Dake SAR 440 User Manual

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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.

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)

SAR 440 SA GDS

REFERENCE TO ACCIDENT - PREVENTION REGULATIONS

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 ).

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

2.1 - 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.

SAR 440 SA GDS

TECHNICAL

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

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

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-

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

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.

SAR 440 SA GDS

DESCRIPTION OF THE

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

- 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.

SAR 440 SA GDS

nim/m

EROTAIRAVONITNALOV

DNAH-ROTAIRAV

LEEHW

°N.SOP

DEEPSGNITTUC

89 01112131415161718191021222324252627282

OILGATID'ATICOLEV

5.72235.635.14641565165.66275.77389859101701311021721331041

SAR 440 SA GDS

- the CUTTING SPEED and the TYPE of BLADE - combined with a suitable lowering of saw frame - are of decisive importance for cutting quality and for machine performance (for further details on this topic, see below in the chapter on “Mate-

rial classification and blade selection”).

- When starting to cut with a new blade, 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 blade selection” in the section on

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

CUTTING DIRECTION

Blade running-in

7.2 - Blade-guide head

Blade guiding is obtained by means of plates which are regulated during the testing phase according to blade thickness.

REGULATING

THE MACHINE

7.1 - Blade tension assembly

The ideal blade tension is obtained by rotating the hand wheel belt tensioner until the blade tension pressure reaches 160 Bars otherwise the saw will not operate. N.B.: when the saw is not in use it is recommend to loosen the blade tension.

It is always recommend to use the blade sizes suggested in this manual.

160 BAR

When replacing a blade, ensure that the belts are 1,1 mm thick as the guiding blade pads have been adjusted to this size. If using different size toothed belts, it will be necessary to proceed with a new registration as follows:

- Loosen the screws ( B ) and loosen dowels (A ) widening the passage between the plates.

- Loosen the dowels ( C ) and rotate the pins to widen the passage between the bearings.

- Mount the new blade and rotate the hand wheel belt tensioner until the relative dip-switch is activated.

- Tighten the dowels ( A ) and then loosen them to allow a play of 0,04 mm to ensure the smooth running of the blade and fasten the screws ( B ).

- Rotate the pins until the bearings rest on the blade and block the screws ( C ).

- Ensure that between the blade and the superior bearings there are 0,2 - 0,3 mm of play; if necessary, loosen the screws ( D ) that block the heads and execute the necessary registration.

SAR 440 SA GDS

7.3 - Vice

-- The rapid advancement of the vice to the object to be cut is

obtained by manually moving the vice and lifting the latch ( F ). Before blocking the object to be cut with the hand wheel check that the latch is gripped to the rack.

- The vice unit can be positioned to the left or right of the blade. Ensure that this positioning has been executed correctly in order to avoid irreparab le damage to the saw .

- It is recommended to keep the vice guide and ribbon clean and oiled at all times.

7.5 - Blade-cleaning brush

Ideal for the cleaning of the blade during its cutting cycle. Periodically check the integrity of the brush and if necessary proceed to an ulterior regulation to guarantee cleansing of the blade.

7.6 - Regulating the height of the cut

It is an accessory that permits the execution of lifting and/or nearing of the arch.

- Operate the selector button ( H ) to move the arch up and down to the desired position.

7.4 - Regulating the cutting angle

- Lift the sawframe.

- Operate the Lever ( G ) to release the rotation of the device.

- Rotate the sawframe to the desired angle referring to the graduated sector.

- Tighten the lever ( G ) to block the device from rotating.

7.7 - Regulating the cutting speed

Regulation of the cutting speed can only be done with the motorbelt in motion. T o change the running speed, adjust with hand wheel and refer to the plaque.

TABELLA LUBRIFICANTI

COMPONENTE

PART.

LUBRIFICANTE

OIL TYPE

QUANTITA'

INDICE

RIDUT T ORE

REDUCT OR

VARIATORE

VARIATOR

SHELL

TIVELA S320

SHELL

DO NAX T A

1,6

1,2

SAR 440 SA GDS

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

7.8 – Replacing the blade

- Lift the sawframe in upright position.

- Loosen the blade with the hand wheel, remove the shield of the mobile blade guide and the shield of the belt cleaning brush.

- Open the posterior and anterior carter flywheels and extract the old blade from the flywheels and from the blade guide blocks.

- Insert the new blade inserting it between the plaques and then on the flywheel holder, taking note of the direction of the teeth in respect to the direction of the cut (refer to diagram below).

- Replace the tension of the blade checking that it is housed perfectly within the flywheels.

- Re-assemble the shields of the mobile guide blade and of the belt cleaning brush and close the carter flywheels cover, checking that the safety dip-switch is activated otherwise the machine will not operate when it is switched on.

WARNING: alwa ys use blades having dimensions spcified in this manual and for which the blade guide heads have been set: otherwise, see chapter on "Description of the

operating cycle" in the section Starting-up..

CUTTING DIRECTION

8.2 - Weekl y maintenance

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

- Removal of pump from its housing, cleaning of the suction filter and suction zone.

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

- Cleaning with compressed air of blade guide arms (guide bearings, pads and drain hole of the lubricating cooling).

- Cleaning flywheel housings and blade sliding surfaces on flywheels.

- Check condition of the blade cleaning brushes.

- Greasing of motor flywheel bearings.

8.3 - Monthly maintenance

- Check the tightening of the motor flywheel screws.

- Check that the blade guide bearings on arms are perfect running condition.

- Check the tightening of the screws of the gearmotor, pump and accident protection guarding.

8.4 - Six-monthly maintenance

REDUCTION UNIT

we suggest to make the first oil replacement after about 300 working hours and wash internal parts carefully. Use synthetic oil SHELL TIVELA OIL 320 type or equiv alent.

The following oil replacement should be made after about 2000 working hours. V ARIATOR UNIT

Make the oil replacement after about 2000 working hours using the SHELL DONAX TA type or equivalent.

PROBABLE REPLACEMENT OF OTHER PARTS – REDUCTION GEAR OR SPEED CONTROL, MOTOR PUMP AND ELECTRICAL COMPONENTS – TO BE EXECUTED BY SPECIALISED AND COMPETENT PERSONNEL.

ROUTINE AND SPECIAL

MAINTENANCE

THE MAINTENANCE JOBS ARE LISTED BELOW, DIVIDED INTO DAILY, WEEKLY, MONTHLY AND SIX-MONTHLY 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.

- Clean the lubricating coolant drain hole to avoid excess fluid.

- Top up the level of lubricating coolant.

- Check blade for wear.

- Rise of saw frame to top position and partial slackening of the blade to avoid useless yield stress.

- Check functionality of the shields and emergency stops.

WARNING : absolutely do not mix synthetic oil and mineral oil. Replace the oil in the hydraulic unit ad least once a year using

SHELL HYDRAULIC OIL 32 type or equiv alent.

- The saw with the ascending arch device, a complete oil change is advisable once a year using SHELL HYDRAULIC OIL 32 or similar.

- Continuity test 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 W ATER IS 8 - 10 %.

8.6 - Oil disposal

The disposal of these products is controlled by strict regulations. Please see the Chapter on “Machine dimensions - Transport - In- stallation” 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. Also the reset of protective and safety equipment and devices, of the reducer, the motor, the motor pump and electric components is to be considered extraordinary maintenance.

SAR 440 SA GDS

MATERIAL CLASSIFICATION AND

CHOICE OF TOOL

Since the aim is to obtain excellent cutting quality, the various parameters such as hardness of the material, shape and thick-

ness, transverse cutting section of the part to be cut, selec- tion of the type of cutting blade, cutting speed and control of saw frame lowering.These specifications must therefore be har-

moniously combined in a single operating condition according to practical considerations and common sense, so as to achieve an optimum condition 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 time will be solved more easily if the operator has a good knoledge of these specifications. WE THEREFORE RECOMMEND YOU TO ALWAYS USE GENUINE SP ARE BLADES 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 - Selecting blade

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;

- pieces cut in bundles require combo tooth design.

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.

BLADE TEETH SELECTION TABLE

THICKNESS MM

TILL 1.5 14 10/14 FROM 1 TO 2 8 8/12 FROM 2 TO 3 6 6/10 FROM 3 TO 5 6 5/8 FROM 4 TO 6 6 4/6

MORE THAN 6 4 4/6

Z CONTINUOUS

TOOTH DESIGN

Z COMBO

TOOTH DESIGN

First of all the pitch of the teeth must be chosen, in the other words, the number of teeth per inch (25,4 mm) suitable for thematerial to

TYPES OF STEEL CHARACTERISTICS

USE

Construction

steels

Carbon

steels

Spring

steels

Alloyed steels for

hardening and

tempering and for

nitriding

Alloyed

casehardening

steels

Alloyed for

bearings

Tool steel

Stainless

steels

Copper alloys Special brass

Bronze

Cast iron

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

56NiCrMoV7C100K

DIN

St37 St44

St52 CK20 CK40 CK50 CK60

50CrV4

60SiCr7

34CrMo4 36CrNiMo4 41CrAlMo7

----

21NiCrMo2

C100W1

X210Cr12

----

4001 4301

----

4401

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

410 304

----

316

S = THICKNESS

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

102

96 103 102

56,5

96 100

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

SAR 440 SA GDS

SOLID Ø OR L MM

TILL 30 8 FROM 30 TO 60 6 FROM 40 TO 80 4 4/6

MORE THAN 90 3 3/4

Z CONTINUOUS TOOTH DESIGN

Ø = DIAMETER L = WIDTH

Z COMBO

TOOTH DESIGN

5/8 4/6

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 widest section.

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

The best combination of these two parameters can be seen directly examining the chips.

Long spiral-shaped chips indicate ideal cutting.

), to its hardness (HRC) and to the dimensions of the

9.7 - Blade type

They differ essentially in their constructive characteristics, such as:

- shape and cutting angle of tooth

- pitch

- set

Shape and angle of tooth

REGULAR TOOTH: 0° rake and constant pitch.

Most common form for transversal or inclined cutting of solid small and average cross-sections or pipes, in laminated mild steel and grey iron or general metal.

POSITIVE RAKE TOOTH: 9° - 10° positive rake and constant pitch. positive

Particular use for crosswise or inclined cuts in solid sections or large pipes, but above all harder materials (highly alloyed and stainless steels, special bronze and forge pig).

Very fine or pulverized chips indicate lack of feed and/or cutting pressure.

Thick and/or blue chips indicate overload of the blade.

9.5 - Blade running-in

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

/min on material of average dimensions with respect

), generously spraying the cutting area with lu-

bricating coolant.

9.6 - Blade structure

Bi-metal blades are the most commonly used. They consist in a silicon-steel blade backing with electron beam or laser welded high speed steel (HHS) cutting edge. The type of stocks are classified in M2, M42, M51 and differ from each other because of their major hardness due to the increasing percentage of Cobalt (Co) and molybdenum (Mo) contained in the metal alloy.

COMBO TOOTH: pitch varies between teeth and consequently varying teeth size and varying gullet depths. Pitch varies between teeth which ensures a smoother, quieter cut and longer blade life owing to the lack of vibration. Another advantage offered in the use of this type of blade in the fact that with an only blade it is possible to cut a wide range of different

distance between teeth

materials in size and type.

COMBO TOOTH: 9° - 10° positive rake. positive

This type of blade is the most suitable for the cutting of section bars and large and thick pipes as well as for the cutting of solid bars at maximum machine capacity. Available pitches: 3-4/4-6.

SAR 440 SA GDS

Set

Saw teeth bent out of the plane of the saw body, resulting in a wide cut in the workpiece.

REGULAR OR RAKER SET: Cutting teeth right and left, alternated by a straight tooth.

Of general use for materials with dimensions superior to 5 mm. Used for the cutting of steel, castings and hard nonferrous materials.

WAVY SET: Set in smooth waves.

This set is associated with very fine teeth and it is mainly used for

9.7.1 - RECOMMENDED CUTTING PARAMETERS

the cutting of pipes and thin section bars (from 1 to 3 mm).

ALTERNATE SET (IN GROUPS): Groups of cutting teeth right and left, alternated by a straight tooth.

This set is associated with very fine teeth and it is used for extremely thin materials (less than 1 mm).

ALTERNATE SET (INDIVIDUAL TEETH): Cutting teeth right and left.

This set is used for the cutting of nonferrous soft materials, plastics and wood.

STEEL C UTTING SPEED LUBRICATION

CONSTRUCTION 60/80 EMULSIFIABLE OIL CEMENTATION 40/50 EMULSIFIABLE OIL

CARBON STEEL 40/60 EMULSIFIABLE OIL HARDENING A ND TE MPE RING 40/50 EMULSIFIABLE OIL BEARINGS 40/60 EMULSIFIABLE OIL SPRINGS 40/60 EMULSIFIABLE OIL

FOR TOOLS 30/40 EMULSIFIABLE OIL FOR VALVES 35/50 EMULSIFIABLE OIL

STAINLESS STEEL 30/40 EMULSIFIABLE OIL SPHEROIDAL GRAPHITE 20/40 EMULSIFIABLE OIL CAST IRON 40/60 EMULSIFIABLE OIL

ALUMINIUM 80/600 KEROSENE BRONZE 70/120 EMULSIFIABLE OIL HARD BRONZE 30/60 EMULSIFIABLE OIL BRASS 70/350 EMULSIFIABLE OIL COPPER 50/720 EMULSIFIABLE OIL

SAR 440 SA GDS

MACHINE COMPONENTS

10.1 - List of spare parts

REFERENCE N° DENOMINATION

1 Bedframe 2 Electric box 3 Electric parts housing guard 4 Revolving arm lock lever 5 Arm lock bush 6 Machine hoisting hook 7 Lateral guard 8 Stroke-end stop 9 Adjustable bracket 10 Refrigeranting liquid tank 11 Electropump 12 Bar stop body 13 Bar stop push rod 14 Bar stop rod 15 Revolving arm pin 16 Countervice pin 17 Revolving arm 18 Bearing 32008 X 19 Bushing 20 Screw 21 Hinge pin protection 22 Bearing 32008 X 23 Hinge pin spacer 24 Hinge pin 25 Ring nut guk M 40x1,5 26 Countervice r.h. ja w 27 Countervice l.h. jaw 28 Interchangeable plate 29 Countervice 30 Countervice anterior guard 31 Pieces support 32 33 Vice support 34 Rack 35 Rack support 36 Vice 37 Vice screw 38 Handwheel 39 Pin 40 Pawl 41 Vice jaw 42 Crucible 43 Ring NILOS 32008 XAV

REFERENCE N° DENOMINATION

44 Bearing fork 45 Bearing SKF NATV 17 PPI 46 Pin

47 Bearing protection

48 Hydraulic vice cilinder 49 Hinge pin support 50 Sheath 51 Saw frame cylinder support 52 Bush 53 Pin 54 Handle

SAR 440 SA GDS

REFERENCE N° DENOMINATION

60 Sawframe 61 Electric motor 62 Speed variator 63 Speed variator handwheel 64 Ring nut guk M 40x1,5 65 Speed reducer 66 Spacer 67 68 Cylinder joint 69 Cylinder superior pin 70 Microswitch 71 Plate 72 Plate 73 Sawframe cylinder 74 75 Adjustable screw 76 transmission flywheel pin 77 Ring nut guk M 45x1,5 78 Blade tightening slide 79 80 81 Handle 82 Blade tightening handwheel

pin 83 Pin 84 Blade tightening Cylinder 85 Bracket 86 Ring NILOS 32209 XAV 87 Bearing 32209 XAV 88 89 T ransmission flywheel 90 Ring nut guk M 45 x 1,5 91 Bearing 3309 2RS 92 Ring NILOS 3309 AV 93 Bearing protection 94 Motor flywheel shaft 95 Motor flywheel 96 Cone clamping

EUROCONIC 97 Blade guide protection 98 Microswitch 99 R.h Flywheel protection 100 L.h. Flywheel protection 101 Blade guide arm guide 10 2 L.h. adjustable blade guide

arm 10 3 R.h. adjustable blade guide

arm 104 Hand lever 105 106 Additional protection

REFERENCE N° DENOMINATION

107 Spacer 108 Bearing 51204 109 Spring washer 110 Manometer 11 1 Pressure switch 112 Rear crucible 113 11 4 Blade guide bearing pin 11 5 Bearing 6200 2RS 11 6 Ring seeger Ø 10 11 7 Upper blade guide pad 11 8 Lateral blade guide pad 119 Hinge 120 Middle protection 121 Brush 12 2 Brush support 12 3 Bearing 626 2RS 12 4 Brush ring 125 Blade protection 126 Auxiliary blade protection 127

130 Distributor block 131 Coupling 132 Cooling liquid cock 133 134 Flexible tube 135 Handgripp

SAR 440 SA GDS

109

108

110

107

ZOOM - 2

133

131

111

130

132

131

134

101

112

SAR 440 SA GDS

135

120

100

104

102

104

103

124

SAR 440 SA GDS

126

125

115

114

116

ZOOM 1

117

118

106

118

117

123

ZOOM 2

122

121

114

115

116

SAR 440 SA GDS

KEY: 401 Main switch

402 Arch movement selector 403 Emergency switch 404 STOP button 405 Regulator arch descent 406 On-line button 407 Start button 408 Vice selector

KEY:

401

404

406

407 402

408 405

403

410 Transformer 411 Fuse cartridge 412 Relay ( Kb ) 413 Remote switch 414 Thermal motor 415 Remote switch 416 Timer 417 Thermal motor

KEY:

421 Motor gear case id. 422 Vice electrovalve-solenoid 423 Gear case tank id.

424 Sawframe electrovalve-solenoid

411 413 417 414 415 410 412 416

421

424

423422

SAR 440 SA GDS

11.1 - Three-phase electric diagram

ELECTRIC DIA GRAM

THOMAS

QS1 Main switch FU1 Fuse cartridge KM1 Central motor control switch id. KM2 Motor belt control switch FR2 Thermal motor belt

M1 Motor gear case id. M2 Belt motor M3 Motor pump FU2 Fuse cartridge TC1 T ransformer

SAR 440 SA GDS

THOMAS

11.2 - Hydraulic electric diagram

SAR 440 SA GDS

01 Sawframe downfeed regulator 02 Sawframe lifting speed regulator

04 Electric valve 05 Valve 06 Valve

DATA: 20/01/06

ELENCO COMPO NENTI ELETTRICI SCH. 1

MOD.: S AR 440 SA GDS OP TIONAL: RIF. DES CRIZIONE CARATTERISTICHE QUANTITA FO RNITORE ART.

QS 1 INTERUTTO RE GE NERALE 20 A 600 V, TRIFA SE 1 GIOVE NZANA P20 0003 R1

P-FU1 PO RT. X M OTORI CE NTRALINA IDRAUL. 32 A 600 V 3 FASI 1

FU1 FUSIB. PROT MOTORE IDRAULICO 10 A 600 V 10 X 38 3

P FU2 PORT X PROT MOT. NASTRO E POM PA 32 A 600 V 3 FASI 1

FU2 FUS.PROT MOT. NASTRO E POMPA 16 A 600 V 10 X 38 3

P-FU3 PORT. X PROT TRASF. 32 A 600 V 2 FASI 1

FU 3 FUS IBILIP RO TEZ, TRAS F OR M ATO RE 1A 600 V 10 X 38 2

P-FU4 PORT. X PROT SECOND. 32 A 600 V 1 FASI 1

FU 4 FU S. P R OT C IR. AUS ILIA RIO 4A 600 V 10 X 38 1 TC1 TRASFORMATO RE AUS, 75 VA USCITA 24 VOLT 1 F.M.T. 75 VA 24 V. SEC

KM 1 TELERUTTORE CEN TR. IDRAULICA 25A 600V 24V 1 C.G.E. CL00A 310 T1 KM 2 TELERUTTORE M OTORE NA STRO 25A 600V 24V 1 C.G.E. CL00A310 T1

FR1 TERMICO PROT.MOT. CENTRAL. IDR. 10 A 750 V N.C. 2,5-4 A 1 C.G.E. RT1 K FR 2 TERM ICO PR OT.M O TORE NA S TRO 10 A 750 V N.C . 4-6 A 1 C.G .E . RT1 L

M1 M OTORE CENTRALINA IDRA ULICA KW 1,1 1400 GIRI 1 TES SA RO M2 MOTORE NASTRO KW 2,2 1400 GIRI 1 TESSARO

M3 POMPA ACQUA KW 0,11 2800 GIRI H 120 1 SACEMI TRIFASE KA1 RELE AUSILIARIO + ZOCCOLO 7A 250 V. 2CONT. SCAMBIO 1 FINDER 55.32 024 +9472 KA2 RELE AUSILIARIO + ZOCCOLO 5A 250 V. 4CONT. SCAMBIO 1 FINDER 55.34 024 +9474

HL SPIA LINEA 24 V. NEON FASTOM V. 1 SIGNALUX TB F SC1 VE 24V. SB1 PULSANTE EMERGENZA 3 A 250 V N.C. 1 TELEMECANIQUE ZB4 BS 844 + BZ102 SB2 PULSANTE LINEA 10A 690 V N.O. 1 LOVATO 8LM 2 TB108 SB3 PULSANTE INIZIO CICLO 10A 690 V N.O. 1 LOVATO 8LM2 TB103 SB4 PULSANTE STOP CICLO 10A 690 V N.C. 1 LOVATO 8LM2 ? SA1 SELETTORE MPV. ARCO 10A 690 V + 2 N.O 1 LOVATO 8LM2 TS231 SA 2 SE LE TTO RE M ORS A 10A 690 V+ 2N.O.+ 2 N.C 1 LOV ATO 8LM 2 TS220

YV I----4 VA LVOLE IDRAULICHE SU CENTRALINA 4 L-C- 21,5 V DC RAC 24 V

SQ 2 M ICRO RIP ARO NASTRO 3 A 250 V CON CHIAV E 1 REITE R RS2 10 11 D SQ 3 M ICRO RIP ARO NASTRO 3 A 250 V CON CHIAV E 1 REITE R RS2 10 11 D SQ1 MICRO ARCO BASSO 3A 400 V NC+NO 1 PIZZATO FR 4501

P PRESSOSTATO TENS. LAM A 0.5 A 250 V 300 BAR N.O 1 ELETTROTEC PMN 14K T 90D X 1 S CA TOLA DE R IV A ZIO NE 6 V IE 1 P A LAZZOLI TAIS 101061 X2 M ORS E TTI CONN ES SIONE 2,5 MM 800 V 47 S IE M E NS 8W A 11 011 DF11

X3 MORSETTI CONNESSIONE TE RMINALI 2 W EIDMULLER EW 35

KTC TEM PORIZZATORE + ZOCCOLO 2 C. SCAMBIO 300 SEC 1 CROUZET TOP 36 24 V+ 9026 KM 1-C CONTATTO AUS. CENTRALINA 1 NC+ 1 NO 10A 750 V. 1 C.G.E. BCLF 10+BCLF01 KM2-C CONTATTO AUS. NA STRO 1 NC + NO 10 A 750 V. 1 C.G.E. BCLF 10+BCLF01

WEBER WEBER WEBER WEBER WEBER WEBER WEBER WEBER

PCH 3 X 38 CH10 X 30 10 A PCH 3 X 38 CH 10 X 38 16 A PCH 2 X 38 CH 10 X 38 1AM PCH 1 X 38 CH 10 X 38 4A

SAR 440 SA GDS

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

Chips sticking onto teeth and in the gullets or material that gums

Defects on the material or material too hard

Ineffective gripping of the part in the vice

Decrease advance, exerting less cutting pressure. Adjust the braking device if mounted on the machine.

Change speed and/or type of blade. See chapter on “Material classification and blade selection”, in the section

tion table according to cutting and feed speed.

Choose a suitable blade. See Chapter “Ma-

terial classification and blade selection”.

Check for clogging of cooling liquid drain holes on the blade-guide pads and that flow is plentiful in order to facilitate the removal of chips from the blade.

Material surfaces can be oxidised or covered with impurities making them, at the beginning of the cut, harder that the blade itself, or have hardened areas or inclusions inside the section due to productive agents used such as casting sand, welding wastes, etc. Avoid cutting these materials or in any case perform cutting with extreme care, cleaning and removing such impurities as quickly as possible.

Check the gripping of the part.

Blade selec-

The blade gets stuck in the material Starting cut on sharp or irregular section bars

Poor quality blade Previously broken tooth left in the cut Cutting resumed on a groove made pre-

viously Vibrations Wrong tooth pitch or shape

Insufficient lubricating refrigerant or wrong emulsion

Teeth positioned in the direction opposite the cutting direction

Reduce feed and exert less cutting pressure. Pay more attention when y ou start cutting.

Use a superior quality blade. Accurately remove all the parts left in.

Make the cut elsewhere, turning the part.

Check gripping of the part. Replace blade with a more suitable one.

See “Material classification and blade selection” in the Adjust blade guide pads.

Check level of liquid in the tank. Increase the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe are not blocked. Check the emulsion percentage.

Turn teeth in correct direction.

Blade Types

section.

FAULT PROBABLE CAUSE REMEDY

SAR 440 SA GDS

PREMATURE BLADE WEAR

Faulty running-in of blade

Teeth positioned in the direction opposite the cutting direction

Poor quality blade Too fast advance

Wrong cutting speed

Defects on the material or material too hard

Insufficient lubricating refrigerant or wrong emulsion

See “Material classification and blade se- lection” in the

Turn teeth in correct direction.

Use a superior quality blade. Decrease advance, exerting less cutting

pressure. Adjust the braking device if mounted on the machine.

Change speed and/or type of blade. See chapter on “Material classification and blade selection”, in the section

Blade running-in

section.

Blade selection table according to cutting and feed speed.

Check level of liquid in the tank. Increase the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe are not blocked. Check the emulsion percentage.

BLADE BREAKAGE

Faulty welding of blade

Too fast advance

Wrong cutting speed

Wrong tooth pitch

Ineffective gripping of the part in the vice

Blade touching material at beginning of cut

The welding of the blade is of utmost importance. The meeting surfaces must perfectly match and once they are welded they must have no inclusions or bubbles; the welded part must be perfectly smooth and even. They must be evenly thick and have no bulges that can cause dents or instant breakage when sliding between the blade guide pads.

Decrease advance, exerting less cutting pressure. Adjust the braking device if mounted on the machine.

Change speed and/or type of blade. See chapter on “Material classification and blade selection”, in the section

Blade selection table according to cutting and feed speed.

Choose a suitable blade. See Chapter “Ma- terial classification and blade selection”.

Check the gripping of the part.

At the beginning of the cutting process, never lower the saw frame before starting the blade motor.

FAULT PROBABLE CAUSE REMEDY

SAR 440 SA GDS

STREAKED OR ETCHED BANDS

Blade guide pads not regulated or dirty because of lack of maintenance

Blade guide block too far from material to be cut

Improper position of blade on flywheels

Insufficient lubricating refrigerant or wrong emulsion

Damaged or chipped blade guide pad

Tight or slackened blade guide bearing

Check distance between blocks (see “Ma- chine adjustments” in the

Blocks

section): extremely accurate guiding may cause cracks and breakage of the tooth. Clean carefully.

Approach head as near as possible to material to be cut so that only the blade section employed in the cut is free, this will prevent deflections that would excessively stress the blade.

The back of blade rubs against the support due to deformed or poorly welded bands (tapered), causing cracks and swelling of the back contour.

Check level of liquid in the tank. Increase the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe are not blocked. Check the emulsion percentage.

Replace it.

Adjust it (see Chapter “Machine adjust- ments” in

Blade guide

Blade Guide

section).

CUTS OFF THE STRAIGHT

Blade not parallel as to the counter-vice

Blade not perpendicular due to the excessive play between the guide pads and maladjustment of the blocks

Too fast advance

Blade guide block too far from material to be cut

Worn out blade Wrong tooth pitch

Check fastenings of the blade guide blocks as to the counter-vice so that they are not too loose and adjust blocks vertically; bring into line the position of the degrees and if necessary adjust the stop screws of the degree cuts.

Check and vertically re-adjust the blade guide blocks; reset proper side guide play (see Chapter “Machine adjustments” in

guide

section).

Decrease advance, exerting less cutting pressure. Adjust the braking device if mounted on the machine.

Approach it as near as possible to material to be cut so that only the blade section employed in the cut is free, this will prevent deflections that would excessively stress the blade.

Replace it. Blade with major density of teeth is being

used, try using one with less teeth (see Chapter “Material classification and blade se- lection” in the

Blade Types

section).

Blade

FAULT PROBABLE CAUSE REMEDY

SAR 440 SA GDS

FAULTY CUT

STREAKED CUTTING SURFACE

Broken teeth

Insufficient lubricating refrigerant or wrong emulsion

Worn out flywheels

Flywheel housing full of chips

Too fast advance

Poor quality blade Worn out blade or with chipped and/or

broken teeth Wrong tooth pitch

Blade guide block too far from material to be cut

Irregular work of the blade due to the lack of teeth can cause deflection in the cut; check blade and if necessary replace it.

Check level of liquid in the tank. Increase the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe are not blocked. Check the emulsion percentage.

The support and guide flange of the band are so worn out that they cannot ensure the alignment of the blade, causing faulty cutting; blade rolling and drawing tracks can have become tapered. Replace them.

Clean with compressed air.

Decrease advance, exerting less cutting pressure. Adjust the braking device if mounted on the machine.

Use a superior quality blade. Replace it.

Blade used probably has too large teeth; use one with more teeth (see “Material classi- fication and blade selection” in the

Types

section).

Approach it as near as possible to material to be cut so that only the blade section employed in the cut is free, this will prevent deflections that would excessively stress the blade.

Blade

NOISE ON GUIDE BLOCKS

Insufficient lubricating refrigerant or wrong emulsion

Chipped bearings

Worn out or damaged pads

Check level of liquid in the tank. Increase the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe are not blocked. Check the emulsion percentage.

Dirt and/or chips between blade and guide bearings. Replace them.

Replace them.

12.2 - Electrical components diagnosis

FAULT PROBABLE CAUSE REMEDY

SAR 440 SA GDS

MACHINE DOES NOT WORK

Power supply

Main disconnect switch

Fuses " FU 1 "

" SQ 1 " safety microswitch

Blade tightening microswitch

Emergency button " SB 1 " on Cycle reset or line button " SB 2 " Thermal relay of main motor

Transformer " TC 1 "

Fuse " FU 2 - FU 3 "

Check: - phases

- cables

- socket

- plug Voltage must arrive upstream from the fuses (terminal board). It must be turned to ON position. Check electrical efficiency. Check power line connections and relative terminals. Check electrical efficiency and check for shorts that trigger these protections on the power side of the circuit. Check closing of the flywheel guard. Check the efficiency of the device; replace it if damaged. Make sure to have tightened the blade with the relevant handwheel and to have actuated the microswitch. Ensure that it is off and that its contacts are unbroken. Check mechanical efficiency; replace if damaged. Check that thermal relay protecting main motor is correctly connected.

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 on the control side of the circuit.

Microswitch " SQ 2 "

MOTOR STOPPED WITH PILOT LIGHT “HL” LIT

In accordance with point 1.7.4.f of the Machines Directive EEC 98/37

2 measurements with the machine operating unloaded.

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

- The weighted equivalent continuous acoustic pressure level was 65,4 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

Remote-control switch " KM "

Motor " M 1 "

After having raised the saw frame, check that the microswitch is not engaged and if necessary check operating efficiency.

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.

PLATES AND LABELS

SAR 440 SA GDS

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

Dake SAR 440 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual