DoAll 400-S User Manual

400S

Serial No: 597-10101 to

Instruction Manual

Band Sawing Machine

DAMAGE CLAIM PROCEDURES

VISIBLE DAMAGE AT THE TIME OF DELIVERY:

1. Note damage on carrier’s delivery receipt. Accept the shipment. It can be returned later if repairs

are not possible in the eld.

2. Request a “damage inspection” from the delivery carrier:

a. The carrier will send his own people or contract an independent agency to make the

inspection.

b. The inspector will request a signature on the report and leave a copy.

c. The carrier “damage inspection” report is not nal. If additional damage is found when

repairs are started, contact the carrier for another inspection; or at least give them the
details of the damage.

3. Do not move the equipment from the receiving area and keep all shipping materials until carrier
“damage inspection” report is complete.

4. If possible, take photographs of the damage and keep them for your les. Photos could possibly

prove a claim at a later time.

5. Keep a record of all expenses and be sure they are documented.

6. Repair damage in the eld whenever possible. Carriers encourage this to keep expenses down.

7. You have nine (9) months to le a claim.

CONCEALED DAMAGE:

1. You have fourteen (14) days to report damage not noted at time of delivery.

a. Report damage as soon as possible. This makes it easier to prove that it did not happen

at cosignee’s plant.

b. Inspect machine(s) carefully before moving from the receiving area. Again, if machine is

not moved, it is easier to prove your case.

2. Request a “damage inspection” from the delivery carrier:

a. The carrier will send his own people or contract an independent agency to make the

inspection.

b. The inspector will request a signature on the report and leave a copy.

c. The carrier “damage inspection” report is not nal. If additional damage is found when

repairs are started, contact the carrier for another inspection; or at least give them the
details of the damage.

3. Do not move the equipment from the receiving area and keep all shipping materials until carrier
“damage inspection” report is complete.

4. If possible, take photographs of the damage and keep them for your les. Photos could possibly

prove a claim at a later time.

5. Keep a record of all expenses and be sure they are documented.

6. Repair damage in the eld whenever possible. Carriers encourage this to keep expenses down.

7. You have nine (9) months to le a claim.

OPERATOR'S INSTRUCTION MANUAL

METAL CUTTING BAND SAW

MODEL FIRST SERIAL NO. LAST SERIAL NO.

400S 597-10101

For your information and future reference, pertinent data concerning your machine
should be written in the spaces provided above. This information is printed on a label
attached to your machine. Be sure to provide machine model and serial numbers
with any correspondence or parts orders.

Specications contained herein were in effect at the time this manual was approved
for printing. The DoALL Company, whose policy is one of continuous improvement,
reserves the right, however, to change specications or design at any time without

notice and without incurring obligations.

PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATING THE MACHINE!

For Sales, Parts and Service, call 1-888-362-5572

For general information, visit our web site at: www.doallsawing.com

DoALL SAWING PRODUCTS

2375B TOUHY AVENUE
ELK GROVE, ILLINOIS 60007 U.S.A.

The following registered trademarks of the DoALL Company are used in this manual:
DoALL, Imperial Bi-Metal, Kleen-Kool, and Tensigage.

PRINTED IN U.S.A. PB-543.3 (3-14)

i

TABLE OF CONTENTS

MACHINE DIMENSIONS

Floor Plan .................................................... 1

Front and Side Views ............................................. 2

Top View ................................................................. 3

MACHINE FEATURES

Front View ................................................... 4

Rear View ............................................................... 5

INSTALLATION

Location .................................................................. 6

Unpacking ............................................................... 6

Cleaning ................................................................. 6

Lifting ...................................................................... 6

OSHA Notice!! ........................................................ 6

Floor Installation and Alignment ............................. 6-7

Electrical Installation ............................................... 7

Plant Air Installation (If Needed) ............................. 7

Preparation for Use ................................................ 7

OPERATION

Safety Precautions ................................................. 8

Using the Saw Band Selector ................................. 8

Cutting Capacity ..................................................... 8

Machine Controls .................................................... 9-10

Saw Band Preparation ............................................ 10-11

Band Speed Adjustment ......................................... 11

Saw Guide Arm Adjustment .................................... 12

Feed Rate Adjustment ............................................ 12

Vise Jaw Adjustment .............................................. 12

Saw Head Positioning For Angle Cuts .................... 12

Coolant Selection and Application .......................... 12-13

Dry Cutting .............................................................. 13

Band Brush and Chip Removal .............................. 13-14

Typical Sawing Procedures .................................... 14

Full Cycle Sawing Operation .................................. 14-15

LUBRICATION

Lubrication Chart .................................................... 16

Lubrication Diagrams .............................................. 17

MAINTENANCE

Saw Guide Insert Replacement .............................. 18

Drive Belt Removal or Replacement ...................... 18

Band Tension Adjustment ....................................... 18

Coolant System ...................................................... 18-19

Chip Removal ......................................................... 19

Replacing Vise Bed Wear Plates ............................ 19

Bandwheels ............................................................ 19

Head Feed Cylinder ................................................ 19-20

Counterbalance Spring ........................................... 20

Electric Motors ........................................................ 20

Band Mist Lubricator ............................................... 20

TROUBLE SHOOTING .................................. 21-24

ACCESSORIES

Roller Stock Conveyors .......................................... 25

Vertical Guide Rollers ............................................. 25

Pneumatic Head Lift ............................................... 25-26

Pneumatic Vise ....................................................... 26

Full Cycle Option .................................................... 26-27

Band Mist Lubricator ............................................... 27

Flushing Hose ......................................................... 27

Large Receiving Tray .............................................. 27

Workstop ................................................................ 27

Worklight ................................................................. 27

Laser Line Generator .............................................. 28

How to read your serial number:

ii

MACHINE DIMENSIONS

INCHES: ± .03

(MILLIMETERS: ± 1 mm)

FLOOR PLAN

1

MACHINE DIMENSIONS (Continued....)

INCHES: ± .03

(MILLIMETERS: ± 1 mm)

FRONT VIEW

SIDE VIEW

2

MACHINE DIMENSIONS (Continued....)

INCHES: ± .03

(MILLIMETERS: ± 1 mm)

TOP VIEW

3

MACHINE FEATURES

FRONT VIEW

4

MACHINE FEATURES (Continued....)

REAR VIEW

5

INSTALLATION

All the "left", "right", "front", "rear" directions

in this manual are as viewed by the operator
when facing the control panel.

Inspect the machine for broken or damaged

parts. Refer to this manual's inside front cover
for damage claim procedures.

LOCATION

1. Plan the work area of the machine to allow adequate

space for all your sawing needs with maximum
convenience.

2. Locate the machine to provide sufcient clearance

for: (a) Material loading and unloading; (b) All
door openings; (c) Head elevation; (d) Head swivel;
(e) Maintenance and lubrication procedures; (f)
Operation of any supplied machine accessories.

3. Approximate oor dimensions for the machine are

shown on pages 1, 2 and 3.

4. Accessories such as roller stock conveyors will
require additional working area.

UNPACKING

Lifting the Machine.

2. Place the straps or chains under the coolant pan

as shown. If chains are used, be sure to position
padding where the chains makes contact with the

machine frame to protect the nish.

3. Accessory roller stock conveyors can be lifted into
position using a fork lift or other means that provides
adequate safety precautions.

1. The machine plus other parts and supplies were
fastened to a wooden skid before shipment.

DO NOT remove the the strapping holding the

saw head to the base until the machine has
been placed to its permanent location.

2. Remove all other protective covers, strapping,
crating, etc. Then: (a) Remove wire if used to
secure bandwheel doors; (b) Remove the screws
attaching the machine to the shipping skid.

CLEANING

1. If necessary, use solvent to remove the rust­preventative coating applied to the machine's
exposed bare metal surfaces before shipping.

LIFTING

Never lift the machine by its sawing head.

1. Use a overhead hoist to lift the machine to its
permanent location. Net weight is approximately
1100 pounds (521.6 kg).

OSHA NOTICE!!

OSHA Regulation No. 1910.212 (5B).

 Machinesdesignedforaxedlocationshall

be securely anchored to prevent walking or
moving.

FLOOR INSTALLATION AND ALIGNMENT

1. Remove the machine from its shipping skid.

2. While the machine is suspended in the air, thread
the provided leveling screws (M16-2.0) into each
machine base foot pad and attach the jam nuts.
Slowly lower the saw into desired position.

3. Place a machinist's level on the vise bed. If the

machine is not level, correct it by: (a) Adjusting
the four (4) leveling screws in the base pads; (b)
Tighten the jam nuts. Machine must rest evenly

on all pads.

4. Place coolant in the base pan and check its ow to

the right side base opening. If the coolant does not

ow as desired. Raise the leveling screws on the

left side or lower the right side leveling screws in

half a turn intervals until desired ow is acheived.

6

FLOOR INSTALLATION AND ALIGNMENT

(Continued....)

5. Install anchoring screws through the base pad holes
next to the leveling screw locations.

ELECTRICAL INSTALLATION

Electrical installation must be made by

an authorized electrical maintenance
personnel!

LARGE DISCHARGE TRAY INSTALLATION

1. Place the optional discharge tray onto the mounting
angle and insert the three (3) at head socket

screws. and then tighten. Then: (a) Adjust the
tray's leveling screw on each leg so the tray surface

is ush with the machine's vise base, or no more

than 0.031 inch (0.8 mm) below it; (b) Elevate the
tray's right side slightly so used coolant will drain
into the tray's coolant trough and then into the base
pan.

1. Bring the incoming line circuit leads to the disconnect
switch terminals in the electrical control box located
on the lower right front of the machine base. Refer
to the furnished electrical schematic, if necessary.

2. Press the "BAND/CYCYLE START" pushbutton.

When the machine is correctly wired, the saw band
will run left to right through the saw guides when
viewed from the front.

3. If saw band movement is reversed: (a) Push

the "BAND/CYCLE STOP" pushbutton, turn the
disconnect switch to "OFF" and remove power at

the source of electrical supply; (b) Reverse the line
leads leads to the disconnect switch; (c) Restore
power and perform Step 2 again.

PLANT AIR INSTALLATION (If Required)

1. Plant air is required to operate the following optional

equipment: vise clamp cylinder, head lift cylinder,
full cycle operation and mist lubricator system.

2. Plant air is connected at the air lter located under

the base pan on the right side of the machine. Air
pressure should be in the range of 80 to 90 psi (5.6

and 6.3 kg/cm²).

 DONOTexceed90psi(6.3kg/cm²).

PREPARATION FOR USE

1. All covers and guards must be in place, doors must
be closed, and operator understands the safety
rules and operation of the machine.

2. Fill coolant reservoir with coolant recommended in

the Lubrication Chart.

3. Be sure that all other points listed in the Lubrication

Chart have been checked and/or serviced.

Break-In Cut

1. The initial cut with a new machine should be made

with a band speed at 105 fpm (32 m/min.) and a

light feed rate.

2. When angle cutting, the saw band may be cutting
partially into the discharge tray establishing a future
kerf path.

3. During the break-in cut, allow blade penetration into
the discharge tray until the saw head reaches the
factory set mechanical stop (horizontal position).

Be sure the saw head falls only enough to cut

completely through the work. TOO LITTLE head
fall will result in an incomplete cut through the
workpiece. See the "MAINTENANCE" chaper
under the heading "Counterbalance Spring"
in this manual for instructions on adjusting
the counterbalance spring mechanism.

Plant Air Connection For Optional Equipment.

7

OPERATION

SAFETY PRECAUTIONS

Warning Label - READ and UNDERSTAND.

USING THE SAW BAND SELECTOR

1. Refer to the Saw Band Selector escutcheon on the
right front bandwheel door for information about
blade choice and pitch, and suggested band speed
for stock type and thickness. It also provides a
handy sawing procedures checklist.

2. For example, to cut low carbon steel which is two
(2) inches (50.8 mm) thick, you would choose: (a)
An Imperial Bi-Metal saw band with 8-10 pitch, and
set the band speed for 275 fpm (84 m/min); or (b)
A Dart saw band with 8-10 pitch, and set the band

speed for 180 fpm (55 m/min).

Saw Band Selector recommendations are a

general guide for correct sawing on a properly
maintained DoALL saw. Values can be
adjusted for special material applications.

CUTTING CAPACITY

1. Your machine is designed to cut retangular stock up
to ten (10) inches (254.0 mm) high and 16 inches
(406.4 mm) wide. It will also cut round stock up to

10-3/4 inches (273.0 mm) in diameter.

2. With the saw head adjusted for 45° cutting, the
machine will saw retangular stock up to 9 inches
(228.6 mm) high and ten (10) inches (254.0 mm)
wide. It will also cut round stock up to ten (10)
inches (254.0 mm) in diameter.

3. Vise bed capacity is 1800 pounds (816.5 kg) evenly
distributed with NO impact.

Saw Band Selector.

8

MACHINE CONTROLS

1. The machine has two (2) signicant control panels:

(a) an electrical control panel mounted on the front
of the electrical enclosure located to the right front
of the machine or a remote console; (b) A hydraulic/
pneumatic control panel located between the right
saw guide arm and right hand bandwheel door.

2. Laser (Optional). This selector switch turns the

laser line generator "ON" and "OFF". Turn the laser
"OFF" when not in use.

3. Saw Head Control and Operation (Full Cycle
Option). These controls are described in the

"ACCESSORIES" chapter under the "Full Cycle
Option" heading in this manual.

4. Band/Cycle Stop.  Push this red pushbutton to
stop the band drive motor. To restart the machine,
this pushbutton must be reset by rotating the button
head clockwise until the head pops up.

5. Coolant. Four (4) position selector switch with

"AUX", "OFF", "BAND ON", and "ON" settings.

• (a) "BAND ON" allows the ood coolant system to
operate when the band drive motor is running; (b)

"ON" allows the ood coolant system to operate

without the band drive motor running; (c) "AUX" is
used for the optional mist lubrication system; (d)

"OFF" turns either system off.

6. Disconnect Switch. Turns the incoming power

"OFF" and "ON" and is located on the front of the

control box enclosure.

Typical Machine Control Panels.

Electrical Controls

1. Band/CycleStart. Push this green pushbutton to
start the band drive motor and saw band.

Be sure the saw band is properly tensioned

before pushing this button.

Hydraulic/PneumaticControls

1. Head Up (Pneumatic Head Lift Option). This
control is described in the "ACCESSORIES"
chapter under the "Pneumatic Head Lift" heading
in this manual.

Typical Electrical Control Panel.

Typical Hydraulic/Pneumatic Control Panel.

9

MACHINE CONTROLS (Continued....)

2. Head Feed Rate. Turning this knob regulates the
pressure being applied by the saw head and saw
band against the material being cut. Turn the knob

counterclockwise to "INCREASE" the feed rate,
clockwise to "DECREASE" it.

3. Head. This selector has "FEED" and "HOLD" and
"RAPID" settings.

• The "FEED" setting is for actual cutting of the

material. The cutting rate is set by the Head Feed
control above.

• "RAPID" is for fast descent of the sawing head for

positioning or moving the saw head to the complete
down position. This setting is NOT for cutting the

material.

• "HOLD" stops saw head movement.

4. Vise (Pneumatic Vise Option). This control is
described in the "ACCESSORIES" chapter under
the "Pneumatic Vise" heading in this manual.

2. Follow these adjustment procedures: (a) Turn the
adjustment screw clockwise until tight against the
saw band (do not over tighten); (b) Turn each
adjustment screw back counterclockwise 1/4 turn.

Saw Guide Detail.

Saw Band Removal

 Alwaysuseextremecarewhenhandlingsaw

bands. Wear gloves.

SAW BAND PREPARATION

Recommended Saw Band

1. The machine is shipped with an Imperial Bi-Metal
Super Silencer saw band installed. Saw bands
recommended for use with the machine should be
158 inches (4013.2 mm) long, one (1) inch (25.4
mm) wide, and have a 0.035 inch (0.89 mm) gage
thickness.

Blade Guards

1. The following blade guards are positioned to provide
operator safety while the machine is running:
(a) A top guard located above and between the
bandwheel doors; (b) Two (2) guards mounted
between the lower left saw guide arm and the left
bandwheel door; (c) A guard between the lower right
saw guide arm and the right bandwheel door. Blade

guards (b) and (c) can be removed to facilitate
saw band changing procedures.

DO NOT defeat their purpose by operating the
machine without these guards attached. THEY
ARE THERE FOR YOUR PROTECTION!

Saw Guide Insert Adjustment

1. Push the Band Stop pushbutton. Then: (a) Turn
the band tension handwheel counterclockwise
(this moves the idler bandwheel to the right and
loosens band tension); (b) Turn the Head control
knob to the "HOLD" setting; (c) Grasp the band
tension handwheel and lift the saw head to a
position where there is space under the saw guide

arms (approximately ve (5) inches (127.0 mm).

2. Open the right and left bandwheel doors. Then: (a)
Remove or reposition the band brush, if necessary;

(b) Loosen and remove the left blade guard;
(c) Loosen the saw guide inserts by turning the
adjusting screws counterclockwise.

3. Place your gloved hand on the non-cutting edge of

the saw band between the saw guide arms. Then:

(a) Push the saw band downward to free it from the

saw guide inserts; (b) Grasp the saw band near the
idler bandwheel and remove it, then remove the saw
band from around the drive bandwheel; (c) Move
the saw band's upper strand out through the slot in
the upper band guard and out form under both saw
guide arms.

If possible, recoil the saw band into its original

holder before storing or scrapping the band.

1. Adjustment screws for the saw guide inserts are
located on the lower portion of each saw guide
arm.

10

SAW BAND PREPARATION (Continued....)

Saw Band Installation

 Alwaysuseextremecarewhenhandlingsaw

bands. Wear gloves.

1. Remove the saw band as described in the previous

section. Clean metal chips and other foreign

materials and debris from around the saw guides
and both bandwheels. Remove the new saw band's
protective cap if necessary.

2. Form the saw band into a loop. Then: (a) Slip
the saw band under the saw guide arms and into
approximate position for placement; (b) With the
saw band's teeth facing towards you, slip the looped
saw band through the slot in the upper band guard
and then around the drive and idler bandwheels.

2. Correct band tension for the machine's standard

one (1) inch (25.4 mm) wide by 0.035-inch (0.89
mm) gage saw band is 27,000 to 30,000 psi (1900

to 2100 kg/cm²) measured by a DoALL Tensigage.

This tension setting is established when the preset
stop bolt contacts the large washer. An escutcheon
near the band tension handwheel describes the
washer to stop bolt relationship in a setting of 30,000

psi (2100 kg/cm²).

3. Important factors which inuence band tension

settings are the size of stock to be cut and desired
band life. General rules-of-thumb are: (a) Lower
tensions will increase saw band life; (b) Greater
tension is required as spacing is increased between
the saw guide arms; (c) Higher band speeds require
greater tension.

DO NOT start the band drive motor unless the
saw band has been properly tensioned.

3. Twist the saw band 90° so that its teeth between the
saw guide arms point down and to the right. Then:
(a) Insert the saw band into the saw guide inserts
and pull up against the back-up bearing; (b) Check
the saw band's position around the bandwheels (its
back edge must rest against each bandwheel's rear

ange).

4. Apply correct band tension by turning the band
tension handwheel clockwise. Then: (a) Turn
the saw guide insert adjustment screws clockwise
until tight (do not over tighten); (b) Turn each
adjustment screws back counterclockwise 1/4
turn.(c) Reposition or mount the band brush and
blade guards(s); (d) Close both bandwheel doors.

Band Tension Handwheel

1. Band tension is applied by turning the handwheel
which protrudes from the saw head's left side. Turn
the handwheel clockwise to increase band tension;

counterclockwise to decrease it.

BAND SPEED ADJUSTMENT

Change band speeds ONLY when the band

drive motor is running. Be sure the saw
band is correctly tensioned before starting
the band drive motor.

1. Band speed is innitely variable between 105 and
275 fpm (32 and 85 m/min) for 60 Hz machine;
90 and 230 fpm (27 and 70 m/min) for 50 Hz

machines. To adjust, turn the band speed adjusting
handwheel clockwise to "INCREASE" band speed;

counterclockwise to "DECREASE" it.

Turn Handwheel to Set Band Tension.

Band Drive Details.

2. Refer to the band speed escutcheon when setting
or adjusting band speed.

11

SAW GUIDE ARM ADJUSTMENT

1. The machine's right saw guide arm is xed. The

left saw guide arm can be adjusted as follows to
accommodate varying stock widths: (a) Loosen
the saw guide insert adjustment screw by turning
counterclockwise; (b) Loosen the left arm's locking
knob by turning it counterclockwise; (c) Move the
arm along the slide bar until it is as close as possible
to the stock; (c) Turn the locking knob clockwise
to tighten; (e) Tighten the insert adjustment screw
as previously instructed.

Adjusting the Vise Jaws and Head Swivel.

DO NOT move the left saw guide arm while

the saw band is running.

2. The best cutting results are generally obtained
when the saw guide arms are positioned as close
as possible to the stock.

FEED RATE ADJUSTMENT

1. The Feed Rate knob regulates the amount of
pressure being exerted by the falling saw head
against the stock.

2. When preparing to cut a piece of stock, turn the
Head selector to "HOLD". Then: (a) Grasp the
band tension handwheel and lift the saw head so it
clears the stock; (b) Position the stock for a cut.

3. Start the saw head's downward movement by
pushing the Band/CycleStart pushbutton. Then:
(a) Turn the Head selector to the "FEED" setting; (b)
Gradually turn the Feed Rate knob until the desired
rate is obtained.

VISE JAW ADJUSTMENT

1. The distance between the movable (left) and xed

(right) vise jaws can be adjusted to accommodate
varying stock widths. To adjust: (a) Lift the pawl
arm attached to the movable vise jaw from the
rack; (b) Slide the pawl arm and movable vise jaw
in the desired direction until the jaw contacts the
positioned stock, or the opening between the vise
jaws is judged sufcient; (c) Lower the pawl arm so
its protruding end segment engages into the nearest
rack notch.

2. Use the vise clamp adjustment handwheel (lower
handwheel on the left side of the machine)
to tighten the vise jaws securely. Turn the
handwheel clockwise to tighten the vise jaws,

counterclockwise to loosen the jaws.

SAW HEAD POSITIONING FOR ANGLE CUTS

1. To position the saw head for angle cutting from 0°
to 45°: (a) Loosen the clamping handle by turning
it counterclockwise; (b) Pivot the saw head to the
desired angle as indicated by the pointer located just
above the clamping handle; (c) Turn the clamping
handle clockwise to lock the saw head in place.

2. The 0° and 45° angle positions have been preset
at the factory. If adjustment becomes necessary, it
can be made with the screws and jam nuts located
on the rear of the pivot weldment.

3. If desired, the operator can make a crop cut to check
angle accuracy.

COOLANT SELECTION AND APPLICATION

Coolant Selection

1. Choosing and using the proper cutting fluid is

important to most cutting procedures. An operator's
coolant choice will depend on such factors as: (a)
The type of material being cut; (b) The material's
machinability rating; (c) Band speed and feed rate
to be used; (d) Saw band type to be used and its
expected life; (e) The overall sawing operation.

2. When making a coolant choice, the operator will
want to consider the following points:

• Excessive heat build-up is the main cause of blade

tooth failure during band machining. Coolant

has both lubricating and cooling properties. Its
application does the following: (a) Helps reduce
the heat generated during sawing; (b) Helps prolong
blade life; (c) Generally promotes more efcient
cutting rates.

• Using more than one (1) coolant variety may provide
maximum sawing results and economy.

12

COOLANT SELECTION AND APPLICATION

(Continued....)

DoALL has developed several cutting uids

specically for band machining. A DoALL

sales representative can provide complete
information about all available coolant types
and their recommended usages.

Coolant Application

DRY CUTTING

1. The operator may nd it desirable to cut some

materials (such as cast iron, aluminum, magnesium,
etc.) without coolant. When dry cutting these
materials, follow the same operating procedures
used when cutting with coolant.

Dry cutting will reduce saw band life.

1. Coolant is supplied by means of a reservoir and

pump to the cutting area through a valve and then
the saw guide inserts on the left saw guide arm.
Turn the valve counterclockwise until coolant
completely covers both sides of the saw band.

Coolant Valve on the Saw Guide Arm.

2. Used coolant ows back to the reservoir through

the open end of the base pan. The screening
and straining within the reservoir removes metal
particles and other impurities before the coolant is
recirculated.

BAND BRUSH AND CHIP REMOVAL

Band Brush

1. A powered band brush removes metal particles from
the saw blade teeth. The band brush is located
inside the right bandwheel door. It is attached to a
bracket that is mounted to the saw head frame.

2. The brush must be properly adjusted to clean blade
tooth gullets if satisfactory sawing performance is to
be obtained. As bristles wear down, adjust brush
position by: (a) Loosening the bolts holding the
brush assembly to the bracket on the saw head; (b)
Move the brush to the correct cleaning position; (c)
Retightening the bracket bolts.

3. Coolant reservoir capacity is nine (9) gallons (34.1

liters). The pump will not operate correctly unless
it is completely submerged in coolant.

Coolant Reservoir.

Band Brush.

NEVER adjust the band brush while the saw
band is running.

Chip Removal

1. Metal fragments removed from the band brush and
from the stockpiece drop onto the base pan. The

chips ow with the coolant and drop into a strainer
above the coolant reservoir compartment. Chip

collections should be removed from the tray when
necessary.

13

BAND BRUSH AND CHIP REMOVAL

(Continued....)

2. In addition, the operator should check often for chip
accumulations around such machine areas as: saw
guides, vise bed, vise jaws, head feed cylinder,
etc. These accumulations may affect machine
performance if not removed. DoALL recommends
removing chip accumulations at least twice per eight
(8) hour shift and more often with heavier use.

3. Use a small shovel or rake to remove accumulated
chips or other materials from the machine's
operating areas.

4. Use the optional Flushing Hose to remove
accumulated chips or other materials from the
machine's operating areas.

Be sure the band drive motor and the saw
band have STOPPED completely before
cleaning the machine.

TYPICAL SAWING PROCEDURES

2. Turn on the Coolant valve located on the left saw

guide arm so coolant ow covers both sides of the
saw band (counterclockwise to "INCREASE"
coolant ow, clockwise to "DECREASE" it).

3. Turn the Feed Rate knob until the desired cutting rate
is established (counterclockwise to "INCREASE"
feed force, clockwise to "DECREASE" it). This
setting can be adjusted as the cut progresses.

4. The operator can adjust band speed, feed rate
and coolant volume rates as necessary during the
sawing process.

After a Cut is Completed

1. The machine will shut off with the saw head down
following the completion of a cut. The operator
should then: (a) Remove the cut-off piece; (b)
Turn the Head control selector switch to "HOLD";
(c) Grasp the band tension handwheel and lift the
saw head until it clears the stock; (d) Prepare for
another cut or clean the machine if it is to remain
idle for any period of time.

Preparation

1. These operations assume that the machine is
prepared as follows: (a) The band drive motor is
"OFF"; (b) The saw band is properly installed and
tensioned; (c) The bandwheel doors are closed;
(d) All guards are in place and/or secured; (e) The
coolant reservoir is full and all lubrication points are
properly serviced; (f) The band brush is properly
positioned.

Loading Stock

1. Turn the Head control selector switch to "HOLD".
Then: (a) Turn the Feed Rate knob clockwise to
its maximum position; (b) Grasp the band tension
handwheel and lift the saw head until it clears the
stock to be cut; (c) Adjust the movable saw guide
arm for stock width; (d) Adjust the saw head for
angle cutting if necessary; (e) Adjust the vise jaws
for stock width; (f) Load stock onto the machine and
secure it in cutting position by turning the vise jaw
clamping handwheel.

Starting the Cut

1. Push the Band/CycleStart pushbutton. Then: (a)
Turn the band speed adjustment handwheel until
the pointer is at the desired band speed; (b) Start
the saw head movement downward by turning
the Head control selector to "FEED"; (c) Turn the

Coolant selector to "BAND ON".

DO NOT remove any cut-off pieces until they

are away from the saw band or the saw band
has stopped completely.

For future reference, keep a record of band

speed, feed rate and coolant application
settings for successful jobs.

FULL CYCLE SAWING OPERATION

See the "ACCESSORIES" chapter under the

"Full Cycle Option"headingforexplanation

of controls and procedures before proceeding
with these instructions.

Manual Operation

1. Start the machine in the following conditions:

(a) Band drive motor is "OFF"; (b) Manual/Auto
selector switch at "MANUAL"; (c) Saw Head
Control selector switch at "HOLD".

2. With no stock between the vise jaws, proceed as
follows: (a) Move the Saw Head Control selector

switch to "DOWN/AUTO" and allow the saw head to

lower completely; (b) Move the work height stop pin
(located on top of the sawing head next to the band
drive motor) to the desired work height position; (c)
Raise the saw head completely by moving the Saw

Head Control selector switch to "UP". The saw

head will raise until it reaches the stop.

14

FULL CYCLE SAWING OPERATION

(Continued....)

If the saw head does not move when the Saw

Head Control selector switch is moved from

"HOLD"to"DOWN/AUTO",movetheselector

switch from "HOLD" to "UP" and then to

"DOWN/AUTO".

3. Place the stock in desired cutting position and clamp
it between the vise jaws. Push the Band/Cycle

Start pushbutton.

4. Move the Saw Head Control selector switch to

"DOWN/AUTO" to start the saw head's downward

motion. Adjust the Feed Rate knob as necessary
as the saw head starts downward to make the cut.

Move the selector to "HOLD" whenever you wish

to stop saw head movement.

Full Cycle (Automatic) Operation

1. Use the above "Manual Operation" instructions to
position and clamp the stock.

2. Place the Saw Head Control selector switch at
"HOLD" and move the Operation selector switch
to "AUTO".

3. Push the Band/Cycle Start pushbutton. Next:

(a) Move the Saw Head Control selector switch

to "DOWN/AUTO"; (b) Adjust the Feed Rate knob
as necessary as the saw head starts downward to
make the cut.

4. After the saw head has completed the cut, the band
drive motor will shut off and the saw head will raise
to the position determined by the stop pin.

During automatic operation, the cut may be

interrupted if necessary by moving the Saw
Head Control selector switch to the "HOLD"
or "UP" setting.

5. The operator can now remove the cut-off piece and
position the stock for another cut.

6. After clamping the stock between the vise jaws,
push the Band/CycleStart pushbutton. The next
cut will now be made. This procedure may be
followed as many times as needed.

15

LUBRICATION

LUBRICATION CHART

LUBRICATION

POINT NO.

1

2

3

4

5

6

7

8

9

LOCATION DESCRIPTION and

SERVICE RECOMMENDATIONS

Band Tension Screw. Clean and apply grease. MONTHLY

Vise Clamp Screw. Clean and apply grease. MONTHLY

Drive Motor Slide. Clean and apply grease. 3 MONTHS

Head Feed Cylinder. 1 pint (0.47 liter) capacity. Check oil

level if head fall rate is not uniform. Add oil if necessary.

Saw Guide Arm Slide. Clean and apply oil. MONTHLY

Head Pivot Shaft Bearing Surfaces. Apply oil. MONTHLY

Micellaneous: Vise Slide, Hinges, Pivot Points, etc. Clean

and apply oil.

Head Swivel Shaft Bearing Surfaces. Apply oil. . MONTHLY

Electric Motor. Drive. Lubricate (if any) per manufacturer's recommendations.

LUBRICATION

INTERVAL*

CHECK 6

MONTHS/

CHANGE

YEARLY

3 MONTHS

RECOMMENDED

LUBRICANT

Premium quality, multi-purpose lithium­base, EP (extreme pressure) grease.

NLGI No. 2.

Union 76, UNOBA EP 2, or equivalent.

Multi-purpose automatic transmission

uid.

General Motors Dexron III, or equivalent.

High quality, rust and oxidation-inhibited,
medium hydraulic and general purpose
industrial oil.

ISO-VG Grade 68 (Formerly ASTM
Grade No. 315).

Union 76, UNAX RX 68, or equivalent.

10

11

Coolant Reservoir. Nine (9) gallon (34.1 liter) capacity.

Drain, clean and rell as necessary.

Band Mist Lubricator (Optional). Sixteen (16) ounces (0.95

liter) capacity. Keep lled and hoses clear.

Premium quality, saw band coolant and

AS REQUIRED

CHECK DAILY/

AS REQUIRED

Lubrication intervals are based on a 8-hour day, 40-hour week.

*

Lubricate more often with heavier use.

lubricant.

DoALL cutting uids and/or oils (Kool

ALL concentrate).

Contact your DoALL sales representative
for the best oils or uids for your

application.

DoALL cutting uids or oils (AL-2000).

16

LUBRICATION DIAGRAM

FRONT VIEW

SIDE VIEW

17

MAINTENANCE

SAW GUIDE INSERT REPLACEMENT

1. The saw band should be removed to replace the
saw guide inserts. See the "OPERATION" section
for saw band removal procedures.

2. Remove the adjusting screw holding the spring
washer housing and movable insert. Then: (a)
Insert a screwdriver through the adjusting screw
hole until it disengages the fixed insert screw
slot; (b) Remove the xed insert; (c) Remove the
shoulder screw located above the adjusting screw
on the saw guide arm; (d) Remove the two (2) ball
bearings from their seat.

DRIVE BELT REMOVAL OR REPLACEMENT

1. To install or remove the band drive belt, turn the
disconnect switch to "OFF". Then: (a) Turn the
band speed handwheel clockwise as far as
possible; (b) Take off the drive cover by removing
the screws holding it to the cover's back-up plate.

2. Slip the old drive belt from around the driven pulley,
then from around the variable speed pulley. Next:

(a) Carefully place a new drive belt into the drive

pulley groove; (b) Pull the belt around and into the
variable speed pulley groove.

3. Check the new belt's tracking in the pulley grooves

by turning the band speed handwheel slowly
counterclockwise. If tracking is correct, replace

the drive cover.

BAND TENSION ADJUSTMENT

1. Tension adjustment of the saw band will be
necessary from time to time. Adjustment is made
by turning the upper handwheel extending from the
machine's left side.

Saw Guide Detail.

3. Thoroughly clean the saw guide body and insert
areas.

4. Inspect the roller bearing's two (2) useable wear
surfaces. If the surface last used is worn: (a)
Reinsert the bearing into the saw guide with the
unworn surface exposed to the back of the saw
band; (b) Reinstall the two (2) ball bearings; (c)
Reinsert the shoulder screw.

5. Install new xed and movable inserts if worn.

6. To reassmble: (a) Install the xed and movable
inserts, plus spring washer housing; (b) Tighten the
adjusting screw until its tight (do not over tighten);

(c) Place the saw band between the inserts and

follow the saw band installation procedures covered
in the "OPERATION" section; (d) Turn each
adjustment screw back counterclockwise 1/4 to

1/2 turn.

2. Correct band tension will stress a high-speed
steel saw band to 30,000 psi (2100 kg/cm²). This

is comparable to a DoALL Tensigage reading

of 27,000 to 30,000 psi (1900 to 2100 kg/cm²) .

Refer also to the band tensioning portion of the
"Operation" section of this manual.

Using a DoALL Tensigage to Measure Band Tension.

COOLANT SYSTEM

1. Check the coolant often for signs of contamination

or breakdown. Drain the entire system and clean
it thoroughly when coolant becomes unsuitable for
further use.

18

COOLANT SYSTEM (Continued....)

2. Empty the reservoir periodically and clean the
coolant screens.

3. Flush the entire coolant system with DoALL's "Kleen
Flush" when changing types of coolant used.

2. A small shovel or rake can be used to remove
chip accumulations and other materials from the
machine's operating areas.

3. Use the optional Flushing Hose to remove
accumulated chips or other materials from the
machine's operating areas.

CHIP REMOVAL

Band Brush

1. The band chip brush should be positioned so that its
bristles remove all metal chips from the blade tooth
gullets, but do not touch the bottom of the gullets.
Replace the brush if its bristles become too worn
for proper blade cleaning. DoALL replacement

chip brushes are recommended.

2. To replace the brush or adjust it to a new position:
(a) Loosen the bracket screws; (b) Replace the
brush or move the unit toward the saw band; (c)
Tighten the bracket.

Be sure the band drive motor and the saw
band are STOPPED completely before
cleaning the machine.

REPLACING VISE BED WEAR PLATES

1. The machine's vise bed is covered by two (2)
steel plates. These must be replaced before their
mounting screw heads become worn and damaged

(making removal difcult).

2. The movable vise jaw assembly must be removed
before the vise bed wear plates can be replaced.

BANDWHEELS

1. Remove the bandwheels every six (6) months to
clean them and the surrounding machine areas.

2. Occasionally check each bandwheel's back-up

ange and wheel tread for wear. Saw bands will not

track properly if the wheel tread's taper is worn.

Band Brush.

Reservoir Chip Collection Tray

1. Most metal chips removed from the saw band and
from the stock drop onto the base pan and into the
reservoir collection tray at the machine's lower right
side.

2. Remove this tray often to dispose of collected chips.

Clean the coolant screens before reinserting the

tray.

Machine Cleaning

1. During the sawing process, metal chips will
accumulate below the band brush. These
accumulations can affect machine performance
and accuracy and should be removed as often as
possible. DoALL recommends removing chips

at least twice per each eight (8) hour shift; more
often with heavier use.

Bandwheel Flange and Tread.

HEAD FEED CYLINDER

1. Oil replenishment and/or air bleeding may be

necessary over a period of time (such as replacement
of the cylinder). This can be accomplished without
removing the cylinder from the machine. Follow
these procedures:

• Raise the saw head enough to remove the pipe plug
from the cylinder's top end cap. Then: (a) Return
the saw head to the down position; (b) Slowly

pour hydraulic oil (see the Lubrication Chart for
recommended oils) into the open port until overow

occurs; (c) Replace the pipe plug and turn the Feed
Rate knob counterclockwise to the maximum.

19

HEAD FEED CYLINDER (Continued....)

• Raise and lower the saw head to its maximum limits
several times. Then: (a) Once more remove the
pipe plug; (b) Slowly pour hydraulic oil into the

open port until overow occurs (this should be done

with the piston rod fully retracted); (c) Repeat this
process several times, if necessary, to purge excess
air from the cylinder.

• With the Feed Rate valve shut off, the piston should

not sag more than 1/4 inch (6.3 mm) when the

handwheel is released after full saw head raise
and full extension of the head feed cylinder piston
rod (measure the sag or piston rod retraction at the
piston rod).

COUNTERBALANCE SPRING

1. After a period of time, the saw head may not cut
through the stock or cuts too far into the receiving
tray. To adjust, follow these procedures:

• There is no need to remove the counterbalance
spring from the machine. (a) Loosen the threaded
collar from the lower hex nut; (b) Adjust the lower
hex nut up or down until the saw band teeth are
approximately 0.06 inch (1.6 mm) below the work
surface; (c) Turn the threaded collar down tightly
on top of the hex nut and secure it.

Be sure the saw head falls only enough to cut

completely through the work. TOO LITTLE
head fall will result in an incomplete cut
through the workpiece.

ELECTRIC MOTORS

1. Follow the manufacturer's maintenance instructions
for each electric motor. These instructions are
located in the pocket inside the main electrical
enclosure.

BAND MIST LUBRICATOR

1. See the instructions sent with the unit for information
on maintenance and adjustments. They are located
in the pocket inside the main electrical enclosure.

Counterbalance Spring.

20

TROUBLE SHOOTING

Repair and adjustment procedures should

be made only by experienced maintenance

personnel, or by a DoALL service
representative. Reference to the machine's

electricalandhydraulic/pneumaticschematics

may be helpful.

MACHINE WON'T START

1. Check that the disconnect switch is in the "ON"

position.

2. Make sure both bandwheel doors are closed.

3. The Band/CycleStoppushbutton needs to be reset
(rotate the button head clockwise).

4. Circuit breakers or motor starter protectors have

tripped. Wait several minutes for them to cool, then
reset.

5. Check for broken belts and/or mechanical

jamming.

6. Raise the saw head off the head down limit switch
(1 LS).

7. Check for a burned out band drive motor.

5. Coolant is not being supplied evenly to both sides

of the saw band.

6. Stock is crooked. This usually results in straight,
but not square cuts.

7. Decrease the distance between the saw guide arms.
Move the left arm as close as possible to the stock
being cut.

8. Check for incorrect blade pitch being used.

9. Band tension is incorrect.

10. Check for incorrectly adjusted saw guide inserts

and back-up bearing.

11. Check for machine misalignment (have a DoALL
service representative check and/or adjust machine

alignment.

12. Tighten the head swivel lock.

13. Make sure the optional workstop is set at desired
scale setting.

VERTICAL CUT INACCURACY (Cut pieces are
thicker at the top or bottom)

8. Check the incoming leads, wiring, and control circuit

breaker for possible malfuction.

SAW BAND RUNS IN WRONG DIRECTION

1. Switch the incoming electrical starter lines.

MACHINE STARTS, BUT WON'T CONTINUE
RUNNING

1. Check for defective band drive motor contactor in

the electrical control box.

INACCURATE CUT-OFF

1. Saw band teeth are dull or worn.

2. The chip brush needs adjustment or replacement.

3. Increase the band speed or decrease the feed
rate.

4. Check for dirty coolant. Replace if necessary.

1. Check for loose or worn saw guide inserts. Tighten

the inserts if loose, replace inserts if worn.

2. Reduce the feed rate being used.

3. Check for crooked stockand/or incorrect stock

positioning between the vise jaws.

4. Move the left saw guide arm closer to the stock.

5. Check for incorrect band tension adjustment.

6. Check for a worn saw band.

7. Check for saw head vertical misalignment . Have a
DoALL service representative check and/or adjust

saw head alignment.

HORIZONTAL CUT INACCURACY (Cut pieces
are thicker on one side)

1. Check for loose or worn saw guide inserts. Tighten

the inserts if loose, replace inserts if worn.

2. Check for crooked stockand/or incorrect stock

positioning between the vise jaws.

21

TROUBLE SHOOTING (Continued....)

BAND TOOTH GULLETS LOADING

3. Check for machine misalignment . Have a DoALL
service representative check and/or adjust machine

alignment.

BAND TEETH STRIPPING

1. Increase the band speed or decrease the feed
rate.

2. Check for chip welding, or for a chipped blade tooth

lodged in the cut.

3. Check for faulty stock: heavy scale, inclusions, hard

spots, etc.

4. Band brush needs adjustment or replacement.

5. Blade pitch is too course if a thin stock section is
being cut.

6. Check for vibration caused by stock not being held
rmly between the vise jaws.

7. Check for worn saw guide inserts and/or back-up

bearing.

1. Use a courser pitch saw band.

2. Increase the band speed or decrease the feed
rate.

3. Band brush needs adjustment or replacement.

4. Check for incorrect coolant application.

5. Check for incorrect band tension adjustment.

PREMATURE BAND TEETH DULLING

1. Band speed and/or feed rate is too high.

2. Check for faulty stock: heavy scale, inclusions, hard

spots,etc.

3. Stock analysis is incorrect. This can result in the
wrong initial cutting recommendations.

4. Check for coolant not covering the saw band

completely.

5. Check for saw band vibration or chip welding.

8. Coolant is not adequately covering both sides of

the saw band.

9. Check for incorrect band tension.

10. Check for an improperly adjusted saw head

counterbalance spring.

PREMATURE SAW BAND BREAKAGE

1. Check for a poor weld in the saw band, or for

incorrect band tension.

2. Saw band is being dropped into the stock. Make
an adjustment with the Feed Rate Control.

3. Increase the band speed and/or decrease the feed

rate.

4. Stock is not being held rmly between the vise

jaws.

5. Check for improper adjustment of the saw guide

inserts and back-up bearing.

6. Install a ner pitch saw band.

7. Increase the coolant volume being supplied.

6. Check for a chipped blade tooth lodged in the cut.

7. Incorrect saw band is being used.

8. Check for incorrect band tension adjustment.

9. Incorrect coolant is being used, or the mixture is
too weak.

10. Decrease the feed rate during the rst few cuts to

break-in the saw band if new.

SAW BAND STALLS DURING A CUT

1. Decrease the feed rate or increase the band
speed.

2. Check for incorrect band tension adjustment.

3. Use a ner pitch blade -- at least three (3) teeth

should be in the stock at all times.

4. Check for a worn or slipping drive motor belt.

SAW BAND VIBRATION (While Sawing)

1. Check for incorrect blade pitch choice.

2. Band speed being used is incorrect.

3. Check for a loose left saw guide arm.

22

TROUBLE SHOOTING (Continued....)

5. Band tension setting is incorrect.

4. Coolant choice is incorrect, or the mixture is too

weak.

5. Make a feed rate adjustment.

6. Stock is not held rmly between the vise jaws.

7. Check for worn or improperly adjusted saw guide

inserts.

8. Check for a worn saw guide back-up bearing.

9. Check for a dull or damaged saw band.

10. Check for incorrect band tension adjustment.

SAW BAND NOT RUNNING TRUE AGAINST
SAW GUIDE BACK-UP BEARINGS (Vibration
may result)

1. Check for chipped or worn back-up bearings.

Replace if chipped or worn more than 0.020-inch
(0.5 mm).

6. Increase the band speed or decrease the feed
rate.

7. Check for incorrect coolant type being used.

CUTTING RATE IS TOO SLOW

1. Use a courser pitch saw blade.

2. Increase the band speed or feed rate.

NO COOLANT FLOW

1. Check for low coolant level in the reservoir.

2. Remove the coolant volume control valve and hose.
Then use an air hose to clean out both units.

3. Clean the coolant pump intake screen.

4. Check for coolant pump failure.

5. Check for a faulty coolant pump circuit breaker.

2. Check for loose saw guide arms, or arms are not

located close enough to the stock.

3. Check machine alignment (Call a DoALL service

representative).

HIGH FREQUENCY SQUEAL DEVELOPS
WHILE SAWING

1. Increase the feed rate (rate being used is not
compatible with th size or type of material being
cut).

2. Increase the coolant volume.

3. Use a courser pitch saw band.

4. Reduce or vary the band speed.

5. Check the band tension setting.

CUT-OFF PIECE SURFACE FINISH IS TOO
ROUGH

SAW HEAD WILL NOT RAISE, OR RAISES
SLOWLY

1. Check for mechanical obstructions.

2. Check for low air system pressure. Pressure should

be between 85 - 90 psi (5.8 - 6.2 bar or 6.0 - 6.3

kg/cm²).

SAW HEAD WON'T LOWER

1. The feed rate is too low.

2. Check for saw head obstructions.

SAW HEAD LOWERS ERRATICALLY

1. Check for mechanical obstruction or binding.

2. Check for worn or damaged head feed cylinder or

head feed valve.

3. Check for air in the head feed cylinder.

1. Check for machine or saw band vibration.

2. Check for a dull or damaged saw band.

3. Use a ner pitch saw blade.

4. Check for worn saw guide back-up bearings.

Replace if necessary.

SAW HEAD DROPS SLOWLY WHEN MACHINE
IS SHUT OFF

1. Check for a worn head feed cylinder.

2. Check for faulty head feed control valve leakage.

23

TROUBLE SHOOTING (Continued....)

INCOMPLETE CUT

1. Clear away build-up of chips or other debris on the

vise bed (check also for build-up below the saw
guides).

2. Check the counterbalance spring adjustment.

24

ACCESSORIES

ROLLER STOCK CONVEYORS

1. Your machine may be equipped with one of the
following roller stock conveyors for moving long
stock into cutting position (or as a staging table).

• The following conveyors are available: Five (5) feet
or ten (10) (1524.0 mm or 3048.0 mm) long by 20
inches (508.0 mm) wide with a weight capacity of
750 pounds (340.2 kg) per roller.

Vertical Guide Roller.

Roller Stock Conveyor.

2. To install a stock conveyor: (a) Position conveyor
behind the machine base; (b) Adjust the conveyor
to the machine with the leveling screws on the
conveyor legs. The forward conveyor roller should
be inline to 0.010-inch (0.25 mm) above the vise
bed wear plate. The remaining rollers should be
within 0.010 inch (0.25 mm) per 24 inches (609.6
mm) of travel.

3. To add or remove a roller, depress the shaft of the
roller for ease of installation or removal.

 Anchor the conveyor to the oor after all

leveling and adjustments are made.

VERTICAL GUIDE ROLLERS

1. Vertical guide rollers are effectively used to help
maintain correct positioning of long stock on the
conveyor.

2. These can be installed either on the front or rear
of a conveyor or between conveyors (if more than
one is supplied).

PNEUMATIC HEAD LIFT

1. This option includes an air cylinder with all of
the necessary mounting hardware and controls.
The cylinder mounts on machine base and head
beam.

Pneumatic Head Lift Option.

2. Plant air supply is connected to the air lter under
the base pan on the right side of the machine. Plant
air supply should be 80 to 90 psi (5.6 to 6.3 kg/cm²)

to operate this option.

25

PNEUMATIC HEAD LIFT (Continued....)

 DO NOT exceed 90 psi (6.3 kg/cm²)  air

pressure.

3. When this option is supplied, a pushbutton control

appears on the hydraulic/pneumatic control panel.
Push the Head Up button to raise the saw head

after completion of a cut.

4. A ow control valve located on the bottom port of

the air cylinder regulates the saw head up speed.
Turn the adjusting screw counterclockwise to

"INCREASE" the head up speed, clockwise to
"DECREASE" it.

Pneumatic Vise Option.

5. An approximate saw head raise time of one (1)
to two (2) seconds is desirable (with a gentle
cushioned effect at maximum head up position).

Individual machines may require slightly

different adjustment to obtain the desired
cushioned effect.

6. To adjust the speed at which the saw head raises:

(a) Turn the adjusting screw on the ow control valve

of the air cylinder clockwise to close the valve
completely, then give it one (1) counterclockwise
turn; (b) With incoming pressure at 85 psi (6.0
kg/cm²), push the Head Up button on the control
panel; (c) If the saw head raises too slowly, give the
adjusting screw counterclockwise turns in 1/4 turn
increments.

7. Raise the saw head after each 1/4 turn until the

desired head raise time and cushioned effect is
achieved.

 Theowcontrolvalvemustnotbeadjusted

so far counterclockwise that the cushioned

effect at the maximum head up position is

eliminated.

8. If this option is not factory installed, follow the above
adjustment procedures when raising the saw head

for the rst time.

PNEUMATIC VISE

1. This option includes an air cylinder with all of the
necessary mounting hardware and controls. The
cylinder mounts to the vise base weldment and
connected to the vise rack.

2. Plant air supply is connected to the air lter under
the base pan on the right side of the machine. Plant
air supply should be 80 to 90 psi ( 5.6 to 6.3 kg/cm²)

to operate this option.

 DO NOT exceed 90 psi (6.3 kg/cm²) air

pressure.

3. When this option is supplied, a pushbutton control

appears on the hydraulic/pneumatic control panel

and air regulator mounted on the base pan to the
right of the electrical control box.

4. Vise. This pushbutton operator is operated by
pulling the button head out to "OPEN" the movable

vise jaw. Push the button head in to "CLAMP" the

vise.

5. Air Regulator (Variable Vise Pressure). Use
this control to regulate vise clamping force against
materials which cannot tolerate full vise clamping
pressure such as thin-walled tubing, pipe, light
structurals, etc. To operate: (a) Pull the knob up;
(b) Turn the knob clockwise to "INCREASE" vise
pressure, counterclockwise to "DECREASE" it;
(c) Make sure the knob is down when adjustments

are nished.

FULL CYCLE OPTION

1. This option allows the operator to select between
manual and automatic operations of a cutting cycle.
This option includes the Pneumatic Head Lift and
Pneumatic Vise options described previously.

2. Plant air supply is connected to the air lter under
the base pan on the right side of the machine. Plant

air supply should be 80 to 90 psi (5.5 to 6.2 bar or

5.6 to 6.3 kg/cm²) to operate this option.

 DO NOT exceed 90 psi (6.3 kg/cm²) air

pressure.

26

FULL CYCLE OPTION (Continued....)

WORKSTOP

3. When this option is supplied, two selector switches
appears on the electrical control panel and a

pushbutton control on the hydraulic/pneumatic

control panel.

Electrical Control Panel

1. Saw Head Control. This selector switch has

"UP", "HOLD" and "DOWN/AUTO" settings. Move
the selector switch to "UP" to raise the saw head;
"HOLD" to stops the saw head at any position. The
"DOWN/AUTO" setting is used to lower the saw

head and to allow operation in the automatic full
cycle mode.

2. Operation. This selector switch allows the operator

to choose between "MANUAL" or "AUTO" machine
operation. Turn the selector to "MANUAL" for
normal operation; "AUTO" for automatic operation

of the full cycle.

3. See the "OPERATION" chapter under the "Full
Cycle Sawing Operation" heading for step by step
procedures for cutting in the Full Cyle mode.

BAND MIST LUBRICATOR

1. See the instructions sent with the unit for information
on operation and adjustments.

2. Plant air supply is connected to the air lter under
the base pan on the right side of the machine. Plant
air supply should be 80 to 90 psi (5.6 to 6.3 kg/cm²)

to operate this option.

 DO NOT exceed 90 psi (6.3 kg/cm²) air

pressure.

FLUSHING HOSE

1. The ushing hose attaches to the coolant pump
and delivers cutting uid through a hand nozzle. It

is used primarily for machine cleaning purposes.

1. This option, used with the optional large discharge
tray only, proves helpful when several cuts of the
same identical length are required. The workstop
attaches to the edge of the discharge tray. A scale
is mounted to the tray to adjust for lengths from 0
to 18 inches (0 to 455 mm).

Workstop.

2. The workstop slides along the edge of the discharge
tray, then is secured at the desired length indicated
by a locking knob. The distance is indicated by a
scale with an attached pointer. The slide bar also
pivots so the stop bar can be positioned to contact
the stock at various heights. When not in use, the
stop bar can be positioned so it does not interfere
with stock movement, or can easily removed from
the tray.

3. To position stock with the workstop for a cut: (a)
Move the workstop along the discharge tray edge
until the distance between the lowered saw band
and lowered stop bar is indicated on the scale; (b)
Tighten the locking knob to secure the stop bar;
(c) Move the stock to be cut through the opened
vise jaws until the stock contacts the lowered stop
bar; (d) Clamp the vise jaws; (e) Proceed with the
cutting operations.

WORKLIGHT

LARGE DISCHARGE TRAY

1. This 24 inch (609.4 mm) long tray attaches to the
outboard side of the saw band and is used as a
helpful work area to catch cut parts, to inspect or
clean parts and return coolant to the base pan.

2. This discharge tray replace can the standard 17.00
by 5.00 inch (431.8 mm by 127.0 mm) discharge
tray.

3. This option will accept the optional workstop.

1. The worklight illuminates the cutting area for better

visibility and safety. It has its own "ON-OFF" switch

mounted on the light.

27

LASER LINE GENERATOR

To avoid eye damage, DO NOT stare into the

laser beam.

1. A laser devise is used to emit a line on the material
to be cut. This line shows the approximate spot
where the cut will take place.

2. The devise is controlled by a selector switch with

"ON" and "OFF" settings and is located on the control
panel. Turn the laser to "OFF" when not in use.

3. The laser is adjustable to position the laser beam
where desirable.

4. When the laser is turned on, a warm-up period of 3
to 5 seconds takes place before a line appears. If

the line is difcult to see, darken the work area to

enhance the line.

5. Remove the protective shipping cap from the laser
devise before operation.

28