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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275 SUPER CUT

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

300 SUPER CUT

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

5

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MACHINE DIMENSIONS

TRANSPORT

4

INSTALLATION
DISMANTLING

4.1 - Transport and handling of the machine

315 SUPER CUT

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.

8