Dake SAR 331 User Manual
USE AND MAINTENANCE MANUAL
SAR 331 SA
GDS
THOMAS
01/2003
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34
Registro Imprese n. 4272//VI116 REA n. 93906/Vicenza
Contents
SAR 331 SA GDS
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"......................." 5
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1"......................................." 5
1.5 - Other risks............................................................... " 5
CHAPTER 2
Recommendations and advice for use ....................... " 5
2. 1 - Recommendations and advice for using the machine. " 5
CHAPTER 3
Technical characteristics ............................................. " 6
3.1 - Table of cutting capacity and technical details ......." 6
CHAPTER 4
Machine dimensions - Transport - Installation
Dismantling.................................................................... " 6
4.1 - Machine dimensions .............................................. " 6
4.2 - Transport and handling of the machine ................." 7
4.3 - Minimum requirements for the premises
housing the machine .............................................. " 7
4.4 - Anchorage of standard 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 or saw frame .................................... " 7
5.2 - Vice.......................................................................... " 7
5.3 - B e d .......................................................................... " 7
CHAPTER 6
Description of the operating cycle ...................................." 8
6.1 - Starting up and cutting cycle ....................................." 8
CHAPTER 7
Regulating the machine ................................................ " 10
7.1 - Blade tension assembly ......................................... “ 10
7.2 - Blade guide blocks ................................................. “ 1 0
7.3 - Vice ......................................................................... “ 10
7.4 - Regulating the cutting angle .................................. “ 1 1
7.5 - Blade-cleaning brush ............................................. “ 11
7.6 - Regulating the height of the cut .............................“ 11
7.7 - Regulating the cutting speed ................................. " 11
7.8 - Regulating the saw frame return spring................." 12
7.9 - Changing the blade ................................................ " 1 2
7.10- Replacing saw frame return spring ........................ " 12
CHAPTER 8
Routine and special maintenance ............................... " 12
8.1 - Daily maintenance ................................................. " 1 2
8.2 - Weekly maintenance .............................................. " 12
8.3 - Monthly maintenance ............................................. " 13
8.4 - Six-monthly maintenance ....................................... " 1 3
8.5 - Oils for lubricating coolant......................................" 1 3
8.6 -Oil disposal..............................................................." 13
8.7 - Special maintenance .............................................. " 13
CHAPTER 9
Material classification and choice of tool.................... " 14
9.1 - Definition of materials ............................................. " 14
9.2 - Selecting blade ....................................................... " 14
9.3 - Teeth pitch .............................................................. " 14
9.4 - Cutting and advance speed ..................................." 1 5
9.5 - Blade running-in ..................................................... " 15
9.6 - Blade structure ....................................................... " 1 5
9.7 - Blade type ............................................................... " 15
Tooth shape and angle ........................................... " 1 5
Set ........................................................................... " 16
9.7.1 - Table of recommended cutting parameters .............. " 16
CHAPTER 10
Machine components ................................................... " 17
10.1- List of spare parts ..................................................." 1 7
CHAPTER 11
Wiring diagrams ..............................................................." 22
Schema elettrico idraulico ................................................" 24
CHAPTER 12
Troubleshooting ................................................................ " 2 5
12.1-Blade and cutting diagnosis ....................................... " 25
12.2-Electrical components diagnosis................................ " 29
CHAPTER 13
Noise tests ....................................................................... " 2 9
Plates and labels .............................................................." 30
Ordering spare parts
- When ordering spare parts you must state:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER
Without these references WE WILL NOT SUPPLY the spares. See point 10.1 - list of spare parts -
Guarantee
- The Company guarantees that the machine to which this manual refers has been designed and built to comply with safety regulations and
that it has been tested for functionality in the factory.
- The machine is guaranteed for 12 months: the guarantee does not cover the electric motors, electric components, pneumatic components
or any damage due to dropping or to bad machine management, the failure to observe maintenance standards or bad handling by the
operator.
- The buyer has only the right to replacement of the faulty parts, while transport and packing costs are at his expense.
- The serial number on the machine is a primary reference for the guarantee, for after-sales assistance and for identifying the machine for any
necessity.
2
Machine certification and identification marking
MACHINE LABEL
via Pasubio, 32 36033 ISOLA VIC. - ITALIA
SAR 331 SA GDS
MODEL
TYP
SERIAL NUMBER
YEAR OF MANUFACTURE
SAR
331 SA GDS
(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)
3
SAR 331 SA GDS
REFERENCE TO ACCIDENT - PREVENTION REGULATIONS
1
This machine has been built to comply with the national and community accident-prevention regulations in force. Improper use
and/or tampering with the safety devices will relieve the manufacturer of all responsibility.
1.1 - Advice for the operator
- Check that the voltage indicated on the plate, normally fixed to the machine motor, is the same as the line voltage.
- Check the efficiency of your electric supply and earthing system; connect the power cable of the machine to the socket and the earth
lead yellow-green in colour) to the earthing system.
- When the saw frame is in suspend mode (up) the toothed blade must not move.
- Only the blade section used for cutting must be kept unprotected. Remove guarding by operating on the adjustable head.
- It is forbidden to work on the machine without its shields (these are all blue or grey in colour).
- Do not use any artful system or device (for ex. shim) to prevent the vice from locking the workpiece. Do not hold the workpiece with
your hand during the cutting process.
- Do not charge the workpiece from the right to the left-hand side with respect of the machine front.
- Always disconnect the machine from the power socket before blade change or carrying out any maintenance job, even in the case
of abnormal machine operation.
- Always wear suitable eye protection.
- Never put your hands or arms into the cutting area while the machine is operating.
- Do not wear loose clothing with sleeves that are too long, gloves that are too big, bracelets, chains or any other object that could get
caught in the machine during operation; tie back long hair.
- Keep the area free of equipment, tools or any other object.
- Perform only one operation at a time and never have several objects in your hands at the same time. Keep your hands as clean as
possible.
- All internal and/or internal operations, maintenance or repairs, must be performed in a well-lit area or where there is sufficient light
from extra sources so as to avoid the risk of even slight accidents.
1.2 - Location of shields against accidental contact with the tool
- Blue or grey metal shield fixed frontally with screws to the fixed blade-guiding block (Ref. A).
- Blue or grey shield fixed with screws to the adjustable blade-guiding block. Guarantees that the section of blade which exceeds the
piece to be cut is covered (Ref. B).
- Grey metal casing fixed with hooks to the frame. Protects the flywheels from blade dragging (Ref. C).
AB
C C
4
SAR 331 SA GDS
1.3 - Electrical equipment according to European Standard "CENELEC EN 60 204-1" which assimilates,
with some integrating modifications, the publication "IEC 204-1"
- The electrical equipment ensures protection against electric shock as a result of direct or indirect contact. The active parts of this
equipment are housed in a box to which access is limited by screws that can only be removed with a special tool; the parts are fed
with alternating current at low voltage (24 V). The equipment is protected against splashes of water and dust.
- Protection of the system against short circuits is ensured by means of rapid fuses and earthing; in the event of motor overload,
protection is provided by a thermal relay.
- In the event of a power cut, the specific start-up button must be reset.
- The machine has been tested in conformity with point 20 of EN 60204.
1.4 - Emergencies according to European Standard "CENELEC EN 60 204-1"
- In the event of incorrect operation or of danger conditions, the machine may be stopped immediately by pressing the red mushroom
button.
- The casual or voluntary removal of the protection shield of the flywheels causes the stepping-in of a microswitch that automatically
stops all machine functions.
- In case blade breaks, the band tightening microswitch/pressure switch disconnects all machine.
NOTE:Resetting of machine operation after each emergency stop is achieved by reactivating the specific restart button.
1.5 - OTHER RISKS
- As the machine is running, any intervention from the operator within the “dangerous zone” or cutting area must be considered a risk
for his own safety.
RECOMMENDATIONS AND ADVICE FOR USE
2
2.1 - Recommendations and advice for using the machine
- The machine has been designed to cut metal building materials, with different shapes and profiles, used in workshops, turner’s
shops and general mechanical structural work.
- Only one operator is needed to use the machine, that must stand as shown in the picture.
Before starting each cutting operation, ensure that the part is firmly gripped in the vice and that the end is suitably supported.
These figures show examples of suitable clamping of different section bars, bearing in mind the cutting capacities of the machine in
order to achieve a good efficiency and blade durability.
- Do not use blades of a different size from those stated in the machine specifications.
- If the blade gets stuck in the cut, release the running button immediately, switch off the machine , open the vice slowly, remo v e the part
and check that the blade or its teeth are not broken. If they are broken, change the tool.
- Check saw frame return spring to ensure proper balancing.
- Before carrying out any repairs on the machine, consult the dealer or apply to THOMAS.
5
SAR 331 SA GDS
TECHNICAL
3
CHARACTERISTICS
3.1 - Table of cutting capacity and technical details
CAP ACITA` DI
TAGLIO
0°
45° DX
45° SX
60°
330 330x330 480x130
310 280x28 0 300x25 0
300 250x25 0 280x25 0
200 180 x180 180 x200
MACHINE DIMENSIONS
TRANSPORT
4
INSTALLATION
DISMANTLING
4.1 - Machine dimensions
2050
Blade motor
Hydraulic motor
Pump electric
flywheel diameter
Blade dimensions
Cutting speed
Vice opening
Saw frame inclination
Height of pieces bearing sur face
Machine weight
KW
KW
KW
mm
mm
m/1'
mm
°
mm
Kg
2150
1.5
0.37
0.18
390
3810x27x0.9
21 ÷ 116
485
25
740
720
1600
6
SAR 331 SA GDS
4.2 - Transport and handling of the machine
If the machine has to be shifted in its own packing, use a fork-lift
truck or sling it with straps as illustrated.
4.3 - Minimum requirements for the premises
housing the machine
- Mains voltage and frequency complying with the machine motor
characteristics.
- Environment temperature from -10 °C to +50 °C.
- Relative humidity not over 90%.
- Position the machine on a firm cement floor, maintaining, at the
rear, a minimum distance of 1000 mm from the wall; anchor it to
the ground as shown in the diagram, using screws and expansion
plugs or tie rods sunk in cement, ensuring that it is sitting level.
4.5 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the customer
must fit a suitable one for his own working conditions:
1 - WIRING DIAGRAM FOR 4-WIRE SYSTEM FOR THREE-
PHASE MACHINE - SOCKET FOR A 16A PLUG
R = L1
S = L2
T = L3
PE = GND
4.6 - Instructions for assembly of the loose parts and
accessories
Fit the components supplied as indicated in the photo:
- Mount the stock stop.
- Mount the coolant liquid holder.
4.7 - Disactivating the machine
4.4 - Anchorage of standard machine
INGOMBRO OPERATIVO = mm 2100
INGOMBRO OPERATIVO = mm 2300
- If the sawing machine is to be out of use for a long period, it is
advisable to proceed as follows:
1) detach the plug from the electric supply panel
2) loosen blade
3)release the arch return spring
4) empty the coolant tank
5) carefully clean and grease the machine
6) if necessary, cover the machine.
4.8 - Dismantling
(because of deterioration and/or obsolescence)
General rules
If the machine is to be permanently demolished and/or scrapped,
divide the material to be disposed of according to type and composition, as follows:
1) Cast iron or ferrous materials, composed of
ondary raw materials, so they may be taken to an iron foundry
for re-smelting after having removed the contents (classified in
point 3);
2) electrical components, including the cable and electronic ma-terial
(magnetic cards, etc.), fall within the category of material classified as being assimilable to urban waste according to the laws of
the European community, so they may be set aside for collection
by the public waste disposal service;
3) old mineral and synthetic and/or mixed oils, emulsified oils and
greases are special refuse, so they must be collected, transported
and subsequently disposed of by the old oil disposal service.
metal alone, are sec-
7
SAR 331 SA GDS
NOTE:since standards and legislation concerning refuse in gen-
eral is in a state of continuous evolution and therefore
subject to changes and variations, the user must keep
informed of the regulations in force at the time of disposing
of the machine tool, as these may differ from those
described above, which are to be considered as a general
guide line.
MACHINE FUNCTIONAL
5
PARTS
5.1 - Operating head or saw frame
- Machine part consisting of the members that transfer the motion
(gearmotor, flywheels), the tightening/guiding (blade guide arms,
blade tightening slide) and the tool lowering control.
5.3 - Bed
- Structure supporting the HEAD OR SAW FRAME, the VICE, the
SWIVEL DEVICE with relative locking system, the ELECTRICALS,
the BAR STOP and housing the coolant TANK for cut and pump.
5.2 - Vice
- Manual locking system for cutting material using the hand wheel.
This device allows for the quick shifting of the vice and the possibility
to cut inclinations to the left and right.
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 “Regulat-
ing the machine”).
6.1 - Getting started
DESCRIPTION OF THE CUTTING CYCLE:
- Manual closing of the vice;
- Activation of the cutting cycle;
- Independent lowering of the blade-carrying
frame;
- Frame raising (with selector);
- Manual opening of the vice.
PRELIMINARY OPERATIONS:
- Make sure that the machine is equipped with all the protections described in paragraph 1.2 of chapter 1.
- Position the side draining system (supplied with the machine)
on the base.
- Make sure that the machine is not in an emergency stop. If it
is, release the red mushroom pushbutton (1) on the command panel.
- Rotate the belt-tightening handwheel (8) until the relative
microswitch activates.
- Rotate the main switch (2) to position 1.
- Press the pushbutton with light (4) and make sure that the
relative indicator lights up.
- Use the selector (5) to raise the frame.
NB: invert the electric supply phases if the frame does not rise
(this should only be done during installation).
8
SAR 331 SA GDS
- Open the vice according to the dimensions of the material to
be cut.
- Place the material to be cut in the vice and lock using the
handwheel. Make sure that the relative pawl is interlocked
with the rack.
- Free the hand le v er and move the mobile belt-guiding arm as
close as possible to the piece to be cut (up to approx. 10mm)
then lock the hand lever.
- Make sure that the cutting angle corresponds to the desired
inclination and that the angling device is locked using the
relative lever (see paragraph 7.4 of chapter 7).
- Make sure that the hydraulic regulator (6) is fully closed, then
rotate counter clockwise to set the most suitable lowering
speed for the characteristics of the material to be cut. It is
advisable to always start from a cautionary speed and increase subsequently if necessary.
2
3
4
SAR
START
1
- Always make sure that the vice is positioned at the extreme
right or left of the countervice to avoid accidental contact with
the frame.
- Before starting the cutting cycle it is advisable to move the
blade to approx. 10mm from the piece to be cut, using the
selector (5) if necessary.
- Press the pushbutton (3) to start the cutting cycle. Make sure
that the belt turns in the correct direction and that a sufficient
quantity of cooling liquid exits.
NB: The weight of the blade-carrying frame causes it to lower
automatically without needing the intervention of Operator. If
greater cutting pressure is necessary, modify the tightness of
the frame return spring (see paragraph 7.8 of chapter 7).
- Use the variator group handwheel to set the most suitable
cutting speed for the material to be cut. This operation must
always be carried out while the motor is running).
To set the necessary speed, refer to the plate applied onboard the machine or shown below.
- Press the emergency pushbutton if incorrect manoeuvres are
made, or if the cutting cycle is to be stopped.
- When finished cutting, the frame stops in the lower position.
Use the selector (5) to raise the frame.
NB: Do not use the sawing machine at full material discharge speed during the first 50 working hours.
Keep a safe distance from the cutting area during machine
operation.
5
1
6
CUTTING DIRECTION
The sawing machine is now ready to start working. Please
remember that the CUTTING SPEED and the TYPE of blade
when combined with suitable frame lowering have a determinate effect on the cutting quality and machine return (for more
information on this topic, refer to the "Material classification
and blade choice" chapter)
- When starting to cut with a new blade, it is necessary to
exert a light pressure on the piece during the first two or
three cuts, in order to use a cutting time that is almost
double the normal one (refer to the
graph in the "Material classification and blade choice" chapter further on in this manual).
- Use the red emergency pushbutton (1) when dangerous conditions or faults in general arise. Doing so immediately interrupts machine operation.
Blade breaking-in
para-
8
9
REGULATING
7
THE MACHINE
7.1 - Blade tension assembly
SAR 331 SA GDS
4
The ideal blade tension is obtained by turning the belt-tightening handwheel until the relative microswitch activates (B).
The position of the microswitch is established by an instrument that measures the blade stretch. This regulation m ust not
be modified.
NB: it is advisable to loosen the blade tension when the saw is not
being used.
It is advisable to always use blades having the dimensions declared
in this manual.
B
7.2 - Blade-guiding arms and plates
The blade is guided by plates that are regulated during the
testing phase according to the thickness of the blade. The minimum clearance indicated in the figures should be maintained.
When the blade is to be replaced, make sure to always fit belts
with a 0.9 mm thickness because the blade-guiding plates have
been regulated for this thickness. If using toothed belts with
different thicknesses a new regulation must be carried out as
follows:
- Loosen the screw (1) and unscrew the grub screws (2), widening the space between the plates.
- Loosen the nuts (3) and the grub screws (4) and rotate the
pins (5 - 6) to widen the space between the bearings (7).
- Insert the new blade, then place the plate (8) against it. Tighten
the grub screws (2), leaving a 0.04 mm clearance to ensure
that the toothed belt slides well. After this, tighten the relative
nuts and the screw (1).
- Rotate the pins (5 - 6) until the bearings lean against the
blade, as indicated in the figure. Lock the grub screws (4) and
the nuts (3).
6
7
3
22
1
5
8
0,04
7.3 - Vice
- The vice can be made to move rapidly towards the piece to be
cut by keeping the hand lever (C) raised and moving the vice
manually. Before using the handwheel to lock the material to
be cut, make sure that the hand lever is interlocked with the
rack.
- The vice group can be positioned to the right or left of the
blade. If positioning is not fully completed, the sawing machine can be permanently damaged by the lowering movement of the frame.
- Always keep the vice guide and relative thread clean and
oiled.
10
C
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