Stock 2. The stack should always be higher than it is wide. 1. Correct stock nesting is essential for proper clamping of the vises and nesting fixture. It is important 3. Increasing the hold-down vise clamping pressure that nesting vise clamping pressure be transmitted will increase the holding load per piece (the Vari- to every stacked piece. Sometimes this can be able Vise Pressure valve control the clamping more easily accomplished by manually jogging the cylinders). stack. 4. Apply as much coolant as possible while cutting. 2. Proper stacking of round stock is important because saw band breakage may occur if round nested pieces 5. Replace wear plates on the moveable vise jaw and slip or spin during sawing. nesting fixture’s vertical clamping jaw when they become worn.

6. 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.

7. In some instances, increased production and blade life may be obtained by nesting fewer pieces than maximum vise capacity permits. Round Stock Stacking Methods. CHIP CONVEYOR 3. Slippage can also be prevented by using polyure- thane wear plates on the front moveable vise jaw 1. During operation, metal chips and used coolant and on both index vise jaws. drop directly into a sloped trough, or flow into it from the machine's run-off surfaces. Coolant then 4. Two (2) workable round stock stacking methods are flows down the trough and through a filtering screen shown in the next illustration (using the same num- before returning to the reservoir. ber 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).

28 CHIP CONVEYOR (Continued...) Controls & Display

Number in text refers to identical number on illustration.

1. Two Green LED's indicate zero or the center of the display. These LED's are always on.

2. Vertical line of Green LED's indicate the machine's normal operating range. Only one at a time is lighted.

Chip Conveyor - Top View.

2. The chip conveyor motor operates simultaneously with the hydraulic pump motor. The conveyor apron moves slowly at the bottom of the trough. Its movement carries metal chips to the opening at the machine's right side where chips empty into a customer-supplied container.

BAND LUBRICATOR

1. See the instructions sent with the unit for information on operation and adjustments. Band Twist Indicator. 3. Amber LED's indicate a caution region. These BAND TWIST INDICATOR LED's remain on and flash if there is a condition which remains for a period of time (seconds). This 1. The Band Twist Indicator gives the operator a graphic is intended to caution the operator that a potentially indication of the twist of the saw band from a true out-of-range condition may occur and corrective cut (direction of twist and its approximate magni- action should be taken. tude). • The operator can still see the approximate mag- • The Band Twist Transducer is mounted on the left nitude of the twist by observing the single amber saw guide arm. LED which is still lighted when the flashing LED's are off. The Band Twist Indicator reduces width capacity by two (2) inches (50.8 mm). • If the machine is running with the Man Auto selector at "man", a situation could occur which causes 2. The unit presents both "manual" and "automatic" a deflection into the amber region. The operator is operating options. In "manual", it functions only able to correct the condition -- perhaps by reducing as a visual indicator. During "automatic", the band feed force, etc. -- and the indicator will return to the drive motor shuts off if the twist is greater than the green region (the amber LED's will still be flashing approximate predetermined amount. as a caution to the operator. These conditions are remembered until the machine is turned off or the 3. If the indicator dot moves during cutting, this signifies Reset button is pushed. that something (dull or improper blade, overfeeding, etc.) is causing the blade to twist. The operator 4. Two Red LED's (on side of the display at the top and can see graphically the direction of twist and take bottom) flash when the indicator moves beyond the appropriate action to correct the problem before amber region. This indicates that the amber region several bad parts are produced. has been exceeded. Under this condition, the operator does not know the approximate magnitude of the error.

29 BAND TWIST MONITOR (Continued....) 3. The laser is adjustable to position the laser beam where desirable. 5. Red LED's at the extremes of the display are un- lighted when the deflection is reduced. This may 4. When the laser is turned on, a warm-up period of allow the operator to see what is happening as the 3 to 5 seconds take place before a line appears. If conditions change. the line is difficult to see, darken the work area to enhance the line. 6. Zero control allows the operator to position the display where desired. Normally this would be in 5. Remove the protective shipping cap from the laser the center of the display as indicated by the two devise before operation. Green LED's which are always on. IDLER WHEEL MOTION DETECTOR 7. Sensitivity control allows the operator to set the full scale of the display -- "1" is the least sensitive 1. This safety devise located on the saw head plate to twist and "10" is the most sensitive. The actual behind the idler bandwheel stops the machine if the values depend on the calibration of the device. saw band should break or stall in the workpiece. Always determine the cause of the stoppage and 8. Man - Auto. This selector permits the operator to correct it before attempting to resume operation. select "manual" operation (machine operation is not interrupted by the band twist monitor), or "automatic" (the saw band is stopped when the red LED's are lighted).

9. Reset. Push the button to turn off the flashing indicators, etc.

FRONT (OUTBOARD) VISE

1. During cutting operations,a front or outboard vise may be helpful to hold cut stock in place. The vise is located in front of the saw band.

2. On the Operations screen there is a FRONT VISE CLAMP and FRONT VISE OPEN keys that operate the front vise.

3. The optional Variable Vise Pressure control and the Vertical Hold-Down Fixture can be added for higher production.

DISCHARGE TABLE

1. Some operations having a long length of stock to be cut will benefit with the discharge table to support the longer cut-off pieces.

LASER LINE OPTION

To avoid eye damage, DO NOT stare into the laser beam.

1. A laser devise is used to emit a line on the material to be cut. This line shows the approximate spot where the cut will take place.

2. The devise is controlled by a selector switch with "on" and "off" settings and is located on or near the control panel. Turn the laser off when not in use. 30