Dake SAR 440 User Manual

USE AND MAINTENANCE MANUAL

SAR 440 SA GDS

01/2006

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

Registro Imprese n. 4272//VI116 REA n. 93906/Vicenza

Contents

SAR 440 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"............................ " 4

1.4 - Emergencies according to European Standard

"CENELEC EN 60 204-1" .........................................." 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 ...................................................................... " 5

4.1 - Machine dimensions ................................................. " 5

4.2 - Transport and handling of the machine ....................." 6

4.3 - Minimum requirements for the premises

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

4.4 - Anchorage of standard machine ..............................." 6

4.5 - Instructions for electrical connection ........................." 6

4.6 - Instructions for assembly of the loose parts and

accessories .............................................................." 6

4.7 - Disactivating the machine ........................................." 6

4.8 - Dismantling .............................................................." 6

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 ...................................................." 9

7.1 - Blade tension assembly...........................................“ 10

7.2 - Blade guide blocks .................................................. “ 10

7.3 - Vice ......................................................................... “ 11

7.4 - Regulating the cutting angle .....................................“ 11

7.5 - Blade-cleaning brush ...............................................“ 11

7.6 - Regulating the height of the cut ................................ “ 11

7.7 - Regulating the cutting speed ...................................." 11

7.8 - Changing the blade .................................................." 12

CHAPTER 8

Routine and special maintenance................................. " 12

8.1 - Daily maintenance ..................................................." 12

8.2 - Weekly maintenance ..............................................." 12

8.3 - Monthly maintenance ..............................................." 12

8.4 - Six-monthly maintenance......................................... " 12

8.5 - Oils for lubricating coolant........................................ " 12

8.6 -Oil disposal ................................................................" 12

8.7 - Special maintenance................................................" 12

CHAPTER 9

Material classification and choice of tool ..................... " 13

9.1 - Definition of materials............................................... " 13

9.2 - Selecting blade ........................................................ " 13

9.3 - T eeth pitch ............................................................... " 13

9.4 - Cutting and advance speed ....................................." 14

9.5 - Blade running-in ....................................................... " 14

9.6 - Blade structure ........................................................" 14

9.7 - Blade type ............................................................... " 14

T eeth shape and angle............................................. " 14

Set..........................................................................." 15

9.7.1 - T a ble of recommended cutting parameters ................... " 15

CHAPTER 10

Machine components .................................................... " 16

10.1- List of spare parts .................................................... " 16

CHAPTER 11

Wiring diagrams ............................................................ " 21

Schema elettrico idraulico ............................................ " 23

CHAPTER 12

T roub leshooting ............................................................ " 24

12.1- Blade and cutting diagnosis ..................................... " 24

12.2- Electrical components diagnosis.............................. " 28

CHAPTER 13

Noise tests ..................................................................... " 28

Plates and labels............................................................ " 29

Ordering spare parts

- When ordering spare parts you must state:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER

Without these references WE WILL NOT SUPPLY the spares. See point 10.1 - list of spare parts -

Guarantee

- The Company guarantees that the machine to which this manual refers has been designed and built to comply with safety regulations and
that it has been tested for functionality in the factory.

- The machine is guaranteed for 12 months: the guarantee does not cover the electric motors, electric components, pneumatic components
or any damage due to dropping or to bad machine management, the failure to observe maintenance standards or bad handling by the
operator.

- The buyer has only the right to replacement of the faulty parts, while transport and packing costs are at his expense.

- The serial number on the machine is a primary reference for the guarantee, for after-sales assistance and for identifying the machine for any
necessity.

2

Machine certification and identification marking

MACHINE LABEL

via Pasubio, 32 36033 ISOLA VIC. - ITALIA

SAR 440 SA GDS

MODEL

TYP
SERIAL NUMBER
YEAR OF MANUFACTURE

SAR

440 SA GDS

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

3

SAR 440 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).

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

- Always wear suitable eye protection.

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

- Do not wear loose clothing with sleeves that are too long, gloves that are too big, bracelets, chains or any other object that could get
caught in the machine during operation; tie back long hair.

- Keep the area free of equipment, tools or any other object.

- Perform only one operation at a time and never have several objects in your hands at the same time. Keep your hands as clean as
possible.

- All internal and/or internal operations, maintenance or repairs, must be performed in a well-lit area or where there is sufficient light
from extra sources so as to avoid the risk of even slight accidents.

1.2 - Location of shields against accidental contact with the tool

- Blue or grey metal shield fixed frontally with screws to the fixed blade-guiding block ( Ref. A ).

- Blue or grey metal shield fastened on the front with screws onto the blade guide adjustable head to ensure maximum covering of
blade and piece to be cut ( Ref. B ).

- Grey metal guards fastened to the saw frame with knobs, protecting the blade driving flywheels ( Ref. C ).

B

C

A

C

4

SAR 440 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.

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, remove the
part and check that the blade or its teeth are not broken. If they are broken, change the tool.

- Check saw frame return spring to ensure proper balancing.

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

5

SAR 440 SA GDS

TECHNICAL

3

CHARACTERISTICS

3.1 - Table of cutting capacity and technical details

0° 440 440 610 x 440

45° DX 440 440 500 x 230

45° SX 440 440 500 x 230

60° DX 320 300 320 x 245

60° SX 340 320 340 x 250

MACHINE DIMENSIONS
TRANSPORT

4

INSTALLATION
DISMANTLING

4.1 - Machine dimensions

2500

TE CHNICAL DATA

ELECTRIC MOTOR - 3-PHASE

HYDRA ULIC PUMP MOTOR

COOLANT PUMP MOTOR

FLYWHEEL Ø

BLADE DIMENSIONS

VARIABLE BLADE SPEED

VICE OPENING

SAW F RAME INCL INA TION

WORKING TA BLE HEIGHT

MA CHINE DIME NS IONS

kW 2,2

kW 1,1

kW 0,18

mm 455

mm 5200 x 34 x 1,1

m/min 28 ÷ 140

mm 615

°0

mm 750

mm 2500x 3000x2500

3000

2400

4.2 - Transport and handling of the machine

MACHINE WE IG HT

6

Kg 1570

In case of transportation in its own packing, use a fork-lift truck.
Sling the machine with special straps as illustrated making
sure that the control panel has been securely placed on the
machine base

QUADRO ELETTRICO

SAR 440 SA GDS

- 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

4.3 - Minimum requirements for the premises
housing the machine

- Mains voltage and frequency complying with the machine motor
characteristics.

- Environment temperature from -10 °C to +50 °C.

- Relative humidity not over 90%.

4.4 - Anchorage of standard machine

INGOMBRO OPERATIVO = mm 2400

INGOMBRO OPERATIVO = mm 3000

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

- If the sawing machine is to be out of use for a long period, it is
advisable to proceed as follows:

1) detach the plug from the electric supply panel

2) loosen blade

3)empty the coolant tank

4)carefully clean and grease the machine

5)if necessary, co ver 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-

NOTE:since standards and legislation concerning refuse in gen-

7

SAR 440 SA GDS

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

- Hydrailic locking system for cutting material. This de vice allows

for the quick shifting of the vice and the possibility to cut
inclinations to the left and right.

8

SAR 440 SA GDS

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 - Getting started

DESCRIPTION OF THE CUTTING PROCESS:

- Start the cutting cycle

- Automatic closure of the vice;

- Lowering of the sawframe ( blade );

- Lifting of the sawframe ( using selector );

- Opening of the vice.

PRELIMINARY OPERATIONS:

- Ensure that the machine is not on emergency stop; in which case
free the red, mushroom shaped, button ( 1 ) on the panel of com­mands.

- Rotate the blade tension handwheel ( 8 ) until the blade tension
pressure reaches 160 Bars.

- Rotate the main switch ( 2 ) in position 1.

- Press the illuminated button ( 3 ) and ensure that the relative
light is lit.

- Rotate the selector ( 5 ) to activate the lifting of the sawframe.
N.B.: if the lifting process does not occur, invert the electric

alimentation phase ( this operation is only to be done during in­stallation ).

Service pressure of the hydraulic unit should be approx. 50
BAR.

WARNING: always ensure that the vice is positioned to the
extreme left or right of the counter vice to avoid accidental
contact with the structure of the sawframe.

- Turn selector ( 9 ) to open the vice.

160 BAR

8

- Activate the hand wheel of the gear and set the speed control
to suit the characteristics of the material to be cut. ( do not
regulate when the motor is off ).
To regulate the desired speed refer to the plaque .

- In case of a wrong manoeuvre or to stop the cutting cycle,
press the STOP button ( 10 ).

- At the end of the cutting cycle, the sawframe will stop in the
inferior position. Rotate the selector ( 5 ) to activate the lifting of
the sawframe.

- Turn selector ( 9 ) to open the vice.

ATTENTION:

- The cutting cycle can be executed even if the selector ( 9 ) has
been switched for the open vice.
In fact, as you press START ( 3 ) the vice will close automatically .
To open the vice again you will have to turn the selector ( 9 )
first to close the vice and then to open the vice.

- Once the cut has been executed the hydraulic pump will keep
running for 20 seconds.

- Position the vice according to the dimension of the material to

cut.

- Put the material to be cut in the vice, and approach the vice
jaw up to 3 - 4 mm with the handwheel.

- Ensuring that the latch is in place on the rack.

- Load the material to cut at the required cutting length and turn
the selector ( 9 ) to lock the material in the vice.

- Bring the mobile blade guiding arm as close as possible to
the object to be cut.

- Ensure that the cutting index correspond with the inclination
desired and that the device is blocked.

- Before starting the cutting process, it is advisable to advance
the blade to more or less 10 mm from the object to be cut,
pressing, if necessary, selector ( 5 ).

- Press regulator ( 6 ) to the ideal cutting speed to suit the
characteristics of the material. It is recommend that one always
start off slowly, increasing the speed if necessary.

- Press button ( 4 ) to initiate the cutting cycle: control that the
blade turns in the correct direction and that the cooling liquid
flows sufficiently.

ATTENTION: Soon after the automatic shut off of the hydraulic
pump, press the button ( 4 ) to open the vice automatically if
the selector ( 9 ) was switched to vice open during the cutting
phase.

Note: It is recommend not to use the saw to its maximum
capacity for the first 50 working hours.

It is absolutely forbidden to approach the hands to
the cutting area.

Note: for a proper lubrication and cooling during the cut, we

recommend to use a mixture of 9 parts of water and one of oil.

9

SAR 440 SA GDS

10

2

1

4

3

5

9

1

6

10

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