DoAll 500SNC Instruction Manual

500SNC

Serial No: 592-13178 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.

500SNC 592-13178

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 or stamped on a plate 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

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-541.3 (5-13)

i

TABLE OF CONTENTS

MACHINE DIMENSIONS

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

Top View ................................................................. 2

Front View .............................................................. 3

MACHINE FEATURES

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

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

Side View ................................................................ 6

INSTALLATION

Location .................................................................. 7

OSHA Notice!! ........................................................ 7

Unpacking ............................................................... 7

Cleaning ................................................................. 7

Lifting ...................................................................... 7

Floor Installation ..................................................... 7-8

Electrical Installation ............................................... 8

Plant Air Installation ................................................ 8

Preparation for Use ................................................ 8

OPERATION

Safety Precautions ................................................. 9

Using the Saw Band Selector ................................. 9

Cutting Capacity ..................................................... 9

Machine Controls .................................................... 9

Operator Workstation ............................................. 10-14

Saw Band Preparation ............................................ 14-16

Saw Guide Arm Adjustment .................................... 16

Work Height Adjustment ......................................... 16

Saw Head Positioning for Angle Cuts ..................... 16

Flood Coolant System ............................................ 17

Dry Cutting .............................................................. 17

Band Brush and Chip Removal .............................. 17-18

Typical Operation Procedures ................................ 18-19

LUBRICATION

Lubrication Chart .................................................... 20

Lubrication Diagrams .............................................. 21

MAINTENANCE

Saw Guide Insert Replacement .............................. 22

Drive Belt Removal or Replacement ...................... 22

Band Tension Adjustment ....................................... 23

Flood Coolant ......................................................... 23

Chip Removal ......................................................... 23

Replacing Vise Bed Wear Plates ............................ 23

Bandwheels ............................................................ 23-24

Counterbalance Spring ........................................... 24

Electic Motors ......................................................... 24

Mist Lubricator ........................................................ 24

TROUBLE SHOOTING .................................. 25-28

ACCESSORIES

Roller Stock Conveyors .......................................... 29

Vertical Guide Rollers (For Conveyors) .................. 29

Nesting Fixture ....................................................... 29-30

Variable Vise Pressure ........................................... 30

Worklight ................................................................. 30

Laser Line Option ................................................... 30-31

Band Mist Lubricator ............................................... 31

How to read your serial number:

ii

ii

MACHINE DIMENSIONS

Note: Additional space will be
required for conveyors, etc.

INCHES (± .03)

(MILLIMETERS) (± 1 mm)

FLOOR PLAN

1

MACHINE DIMENSIONS (Continued....)

INCHES (± .03)

(MILLIMETERS) (± 1 mm)

TOP VIEW

2

MACHINE DIMENSIONS (Continued....)

INCHES (± .03)

(MILLIMETERS) (± 1 mm)

FRONT VIEW

3

MACHINE FEATURES

FRONT VIEW

4

MACHINE FEATURES (Continued....)

REAR VIEW

5

MACHINE FEATURES (Continued....)

SIDE VIEW

6

INSTALLATION

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

in this manual are as viewed by the operator
when facing the control box and machine
controls.

LOCATION

1. Position 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) Maintenance and
lubrication procedures; (e) Operation of the 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.

OSHA NOTICE!!

LIFTING

Never lift the machine by its sawing head.

1. Lift pockets located on the lower portion of the base
weldment are provided for lifting purposes.

2. Use a fork lift truck to lift the machine to its
permanent location. Lifting should be done from
the front and the forks should be a minimum of six

(6) feet (2 meters) long to sufciently support the

machine. Net weight for the standard machine is
approximately 3000 pounds (1360.8 kg). Added
features and options will increase the weight by as
much as 500 pounds (226.8 kg).

The use of an overhead hoist is NOT

recommended.

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

FLOOR INSTALLATION

OSHA Regulation No. 1910.212 (5B).

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

be securely anchored to prevent walking or
moving.

UNPACKING

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

DO NOT remove the red metal bracket holding

the saw head to the vise base until the
machine has been lifted and positioned at its
permanent location.

2. Remove all other protective covers, strapping,
crating, etc. Then: (a) Remove the bolts or screws
attaching the machine to the shipping skid.

3. Inspect the machine for broken or damaged parts.
Refer to this manual's inside front cover for damage
claim procedures.

CLEANING

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

1. Before placing the machine down, install one (1)
M16 leveling screw and nut into each base foot
pad. Then: (a) Adjust the leveling screws to
extend an equal distance through the mounting
pad - approximately one-half inch (12.7 mm); (b)
Tighten the jam nuts. Now lower the machine in
the desired location.

2. Remove the bracket holding the saw head to the
base. Save this bracket for use in case machine

relocation becomes necessary at a future
date.

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

adjust the leveling screws until the vise base wear
plates are level and weight of the machine is
resting evenly on all mounting pads.

4. Adjust the two (2) leveling screws on the right side
of the saw base to raise the machine slightly to
allow coolant to drain towards the open end of the
coolant pan and drop into the reservoir.

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

Machine must rest evenly on all pads.

7

FLOOR INSTALLATION (Continued....)

Relocation Procedures

1. Should machine relocation become necessary at a
later date, it will be extremely important to protect
the frame against undue stress. Before moving,
reinstall the shipping bracket (if supplied) or use
strapping to connecting the saw head to the base.

2. Plant air is connected at the air lter on the lower

base in the rear of the machine. Air pressure should
be in the range of 80 to 90 psi (5.5 to 6.2 bar or 5.6
to 6.3 kg/cm²).

DO NOT exceed 90 psi (6.2 bar or 6.3 kg/

cm²).

PREPARATION FOR USE

2. To move the machine, follow the instructions on
lifting stated previously.

ELECTRICAL INSTALLATION

Electrical installation must be made by

authorized electrical maintenance personnel!

1. Bring the incoming line circuit leads to the
disconnect switch terminals in the electrical control
box enclosure attached to the right side of the
machine base. Refer to the furnished electrical
schematic, if necessary.

2. Turn the electrical supply and machine disconnect
switch to "ON".

See the "Operation" section later in this

manual on how to operate the workstation
controls such as starting the hydraulics,
etc.

3. Start the hydraulics. Then raise the saw head. If
the hydraulic motor rotates correctly, the saw head
will now raise from the full down position.

1. If required, ll the coolant and hydraulic reservoirs
with uid recommended in the Lubrication Chart.

Be sure that all other points listed in the Lubrication

Chart have been checked and/or serviced.

2. Make electrical connections to the machine while
referring to the electrical schematic.

3. All covers and guards must be in place and all doors
must be closed.

DO NOT defeat the purpose of any guard

or safety devise. They are there for YOUR
PROTECTION!

4. The operator must understand the safety rules
and operation of the machine and has read
the instruction manual BEFORE operating the
machine.

4. If the saw head does not raise, it means that the
hydraulic motor’s rotation is reversed (this can

be veried by observing motor rotation). Motor

rotation must be according to the arrow on the
pump body. Hydraulic system operation cannot

be maintained if the saw head is not raised.

5. If hydraulic pump motor rotation is reversed: (a) Turn
the disconnect switch to "OFF" and remove power
at the source of electrical supply; (b) Interchange
two (2) of the L1, L2, or L3 leads to the disconnect
switch; (c) Restore power and perform Step 3
again.

PLANT AIR INSTALLATION

1. Plant air is required to operate the optional mist

lubricator system.

8

OPERATION

SAFETY PRECAUTIONS

Warning Label - READ and UNDERSTAND.

USING THE SAW BAND SELECTOR

1. Refer to the Saw Band Selector label located on
the drive motor cover for information about blade
choice and pitch, and suggested band speed for
stock type and thickness.

Saw Band Selector.

2. For example, to cut low carbon steel which is two
(2) inches (50.8 mm) thick, you would choose a saw
band with 5-8 pitch, and set the band speed for 275
fpm (84 m/min).

CUTTING CAPACITY

1. Your machine is designed to cut retangular stock up
to 14 inches (355.6 mm) high and 20 inches (508.0
mm) wide. It will also cut round stock up to 14.75
inches (374.6 mm) in diameter.

2. With the saw head adjusted for 45° cutting, the
machine will saw retangular stock up to 14 inches
(355.6 mm) high and 13 inches (330.2 mm) wide
and round stock up to 13 inches (330.2 mm) in
diameter.

3. With the saw head adjusted for 60° cutting, the
machine will saw retangular stock up to 14 inches
(355.6 mm) high and 9 inches (330.2 mm) wide
and round stock up to 13 inches (330.2 mm) in
diameter.

4. The index length range is .25 to 40 inches (6.4 to

1016.0 mm) or up to 320 inches (26.67 feet/8128.0
mm) with multiple indexing capability; minimum
indexable stock length is 14 inches (355.6 mm).

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

9

MACHINE CONTROLS

1. All controls for the machine are located on a remote
control console (or a base mounted on the front left

side of the machine). Controls include an Operator
Workstation, Emergency Stop pushbutton and
Hydraulic controls.

1. Feed Force. This valve regulates the amount of
pressure being placed by the saw band against the
workpiece. Turn the knob counterclockwise to
“increase” the pressure; clockwise to “decrease”
it. The valve’s lower locking knob helps maintain
the setting.

2. Feed Rate. This valve regulates the saw head’s
descending rate. Turn the knob counterclockwise
to “increase” the velocity; clockwise to “decrease”
it.

Other Controls

1. A power Disconnect Safety Switch is located on
the front of the electrical box enclosure.

Do not try to open the control box unless this

switch is turned off. Always disconnect power
to the machine before opening the electrical
control box.

Machine Controls.

2. Emergency Stop. Pushing this red mushroom
head button stops all machine motors (band drive,
hydraulic pump) simultaneously. This button must

be released or reset (rotate clockwise) before
the machine can be restarted.

Hydraulic Controls

2. Head Pivot Lock. Located below and to the left
of the pivot weldment, this lock handle is used to
secure the saw head at the desired cutting angle.
Turn the clamping handle counterclockwise to

"UNLOCK" the saw head; turn the clamping handle
clockwise to "LOCK" the saw head in place.

3. Work Height Setting Mechanism. This mechanism
allows the head to rise only high enough to clear
the work being cut. See "Work Height Adjustment"
later in this section.

OPERATOR WORKSTATION

1. There is three (3) main screens that operate the
machine: VIEW, SETUP and JOBS. Each are
described later in this section.

2. Inthe upper left corner on most screens is the Display
window. This window shows messages, prompts
and error messages.

3. There is a set of keys in the upper right corner of
the screen. These keys access the other screens
for more machine controls, parameters and
information.

Hydraulic Controls.

4. Certain keys will allow the operator to enter data

when pressed. A Keypad will appear when one
of these keys are activated and data then can be
entered.

Keypad

1. When the operator presses a key where data may
be entered, a keypad will be displayed.

10

OPERATOR WORKSTATION (Continued....)

View Screen

1. When power is rst turned on, the following screen
appears.

Keypad.

2. Features of the keypad include:

3 Display Window. Located in the upper left corner,

the display shows the values entered.

4. Backspace. Pressing this key will delete the last
entry keyed in.

5. Clear. This will delete the entry in the display.

6. Data Limits. Below the display window will show a
"LOW" and a "HIGH" value. These values are the
low and high limits of the data that can be entered
for that function.

7. 0 - 9, Decimal Point, + / -. These keys are used to
enter values for that function. Enter them in order
including the decimal point.

If you make an error in entering data, just press

the Backspace or Clear key, correct or reenter
you value and then press the OK key.

8. OK. Pressing this key will enter the data into memory
and then will return to the previous screen.

9. Cancel. Pressing this key will bring you back to the
previous screen. No data will be entered.

10. A thru F. These keys are not functional and are
not used.

View Screen.

2. This screen shows a collection of keys to operate
the machine manually and to enter certain data.

For the saw head and vise functions to operate,

the hydraulics MUST be on and the operation
in the MANUAL MODE.

3. Saw Head Up. This key raises the saw head up

until the "SAW HEAD HOLD" key is pressed.

• When in "AUTO MODE", pressing the "SAW HEAD

UP" key will raises the saw head, stop the saw band

and will switch the saw to "MANUAL MODE".

4. Saw Head Hold. This key stops all saw head

movement.

5. Saw Head Down. Press and hold this key to lower

the saw head.

6. Index Vise Clamp. Press this key will close the

index vise.

7. Index Vise Open. Press and hold this key will open

the index vise. Release the key to stop vise jaw
movement.

"Format" is NOT to be changed for any reason.

The "Dec" button should ALWAYS be selected.
Any other selection will cause errors and
undesireable results in setpoint values.

8. Hydraulic Start. Pressing this key starts the

hydraulic pump motor.

9. Hydraulic Stop. This key stops the hydraulic pump

motor.

11

OPERATOR WORKSTATION (Continued....)

10. Indexer Rapid/Creep Speed. This key toggles

between "INDEXER RAPID" or "INDEXER CREEP"
SPEED and is used to increase or decrease the index

rate of travel of the indexer when the "INDEXER
REVERSE" or "INDEXER FORWARD" keys are
activated.

11. Indexer Reverse. Press and hold this key will move
the index vise away from the saw band. Release
the key to stop vise movement. At least one vise
must open for this control to operate.

12. Indexer Forward. Press and hold this key will move
the index vise towards the saw band. Release the
key to stop vise movement. At least one vise must
open for this control to operate.

13. Band Speed. Press this key and the keypad will
appear. Enter the desired band speed and then
press OK. The band speed can be changed at any
time.

• The "ARROW" keys below the "BAND SPEED" key

can be used to adjust the band speed in increments
of 5 fpm or 1 meter/min. depending on the "UNITS"
selection.

14. Manual/Auto Mode. This key shows the current

operating mode of the saw. Press the key will switch

between "AUTO" and "MANUAL" mode.

• In "MANUAL MODE", the saw band will stop and
saw head will remain in the down position at the
end of the cycle.

• In "AUTO MODE", the saw band will stop and saw
head will raise to the up position at the end of the
cycle.

18. Band/Cycle Start. This key will start the band drive
motor.

For the band drive motor to start, the following

MUST be: (a) The hydraulics are on; (b) Both
vises are clamped for auto cycle, or front vise
clamped for manual.

19. Band/Cycle Pause/Resume. After pressing the

"BAND/CYCLE START" key, it changes to "BAND
CYCLE/PAUSE/RESUME" only when in "AUTO
MODE". Pressing this key will stop the cycle when

the index vise reaches the set point position and the
front vise opens to accept the next cut regardless
of where the cycle sequence is at.

• For example, if the operator pressed the key during
cutting portion of the cycle, the machine will continue
through the cycle sequence until the index vise
reaches the set point position, the front vise opens
and then the cycle will stop and the band drive motor
will stop.

• This function is usually done, for example, if the
operator needs to be away from the machine for a
time or the operator desires to check the previous
cut part.

• Pressing "RESUME" and the cycle will continue at

the "paused" point.

20. Band/Cycle Stop. This key will stop the band drive
motor.

Setup Screen

1. This screen shows more machine controls as well as
certain setup parameters for machine operation.

15. Front Vise Clamp. Press this key will close the
front vise.

16. Front Vise Open. Press and hold this key will open
the front vise. Release the key to stop vise jaw
movement. In manual mode, the saw head must
be up to open the vise.

17. Cut Length, Qty, Done. When "JOB MODE RUN
LIST" is selected, these three (3) controls are
display only showing the current job being run. The
operator must go to the JOBS Screen to change
these values.

• When "JOB MODE SINGLE JOB" is selected,
these three (3) controls are active can be changed
if desired.

Setup Screen.

2. Kerf Width. Press this key and the keypad will
appear. Enter the kerf width of the saw band being
used and then press OK.

12

OPERATOR WORKSTATION (Continued....)

3. Nesting Mode On/Off. When the optional Nesting
Fixture is supplied and "NESTING MODE "ON",
there is vise open time delays and "out of stock"
lengths change.

• See the "ACCESSORIES" section of this manual
for information on use of the optional Nesting Vise
Fixture.

4. Cycle Mode Home Front/Rear. This key toggles
between "HOME REAR" and "HOME FRONT" and
is used to select the position the index vise during
"AUTO MODE" cycle.

• "HOME REAR" is the shortest cycle time and is
preferred for most operations when not using the

Nesting Fixture and/or Variable Vise Pressure

options.

• "HOME FRONT" is preferred for most operations
when using the Nesting Fixture and/or Variable

Vise Pressure options. It allows the use of both

vises to provide extra clamping (one vise is always
clamped).

5. Job Mode Single Job/Run List. The operator
selects the type of job to run, a "SINGLE JOB"
in which the operator goes to the VIEW Screen

and enters the data for "CUT LENGTH and

QUANTITY.

• "RUN LIST" allows multiple jobs to be programmed
into a library. The operator must press the "JOBS"
key to access the library.

9. Coolant On With Band. Press this key for the Flood

Coolant to ow through the entire system while the

saw band is running. This is the recommended
setting.

10. Coolant On. This key operates the coolant without
the band drive motor being on and is used mainly

for the use of the ushing hose.

11. Mist Coolant On W/Band (Optional). Pressing
this key activiates the optional Mist Lubricator
solenoid.

12. Worklight (Optional). Press the key turns the
optional Worklight "OFF" and "ON". The key will
highlight when it's on.

13. Band Load %. This displays the percentage of the
band drive motor amperage being used.

14. Fault Code. This displays a code when there is a
fault in the VFD module. Refer to the VFD manual
for more information.

15. Band VFD Fault Reset. When there is a fault in
the VFD module, pressing this key will reset the
module and operation will be allowed to continue.

16. Band Hours. This displays an accumulative total
of hours that the band drive motor have been
running.

17. Index Vise Clamped Delay. Press this key and
the keypad will appear. Enter a time in seconds
allotted for the index vise jaws to clamp before
indexer movement is allowed and then press OK.

• See JOBS Screen later in this manual to create a
library of jobs.

6. Units. This key allows the operator to select between
inches or millimeters (mm) for measurement data.
When switching from one to another, the data is
converted to the new measurement mode.

7. Laser (Optional). Press the key to turn the optional
laser "OFF" and "ON". The key will highlight when
it's on.

• See the "ACCESSORIES" section of this manual
for information on use of the optional Laser Line.

8. Coolant Off. This key turns off both the Flood

Coolant system and the optional Mist Lubricator

system.

18. Front Vise Clamped Delay. Press this key and
the keypad will appear. Enter a time in seconds
allotted for the front vise jaws to clamp before indexer
movement is allowed and then press OK.

19. Machine Hours. This displays an accumulative total
of hours that the hydraulics have been running.

13

OPERATOR WORKSTATION (Continued....)

Help Screen

Jobs Screen

1. The Jobs Screen shows a collection of keys to enter
data for running a series of cuts automatically. The
top row shows a group of keys help accomplish this
task.

• On the SETUP Screen, the "JOB MODE RUN LIST"
must active for this screen to be accessed.

1. This screen shows the operator a series of keys to
help solve common problems that may occur during
operation.

Help Screen.

2. Press the key that matches the problem and then

follow the prompts listed.

Jobs Screen.

2. Clear All Jobs. Pressing this key completely clears
all data on the screen.

3. Reset All Dones. When pressed, all entries in the
dones column are changed to 0 (zero).

4. To enter data in the run list: (a) Press the "#1
LENGTH" key and the keypad will appear; (b) Enter
the desired cut length and then press OK; (c) Press
the "#1 QTY" key and the keypad will appear; (d)
Enter the desired number of cuts and then press
OK.

5. Press the "#2 LENGTH" and proceed as before until
the run list is nished.

Check and make any corrections/additions to

the run list before exiting the JOBS Screen.
Once exited, the jobs programmed in the list
can not be changed while running in "AUTO
MODE".

6. To skip a job or jobs in the list, set the quantities to
0 (zero) on the jobs to be skipped.

7. Operator notes about entering jobs into the list: (a)
The minimum automatic index length is.250 inch
(9.5 mm); (b) The maximum index length that can
be entered is 9999.99 inches or millimeters; (c) The
maximum quantity that can be entered is 999.

PLC Input/Output Screens

1. On the HELP Screen, it shows "PLC INPUTS" and
"PLC OUTPUTS". These screens show different
PLC input and output modules and their status.

These modules are for diagnostics and service only
and needs NO interaction from the operator.

SAW BAND PREPARATION

Recommended Saw Band

1. The machine is shipped with a saw band installed.
The saw band recommended for use with this
machine is 197 inches (5003.8 mm) long, 1-1/4 inch
(31.7 mm) wide, and has a 0.042-inch (1.67 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) A guard mounted between
the lower left saw guide arm and the left bandwheel
door; (c) A guard assembly between the lower
right saw guide arm and the right bandwheel door.

Blade guards (b) and (c) may be removed to help
facilitate saw band changing procedures.

DO NOT defeat the purpose of any guard

or safety devise. They are there for YOUR
PROTECTION!

14

SAW BAND PREPARATION (Continued....)

Saw Guide Insert Adjustment

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

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) Work the
saw band's upper strand through the upper blade
guard above the saw guide arms; (d) Move the saw
band down and under both saw guide arms.

Immediately store or dispose of the old or

broken saw band. If possible, recoil the saw
band into the original holder before scrapping
it.

Saw Band Installation

Always use extreme care when handling saw

bands. Wear gloves.

1. Remove the old or broken 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.

Saw Guide Detail.

2. Follow these adjustment procedures: (a) Turn the
adjustment screw clockwise until the xed and the
movable inserts are tight against the saw band (do
not tighten further); (b) Turn the adjustment screw
back counterclockwise a 1/4 turn.

Saw Band Removal

Always use extreme care when handling saw

bands. Wear gloves.

1. Press the Band/Cycle Stop key. Then: (a)
Raise the saw head to a position where there is
space under the saw guide arms and clears the
front vise clamp cylinder. (b) Turn the head swivel
clamping handle clockwise to "LOCK" the saw
head in place; (c) Turn the band tension handwheel
counterclockwise (this moves the idler bandwheel
to the right and loosens band tension).

2. Open the right and left bandwheel doors. Then: (a)
Remove or reposition the band brush, if necessary;
(b) Loosen and remove the right and left blade
guards; (c) Loosen the saw guide inserts by turning
both adjustment screws counterclockwise.

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

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) Remove
the new saw band's protective cap; (b) Turn the saw
guide insert adjustment screws clockwise until tight
(do not over tighten); (c) Turn each adjustment
screw back counterclockwise a 1/4 turn.(d)
Reposition or mount the band brush and reinstall
both blade guards; (e) Close both bandwheel
doors.

Band Tension Handwheel

1. Band tension is applied by turning the handle which
protrudes from the saw head's right side. Turn the
handwheel clockwise to "increase" band tension;
counterclockwise to "decrease" it.

15

SAW BAND PREPARATION (Continued....)

Turn Handle to Set Band Tension.

2. Correct band tension for the machine's standard 1-

1/4 inch (31.7 mm) wide by 0.042-inch (1.067 mm)
gage saw band is 4.0 units or 30,000 psi (2115 kg/
cm²) measured by a DoALL Tensigage. This tension
setting is established when the factory 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
(2115 kg/cm²).

WORK HEIGHT ADJUSTMENT

1. The work height mechanism works in conjunction
with the head clear proximity switch (1 PRS) to

assure that the saw head has raised sufciently

above the stock so manual stock positioning can
be accomplished safely.

DO NOT start the band drive motor unless the

saw band has been properly tensioned.

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.

SAW GUIDE ARM ADJUSTMENT

1. From the rear of the machine, the right saw guide

arm is xed. The left saw guide arm can be adjusted

as follows to accommodate varying stock widths: (a)
Loosen the left 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 without making
contact with the stock when the head is raised or
lowered; (d) Turn the locking knob clockwise to
tighten; (e) Tighten the insert adjustment screw as
previously instructed.

DO NOT move the left saw guide arm while

the saw band is running.

Work Height Adjustment.

2. To adjust, lower the saw head all the way. Then:
(a) Loosen the lock knob; (b) Rotate the adjustment

ag to the desired work height indicated with the

pointer; (c) Tighten the lock knob.

3. There is a convenient metric equivalent chart for
converting the work height to millimeters.

SAW HEAD POSITIONING FOR ANGLE CUTS

1. To position the saw head for angle cutting from 0° to
60°: (a) Loosen the head swivel clamping handle,
located below the pivot weldment, by turning it
counterclockwise; (b) Pivot the saw head to the
desired angle as indicated by the pointer located
below the handle; (c) Turn the handle clockwise

to "LOCK" the saw head in place.

The capacities of the machine are reduced

when angle cutting.

2. The 0° and 60° 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 front of the pivot weldment.

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

16

FLOOD COOLANT SYSTEM

1. The ood coolant system applies coolant through

the saw giude insert area to deliver coolant at the
point of cut. On the SETUP Screen of the operator
workstation are a set of keys to select between

the Flood Coolant system and the optional Mist

Lubrication system.

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 may
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.

Coolant Pump and Reservoir.

3. Coolant reservoir capacity is nine (9) gallons (34.0

liters). The pump will not operate correctly unless
the filter element is completely submerged in
coolant.

Flushing Hose

1. Part of the Flood Coolant System, the ushing hose

is attached to the coolant pump and delivers cutting

uid through a hand nozzle. It is used primarily for

machine cleaning purposes.

• Using more than one coolant variety may provide
maximum sawing results and economy. Always
follow the coolant manufacturer's instructions.

Coolant Application

1. Coolant is supplied by means of a reservoir and

pump to the cutting area through the saw guide
inserts on the saw guide arm. A valve on each saw

guide arm regulates the ow to the saw guides.

Turn the valve counterclockwise until coolant
completely covers both sides of the saw band.

2. Used coolant ows back to the reservoir through

the open end of the coolant pan. The reservoir has

a lift-off top access the ltering screen that strains

the coolant to remove metal particles and other
impurities.

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. However, dry

cutting will reduce saw band life.

BAND BRUSH AND CHIP REMOVAL

Band Brush

1. A band brush removes metal particles from the
saw blade teeth. The band brush is located
inside the right bandwheel door and powered by
the bandwheel. 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 clean chips from the blade teeth
gullets, but do not contact the bottom of the gullets;
(c) Retightening the bracket bolts.

17

BAND BRUSH AND CHIP REMOVAL

(Continued....)

NEVER adjust the band brush while the

saw band is running or allow metal chips to
accumulate on the brush.

Chip Removal

1. Metal fragments removed from the band brush and

from the stockpiece drop onto the coolant pan. Chip

collections should be removed from the coolant pan
when necessary.

5. Go to the VIEW Screen and then press the "SAW

HEAD UP" key. Raise the saw head all the way to

the head clear position. The vises now enabled be
opened to its full open position.

6. Press and hold the "INDEX VISE OPEN" key to

open the vise wide enough for stock to be placed
between the jaws. Release the keys to stop vise
movement. Repeat the action for the front vise.

7. Load the stock to be cut onto the indexer roller bed

near the xed vise jaws and manually position for

a crop cut if desired.

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. Remove chip
accumulations at least twice per eight (8) hour shift
and more often with heavier use.

Be sure the band drive motor and the saw band

are STOPPED completely before cleaning the
machine.

TYPICAL OPERATION PROCEDURES

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) Both bandwheel doors are closed;
(d) All guards are in place and/or secured; (e) The
coolant reservoir or the optional Mist Lubricator
reservoir is full and all lubrication points are properly

serviced and if necessary, press the "COOLANT"

key with the desired delivery mode; (f) The band
brush is properly positioned; (g) The work height is
adjusted for material size.

• To move the stock into position for clamping using the
indexer: (a) Press the "INDEXER REVERSE" key to
move the index vise to the rear limit of its travel; (b)

Press the "INDEX VISE CLAMP" key to clamp the

stock; (c) Press the "INDEXER FORWARD" key to
position the stock extending beyond the saw band
and enough stock for the front vise to clamp.

8. On the hydraulic control panel, turn the Feed Rate
control fully clockwise to stop the feed.

DO NOT over tighten. To prevent damage to

the Feed Rate valve, turn only enough to seat
the needle of the valve.

9. Press the "FRONT VISE CLAMP" key to clamp the

stock. Then: (a) Press the "SAW HEAD DOWN"
key and release the "SAW HEAD DOWN" key when
the saw band is just above the stock to be cut; (b)

Press the "BAND SPEED" key and enter the desired

speed and press OK.

10. Press the "BAND/CYCLE START" key. As the saw

band drive comes up to speed and coolant begins to

ow, the saw head will descend when the operator

adjusts the Feed Rate control counterclockwise
to begin saw head feed.

Manual Operation

1. On the VIEW screen, make sure the "MANUAL
MODE" key is activated.

2. Go to the VIEW Screen and then press the

"HYDRAULIC START" key.

3. If desirable, press the "VISE CLAMPED DELAY"

key(s) to change the time delay values, enter the
value for each using the pop-up keypad and then
press OK.

4. Press a "COOLANT" key selection that is correct

for the application.

11. The operator may adjust band speed, coolant ow,

feed rate, and/or feed force at any time during the
sawing process.

DO NOT remove the cut-off piece until the saw

band has stopped completely.

12. After the cut has been completed, the saw band
will shut off with the saw head in the down position.
Remove the cut-off piece.

14. If more cuts are to be made: (a) Raise the saw
head until the desired saw head height is reached;
(b) Unclamp the vise jaws; (c) Position stock for
another cut; (d) Clamp the vises; (e) Press the

"BAND/CYCLE START" key.

18

TYPICAL OPERATION PROCEDURES

(Continued....)

8. The automatic cycle will continue to cycle until all
programmed jobs have been completed.

Automatic Operation

1. Follow steps 1 through 8 of the "Manual Operation"
section.

2. Go to the SETUP Screen and select either the "JOB
MODE SINGLE JOB" or "JOB MODE RUN LIST".

• If the "SINGLE JOB" mode is selected, go to the
VIEW Screen and enter the cut length and quantity
of parts desired.

• If the "RUN LIST" mode is selected, go to the JOBS
Screen and start entering the cut length and quantity
of parts for each job to be done using the pop-up
keypad. Make sure to press "RESET ALL DONES"
to clear the "DONE" column.

3. Clamp both front and index vises. Both vises must
be clamped for the automatic cycle to operate.

4. Press the "BAND/CYCLE START" key. As the saw

band drive comes up to speed, the index vise jaws
open, the indexer moves to a full forward position
to reset, and then moves back to the set index cut
length and clamps. The saw head will descend
when the operator adjusts the Feed Rate control
counterclockwise to begin saw head feed.

9. When the number of cuts has been reached, the
saw head will move to the head clear position and
the band drive motor will shut off.

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.

5. After the rst cut has been completed: (a) The saw
head will raise just above the material; (b) The xed
vise will open and the index vise moves the material
forward for the next cut; (c) When the forward stop

is reached, the xed vise clamps, the indexer moves

back to the set index cut length and clamps and the
saw head lowers to make the next cut.

6. The operator may adjust band speed, coolant ow,

feed rate, and/or feed force at any time during the
sawing process.

7. There is several ways in which the operator may
interrupt the sawing cycle:

• Pressing the "SAW HEAD UP" key. The saw head

will move to the maximum up position, the saw band
will stop and the saw will go to manual mode.

• Pressing the "BAND/CYCLE STOP" or the "AUTO

MODE" keys. The saw band will stop and puts the
saw into manual mode.

• To continue the auto cycle, the operator presses

the "BAND/CYCLE START" key. The saw band will

start, come up to speed and then the saw head will
descend from where it was paused.

19

LUBRICATION

LUBRICATION CHART

LUBRICATION

POINT NO.

1

2

3

4
5
6

7

8

9

10

11

LOCATION DESCRIPTION and

SERVICE RECOMMENDATIONS

Bandwheel Bearings. One (1) grease tting each bandweel. MONTHLY

Band Tension Screw. Clean and apply grease. MONTHLY

Head Swivel Lock Linkage. Clean and apply lubricant. MONTHLY

Saw Guide Arm Slide. Clean and apply oil. MONTHLY

Head Pivot Shaft Bearing Surfaces. Apply oil. MONTHLY

Saw Guide Adjustment Screws. Clean and apply oil. INSERT CHANGE

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

and apply oil.

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

Coolant Reservoir. Nine (9) gallon (34.0 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.

Hydraulic Reservoir. 15 gallon (56.7 liter; Some machines

had a 12 gallon (45.4 liter) capacity. Check uid level daily
and keep the reservoir full. Drain, change the lter element
and rell after the 1st month; every six (6) months thereafter.

LUBRICATION

INTERVAL*

3 MONTHS

CHECK DAILY

AS REQUIRED

CHECK DAILY/

AS REQUIRED

CHECK DAILY/

AS REQUIRED

RECOMMENDED

LUBRICANT

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

NLGI No. 2.

Union 76, UNOBA EP 2, or equivalent.

High quality, rust and oxidation-inhibited,
anti-seize compound.

LPS Copper Anti-Seize, 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.

Premium quality, saw band coolant and

lubricant.

DoALL cutting uids and/or oils (Kool

All).

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

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

Multi-purpose automatic transmission

uid.

General Motors Dexron III, or equiva­lent.

20

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

*

Lubricate more often with heavier use.

LUBRICATION DIAGRAM

FRONT VIEW

REAR VIEW

21

MAINTENANCE

SAW GUIDE INSERT REPLACEMENT

1. Remove the adjusting screw holding the spring
washer housing and movable insert. Then: (a)
Insert a screwdriver through the adjusting screw

hole until it engages the xed insert screw slot; (b)
Remove the xed insert; (c) Remove the shoulder

screw located above the adjusting screw on the rear
side of saw guide arm; (d) Remove the back-up
bearing from their seat.

DRIVE BELT REMOVAL OR REPLACEMENT

1. To install or remove the band drive belt, turn the
machine off. Then remove the drive cover by
removing the screws holding it to the mounting
plate.

Saw Guide Detail.

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

3. Inspect the back-up bearing's 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 back-up bearings; (c)
Reinsert the shoulder screw.

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

5. To reassmble: (a) Install the xed and movable
inserts, plus spring washer housing; (b) Place
the saw band between the inserts; (c) Turn the
adjusting screws clockwise until tight (do not

overtighten); (d) Turn each adjusting screw back
counterclockwise a 1/4 turn.

6. Replacing the saw guide inserts should be done to
both saw guide arms at the same time.

Replacing Drive Belt.

2. Loosen the screws that hold the drive motor to the
mounting bracket and slide to the left to relax the
tension the drive belt.

3. Stretch the old belt and remove it from the motor
pulley and then the driven pulley. Next: (a) Carefully
place a new drive belt into the motor pulley groove;
(b) Stretch and pull the belt around and into the
driven pulley groove.

4. Slide the drive motor to the right towards the center
of the machine to tension the drive belt. Tighten the
screws to hold in place. For correct tension, there

should be little or no deection at the center span

of the belt.

5. Also check the new belt's tracking in the pulley
grooves by turning the driven pulley slowly
clockwise.

6. If tracking and belt tension is correct, tighten the
screws holding the motor mounting bracket and
then reinstall the drive cover.

22

BAND TENSION ADJUSTMENT

Chip Collection

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.

2. Correct band tension will stress a high-speed steel

saw band to 30,000 psi (2115 kg/cm²). This is
comparable to a Tensigage reading of 4.0 units or
30,000 psi (2115 kg/cm²) measured by a DoALL
Tensigage. Refer also to the band tensioning portion
in the "OPERATION" section of this manual.

FLOOD COOLANT

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.

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

3. Flush the entire coolant system with DoALL's "Kleen
Flush" when changing to a different coolant type.

CHIP REMOVAL

1. Most metal chips removed from the saw band
and from the stock drop onto the coolant pan.

Periodically remove the chips.

Machine Cleaning

1. During the sawing process, the operator should
check often for chip accumulations around such
machine areas as: saw guides, vise bed, vise
jaws, head feed cylinder, bandwheels, etc. These
accumulations can affect machine performance
and accuracy and should be removed from these
areas as often as possible. Removing chips

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

Be sure the band drive motor and the saw band

are STOPPED completely before clean­ing the machine.

REPLACING VISE BED WEAR PLATE

1. The machine's vise bed is covered by three (3) steel
plates which must be replaced before their mounting
screw heads become worn and damaged (making

removal difcult). It can be removed when the vise

jaw is at the maximum open position.

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.

2. To replace the brush or adjust it to a new position:

(a) Loosen the carriage bolts that hold the band

brush to the mounting bracket; (b) Remove the
nut to replace the brush; (c) Place new brushes
and reinstall the nut; (d) Adjust the band brush into
position as described above.

2. Follow these vise bed replacement directions: (a)
Move the vise jaw to its maximum open position; (b)
Remove all wear plate mounting screws; (c) Install
new wear plate and mounting screws.

• The operator will have to remove the larger wear

plate rst to remove the wear plate under the vise

jaws.

BANDWHEELS

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

Band Brush.

Bandwheel Flange and Tread.

23

BANDWHEELS (Continued....)

MIST LUBRICATOR

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.

COUNTERBALANCE SPRING

1. After a period of time, the saw head may not cut
through the stock or cuts too far into the vise bed
wear plates. 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 (1.52 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 MUCH
head fall could result in cutting the vise bed
wear plates too deeply or completely off. TOO
LITTLE head fall will result in an incomplete
cut through the workpiece.

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.

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.

24

TROUBLE SHOOTING

Repair and adjustment procedures should

be made only by experienced maintenance
personnel. Reference to the machine's
electrical and hydraulic schematics will be
helpful.

MACHINE WON'T START

1. Make sure the disconnect switch is turned to
"ON".

2. Make sure that the bandwheel doors are closed.

3. Hydraulics must operating before the band drive
motor can be turned on.

4. Make sure the Emergency Stop pushbutton is reset
(turn the button head clockwise).

5. A circuit breakers has tripped. Flip to "OFF" rst,

then to "ON".

6. Check for broken belts and/or mechanical

jamming.

7. Raise the saw head to deactivate the head down
proximity switch (4 PRS).

8. Check for a burned out band drive motor.

9. Check the incoming leads, fuses, wiring, and control

circuit fuse for possible malfuction.

MACHINE STARTS, BUT WON'T CONTINUE
RUNNING

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. Stock is not being held rmly between the vise

jaws.

11. Check for incorrectly adjusted saw guide inserts

and back-up bearing.

12. Check for machine misalignment (have a service

representative check and/or adjust machine
alignment).

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

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 stock and/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.

1. Check for defective band drive contactor in the

electrical control box.

2. The saw head has not cleared the head down
proximity switch (4 PRS). Move the saw head up.

INACCURATE CUT-OFF

1. Saw band teeth are dull or worn.

2. The band brush needs adjustment or
replacement.

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

4. Check for dirty coolant. Replace if necessary.

5. Coolant is not being supplied evenly to both sides

of the saw band.

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

jaws.

7. Check for a worn saw band.

8. Check for saw head vertical misalignment. Have

a service representative check and/or adjust saw
head alignment.

HORIZONTAL CUT INACCURACY (Cut piece
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 that the saw head angle is at 0° and locked

in place.

25

TROUBLE SHOOTING (Continued....)

inserts and back-up bearing.

3. Check for crooked stock and/or incorrect stock

positioning between the vise jaws.

4. Check for incorrect coolant application.

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

jaws.

6. Check for machine misalignment. Have a

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.

7. Install a ner pitch saw band.

8. Increase the coolant volume being supplied.

BAND TOOTH GULLETS LOADING

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 cutting 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.

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

8. Coolant is not adequately covering both sides of

the saw band.

9. Check for incorrect band tension.

PREMATURE SAW BAND BREAKAGE

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

incorrect band tension.

2. Check for incorrect band tension.

3. Saw band is being dropped into the stock. Make
an adjustment with the Feed Rate control.

4. Increase the band speed and/or decrease the feed
rate.

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

jaws.

6. Check for improper adjustment of the saw guide

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 RUNNING IN THE WRONG

DIRECTION

1. Switch any two (2) of the incoming electrical lines.

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

26

TROUBLE SHOOTING (Continued....)

5. Check the band tension setting.

should be in the stock at all times.

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

5. Excessive coolant are making the bandwheels
slippery.

SAW BAND VIBRATION

1. Check for incorrect blade pitch choice.

2. Band speed being used is incorrect.

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

weak.

4. Make a saw head feed rate adjustment.

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

6. Check for worn or improperly adjusted saw guide

inserts.

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

CUT-OFF PIECE SURFACE FINISH IS TOO
ROUGH

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.

5. Band tension setting is incorrect.

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.

8. Check for a dull or damaged saw band.

9. 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).

2. Check for loose saw guide arm, or arm that is not

located close enough to the stock.

3. Check machine alignment (Calling a service

representative is recommended).

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.

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 (if any).

4. Check for coolant pump failure.

5. Check for a faulty coolant pump circuit.

SAW HEAD WILL NOT RAISE, OR RAISES
SLOWLY

1. Hydraulics must be on and must in the "MANUAL
MODE" setting.

2. Check for faulty Solenoid 1.

3. Check for mechanical obstructions.

4. Check for low hydraulic system pressure. Pressure

should be approximately 450 psi (31.0 bar or 14.1
kg/cm²).

3. Use a courser pitch saw band.

4. Reduce or vary the band speed.

27

TROUBLE SHOOTING (Continued....) INDEX LENGTH PROBLEMS

SAW HEAD WON'T LOWER

1. Hydraulics must be on and must in the "MANUAL
MODE" setting.

2. Check for faulty Solenoid 2.

3. The feed rate is too low.

4. 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.

SAW HEAD DROPS SLOWLY WHEN MACHINE
IS SHUT OFF

1. Check for a worn head feed cylinder.

1. Go to the HELP Screen and press "INDEX LENGTH

PROBLEMS" and follow the prompts if any.

INDEXER WON'T MOVE

1. Hydraulics must be on and must in the "MANUAL
MODE" setting.

2. The out of stock proximity switch (2 PRS or 1 PCS­Nesting option) has been activated.

3. One of the vises must be unclamped before the
indexer will operate.

4. Check for a worn indexer feed cylinder.

4. Check for index vise obstructions.

5. Check for faulty Solenoid 3 and 4.

OUT OF STOCK PROBLEMS

1. Go to the HELP Screen and press "OUT OF STOCK
PROBLEMS" and follow the prompts if any.

2. Check for hydraulic system leaks.

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. Adjust the head down proximity switch (4 PRS).

3. Check the counterbalance spring adjustment.

VISES WON'T CLAMP

1. Hydraulics must be on and the CYCLE MODE must
in the "MANUAL" setting.

2. Saw head not raised high enough.

3. Check for faulty Solenoid 8 and 9 for index vise,
Solenoid 6 and 7 for front vise.

3. Check for a worn vise clamp cylinder.

4. Check for vise obstructions.

5. Check the optional Variable Vise Pressure

settings.

28

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 an unloading add­on). The following conveyors are available:

• Stock conveyor ve (5) feet (1525.0 mm) long by

18 inches (457.2 mm) wide rollers with a weight
capacity of 750 pounds (340.2 kg) per roller.

• Stock conveyor ten (10) feet (3050.0 mm) long by
18 inches (457.2 mm) wide rollers with a weight
capacity of 750 pounds (340.2 kg) per roller.

2. These can be installed between the discharge tray
and conveyor or between conveyors (if more than
one is supplied).

Vertical Guide Roller.

Roller Stock Conveyor.

2. To install a roller stock conveyor: (a) Position
the assembled conveyor(s) behind or in front of
the machine base; (b) Adjust the conveyor to the
machine with the leveling screws on the conveyor
legs. The top of the front conveyor roller should be
inline to 0.010-inch (0.25 mm) above the vise bed
wear plate.

3. The remaining rollers must be parallel to, and in the
same plane with the vise beds to within 0.010-inch
(0.25 mm) per 24 inches (609.6 mm) of travel.

4. Depress the roller shafts for ease of installation or
removal of rollers.

The conveyor DOES NOT attach to the machine

base.Anchortheconveyortotheoorafter

all leveling and adjustments are made.

VERTICAL GUIDE ROLLERS (Conveyors)

NESTING FIXTURE

1. This optional feature is designed for high-production,
multiple sawing of stacked bars, rounds and tubing.
Its jaws have the capacity to hold stock from 1.00
minimum to 19 inches (25.4 to 482.6 mm) wide, and
from 1.00 minimum to 14 inches (25.4 to 355.6 mm)
high.

2. Vertical nesting clamp cylinders are mounted to
the machine’s roller bed rail and index vise. The
cylinders operate simultaneously with the regular
vise clamping cylinders.

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

Nesting Fixture Vise Adjustments.

29

NESTING FIXTURE (Continued....)

3. Additional rollers are added to the roller bed to
accommodate the material. Install rollers in the
empty hex. holes in the roller bed rail by depressing
the roller shaft to slip the rollers in place.

The Nesting Fixture can also be used with the

Variable Vise Pressure control.

4. To prepare the machine and its vises for sawing

with the optional nesting xture:

Stacking Stock

1. Correct stock nesting is essential for proper clamping
of the vises and nesting xture. It is important that

nesting vise clamping pressure be transmitted
to every stacked piece. Sometimes this can be
more easily accomplished by manually jogging the
stack.

• When activated. the machine software switches the
out of stock proximity switch (2 PRS) to the photo
sensors (1 PCS) mounted on the legs of the index

vise nesting xture.

• The minimum index length for the Nesting Fixture
increases to 18.00 inches (457.2 mm).

3. Adjust the nesting vise clamp cylinder by sliding it
along the horizontal support so the clamp bar will
rest at the center of the bundle being cut.

4. Adjust the indexer’s vertical guide rollers (if supplied)
so the stock will be guided correctly toward the saw
band.

5. If the horizontal clamping vises and the vertical

nesting clamp do not release at approximately the
same time: (a) Adjust the hydraulic restrictor valve
at the rod end of the front and/or index vise cylinders
to achieve relatively equal release.

2. Proper stacking of round stock is important because

saw band breakage may occur if round nested pieces
slip or spin during sawing.

3. Two (2) workable round stock stacking methods
are shown in the next illustration. Using the same
number of rounds in each row usually provides
the best sawing results, although the alternate
method can be used if the material is not stacked
too high.

Round Stock Stacking Methods.

4. Pieces should be stacked as closely together

as possible. Metal chips lodged in open spaces
between individual pieces will affect cutting
accuracy.

VARIABLE VISE PRESSURE

1. The Variable Vise Pressure control valves, located

under the cap end of each vise clamping cylinder,
is used to adjust vise clamping force against
materials which cannot tolerate full vise clamping
pressure (examples are thin-walled tubing, pipe,
light structurals, etc.). This control can be used
with or without the optional Nesting Fixture.

2. Clamping pressure is set by loosening the locknut

and turn the adjustment knob until the desired
pressure is shown on the indicator gauge. The
lower the number, the lighter the clamping pressure
and vise versa.

WORKLIGHT

1. The worklight illuminates the cutting area for better
visibility and safety. The devise is controlled on
the SETUP Screen by a key that toggles betwwen
"OFF" and "ON". Turn the worklight "OFF" when
not in use.

Vise Adjustment

1. The vise is controlled on the SETUP Screen by a
key that toggles betwwen "NESTING MODE OFF"
and "NESTING MODE ON".

2. When "NESTING MODE ON" is activated, this allows
a time delay for the nesting clamp bar to clamp the
material. Also, one vise is always clamped to keep
the bundled material in place.

LASER LINE OPTION

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 on the SETUP Screen by
a key that toggles betwwen "OFF" and "ON". Turn
the laser "OFF" when not in use.

30

LASER LINE OPTION (Continued....)

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 and replace the cap when
not in use.

MIST LUBRICATOR

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

2. Shop air is required to operate the optional Band
Mist Lubricator. Incoming air supply should be
between 80 and 90 psi (5.5 and 6.2 bar / 5.6 and

6.3 kg/cm²).

DO NOT exceed 90 psi (6.2 bar / 6.3 kg/cm²).

31