Dake 315CE User Manual

USE AND MAINTENANCE MANUAL

275 SUPER CUT

300 SUPER CUT
315 SUPER CUT

THOMAS

THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34

Registro Imprese 4272//VI 116 REA n. 93906/Vicenza

Contents

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Contents ........................................................................ " 2

Ordering spare parts .................................................... " 2

Guarantee ...................................................................... " 2

Machine certification and identification marking ....... " 3

CHAPTER 1

Reference to accident-prevention regulations........... " 4

1.1 - Advice for the operator............................................" 4

1.2 - Location of shields against accidental contact with

the tool .................................................................... " 4

1.3 - Electrical equipment according to European

Standard "CENELEC EN 60 204-1" (1992) ............" 4

1.4 - Emergencies according to European Standard

"CENELEC EN 60 204-1" (1992) ..........................." 4

CHAPTER 2

Recommendations and advice for use ....................... " 4

2.1 - Recommendations and advice for using the machine .." 4

CHAPTER 3

Technical characteristics ............................................. " 5

3.1 - Table of cutting capacity and technical details ........ " 5

CHAPTER 4

Machine dimensions - Transport - Installation

Dismantling ................................................................... " 6

4.1 - Machine dimensions ..............................................." 6

4.2 - Transpor t and handling of the machine.................." 6

4.3 - Minimum requirements for the premises

housing the machine .............................................." 6

4.4 - Anchoring the machine..........................................." 7

4.5 - Instructions for electrical connection ......................" 7

4.6 - Instructions for assembly of the loose parts and

accessories............................................................." 7

4.7 - Disactivating the machine ....................................... " 7

4.8 - Dismantling ............................................................. " 7

CHAPTER 5

Machine functional parts ............................................. " 7

5.1 - Operating head ....................................................... " 7

5.2 - Vice ......................................................................... " 7

5.3 - Bed .......................................................................... " 8

CHAPTER 6

Description of the operating cycle ............................. " 8

6.1 - Starting up and cutting cycle .................................. " 8

CHAPTER 7

Regulating the machine ............................................... " 8

Ordering spare parts

7.1 - Disk head ................................................................ " 8

7.2 - Vice ........................................................................." 8

7.3 - Cutting angle adjustment........................................" 9

7.4 - Changing the disk ..................................................." 9

7.5 - Changing the lubricating coolant pump .................." 9

CHAPTER 8

Routine and special maintenance .............................. " 9

8.1 - Daily maintenance .................................................." 9

8.2 - Weekly maintenance .............................................. " 9

8.3 - Monthly maintenance ............................................. " 9

8.4 - Six-monthly maintenance ....................................... " 9

8.5 - Oils for lubricating coolant ...................................... " 9

8.6 - Oil disposal ............................................................." 10

8.7 - Special maintenance .............................................. " 10

CHAPTER 9

Material classification and choice of tool .................. " 10

9.1 - Definition of materials ............................................." 10

9.2 - Choosing the disk ................................................... " 10

9.3 - Teeth pitch .............................................................." 11

9.4 - Cutting and advance speed...................................." 11

9.5 - Running in the disk ................................................. " 11

9.6 - Disk structure.........................................................." 11

9.7 - Type of disks..........................................................." 11

Tooth shape ..........................................................." 11

Tooth cutting angle ................................................ " 11

9.7.1 - Table of recommended cutting parameters................. " 12

9.7.2 - Ta ble of cutting speed according to disk diameter ....... " 12

CHAPTER 10

Machine components ................................................... " 13

10.1- List of spare parts .................................................. " 13

CHAPTER 11

Wiring diagrams ........................................................... " 17

CHAPTER 12

Troubleshooting............................................................ " 19

12.1-Blade and cutting diagnosis...................................." 19

12.2-Electrical components diagnosis ............................" 21

CHAPTER 13

Noise tests ..................................................................... " 21

CHAPTER 14

Optional ......................................................................... " 22

14.1 - Pneumatic vice ......................................................" 22

14.2 - Connection to the pneumatic system ..................." 22

Plates and labels .......................................................... " 22

Notes .............................................................................. " 23

- 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 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

Machine certification and identification marking

MACHINE LABEL

via Pasubio, 32 36033 ISOLA VIC. - ITALIA

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MODEL
TYP
SERIAL NUMBER

YEAR OF MANUFACTURE

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(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)

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REFERENCE TO ACCIDENT-

1

PREVENTION REGULA TIONS

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 tool head is in rest position (raised), the toothed
disk must be stationary.

- It is forbidden to work on the machine without its shields (these
are all white, grey or blue in colour).

- Always disconnect the machine from the power socket before
changing the disk or carrying out any maintenance job, even
in the case of abnormal machine operation.

- It is forbidden to disconnect the “man present” device, known
more correctly in the EEC as the “safety switch with hold­down action”.

- Always wear suitable eye protection.

- Never put your hands or arms into the cutting area while the
machine is operating.

- Do not shift the machine while it is cutting.

- 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.

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 probe.

- 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.

NOTE: Resetting of machine operation after each emergency

stop is achieved by reactivating the specific restart
button.

RECOMMENDATIONS AND

2

AD VICE 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.

1.2 - Location of shields against accidental
contact with the tool

- Green metal shield screwed onto the disk head.

- Self-regulating mobile blue plastic shield, fitted coaxially with
the fixed shield.

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

4

- To obtain good running-in of the machine it is advisable to
start using it at intervals of about half an hour. This operation
should be repeated two or three times, after which the machine
may be used continuously.

- Before starting each cutting operation, ensure that the part is
firmly gripped in the vice and that the end is suitably supported.

- Do not use disks of a different size from those stated in the
machine specifications.

- If the disk 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 disk or its teeth are not
broken. If they are broken, change the tool.

- Before carrying out any repairs on the machine, consult the
dealer or apply to THOMAS.

TECHNICAL

3

CHARACTERISTICS

3.1 -

Tab le of cutting capacity and tec hnical details

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0° 85 70 95 x 60

45° DX - SX 72 65 75 x 60

2-speed three-phase electri c motor KW 1,1 ÷ 1,5

1-speed single-phase electri c motor KW 1,5

Max. electric absorption KW 1,55

Oil-bath reduction uni t i 34 : 1

Max. blade diameter mm 275

Min. blade diameter mm 250

Blade rotation speed rpm 41 ÷ 82

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0° 90 75 100 x 65

45° DX - SX 80 70 80 x 60

2-speed three-phase electric motor KW 1,2 ÷ 1,6

1-speed single-phase electri c motor KW 1,5

Max. electric absorption KW 1,55

Oil-bath reduction unit i 34 : 1

Max. blade diameter mm 300

Min. blade diameter mm 250

Blade rotation speed rpm 41 ÷ 82

Vice opening mm 120

Machine Weight KG 123

Coolant liquid L 5

Working table height with base mm 980

1050

1800 CON PIEDISTALLO

1100

170

520

1000

310

Vice opening mm 120

Machine Weight KG 125

Coolant liquid L 5

Working table height with base mm 980

1080

1800 CON PIEDISTALLO

1100

170

520

310

1000

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MACHINE DIMENSIONS

TRANSPORT

4

INSTALLATION
DISMANTLING

4.1 - Transport and handling of the machine

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0° 95 82 110 x 70

45° DX - SX 90 80 85 x 70

2-speed three-phase electric motor KW 1,3 ÷ 1,9

1-speed single-phase electric motor KW 1,5

Max. electric absorption KW 1,95

Oil-bath reduction unit i 34 : 1

Max. blade diameter mm 315

Min. blade diameter mm 250

Blade rotation speed rpm 41 ÷ 82

Vice opening mm 120

If the machine has to be shifted in its own packing, use a fork­lift truck or sling it with straps as illustrated.

4.2 - 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%.

Machine Weight KG 128

Coolant liquid L 5

Working table height with base mm 980

1080

1800 CON PIEDISTALLO

1100

6

170

520

1000

310

4.3 - Anchoring the machine

690

7055070

185

AA

630

445

- Position the machine on a firm cement floor maintaining, at
the rear, a minimum distance of 800 mm from the w all; 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.

M8

12

SEC. A - A

PEDEST AL PROFILE

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4.4 - 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 THREE-PHASE MACHINE -

SOCKET FOR A 16A PLUG

R = L1
S = L2
T = L3
PE = GND

2 - WIRING DIAGRAM FOR THE SINGLE-PHASE SYSTEM

SOCKET FOR A 16A PLUG

= L1
= L2

= PE

4.5 - Instructions for assembly of the loose parts

and accessories

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 ma­terial (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

general 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.

MACHINE FUNCTIONAL

5

PARTS

5.1 - Operating head

- Machine part composed of the parts that transmit movement

(motor, reduction unit), the lubricating coolant pump and the
electrical components.

Fit the components supplied as indicated in the photo:

- part. 1 Screw the lever onto the head and fix it

- part. 2 Fit the bar holding rod

- part. 3 Fix the pedestal firmly onto the base ( optional )

- part. 4 Fit and align the roller carrying arm on the counter­vice bench.

4.6 - Disactivating the machine

- 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) release the head return spring

3) empty the coolant tank

4) carefully clean and grease the machine

5) if necessary, cover the machine.

4.7 - 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:

5.2 - Vice

- System for gripping material during the cutting operation,
operated with handwheel and fast manual blocking lever.
It is provided with an anti-burr device for blocking the part that
is to be cut.

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5.3 - Bed

- Support structure for the OPERATING HEAD (rotating ar m
for gradual cutting, with respective blocking system), the VICE,
the BAR STOP, the material support ROLLER and the housing
for the cutting coolant TANK.

DESCRIPTION OF THE

6

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 - Starting up and cutting cycle

6

4

5

7

and that sufficient coolant is coming out.
The cropper is now ready to start work, bearing in mind that the

CUTTING SPEED and the TYPE of DISC - combined with a
suitable descent of the head - 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 choice of disks”).

- When starting to cut with a new disk, 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 choice
of disks” in the section on

Running in the disk

).

2

3

1

- Ensure that the machine is not in emergency stop condition;
if it is, release the red mushroom button ( 1 ).

- Select the cutting speed on the switch ( 3 ):
position 1 = 41 rpm.
position 2 = 82 rpm.

- Press the start/reset button ( 2 ): its green light will go on.

- Place material to be cut in the vice ( 4 ). Close jaws against
piece, keeping a distance of approx. 3 - 4 mm then clamp
with lever.

- Grip the handle ( 6 ) of the HEAD control arm and press the
button, checking that the disk is turning in the direction
indicated (if not, invert the two phase leads):

- Press the red emergency button ( 1 ) when there are conditions
of danger or malfunctions in general, so as to stop machine
operation immediately.

REGULATING
THE

7

MACHINE

7.1 - Disk head

- If excessive axial pla y is f ound on the hinge , it will be sufficient
to tighten the screws ( 7 ), paying attention not to make the
joint too tight.

7.2 - Vice

- The device does not require any particular adjustment.

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7.3 - Cutting angle adjustment

- Release lever ( 1 ), rotate the cutting head and make sure
that the wanted cutting angle perfectly meets with the reference
index before locking with the lever ( 1 ).

1

BEFORE PERFORMING THE FOLLOWING OPERATIONS,
THE ELECTRIC POWER SUPPLY AND THE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.

7.4 - Changing the disk

To change the disk:

- Release the mobile yellow, white or orange guard and turn it back.

- Block a piece of wood in the vice and lean the disk on it.

- Insert the special spanner provided and remove the screw
( 1 ), slackening it in a clockwise direction because it has a
left-handed thread, then slip off the flange that holds the disk.

- Fit the new disk, checking the cutting direction of the teeth,
then replace the flange, the screw and the mobile white, yellow
or orange guard.

ROUTINE
AND SPECIAL

8

MAINTENANCE

THE MAINTENANCE JOBS ARE LISTED BELOW , DIVIDED

DAILY, WEEKL Y, MONTHLY AND SIX-MONTHLY

INTO
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.

- Top up the level of lubricating coolant.

- Check the disk for wear.

- Lift the head into a high position to avoid yield stress on the
return spring.

- Check functionality of the shields and emergency stops.

8.2 - Weekly maintenance

- More accurate general cleaning of the machine to remove
shavings, especially from the lubricant fluid tank.

- Clean the filter of the pump suction head and the suction
area.

- Clean and grease the screw and the sliding guide of the vice.

- Clean the disk housing.

- Sharpen the disk teeth.

8.3 - Monthly maintenance

- Check tightness of the screws on the motor, the pump, the
jaws and shields.

- Check that the shields are unbroken.

- Grease the head hinge pin.

8.4 - Six-monthly maintenance

1

7.5 - Changing the lubricating coolant pump

- Takes the pipes of the lubricating-refrigerating system off.

- Remove the fastening screws and replace the little pump, being
careful to keep the driving stem centred on the drive shaft
bearing.

- Change the oil in the reduction unit using oil type GEARCO
85W-140 by NATIONAL CHEMSERACH or MOBIL GLYCOLE
30 or KLUBER SINTHESO 460 EP or an equivalent oil,
proceeding as follows:

- Remove the connecting plug
from the electric box and un­screw the head moving
lever.

- Drain off the old oil from the
cap at the side ( 1 ).

- Pour in new oil up to the
mark ( 2 ), through the lever
fixing hole, keeping the head
in a horizontal position.

- Reassemble all the parts.

2

1

- Check continuity 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 %.

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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. The ter m special maintenance also
covers the resetting of protection and safety equipment and
devices.

MATERIAL
CLASSIFICATION AND

9

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, choice of the type of cutting disk, cutting speed and
con-trol of head descent, must be suitably combined.These
spe-cifications must therefore be harmoniously combined
in a single operating condition according to practical consi-

dera-tions and common sense, so as to achieve an optimum
condi-tion 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 ti-me will be solved more easily if the operator has a
good know-ledge of these specifications.

WE THEREFORE ADVISE YOU ALWAYS TO CHOOSE
ORIGINAL SPARE DISKS 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.

9.2 - Choosing the disk

First of all the pitch of the teeth must be chosen, suitable for the
material to 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.

USE

Construction

steels

Carbon

steels

Spring steels

Alloyed steels for

hardening and

tempering and for

nitriding

Alloyed

casehardening

steels

Steel for
bearings

Tool steel

Stainless

steel

Copper alloys
Special brass

Bronze

Cast iron

TYPES OF STEEL CHARACTERISTICS

I

UNI

Fe360
Fe430
Fe510

C20
C40
C50
C60

50CrV4

60SiCr8

35CrMo4
39NiCrMo4
41CrAlMo7

18NiCrMo7
20NiCrMo2

100Cr6 100Cr6 100C6 534 A 99 52100 207 95 690÷980

52NiCrMoKU

C100KU

X210Cr13KU

58SiMo8KU

X12Cr13
X5CrNi1810
X8CrNi1910

X8CrNiMo1713

Aluminium copper alloy G-CuAl11Fe4Ni4 UNI 5275
Special manganese/silicon brass G-CuZn36Si1Pb1 UNI5038
Manganese bronze SAE43 - SAE430
Phosphor bronze G-CuSn12 UNI 7013/2a

Gray pig iron G25
Spheroidal graphite cast iron GS600
Malleable cast iron W40-05

D

DIN

St37
St44

St52
CK20
CK40
CK50
CK60

50CrV4

60SiCr7

34CrMo4
36CrNiMo4
41CrAlMo7

----

21NiCrMo2

56NiCrMoV7

C100W1

X210Cr12

----

4001
4301

----

4401

F

AF NOR

E24
E28
E36

XC20

XC42H1

----

XC55

50CV4

----

35CD4

39NCD4

40CADG12

20NCD7
20NCD2

----

----

Z200C12

Y60SC7

----

Z5CN18.09

----

Z6CDN17.12

GB
SB

---­43
50

060 A 20
060 A 40

----

060 A 62
735 A 50

----

708 A 37

----

905 M 39

En 325

805 H 20

----

BS 1

BD2 - BD3

----

----

304 C 12

----

316 S 16

USA

AISI-SAE

----

----

---­1020
1040
1050
1060

6150
9262

4135
9840

---­4320

4315

----

S-1

D6 - D3

S5

410
304

----

316

Hardness
BRINELL

HB
116
148
180
198
198
202
202

207
224

220
228
232

232
224

244
212
252
244

202
202
202
202

220
140
120
100

212
232
222

Hardness

ROCKWELL

HRB

67
80
88
93
93
94
94

95
98

98
99

100
100

98

102

96
103
102

94

94

94

94

98

77

69

56,5

96
100

98

R=N/mm2

360÷480
430÷560
510÷660
540÷690
700÷840
760÷900
830÷980

1140÷1330
1220÷1400

780÷930
880÷1080
930÷1130

760÷1030

690÷980

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

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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.

S (MM) PICTH SHAPE SPEED

B

shaped

C

solid

C

solid

C

solid

C

solid

C

solid

2
2
1
1
1
1

S

SS

up to 2 4 - 6

2 ÷ 5 8

5 ÷ 10 8

over 10 8

up to 20 8

20 ÷ 50 10

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/mm
dimensions of the widest section.

- Too high an advance speed (= disk descent) tends to cause
the disk to deviate from the ideal cutting path, producing non
rectilinear cuts on both the vertical and the horizontal plane.

2

), to its hardness (HRC) and to the

9.5 - Running in the disk

Tooth shape

The profile of the toothing depends on the size, shape and
thickness of the section to be cut, either straight or at an angle.
It may also vary according to the pitch, but not so distinctly as
to make this an element for classification.

- Fine toothing is to be chosen for cutting small sections with a
profiled shape and tubular sections with thin walls (2-5 mm
depending on the material).

- Large toothing is suitable for cutting medium and large solid
sections or fairly thick profiled or tubular sections (over 5 mm).

"A" toothing:
normal fine toothing

"B" toothing:
normal large toothing with or
without shaving breaking inci­sion

“C (HZ)” toothing:
large toothing with roughing
tooth with rake on both sides,
alternating with a finishing
tooth without rake. The rou­ghing tooth is 0.15-0.30 mm
higher

"AW" toothing:
fine toothing with alternate side
rake

"BW" toothing:
large toothing with alternate
side rake

Added toothing:
disks made in this way are
used for cutting non-ferrous
metals, such as light alloys,
and plastics, and above all in
wood-working. The teeth are
hard metal (HM) plates brazed
onto the body of the disk; there
are various types and shapes
and, considering the vastness
of the field, the topic is not
developed further here.

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 cm
to the cutting capacity and solid section of normal steel with
R = 410-510 N/mm

with lubricating coolant.

2

/min on material of average dimensions with respect

2

), generously spraying the cutting area

9.6 - Disk structure

The most commonly used disks are made of extra high speed
steel (HHS) of normal quality (HHS/DMo5) or superior quality
(HHS/Mo5 + Co5) with a treated tooth, which differentiates them
from the former on account of the high value of structural
resistance, greater resistance to seizing, absence of stress in
the mass and a better holding of lubricating coolant during work.

9.7 - Type of disks

The disks differ essentially in their constructive characteristics,
such as:

- Tooth shape

- Tooth cutting angle

Tooth cutting angle

Each tooth has two cutting angles:

αα

α : front rake angle

-

αα
γγ

γ : rear rake angle

-

γγ

SHARPENING CIRCULAR SAWS

αα

α

αα

γγ

γ

γγ

3 4 5 6 7 8 9 10 12 14 16

T

1,3 1,6 2,1 2,5 2,9 3,4 3,8 4,2 5,1 5,9 7,2

p

1,5 2 2,5 3 3,5 4 4,5 5 6 7 8

d

h = 0,2 mm h = 0,3 mm

The rake varies especially according to the type of material
to be cut.

11

9.7.1 - RECOMMENDED CUTTING PARAMETERS

2

2

Mild steel

R = 350-500 N/mm

Semi-hard steel

R = 500-700 N/mm

CUTTING ANGLES

*T mm
Vt m/1'

Av mm/1'

*T mm

Vt m/1'

Av mm/1'

*T mm
Vt m/1'

Av mm/1'

*T mm
Vt m/1'

Av mm/1'

*T mm
Vt m/1'

Av mm/1'

SECTION TO BE CUT (IN MM)

RECOMMENDED LUBRIFICANTS Emulsion - Cutting oil

*T mm
Vt m/1'

Av mm/1'

*T mm
Vt m/1'

Av mm/1'

2

2

Extra-hard steel

Hard steel

R = 950-1000 N/mm

R = 750-950 N/mm

Heat-treated steel

2

2

Austentic stainless

steel

R = 500-800 N/mm

Martensitic stainless

R = 950-1300 N/mm

steel

2

R = 500-800 N/mm

Grey cast iron

Aluminium and alloys

Kerosene

Dry

2

2

Aluminium and alloys

R = 300-300 N/mm

R = 200-400 N/mm2Copper

Dry

R = 200-350 N/mm

Emulsion

2

2

Phosphor bronze

R = 400-600 N/mm

Hard bronze

R = 600-900 N/mm

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2

Brass

R = 200-400 N/mm2Titanium and alloys

Alloyed brass

Cutting oil Emulsion

R = 300-800 N/mm

Tubes and beams

R = 400-700 N/mm

0,05. D

2

2

Tubes and beams

0,025. D

R = 300-600 N/mm

R = 300-600 N/mm

9.7.2 - DIAGRAM OF CUTTING SPEEDS ACCORDING TO DISK DIAMETER

Vt m/min

KEY

T Tooth pitch in millimetres
Av mm/min Advance in millimetres per minute
Vt m/min Cutting speed in metres per minute
Az Tooth advance
Ng/min Number of revs per minute
Z Number of teeth on the disk
p Tooth depth

d Diameter of the tooth fillet cone distance
h Tooth protrusion

γ Front rake
α Rear rake

N/mm Ultimate tensile stress
a-f Flat parts of the cutting edge
Ø Tube diameter or profile width

12

n = g/min

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10

MACHINE COMPONENTS

10.1 - List of spare parts

REFERENCE N° DESCRIPTION

1 Machine bed
2 Revolving arm
3 Revolving arm locking pin
4 Revolving arm locking bush
5 Revolving arm locking lever
6 Screw M8
7 Countervice
8 Pin
9 Countervice jaws
10 Burr-free jaws
11 Countervice fixing pin
12 Roller arm
13 Roller
14 Washer M10
15 Vite M10
16
17 Vice
18 Vice jaws
19 Vice jaws washer
20 Screw M12
21 Vice jaws washer
22 Screw M12
23 Grain M8
24 Lever bush
25 Quick lock vice lever
26 Thrust bearing AX 3047

+ CP 3047
27 Quick lock vice lever washer
28 Vice closing handwheel Ø 18
29 Elastic pin Ø 5
30 Washer
31 Screw M8
32
33
34
35 Vice thread
36 Lock vice spring
37 Burr-free transverse plate

REFERENCE N° DESCRIPTION

38 Burr-free plate
39 Grain M8
40 Screw M8
41 Tank filter
42 Screw M6
43 Bar stop rod
44
45
46 Bar stop
48 Screw M8
49 Support tank cover
50 Ring seeger Ø 42 I
51 Tank cover filter
52 Tank cover filter
53 Tank cover
54 Washer
55 1/4" gas tap
56 Coolant tube
57 Oiler Ø 8
58 Return spring connection
59 Head return spring
60 Nut M12
61 Screw M12
62 Head
63 plug
64 Oil level plug
65 Oil drain plug
66 Screw M10
67 Hinge pin
68 Hinge pin washer
69 Hinge pin bush
70 Grain M8
71 Nut M8
72 Nut M16
73 Head lever
74 Head lever handgrip
75 GUK ring nut M25x1,5
76 Worm wheel

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REFERENCE N° DESCRIPTION

N° RIFERIMENTO DENOMINAZIONE

REFERENCE N° DESCRIPTION

N° RIFERIMENTO DENOMINAZIONE

77 Ring SM 35-47-7
78 Blade shaft
79 Pin
80 Blade
81 Shaft flange stakes
82 Screw M12
83 Fixed blade guard
84
85
86 Coolant distributor
87 Coolant tube
88 Grain M6
89 Mobile blade guard
90 Ring seeger Ø 60E
91
92
93 Tir rod support
94 Washer
95 Screw M8
96 Mobile guard rod
97 Screw M8
98 Washer
99 Bearing 6301
100 GUK ring nut M17x1
101 Worm screw
102 Spacer
103 Spacer Ø 47
104 Bearing 3204
105 Ring DPSM 25-40-7
106 Head gasket
107 Front motor flange
108 Motor shaft (rotor)
109 Key
110 Washer
111 Stud bolt
112 Nut
113 Motor and stator casing
114
115
116 Rear motor flange

REFERENCE N° DESCRIPTION

REFERENCE N° DESCRIPTION

118
119 Bearing 6205 2Z
120 Ring seeger Ø 25E
121 Fan
122 Screw M4
123 Fan cover
124 Bearing 609
125 Pump connection box
126
127 Screw M5
128 Coolant pump
129 Washer
130 Screw M6

14

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15

LEGENDA
140 Auxiliary relay

141 Remore control switch
142 Fuse carrier
143 Transformer
144 Socket connector
145 Plug connector

142

144

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140

141

143

LEGENDA
146 Speed switch

147 Reset button
148 Emergency push button
149 Electric components box

145

146

147

149

148

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WIRING DIAGRAMS

CIRCUIT DIAGRAM SINGLE-PHASE

V 230/50 Hz

CODE DESCRIPTION

SQ1 Microswitch

SB1 Mushroom button

SB2 Luminous button

HL Pilot lamp

CODE DESCRIPTION

M1 Disk motor

XP Socket

XS Plug

QS Isolating switch

C Condenser

KA Auxiliary relay

KM Remote-control switch

ST1 Thermal probe

FU1 Fuse cartridge

FU2 Fuse cartridge

TC1 Transformer

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CIRCUIT DIAGRAM THREE-PHASES

18

V 400 / 50 Hz

SIGLA DESCRIZIONE

SQ1 Microinterruttore

SB1 Pulsante a fungo

SB2 Pulsante luminoso

HL Lampada spia

SIGLA DESCRIZIONE

M1 Motore disco

XP Presa

XS Spina

SA Commutatore

FU1 Cartuccia fusibile

KA Relè ausiliario

KM Teleruttore

ST1 Sonda termica

FU2 Cartuccia fusibile

TC1 Trasformatore

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12

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.

TROUBLESHOOTING

12.1 - Blade and cut diagnosis

FAULT PROBABLE CAUSE REMEDY

TOOTH BREAKAGE Too fast advance

Wrong cutting speed

Wrong tooth pitch

Low quality disk
Ineffective gripping of the part in the
vice.
Previously broken tooth left in the cut
Cutting resumed on a groove made
previously.
Insufficient lubricating refrigerant or
wrong emulsion

Sticky accumulation of material on
the disk.

Decrease advance, exerting less cutting
pressure
Change disk speed and/or diameter.
See Chapter

and choice of disks” and the

cutting speeds according to disk diameter.

Choose a suitable disk.
See Chapter “Material classification

and choice of disks”.

Use a better quality disk.
Check the gripping of the part.

Accurately remove all the parts left in.
Make the cut elsewhere, turning the part.

Check the level of the liquid in the tank.
Increase the flow of lubricating refrigerant,
checking that the hole and the liquid outlet
pipe are not blocked.
Check the blend of lubricating coolant and
choose a better quality disk.

“

Material classification

Table of

PREMATURE DISK WEAR Wrong running in of the disk

Wrong cutting speed

Unsuitable tooth profile

Wrong tooth pitch

Low quality disk
Insufficient lubricating refrigerant

Hardness, shape or flaws in the mate-

CHIPPED DISK

rial (oxides, inclusions, lack of homo­geneity, etc..)
Wrong cutting speed

Wrong tooth pitch

Vibrations
Disk incorrectly sharpened

Low quality disk

See Chapter “Material classification

and choice of disks”

on

Running in the disk.

Change disk speed and/or diameter.
See Chapter “Material classification
and choice of disks” and the

cutting speeds according to disk diameter.

Choose a suitable disk. See Chapter

“Material classification and choice of
disks” in the paragraph on

Choose a suitable disk.
See Chapter “Material classification

and choice of disks”.

Use a better quality disk.
Check the level of the liquid in the tank.
Increase the flow of lubricating refrigerant,
checking that the hole and the liquid outlet
pipe are not blocked.

Reduce the cutting pressure and/or the
advance.

Change disk speed and/or diameter. See
Chapter “Material classification and

choice of disks” and the
cutting speeds according to disk
diameter.

Choose a suitable disk.
See Chapter “Material classification

and choice of disks”.

Check gripping of the part.
Replace the disk with one that is more
suitable and correctly sharpened.
Use a better quality disk.

in the paragraph

Table of

Type of disks.

Table of

19

FAULT PROBABLE CAUSE REMEDY

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DISK VIBRATION

RIDGES ON THE CUTTING SURFACE

Incorrect emulsion of the lubricating
refrigerant

Wrong tooth pitch

Unsuitable tooth profile

Ineffective gripping of the part in the
vice.
Dimensions of the solid section too
large with respect to the maximum
admissible cutting dimensions
Disk diameter incorrect and/or too
large

Disk diameter incorrect and/or too
large

Ineffective gripping of the part in the
vice.
Too fast advance

Disk teeth are worn
Insufficient lubricating refrigerant

Toothing does not unload shavings
well

Check the percentage of water and oil in
the emulsion.

Choose a suitable disk.
See Chapter “Material classification

and choice of disks” .

Choose a suitable disk.
See Chapter

and choice of disks”

on Type of disks.

Check the gripping of the part.
Abide by the instructions.

Decrease the disk diameter, adapting it
to the dimensions of the part to be cut;
the cutting part of the disk must not be
too large for the shape of the part to be
cut.

Decrease the disk diameter, adapting it
to the dimensions of the part to be cut;
the cutting part of the disk must not be
too large for the shape of the part to be
cut.
Check the gripping of the part.

Decrease advance, exerting less cutting
pressure.
Sharpen the tool.
Check the level of the liquid in the tank.
Increase the flow of lubricating refrigerant,
checking that the hole and the liquid outlet
pipe are not blocked.
Choose a blade with a larger tooth pitch
that allows better unloading of shavings
and that holds more lubricating refrigerant.

“Material classification

in the paragraph

CUTS OFF THE STRAIGHT

BLADE STICKS IN THE CUT Too fast advance

20

Too fast advance
Ineffective gripping of the part in the

vice
Disk head off the straight
Disk sides differently sharpened.
Disk thinner than the commercial
standard.
Dirt on the gripping device

Low cutting speed
Wrong tooth pitch

Sticky accumulation of material on
the disk.
Insufficient lubricating refrigerant

Decrease advance, exerting less cutting
pressure.
Check the gripping of the part which may
be moving sideways.
Adjust the head.
Choose tool quality carefully in every detail
as regards type and construction cha­racteristics.
Carefully clean the laying and contact
surfaces.

Decrease advance, exerting less cutting
pressure.
Increase speed.
Choose a suitable disk.
See Chapter “Material classification

and choice of disks” .

Check the blend of lubricating coolant and
choose a better quality disk.
Check the level of the liquid in the tank.
Increase the flow of lubricating refrigerant,
checking that the hole and the liquid outlet
pipe are not blocked.

12.2 - Electrical components diagnosis

FAULT PROBABLE CAUSE REMEDY

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THE GREEN PILOT LIGHT
“HL” DOES NOT LIGHT UP

Fused lamp
Power supply

Fuses “FU 1”
Short circuits
Speed switch “SA” in position “0”
Emergency button “SB 1” on

Cycle reset or line button “SB 2”
Thermal probe built into the stator
winding has tripped due to motor
overheating

Transformer “TC 1”

Fuse “FU 2”

Auxiliary relay “KA”

Change it.
Check: - phases

- cables

- socket

- plug
Voltage must arrive upstream from the
fuses.
Check for efficiency.
Identify and eliminate.
It must be turned to position 1 or 2.
Ensure that it is off and that its contacts
are unbroken.
Check mechanical efficiency.
Check current continuity on the two wires
in the prone after letting the motor cool
for about 10-15 minutes. If after this time
there is no current continuity in the two
wires, the motor must be changed or
rewound.
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
to trip.
Check that 24 V reach the coil terminals
when the button “SB 2” is pressed; if this
happens and the relay is not self-fed, it
must be changed.

MOTOR STOPPED WITH PILOT
LIGHT “HL” LIT

13

In accordance with point 1.7.4.f of the Machines Directive EEC 89/392

SOUND LEVEL CALIBRATOR MOD. BRUEL & KIAER 2260
2 measurements with the machine.

- The microphone was been located close to the operator's head, at medium height.

- The weighted equivalent continuous acoustic pressure level was 71,6 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.

NOISE TESTS

Socket and plug connecting the
electric box/ microswitch in the handle

Microswitch “SQ 1” in the handle
Remote-control switch “KM”

Motor “M 1”

Check that the plug is correctly inserted
and look for any bad connections inside
the box.
Check operation and/or efficiency; replace
if broken.
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.

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14

14.1 - Pneumatic vice

- System for clamping material during the cutting operations,

14.2 - Connection to the pneumatic system

OPTIONAL

with an automated pneumatic device.
It is provided with an anti-burr device for blocking the part of
the piece that has been cut off.

2

1

1

- Connect the tube of the pneumatic system to the filter unit
part ( 1 ) and check that the pressure gauge part ( 2 ) shows
a pressure of 6 - 7 BAR, sufficient to ensure optimum
functioning of the device.

PLATES AND LABELS

- The vice opening mechanism is controlled by the valve part
( 1 ) operated only if the head is completely lifted.

- Leave a play of 3 - 4 mm between the jaws and the piece to
be clamped, then lower the head to block the piece.

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NOTES: _________________________________________________________________________

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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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