DoAll DC-330NC User Manual

Models:

DC-280NC
DC-330NC
DC-420NC

By

DC-460NC

Instruction Manual

DC-500NC
DC-560NC

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

For your information and future reference, pertinent data concerning your machine
should be written in the spaces provided above. This information is 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

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.

PRINTED IN U.S.A.

PB-560 (10-13)

i

TABLE OF CONTENTS

SAFETY RULES ............................................... 1

MACHINE SPECIFICATIONS .................... 2

MACHINE DIMENSIONS

Installation Dimensions ......................................... 3

DC-280NC Dimensions ........................................ 4

DC-330NC Dimensions ........................................ 5

DC-420NC Dimensions ........................................ 6

DC-460NC Dimensions ........................................ 7

DC-500NC Dimensions ........................................ 8

DC-560NC Dimensions ........................................ 9

MACHINE FEATURES ................................. 10

INSTALLATION

Location ................................................................ 11

OSHA Notice!! ...................................................... 11

Unpacking ............................................................. 11

Lifting .................................................................... 11

Cleaning ............................................................... 12

Floor Installation ................................................... 12

Electrical Installation ............................................. 12-13

Preparation for Use .............................................. 13

OPERATION

Selecting Band Speed and Cutting Rate .............. 14

Control Console .................................................... 15-

Saw Band Preparation .......................................... 15-16

Left Hand Guide Arm Adjustment ......................... 16

Band Speed Adjustments ..................................... 16

Feed Force Adjustments ....................................... 16-17

Saw Head Positioning and Approach ................... 17

Automatic Head Elevation and Sensing Arm ........ 17-18

Stock Indexing Handwheel and Readout ............. 18-19

Minimum Bar End/Split Front Vise ........................ 19

Hydraulic System .................................................. 19

Coolant System .................................................... 19

Chip Removal ....................................................... 19-20

Positioning Stock .................................................. 20-21

Typical Operating Procedures .............................. 21-22

LUBRICATION

Lubrication Chart .................................................. 24

Lubrication Diagrams ............................................ 25

MAINTENANCE

Replacing Saw Guide and Back-Up Inserts ......... 26

Replacing Saw Band Anti-Squeal Rollers ............. 26

Band Drive Belt Replacement .............................. 26

Hydraulic System .................................................. 26-27

Coolant System .................................................... 27

Machine Cleaning ................................................. 27

Machine Alignment ............................................... 27

Band Brush ........................................................... 28

Band Tension Measurement ................................. 28

Wear Plate Replacement ...................................... 28

Band Drive Worm Gear Reducer .......................... 28

Bandwheels .......................................................... 29

Cleaning Chip Box or Chip Conveyor ................... 29

Cut Counter Self-Test ........................................... 29

TROUBLE SHOOTING ................................ 30-33

ACCESSORIES

Roller Stock Conveyor .......................................... 34

Vertical Guide Rollers ........................................... 34

Nesting Fixture ..................................................... 34-35

Vertical Guide Rollers (For Nesting) ..................... 35

Discharge Tray Side Fences ................................ 36

Variable Vise Pressure ......................................... 36

Band Lubricator .................................................... 36

Laser Line Option ................................................. 36

Chip Conveyor ...................................................... 36-37

Band Twist Indicator ............................................. 37-38

Material Handling Equipment ............................... 38

ii

SAFETY RULES

1. CLOTHING. To protect the operator from
entanglement or being pulled by a clamped

vise, the operator should not wear loose tting

clothing or wear gloves while operating the
machine. Wear safety shoes to protect against
foot injury.

2. INSTALLATION. The machine must be properly
grounded to protect against electric shock. Use
durable insulating material to protect power

lines that lie on the oor.

3. DO NOT defeat the purpose of any guards or
any other safety devises. THEY ARE THERE
FOR YOUR PROTECTION!

4. Keep hands away from moving saw band while
the machine is running.

5. If the operator needs to check the interior of the
machine during operation, turn the machine off
and wait until the machine come to a complete
stop.

6. Do not enter the index vise moving area. Lifting
of workpieces to the feeding table is done by
overhead hoist.

14. Periodically perform a machine check before
starting. After completing a job, clean both the
machine and the work area thoroughly.

15. The machine operator must be trained and must
understand the operation, lifting, saw band
replacement and maintenance of the machine.

16. Maintenance personnel must be trained and
knowledgeable of electrical controls systems.

17. This machine is designed to cut steel bars and

proled tubes only. Do not cut food, wood,

plastic, poisonous material, magnesium or
magnesium alloys.

7. Do not touch the circuit breakers, switches or
buttons with wet hands.

8. Turn power off before servicing, cleaning or
maintenance.

9. Wear gloves when replacing the saw band,

removing chips, replacing cutting uid and/or

moving material.

10. Coolant is not edible. If swallowed, immediately
spit it out and rinse the mouth thoroughly.

11. Do not operate, maintain or check the machine
while under the influence of alcohol or
medication.

12. The machine will stop when a door or guard
is opened. Wait until the machine come to a
complete stop before entering the area.

13. Do not stand on the front or rear supporting
rollers.

1

MACHINE SPECIFICATIONS

English Std.

(Metric)

Specication DC-280NC DC-330NC DC-420NC

Cutting
Capacity

Bundle
Cutting

Band Saw Blade

Band Speed

Band Drive Motor 5 HP (3.7 kW) 5 HP (3.7 kW) 7.5 HP (5.5 kW)

Hydraulic Pump Motor 1 HP (.75 kW) 1 HP (.75 kW) 2 HP (1.5 kW)

Coolant Pump Motor

Band Drive Gearbox Capacity 1.2 Gal. (4.5 liters) 1.9 Gal. (7 liters) 3.0 Gal. (11.5 liters)

Hydraulic Tank Capacity 16 Gal. (60 liters) 16 Gal. (60 liters) 22 Gal. (85 liters)

Coolant Tank Capacity 20 Gal. (80 liters) 24 Gal. (90 liters) 26 Gal. (100 liters)

Indexing Length

Net Weight 3859 lbs. (1750 kg) 4410 lbs. (2000 kg) 5402 lbs. (2450 kg)

Rounds

Rectangles
(W x H)

Minimum (W x H)

Maximum (W x H)

Single 15.75 (400 mm) 19.68 (500 mm) 19.68 (500 mm)

Multiple 141.73 (3600 mm) 177.16 (4500 mm) 177.16 (4500 mm)

.38 - 11.00"

(10 mm - 280 mm)

11.75" x 11.00"

(300 mm x 280 mm)

6.50" x .63"

(165 mm x 15 mm)

9.75" x 4.00"

(250 mm x 100 mm)

1.25" x 150"

(32 mm x 3820 mm)

50 - 400 fpm

(15 - 120 m/min.)

1/6 HP (.12 kW) 1/6 HP (.12 kW) 1/4 HP (.2 kW)

.38 - 13.00"

(10 mm - 330 mm)

15.75" x 13.00"

(400 mm x 330mm)

6.50" x 2.00"

(165 mm x 50 mm)

14.50" x 6.63"

(370 mm x 170 mm)

1.25" x 167"

(32 mm x 4242 mm)

50 - 400 fpm

(15 - 120 m/min.)

.38 - 16.50"

(10 mm - 420 mm)

16.50" x 16.50"

(420 mm x 420 mm)

6.50" x 3.25"

(165 mm x 80 mm)

14.50" x 7.88"

(370 mm x 200 mm)

1.50" x 192"

(38 mm x 4880 mm)

50 - 400 fpm

(15 - 120 m/min.)

Specication DC-460NC DC-500NC DC-560NC

Cutting
Capacity

Bundle
Cutting

Band Saw Blade

Band Speed

Band Drive Motor 7.5 HP (5.5 kW) 7.5 HP (5.5 kW) 10 HP (7.5 kW)

Hydraulic Pump Motor 2 HP (1.5 kW) 2 HP (1.5 kW) 3 HP (2.2 kW)

Coolant Pump Motor 1/4 HP (.2 kW) 1/4 HP (.2 kW) 1/4 HP (.2 kW)

Band Drive Gearbox Capacity 4.8 Gal. (18 liters) 6.1 Gal. (23 liters) 7.4 Gal. (28 liters)

Hydraulic Tank Capacity 22 Gal. (85 liters) 22 Gal. (85 liters) 34 Gal. (130 liters)

Coolant Tank Capacity 29 Gal. (110 liters) 29 Gal. (110 liters) 37 Gal. (140 liters)

Indexing Length

Net Weight 6284 lbs. (2850 kg) 6835 lbs. (3100 kg) 9923 lbs. (4500 kg)

Rounds

Rectangles
(W x H)

Minimum (W x H)

Maximum (W x H)

Single 19.68 (500 mm) 19.68 (500 mm) 15.75 (400 mm)

Multiple 177.16 (4500 mm) 177.16 (4500 mm) 141.73 (3600 mm)

.38 - 18.00"

(10 mm - 460 mm)

19.50" x 18.00"

(500 mm x 460 mm)

9.38" x 3.12"

(240 mm x 80 mm)

18.88" x 9.75"

(480 mm x 240 mm)

1.50" x 209"

(41 mm x 5300 mm)

50 - 400 fpm

(15 - 120 m/min.)

.38 - 19.50"

(10 mm - 500 mm)

22.00" x 19.50"

(560 mm x 500mm)

9.38" x 3.12"

(240 mm x 80 mm)

18.88" x 9.75"

(480 mm x 240 mm)

1.50" x 215"

(41 mm x 5450 mm)

50 - 400 fpm

(15 - 120 m/min.)

.38 - 22.00"

(10 mm -560 mm)

24.00" x 22.00"

(610 mm x 560 mm)

NA

NA

2.00" x 260"

(54 mm x 6605 mm)

50 - 400 fpm

(15 - 120 m/min.)

2

MACHINE DIMENSIONS

INSTALLATION DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

Dimension DC-280NC DC-330NC DC-420NC DC-460NC DC-500NC DC-560NC

A

B

C

D

E

108.25"

(2750 mm)

23.50"

(600 mm)

124.50"

(3160 mm)

41.75"

(1060 mm)

37.50"

(950 mm)

117.50"

(2980 mm)

23.50"

(600 mm)

134.50"

(3420 mm)

46.00"

(1170 mm)

41.25"

(1050 mm)

117.50"

(2980 mm)

23.50"

(600 mm)

145.00"

(3680 mm)

50.00"

(1265 mm)

45.00"

(1150 mm)

118.00"

(3000 mm)

23.50"

(600 mm)

153.50"

(3900 mm)

53.00"

(1350 mm)

49.25"

(1250 mm)

118.00"

(3000 mm)

23.50"

(600 mm)

156.50"

(3980 mm)

54.00"

(1370 mm)

49.25"

(1250 mm)

112.25"

(2850 mm)

23.50"

(600 mm)

187.50"

(4760 mm)

63.00"

(1600 mm)

57.00"

(1450 mm)

3

MACHINE DIMENSIONS (Continued....)

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DC-280NC DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

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MACHINE DIMENSIONS (Continued....)

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3DVVOLQH

DC-330NC DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

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MACHINE DIMENSIONS (Continued....)

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3DVVOLQH

DC-420NC DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

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MACHINE DIMENSIONS (Continued....)

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3DVVOLQH

DC-460NC DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

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7

MACHINE DIMENSIONS (Continued....)

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3DVVOLQH

DC-500NC DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

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8

MACHINE DIMENSIONS (Continued....)

DC-560NC DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

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9

MACHINE FEATURES

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10

INSTALLATION

All the “left”, “right”, “front” and “rear”

designations in this manual are as viewed by
the operator facing the control console.

LOCATION

1. Locate the machine to provide sufcient clearance

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

3. Accessories such as roller stock conveyors will
require additional work area.

OSHA NOTICE!!

OSHA Regulation 1910.212 (5B).

Machines designed for a xed location shall

be securely anchored to prevent walking or
moving.

UNPACKING

1. The machine is fastened to and shipped on a wooden
skid. Overseas shipments are also crated.

2. Six (6) permanent lifting eye lugs are provided for
machine lifting purposes: (a) Two (2) pairs of lifting
lugs are located at the rear of the index vise roller
table; (b) Two (2) other lifting lugs are located on
the machine's front left and right corners.

Lifting By Overhead Hoist.

3. Using chains or heavy duty straps attached to
the lifting lugs, it is recommended that lifting and
transporting of the machine be done with an
overhead hoist.

4. It is also recommended to protect painted surfaces
from damage due to the lifting chains coming into
contact with machine surfaces.

2. Remove all protective covers, strapping, crating,
etc. Then: (a) Remove all bolts which fasten the
machine to the shipping skid; (b) Do not remove

the shipping bracket that attaches the saw
head to the vise base yet; (c) Remove any loose

items and boxes that may have been placed on the
machine; (d) Inspect the machine and all parts for

shipping damage. Claim procedures are listed on

this manual’s inside front cover.

LIFTING

NEVER lift the machine by its sawing head.

1. The chart below shows the recommended capacities
for lifting the machine.

DC-280NC DC-330NC DC-420NC

Overhead

Hoist

Fork Lift

Overhead

Hoist

Fork Lift

3 Ton 3 Ton 4 Ton

3 Ton 3 Ton 4 Ton

DC-460NC DC-500NC DC-560NC

5 Ton 5 Ton 6 Ton

5 Ton 5 Ton 8 Ton

5. If a fork lift truck is used, make sure it has appropriate
capacity to lift the machine safely. It is recommended
that you lift the machine from the front as shown.

Lifting By Fork Lift Truck.

6. Roller stock conveyors can be lifted and transported
by overhead hoist, fork lift, or by other means that
provides adequate safety precautions.

11

CLEANING

1. If necessary, use a mild cleanser to remove rust-

preventive coating applied to exposed bare metal
surfaces.

ELECTRICAL INSTALLATION

Electrical installation must be made by

authorized electrical maintenance personnel
only.

Do not use volatile solvents such as gasoline

or benzene.

FLOOR INSTALLATION

1. Before placing the machine down, install one (1)
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 (13 mm); (b) Tighten the jam nuts; (c)
Just before lowering to the oor, place a foot pad

under each leveling screw. Now lower the machine
in the desired location.

2. Place a machinist’s level on the bracket in the front

of the vise. Adjust the leveling screws until the
machine is level and weight bears evenly on all
mounting pads.

3. Place the level front to back on the xed vise bed

and adjust. Again, weight must bear evenly on all
foot pads.

4. Now adjust the leveling screws to make the front
of the machine .014 (.35 mm) lower than the rear.
Then adjust the leveling screws to make the indexing
vise .001 (.03 mm) higher than the front vise.

5. Install anchoring screws through the base pad holes
(those pads that have a hole) next to the leveling
screws.

6. Remove the protective shipping bracket installed
to connect the saw head to the base frame during
shipping. Keep this bracket in case the machine

needs to moved at a later time.

7. Install roller stock conveyor at the rear of the machine
approximately three (3) feet (1 meter) from the
machine. Anchor the conveyor to prevent moving.

1. Refer to the machine specications plate on the

saw head frame to verify that the electrical supply
circuit will meet the voltage/phase/frequency/
amperage requirements listed. The basic data
plate is reproduced on this manual’s introductory
page.

2. The electrical supply to this machine must be a
dedicated circuit.

Electrical Enclosure

1. The main enclosure is combined with the operator’s

control panel on the front of the machine. Power

is connected to this enclosure.

2. The following are important disconnect precautions:

The disconnect switch must be in the

"ON"position before the machine will operate.
Turning "OFF" the disconnect will shut down
the machine.

The enclosure must be closed and the

appropriate securing screws must be in place
before starting machine operation.

3. Turn the disconnect switch on the electrical cabinet
to "OFF". Then: (a) Use the keys found in the box
of extra parts and unlock the electrical cabinet at
the left door edge and open the door; (b) Familiarize
yourself with operation of the disconnect switch
operating handle, door interlock function, switch
drive dog and shaft/clamp operating positions.

4. Punch a one (1) inch (25 mm) diameter or larger

hole in the side of the electrical cabinet. Then: (a)
Bring power wiring (L1, L2, L3 and ground) through
the hole (the cable and connector are to be supplied
by the customer).

Conveyors are not attach to the machine and

should be anchored to the oor separately.

Electrical Connections to Disconnect Switch.

12

ELECTRICAL INSTALLATION (Continued....)

5. Bring the power cable leads up to the disconnect
switch. Then: (a) Connect L1, L2 and L3 to their
respective terminals; (b) Connect the ground wire to
the ground terminal (refer to the electrical schematic
if necessary).

3. Turn on the electrical supply and turn the machine

disconnect switch to the "ON" position.

For information on using the controls for

the following steps, see the "OPERATION"
chapter under the heading "OPERATOR
WORKSTATION".

6. Make sure to place the operating shaft and operating

handle of the disconnect switch in the "OFF"

position. Then: (a) Close the electrical cabinet
door and secure with the keys; (b) Now turn "ON"
the electrical supply and the disconnect switch (no
action will occur until the Hydraulic Start button on
the control console has been pushed).

DO NOT start machine hydraulics until the

following “Preparation for Use” procedures
have been performed.

PREPARATION FOR USE

1. Check the hydraulic reservoir uid level. Capacity

is between 16 and 34 gallons (60 and 130 liters)
depending on machine model. (See Machine
Specications Chart). If the reservoir level is low
(or empty), check to see that the reservoir’s drain
plug is installed tightly.

2. Fill the coolant reservoir with oil or cutting uid
recommended by the Lubrication Chart (remove

the splash guard and pour coolant slowly into the
chip conveyor trough). DO NOT let coolant spill

over the trough end and onto the oor. Capacity
is between 20 and 37 gallons (80 and 140 liters)

depending on machne model. (See Machine

Specications Chart).

4. Press the green Hydraulic Start pushbutton on the
electrical control panel to start the hydraulic system.
Then: (a) Press the "MANUAL" key; (b) Move the

Saw Head Up pushbutton to raise the saw head;
(c) If the hydraulic motor rotates correctly, the saw

head will now raise from the down position.

5. If the saw head does not raise, it means that the
hydraulic motor’s rotation is reversed. Hydraulic

system operation cannot be maintained if the
saw head is not raised.

6. If the saw head does not raise: (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 4 again.

7. As soon as hydraulic motor rotation is correct, jog the
Hydraulic Start and Hydraulic Stop pushbuttons
several times to make sure the hydraulic and coolant
pumps are primed. Then allow the machine to run
for several minutes to remove entrapped air.

8. If the hydraulic or band drive motor overloads open,

the machine will shut down.

3. Check the band drive gearbox reservoir level gauge
while the saw head is down. Capacity is between

1.2 and 8.2 gallons (4.5 and 28 liters) depending

on machne model. (See Machine Specications

Chart).

4. Check to see that all other points listed by the
Lubrication Chart have been properly checked or

serviced.

Hydraulic Start-Up

1. If the rst motor to be checked (hydraulic power

unit motor) rotates correctly, the band drive motor
will do likewise.

2. All hydraulic and coolant system uid connections
were leak-tested at the factory. They should be
rechecked as start-up proceeds.

13

OPERATION

SELECTING BAND SPEEDS and CUTTING
RATES

1. The chart below has information about the
recommended band speeds and cutting rates
according to the type of material to be cut.

2. Touse,ndthematerialtobecutintherstcolumn.
Thenmovetotherighttondinformationonband

speed recommendations and cutting rates.

CODE

MATERIAL

Low Carbon Steel

Mild Carbon Steel

Cromolybedenum

Steel

Nickel

Cromolybedenum

Cromolybedenum

Steel

Nickel

Cromolybedenum

Tool Steel

Alloy Tool Steel

Alloy Tool Steel

(15) Alloy Tool Steel

Alloy Tool Steel

Stainless Steel

Bearing Steel

JIS AISI DIN

SS41 A570 St44-2

S10C 1010 C10

S15C 1015 C15

S45C 1045 C45

S55C 1055 CK55

SCM440 4140 42CrMo4

SNCM8 4340 34CrNiMo8

SCM21 4118 15CrMo5

SNCM21 8620 21CrNiMo2

SK2 W1C125W C125W

SKS3 D1 105WCr6

SKD1 D3 X210Cr12

SKD11 D2 X155CrVMo121

SKD61 H13 X40CrMoV51

SUS304 304 X5CrNi1810

SUS316 316 X5CrNiMo17121

SUS430 430 X6Cr17

SUJ2 52100 100Cr6

This chart is a guide only and the

recommendations shown can be adjusted to
meet special material requirements.

BAND SPEED

Feet/Min.

(m/Min.)

200 - 230 fpm

(60 - 70 m/min.)

245 - 265 fpm

(75 - 80 m/min.)

245 - 265 fpm

(75 - 80 m/min.)

165 - 200 fpm

(50 - 60 m/min.)

165 - 200 fpm

(50 - 60 m/min.)

150 - 165 fpm

(45 - 50 m/min.)

130 - 150 fpm

(40 - 45 m/min.)

165 - 200 fpm

(50 - 60 m/min.)

180 - 200 fpm

(56 - 60 m/min.)

100 - 150 fpm

(30 - 45 m/min.)

100 - 115 fpm

(30 - 35 m/min.)

100 - 115 fpm

(30 - 35 m/min.)

100 - 115 fpm

(30 - 35 m/min.)

65 - 100 fpm

(20 - 30 m/min.)

115 - 130 fpm

(35 - 40 m/min.)

85 - 100 fpm

(25 - 30 m/min.)

100 - 115 fpm

(30 - 35 m/min.)

115 - 150 fpm

(35 - 45 m/min.)

CUTTING RATE

Sq. Inches/Min.

(cm²/min.)

7.8 - 9.3 in²/min.

(50 - 60 cm²/min.)

8.5 - 10.0 in²/min.
(55 - 65 cm²/min.)

8.5 - 10.0 in²/min.
(55 - 65 cm²/min.)

6.2 - 7.8 in²/min.

(40 - 50 cm²/min.)

6.2 - 7.8 in²/min.

(40 - 50 cm²/min.)

4.6 - 6.2 in²/min.

(30 - 40 cm²/min.)

4.6 - 6.2 in²/min.

(30 - 40 cm²/min.)

5.4 - 7.0 in²/min.

(35 - 45 cm²/min.)

5.4 - 7.0 in²/min.

(35 - 45 cm²/min.)

4.6 - 5.4 in²/min.

(30 - 35 cm²/min.)

3.9 - 4.6 in²/min.

(25 - 30 cm²/min.)

3.9 - 4.6 in²/min.

(25 - 30 cm²/min.)

3.9 - 4.6 in²/min.

(25 - 30 cm²/min.)

1.2 - 1.9 in²/min.
(8 - 12 cm²/min.)

3.9 - 4.6 in²/min.

(25 - 30 cm²/min.)

2.3 - 3.1 in²/min.

(15 - 20 cm²/min.)

3.1 - 3.9 in²/min.

(20 - 25 cm²/min.)

3.9 - 5.4 in²/min.

(25 - 35 cm²/min.)

14

CONTROL CONSOLE

Pushbutton Panel

Number in text refers to identical number on

illustration.

1. Emergency Stop. Except for damage to the
machine or personal injury, pushing this red
mushroom head pushbutton stops all machine
motors simultaneously. This button must be
released or reset before the machine can be
restarted.

4. Band Drive Start/Stop. Push the upper green

button to start the hydraulic system. Push the lower

red button to stop the hydraulic system.

• The following conditions must exist before pushing

the Band Start button: (a) Hydraulics must be
"ON"; (b) All doors and covers must be closed; (c) A
saw band must be installed and the Band Tension
selector must be at “ON”.

• In "MANUAL" mode, the index vise must be in the
maximum "REAR" of "Forward" position.

• In "AUTO mode, one the vises must be clamped.

• To reset, turn the button head clockwise until the
head pops up. To reactivate machine motors:

• To normally stop the machine in non-emergency
situations, push the "SAW HEAD UP" pushbutton.

2. Power On. When the disconnect switch is turned

to "ON", this lamp will glow indicating power is on.

3. Hydraulic Start/Stop. Push the upper green button
to start the hydraulic system. Push the lower red

button to stop the hydraulic system.

5. Band Speed. Turn the knob clockwise to

"INCREASE" the band speed, counterclockwise
to "DECREASE" it.

• The band speed is shown on the VIEW Screen.

6. Index Forward. Push and hold this button to move
the index vise forward. Release the button to stop
movement.

• When the index vise reaches the front limit, the
yellow light shines.

Pushbutton Panel.

15

CONTROL CONSOLE (Continued....)

Hydraulic Panel

7. Index Reverse. Push and hold this button to move
the index vise backwards. Release the button to
stop movement.

• When the index vise reaches the rear limit, the
yellow light shines.

8. Creep Speed. When this button is pushed and
held, the indexing vise speed is reduced to a
slower speed in either forward or reverse direction.
Release the button to return to normal speed.

9. Indexing Vise Open. When this button is pushed
and held, the movable index vise jaw retracts form

the xed vise jaw. Release the button to stop

movement.

10. Indexing Vise Clamp. When this button is pushed
and held, the movable index vise jaw clamps

towards the xed vise jaw. Release the button to

stop movement.

• When the index vise is clamping, the yellow light
shines.

1. Feed Force. Set the feed force by turning the upper
knob to the material to be cut. The chart of material
is color coded to give a feed force range the operator
may choose from. Turn the knob clockwise to

“INCREASE” pressure; counterclockwise to
“DECREASE” it.

Turning the Feed Force control knob to zero

(0) WILL NOT stop sawing head motion.

11. Front Vise Open. When this button is pushed
and held, the movable front vise jaw retracts form

the xed vise jaw. Release the button to stop

movement.

12. Front Vise Clamp. When this button is pushed and
held, the movable front vise jaw clamps towards

the xed vise jaw. Release the button to stop

movement.

• When the front vise is clamping, the yellow light
shines.

13. Saw Head Down. When this button is pushed and
held, the sawing head lowers. Release the button
to stop movement.

• When the sawing head reaches the down limit, the
yellow light shines.

14. Saw Head Up. When this button is pushed and
held, the sawing head raises. Release the button
to stop movement.

• When the sawing head reaches the upper limit, the
yellow light shines.

Hydraulic Panel.

2. Feed Rate. Turn the lower knob to the best suited
cutting rate for the material being cut. Adjust the

rate to t your needs such as cut time or cut nish,

etc. Turn the knob clockwise to “INCREASE” the
feed rate; counterclockwise to “DECREASE” it.

Turning the Feed Rate control knob to zero (0)

WILL stop sawing head motion.

15. Operator Workstation. The operator workstation
has most of the controls to operate the machine.
See the heading "OPERATOR WORKSTATION"
later in this chapter for information on controls and
their use.

16

CONTROL CONSOLE (Continued....)

Other Controls

1. Variable Vise Pressure. Located on the left

side of the machine behind the control console,
these valves are 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.

• Turning the selector to “OFF” releases band tension
and enables saw band removal or installation.

• The “HOLD” setting stops band tension cylinder
movement and allows the operator to position the
saw band over the bandwheels.

• The “ON” setting pressurizes the cylinder and
establishes band tension required for cutting.

The Band Tension selector must be at "ON"

before the saw head will descend or the band
drive motor to start.

OPERATOR WORKSTATION

1. Most of the machine controls are on the operator
workstation.

2. Most screens have a "FUN" or "FUNCTION" key in
the upper right corner of the screen. Pressing this

key gives the operator to view other screens and
their controls.

"F1" - View Screen

"F2" - Run (Manual) Screen
"F3" - Alarm message Screen
"F4" - Error Message Screen
"SYS" - System Screen (hold key for 5 seconds)

Variable Vise Pressure Controls.

• Clamping pressure is set with the Index Vise and
Fixed Vise adjustment knobs until the desired

pressure is shown by the indicator gauges. Turn
each knob clockwise to "INCREASE" the pressure;

counterclockwise to "DECREASE" the pressure.

• When the desired pressure has been reached,
tighten the locking knob to hold the setting.

2. Band Tension Control. Located on the left side of
the machine at the end of the band tension cylinder,
this selector switch with "OFF", "HOLD" and "ON"
settings is used when changing saw bands.

Keypad

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

Keypad.

2. Features of the keypad include:

Band Tension Control.

3 Display Window. Located at the top of the window,

the display shows the values entered.

17

OPERATOR WORKSTATION (Continued....)

4. 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.

5. 0 - 9, Decimal Point, + / -. These keys are used to
enter values for that function. Enter them in order
including the decimal point.

6. CLR (Clear). This will clear the entry in the display.

2. SIZE SET. For displaying jobs and/or setting length
of cut for jobs. When changing lengths are required,

see the heading "SETUP FOR A JOB" later in this

section.

3. MOVE Q'TY. For displaying the position of the index
vise.

4. Q'TY (Quantity). Displays the number to be cut.

5. COUNT. For displaying the quantity that has been
cut.

7. DEL (Delete). Pressing this key will delete the last
keystroke entered.

If you make an error in entering data, just

press the "DELETE" or "CLEAR" key, correct
or reenter you value and then press the "OK"
key.

8. Enter. Pressing this key will enter the data into

memory and then will return to the previous screen.

View Screen

Number in text refers to identical number on

illustration.

6. MODE SET. Used for selecting operation mode.

Press the "MANUAL" key for entering into manual
operation mode. Press the "AUTO" key for entering

into automatic mode.

7. FUN (Function). Press this key will take the operator
to other screens as described earlier.

8. Displaying the current date.

9. COOLANT. When the machine is not in cutting

operation, selecting "MANUAL" will start coolant
ow. Press again to stop the ow.

Press the "AUTO" button before cutting operation.

The coolant will automatically ow when the saw
blade is running. When the cutting nishes, the
coolant ow will stop.

10. Displaying the current time.

11. LAMP. Switches to turn the worklamp "OFF" and

"ON".

12. CUT EXCLUDE. In automatic mode, if the front end

of the material is poor, the rst cutting is not counted

or excluded. This function is preset. If the front

end material is good, press the "CUT EXCLUDE"
after cutting begins. It will display "COUNTED" for

including in this job. This function is effective only

when pressing "CUT EXCLUDE" after cutting begins.

View Screen.

1. Displays the current job number being performed.

13. LINE SPEED. Displays the band speed.

14. PHOTO ON/OFF. To turn the out of stock photo

switch "OFF" and "ON".

• Press the "FUN" key and then press "F1" key will

bring the operator back to the Run Screen.

• Press the "FUN" key and then press "F2" key will

bring the operator to the next screen.

18

OPERATOR WORKSTATION (Continued....)

Run (Manual) Screen

Number in text refers to identical number on

illustration.

For most of these controls, the "MODE SET"

key must be in "MANUAL".

1. HYD (Hydraulics). Switches to turn the hydraulic

system "OFF" and "ON".

8. SYSTEM. This key takes the operator to a screen

to allow mode selections, diagnostics and certain
parameters changes. See "System Screen" later
in this chapter for information on this screen.

9. HOME. If power has been interrupted, cut lengths
are inaccurate, an auto cycle alarm is indicated or
auto cycle fails to initiate, the index vise may need

to be "homed". When this button is pressed, the

index vise is calibrated to the zero (0) point.

10. TOTAL TIME. Displays the total time of the job.

2. BLADE (Band Drive). Switches to turn the band

drive motor "OFF" and "ON".

3. CUT TIME. Displays the current cut time.

4. LAST TIME. Displays the previous cut time.

11. SAW ARM (Saw Head). Push and hold the switches

to move the sawing head "DOWN" or "UP".

12. REAR VISE (Index Vise). Push and hold the
switches to "RELEASE" or "CLAMP" the vise.

13. FRONT VISE. Push and hold the switches to
"RELEASE" or "CLAMP" the vise.

• Press the "FUN" key and then press "F1" key will

bring the operator back to the Run Screen.

• Press the "FUN" key and then press "F3" key will

bring the operator to the next screen.

Alarm Screen

Run (Manual) Screen.

5. FEED. These set of keys control the indexing vise

and gives the operator a choice of "FAST" or "SLOW"
speed in either "FORWARD" or "BACKWARD"

directions.

6. FUN (Function). Press this key will take the operator
to other screens as described earlier.

7. ABS POSI (Absolute Position). For displaying the

position of the index vise in relation to the "HOME"

position.

Alarm Screen.

1. In the case of machine malfunction, this screen will
display the alarm message providing a starting point
for troubleshooting.

• Press the "FUN" key and then press "F1" key will

bring the operator back to the Run Screen.

• Press the "FUN" key and then press "F4" key will

bring the operator to the next screen.

19

OPERATOR WORKSTATION (Continued....)

Error Message Screen

1. In the case of machine malfunction, this screen will
display the error message providing a starting point
for troubleshooting.

• Press the "FUN" key and then press "F1" key will

bring the operator back to the Run Screen.

3. Pressing "DIAGNOSTIC" will 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.

4. Pressing "PARAMETER" will give access to certain

features that can be changed. See "Parameter
Screen" later in this section.

Mode Select Screen

Number in text refers to identical number on

illustration.

Error Message Screen.

System Screen

1. When the "SYSTEM" key on the Run (Manual)
Screen is pressed, the following screen appears.

System Screen.

Mode Select Screen.

1. Material. Choose the material mode operation
between "BUNDLE" and "SINGLE".

• When "BUNDLE" is selected, the "CUT & MOVE"
and "REAR POSI" keys are not available.

• When "SINGLE" is selected, the "DO" key is not

available.

2. Stop Mode. Choose how the machine will stop
after the cut is completed.

• "STILL" stops the saw band after the cut and then

the machine stops.

2. Pressing "MODE SELECT" brings the operator to

a screen that gives choices to common settings for
operation. See "Mode Select Screen" later in this
section.

• "LITTLE UP" brings the saw band up .20 to .40 inch

(5 to 10 mm) after the cut and then the machine
stops.

20

OPERATOR WORKSTATION (Continued....)

• "UP LIMIT" allows the saw band to raise higher than

the material and then the machine stops.

3. Feeder Posi (Index Vise Position). After material
is been moved to cutting position, select the position
of the index vise when cutting starts.

• To leave the index vise in the forward position, select

"FRONT POSI" (Position).

8. Coolant Delay. Choose how the coolant system
is left after cutting is nished.

• "NONE" allows the coolant system to stay "ON"

after cutting is complete.

• If the operator desires the coolant system to turn

"OFF" after a certain length of time, select "TIMER".

The preset setting is 30 minutes. Maximum setting
is 99 minutes. See the "Parameters Screen" to
change to a different length of time.

• "CUT & MOVE" allows the index vise to move to

the index setting while the machine is cutting. This

key is non-functional when "BUNDLE" cutting is

selected.

• The index vise moves in the index setting position and

then cutting begins, select "REAR POSI" (Position).
This key is non-functional when "BUNDLE" cutting

is selected.

4. FUN (Function). Press this key will take the operator
to other screens as described earlier.

5. Escape. Choose how the index vise responds after
one cut is completed.

• "DO" allows the index vise to move back a little to

avoid the saw band from touching the material as
the saw band is raised. It is designed for bundle
cutting.

• Selecting "NONE" keeps the index vise stationary

while the saw band is raised. It is designed for
single cutting.

6. Raise Mode. Select the front vise position when
the saw band rises.

• Return. Press this key to bring you back to the

"System Screen".

Parameter Screen

1. Pressing "PARAMETER" will give access to certain

features that can be changed. However, you must
use a password to gain access to these parameters.

Use EXTREME CAUTION when changing any

parameter on the list as undesirable results
may occur.

2. Use the password "11111111" to gain access to the
parameters list.

3. Be mindful that certain items have limits on the value

you set. Trial and error may be necessary to nd

the right value.

SETUP FOR CREATING JOBS

Job Screen

1. Pressing "SIZE SET" on the "View Screen" will bring
the operator to a screen where part parameters and
jobs can be created.

• Select "OPEN CLAMP" to have the front vise open

when the cut is complete and the saw band rises.

• Select "CLOSE CLAMP" to have the front vise clamp

when the cut is complete and the saw band rises.

7. Auto Stop. Choose how the machine is left after

cutting is nished.

• "NONE" allows the machine to stay "ON" after cutting

is complete.

• If the operator desires the machine to turn "OFF"
after a certain length of time, select "TIMER". The

preset setting is 30 minutes. Maximum setting is 99
minutes. See the "Parameters Screen" to change
to a different length of time.

Job Screen.

21

SETUP FOR CREATING JOBS (Continued....)

2. The operator can program up to twenty (20) jobs in
the library. Under each job number, you can enter
the cut length, and quantity.

3. To enter data in the job list: (a) Press the key

under the "SIZE" column next to the job number.

The keypad will appear; (b) Enter the desired cut

length and then press "ENTER"; (c) Press the key
under the "QTY column in the same job row and the

keypad will appear; (d) Enter the desired number

of cuts and then press "ENTER".

4. Make sure the "COUNT" column values are zero

(0).

2. A machine in correct adjustment, good operating

condition and using proper cutting uid is essential
to efcient sawing.

3. Proper blade care should include: (a) Pushing uncut

stock away from the saw band and lowering the saw
head if the machine is to remain idle for a period of
time; (b) Using correct band speed, feed force and
cutting uids during operation; (c) Removing scale
from stock before sawing.

Blade Guards

1. The machine has two (2) blade-covering guards

for operator safety. All guards must be in place
before any sawing procedure is started.

5. Go to row for job number 2 and proceed as before
until the job list is completed.

Check and make any corrections/additions/

deletions to the job list before exiting the "Jobs
Screen".

6. Go to row for job number 2 and proceed as before
until the job list is completed.

7. Pressing a square under the "EXEC" column next

to a job number will be displayed on the "View
Screen".

8. Each job selected will turn the key to red with a blue
asterisk (*) in the "EXEC" column.

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

10. Operator notes about entering jobs into the list:

(a) The minimum automatic index length is .38 inch

(10.0 mm); (b) The maximum index length that can
be entered is 9999.99 inches; (c) The maximum
quantity that can be entered is 9999.

11. In automatic mode, when the "COUNT" quantity
reaches the programmed "QTY", the machine will
automatically perform the next "EXEC" station until

all selected jobs are done.

MACHINE PREPARATION

Saw Band Recommendations

• Left Guard. This guard is attached to the left saw
guide arm and extends toward the idler bandwheel.

• Right Guard. This guard extends between the right
saw guide arm and the drive bandwheel. This is a

xed, integral part of the right bandwheel door.

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

Saw Guide Insert Adjustment

1. On each saw guide arm loosen the adjustment screw
by turning it counterclockwise. Then: (a) Check

that the saw band is up against the back-up insert;

(b) Turn the insert adjustment screw clockwise
until tight and then back off 1/4 turn.

Saw Band Removal

Always use extreme care when handling saw

bands. Wear gloves.

1. Turn the band drive motor to "OFF" and then push

the Hydraulic Start pushbutton . Then: (a) Push
and hold the Saw Head Up button and allow the
saw head to raise to its maximum height; (b) Turn
the Band Tension selector to "OFF" (this moves
the idler bandwheel to the right).

2. Open both bandwheel doors until they engage and
stay open; Then: (a) Loosen the clamp handle on
the band brush; (b) Push the band brush down away
from the blade teeth.

1. A high-speed DoALL Imperial Bi-Metal 100 saw
band with protective Saw Cap is supplied with the

machine. Band length, width and recommended
gage is dependent on machine model. (See Machine

Specications Chart).

3. Loosen the saw guide inserts on both saw
guide arms by turning each adjustment screw

counterclockwise (do not allow the inserts to
fall out). Next: (a) Loosen the left saw guide arm

lock handle; (b) Slide the left saw guide arm to the
right until it is about 10 inches (254.0 mm) from the
right saw guide arm.

22

MACHINE PREPARATION (Continued....)

4. Place a gloved hand on the back of the saw band

portion between the saw guide arms; (a) Push the
saw band down and out to disengage it from the saw
guide inserts (you will want to grip the saw band
rmly as you manipulate it); (b) Remove the saw
band from around the drive and idler bandwheels,
then from the top channel.

5. Maneuver the drive bandwheel end loop of the saw
band outward and to the right while maneuvering
the idler bandwheel end loop between the idler
bandwheel and the left saw band guard. Then: (a)
Manipulate the top part of the saw band out between

the right saw band arm and the band brush deector

shield; (b) Recoil the saw band and store/dispose
of it immediately.

Saw Band Installation

Always use extreme care when handling saw

bands. Wear gloves.

5. Check the saw band’s position around both

bandwheels and make adjustments (its back edge

must rest against each wheel’s rear ange). When
satised that saw band positioning is correct: (a)

Turn the Band Tension selector to “ON”; (b) Move
the left saw guide arm to the desired position; (c)
Tighten both saw guide insert adjustment screws.

6. Reposition the band brush and tighten the clamp
handle (brush bristles should clean the blade

teeth gullets, but not contact the bottom of the
gullets). Then: (a) Lift the bandwheel doors to

disengage the lock and then close both bandwheel
doors; (b) Jog the band drive motor; (c) Open each
bandwheel door to make certain that the saw band

is against the bandwheel anges; (d) Close each

door when everything is satisfactory.

BAND SPEED RANGE

1. The operator can select between "HIGH" and "LOW"

band speed ranges by switching the drive belt from
one set of pulleys to the other.

1. Carefully follow all "Saw Band Removal" procedures.
Then use the Flushing Hose to clean areas around
the saw guides and inserts, plus the drive and idler
bandwheels.

2. Slip the saw band under both saw guide arms by
following the reverse procedure of step 4 in the "Saw
Band Removal" section. Then: (a) Position the saw
band around the drive and idler bandwheels.

3. Slip the top portion of the saw band loop into the
top channel. Then: (a) Grasp the saw band portion
between the saw guide arms and twist it so the blade
teeth are pointing downward; (b) Slip this twisted
saw band portion up and between the saw guide
inserts.

Placing the Saw Band Between the Saw Guide Inserts.

4. Turn the Band Tension selector to “ON” and then to

"HOLD" until the saw band is tensioned just enough

to be held in place and adjustments can be made.

2. "LOW" range is the front set of pulleys and the
HIGH" range is the rear set.

Band Speed Range.

3. Band speed range is as follows:

LOW 50 - 280 fpm (15 - 85 m/min.)

HIGH 76 - 400 fpm (25 - 120 m/min.)

4. To change the band speed range, open the right
bandwheel door. Then: (a) Undo the guard clips
and remove the screws; (b) Located in the rear of
the machine between the band drive motor and the
gearbox, turn adjustment knob counterclockwise
to relax belt tension; (c) Install the belt to desired
speed range set of pulleys.

5. Turn adjustment knob clockwise to tension the belt.

There should very little deection at the center span

of the belt.

6. Flip the cover up and engage the clips and install
the screws.

23

LEFT SAW GUIDE ARM ADJUSTMENTS

The right saw guide arm cannot be adjusted.

1. The left saw guide arm moves along the slide bar to
accommodate various stock widths (the arm should
be positioned as close as possible to the clamped
stock).

2. Stock width settings are depicted by a slide bar
scale with both inch and metric measurements.

3. To adjust the left saw guide arm according to stock
width, the operator loosens the left insert adjustment
screw and the guide arm locking handle. Next: (a)
Line up the left saw guide arm's right edge with the
proper inscribed scale line; (b) Secure the saw guide
arm in the chosen location by tightening the guide
arm handle; (c) Tighten the left insert adjustment
screw.

DO NOT hammer the lobes of the locking

handwheel. Hand tightening is adequate to
lock the left saw guide arm in place.

• Feed force adjustments are not necessary for

changing stock cross-sections. A balancing valve

enables the saw band to maintain a uniform cutting
rate.

Reducing Cutting Rate & Band Speed for Pipe, Tubing
and Structurals

1. Increasing loading per tooth occurs when sawing
thin stock sections. Although the blade teeth can
bear some overloading, a cutting rate reduction
must be made.

2. When it becomes necessary to modify solid
section sawing recommendations: (a) Measure
the thinnest stock section to be cut; (b) Apply a
percentage factor of 40% for thin material to up to
70% materials over 1.00 inch (25.4 mm); (c) Use a
high band speed, but never exceed the maximum

speed recommended on the chart found at the
beginning of "OPERATION" chapter) for stock
sections of the same size.

FEED RATE

FEED FORCE ADJUSTMENTS

1. Feed force is the pressure exerted by the workpiece
against the saw band's cutting edge. It is controlled
hydraulically and regulated with the Feed Force
valve. Turn the valve clockwise to "DECREASE"
pressure, counterclockwise to "INCREASE" it.

2. The following are important factors to consider when
setting or adjusting the Feed Force valve:

• Turn the Feed Force valve to a low setting if the
correct feed force is not known. The operator can
then increase or decrease pressure during operation
to obtain the best cutting rate consistent with desired

blade life and stock cut nish. Always be sure to
take a good chip.

• Never start a cut with the maximum Feed Force
valve setting. Blade damage may occur.

• Certain work-hardening materials will require a

moderately heavy initial Feed Force valve setting to
assure immediate penetration of blade teeth. Light
feeds on these materials may cause the blade to
slide over the stock resulting in saw band damage.

• Generally, top performance from a sharp saw band
results from relatively low Feed Force valve
settings. It will be necessary to increase the setting
as the saw band becomes duller. This will help keep
the cutting rate constant throughout the life of the
saw band.

1. Correct feed rate is important for helping: (a)
Determine overall cutting accuracy and nish of

cut; (b) Improve blade life by eliminating breakage

and tooth strippage at the cut's start and break-out

points.

HEAD ELEVATION and SENSING ARM

Head Elevation

1. Saw head elevation during automatic sawing cycle
is initiated when the head down proximity switch
is actuated. The saw head then raises to a height
determined by the sensing arm.

2. After a cut has been made in the manual operating
mode, the actuated head down proximity switch
stops machine operation. To lift the saw head off
the limit switch and resume operation, the operator
must; (a) Push the Hydraulic Start pushbutton; (b)

Push and hold the Saw Head Up button;

Sensing Arm

1. The sensing arm works in conjunction with the head
clear proximity switch to assure that the saw head

has raised sufciently above existing stock so that

automatic indexing or manual stock positioning can
be accomplished safely.

24

Sensing Arm Operation When the Saw Head Raises

1. The saw head lifts the sensing arm above the stock
at a rapid rate (there is no slow head raising rate)
until it actuates the head clear proximity switch.
This causes saw head upward movement to stop
when the blade is approximately one (1) inch (25.4
mm) above the stock. This clearance anticipates

potentially crooked and/or out-of-round stock being

used.

VERTICAL GUIDE ROLLERS

1. These rollers are mounted near the end of the index
table and provides two (2) laterally adjustable vertical
rollers.

2. When the vertical roller is not needed, it can be
swiveled in the down position.

HYDRAULIC SYSTEM

2. If operating in automatic mode, the xed vise then

unclamps, the index vise clamps, and stock is
indexed forward. Following the advance of stock,

the xed vise clamps and the index vise unclamps.

3. When the xed vise unclamps prior to indexing, its

jaws open just enough to allow stock advancement.
The vise jaws can be opened wider only when the

saw head has been manually raised to the full "UP"

position to actuate the head up proximity switch: this
assures that the left saw guide arm will clear the

xed vise when it opens to receive larger stock.

Left saw guide arm adjustment for stock width

must be made manually by the operator.

Sensing Arm Operation When the Saw Head Lowers

1. The saw head lowers at the rapid approach rate
until stock is contacted by the sensing arm. A feed
rate is then established and cutting begins.

2. Sensing arm contact with the stock is maintained

throughout the cut. After a cut has been nished:

(a) The head down proximity switch is actuated; (b)
The saw head raises.

1. The hydraulic and band drive systems operate
independently. This allows the operator to perform
the following tasks while the band drive motor is
not running: (a) Change saw bands; (b) Raise or
lower the sawing head; (c) Clamp or unclamp the
vises; (d) Position stock manually.

2. The machine's hydraulic reservoir capacity depends
on machine model. (See Machine Specications
Chart). Refer to the Lubrication section of this
manual for recommended oils.

COOLANT SYSTEM

Coolant Selection

1. The main cause of tooth failure during band

machining is excessive heat build-up. Using the
proper cutting uid reduces the heat generated

during operation. It also helps the machine take

full advantage of its high-speed steel saw bands.

Literature describing these and other coolant

types is available from a DoALL sales
representative.

MINIMUM BAR END

1. When the indexing vise is completely forward, both
of its vise jaws extend toward the front vise jaws.
This extension, together with the nesting design of
the vises, permits automatic indexing of stock until
a small butt end remains.

DC-280NC DC-330NC DC-420NC

Minimum

Bar End

Minimum

Bar End

2. If the stock is shorter, it will not be stable in the index
vise.

3.75"

(95)

DC-460NC DC-500NC DC-560NC

4.53"

(115)

4.33"

(110)

4.53"

(115)

4.33"

(110)

6.10"

(155)

Coolant Application

1. Coolant is applied as follows during sawing:

• To the saw band and cutting area through the saw
guide inserts. Flow is regulated by a valve on each
saw guide arm.

• To the band brush cleaning area through a ushing

nozzle. Flow from this point is controlled by a valve.

• To the cutting area through a ushing nozzle. Flow

from this point is controlled by a valve.

• On some models, an additional ushing nozzle

located between the two saw guide arms on top of
the saw band to cool the cutting area.

25

COOLANT SYSTEM (Continued....)

Coolant Application Points.

2. Coolant ow is started by: (a) Pushing the Hydraulic
Start pushbutton; (b) Turning the Coolant selector to

"ON" or "BAND ON"; (c) Turn all the coolant valves
on until uid completely shrouds the saw band.

DO NOT start cutting until coolant is owing

adequately. Dry cutting will greatly reduce
blade life.

3. Check the coolant reservoir level if ow is stopped

or reduced. Reservoir capacity is dependent on
machine model. (See Machine Specications
Chart). A coolant level sight gauge is located next
to the coolant pump.

CHIP REMOVAL

1. Metal chips should be removed from the work area as
soon as possible. They can be washed or scraped
into the chip conveyor trough, or scooped out with
the shovel and/or rake.

DO NOT shovel or rake chips while the saw

band is running.

2. As the bristles wear, move the brush closer to the
blade. To do so: (a) Open the right wheel cover;
(b) Loosen the clamping handle; (c) Position the
brush for correct blade cleaning; (d) Tighten the
clamping handle and close the wheel cover.

Flushing Hose

1. Metal chips and other debris may accumulate over
time around such machine areas as: saw guides,
drive and idler bandwheels, vises, slides, brush
housing, head lift cylinder, feed and discharge areas,
etc.

2. The operator should check often for metal chip
collections which can adversely affect machine
performance. They should be removed with the
Flushing Hose as soon as possible.

The DoALL Company recommends using the

Flushing Hose to remove chips at least twice
per each eight (8) hour shift, and more often
with heavier use.

Chip Conveyor

1. During operation, metal chips and used coolant

drop directly into a sloped trough, or ow into it
from the machine's run-off surfaces. Coolant then
ows down the trough and through a ltering screen

before returning to the reservoir.

2. The chip conveyor motor operates simultaneously
with the hydraulic pump motor. The conveyor
screw rotates slowly at the bottom of the trough.
Its movement carries metal chips to the opening at
the machine's right side where chips empty into a

customer-supplied container.

3. A needle valve located below the auger allows the
chip auger motor to be adjusted for faster or slower
operation.

NESTING FIXTURE

Band Brush

1. A covered, band drive motor driven band brush
is located near the right saw guide arm. During
machine operation, the brush bristles should be
positioned so that the tips clean chips from the blade
teeth gullets, but do not contact the bottom of the
gullets. DO NOT allow metal chips to accumulate

on the brush.

1. This feature is designed for high-production, multiple

sawing of stacked bars, rounds and tubing.

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

3. Vise capacity is dependent on machine model. (See
Machine Specications Chart).

The hydraulically operated Nesting Fixture can

also be used with the Variable Vise Pressure
control.

26

NESTING FIXTURE (Continued....)

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.

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).

2. Loosen the screw on each side of the clamp bars
adjust the clamp bars commensurate with the size
of the nested stock. Then adjust the index table’s
vertical guide rollers so the stock will be guided
correctly toward the saw band.

3. 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.

Round Stock Stacking Methods.

5. Pieces should be stacked as closely together

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

Vise Adjustment

Nesting Fixture Vise Adjustments.

Nesting Fixture Positions on the Index Vise.

3. The indexing vise has two (2) positions to place the

nesting xture.

• "POSITION A" is the forward position on the index

vise.

• "POSITION B" is the rear position on the index vise.

4. The remnant will change depending on the position

the nesting xture position. See chart below.

DC-280NC DC-330NC DC-420NC

Position A

Position B

Position A

Position B

7.75"

(190)

13.00"

(330)

DC-460NC DC-500NC DC-560NC

8.47"

(215)

14.75"

(375)

7.88"

(200)

13.00"

(330)

8.47"

(215)

14.75"

(375)

8.47"

(215)

13.00"

(330)

Not Applicable

Not Applicable

1. Stack stock to be cut between the machine’s vise
jaws. Then: (a) Push the Front Vise Rel (Release)
and Rear (Index) Vise Rel (Release) buttons; (b)

Bolt the supporting bar tightly to the xed vise jaw(s),

but not to the movable vise jaw(s).

27

NESTING FIXTURE (Continued....)

Manual Operation

Controls

1. Go to the "MODE SELECT" Screen.

2. Under "ESCAPE", choose how the index vise

responds after one cut is completed.

• "DO" allows the index vise to move back a little to

avoid the saw band from touching the material as
the saw band is raised. It is designed for bundle
cutting.

• Selecting "NONE" keeps the index vise stationary

while the saw band is raised. It is designed for
single cutting.

For Best Nesting Cutting Results

1. Stack the same number of stockpieces in each row.

2. The stack should always be higher than it is wide.

3. Increase the nesting vise clamping pressure will
increase the holding load per piece.

4. Apply as much coolant as possible while cutting.

5. Replace wear plates on the movable vise jaw when
they become worn.

6. Adjust the index table’s vertical guide rollers to
keep the stack from collapsing when the vises are
unclamped.

7. Generally, reduced band speed and feed force are
necessary when sawing stacked materials. This
results in a lower cutting rate than possible when
sawing solid stock.

8. In some instances, increased production and blade

life may be obtained by nesting fewer pieces than
maximum vise capacity permits.

TYPICAL OPERATING PROCEDURES

Preparation

1. Turn the hydraulics on, raise the saw head and
open both front and rear vises to accommodate the
material to be cut.

2. Adjust the vise location pins accordingly for the size
of the material to be cut.

3. Remove or add the xed vise drop plates according

to the size of material to be cut.

4. Verify or adjust variable vise pressure for the type
of material to be cut.

5. Place material on the index vise bed.

6. Loosen the saw guide adjusting screws and adjust left
movable saw guide arm to the size of the material to
be cut. Tighten the saw guide arm and then tighten
the saw guide adjusting screws.

7. Clamp both front and rear vises.

8. Check the band brush for correct positioning, verify

that the chip conveyor is operating and choice of

coolant ow has been selected.

9. Press the "BAND CYCLE START" button.

10. Saw head will lower cut through the material, energize
head down limit switch, saw head will rise above
the material and the blade will shut off.

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

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

Automatic Operation

1. Start the operation by following steps 1 through 8

from the preceding "Manual Operation" section.

2. If necessary, "HOME" the indexing vise. After homing,
make sure the indexing vise is not at the "HOME"
position. This is done in "MANUAL" mode and only

when the front vise is clamped and the rear vise is
opened.

1. These operation procedures 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 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.

3. Press "MODE SET" on the View Screen and enter
your data for "EXEC", "SIZE", "QTY" and "BLADE
SPEED" parameters for each job. Double check

your data. Make any changes before starting.

4. Press "F1" to go to the "View Screen". Select
"AUTO", "COOLANT AUTO" or "MANUAL"
and choose between "CUTS EXCLUDED" or
"COUNTED".

28

TYPICAL OPERATING PROCEDURES

(Continued....)

5. Press the green "BAND DRIVE ON" button on the
control panel or the "BLADE ON" key on the "Run

(Manual)" Screen of the workstation.

6. The saw head will lower cut through the material,
energize head down limit switch, saw head will rise
above the material, vise will transfer the material for
the next cut, vise(s) will clamp and the saw head
will lower and begin the process over again.

7. When all jobs entered have been completed, the
saw band shut off.

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

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

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, feed force and coolant
application settings for successful jobs.

29

LUBRICATION

LUBRICATION CHART

LUBRICATION

POINT NO.

1
2
3
4

5

6

7

8

9

10

11

12

LOCATION DESCRIPTION and

SERVICE RECOMMENDATIONS

Idler Bandwheel Bearings. One (1) grease tting. WEEKLY

Index Vise Movable Jaw Ways. Two (2) grease ttings. WEEKLY

Gearbox Shaft Bearings. Two (2) grease tting. WEEKLY

Band Tension Slide. One (1) grease tting. WEEKLY

Saw Head Tube. One (1) grease tting. MONTHLY

Sensing Arm. Clean and apply oil. MONTHLY

Miscellaneous: Vise Slide, Hinges, Pivot Points,
Component Parts, Unpainted Surfaces, etc. To ensure

function and maintain appearance while reducing wear,
corrosion, rust, etc. Apply when and where needed in
amounts required.

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

Band Drive Gearbox. Capacity depending on model. See

Specication Chart. Drain, change and rell after the rst

three (3) months; every six (6) months thereafter. Do not

overll. Fill until above the red line.

Electric/Hydraulic Motors. Band Drive, Hydraulic Pump,

Coolant Pump, Chip Auger.

Coolant Reservoir. Capacity depending on model. See
Specication Chart. Drain, clean and rell whenever coolant
becomes undesirable for further use. Clean the mesh screen

at the same time.

Hydraulic Reservoir. Capacity depending on model. See

Specication Chart. 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*

AS REQUIRED

6 MONTHS

Lubricate (if any) per manufacturer's recommendations.

CHECK DAILY/
AS REQUIRED

CHECK DAILY/
AS REQUIRED

RECOMMENDED

LUBRICANT

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

NLGI No. 2.

Union 76, UNOBA EP 2, 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.

High quality, 4EP (extreme pressure)
multi-purpose gear oil.

Mobil Gear (629-YC1F4), Union Extra

duty NL Gear Lube.

S.A.E Grade No. 90.

Premium quality, saw band coolant and

lubricant.

DoALL cutting uids and/or oils (Kool

All).

Multi-purpose automatic transmission
uid.

General Motors Dexron III, or equivalent.

30

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

*

Lubricate more often with heavier use.

LUBRICATION DIAGRAM

31

MAINTENANCE

REPLACING SAW GUIDE AND BACK-UP
INSERTS

These instructions can be used to replace

the saw guide inserts and back-up roller on
both left and right saw guide arms.

The band drive motor MUST NOT be running

when replacing saw guide and back-up inserts.

1. Loosen the insert adjustment screw on each saw
guide arm. Then: (a) Remove the left saw band
guard (if necessary); (b) Remove the adjustment
screw being very careful not to drop or lose the
front insert when it falls from the assembly; (c)
Loosen the socket cap screw from the rear side of
the saw guide and remove the rear insert.

2. Thoroughly clean the saw guide arm and inserts
area. Then: (a) Check the back-up roller for wear
and replace the roller if it has deteriorated (this will
help prevent coolant leakage).

3. Install the new xed insert and tighten the screw.

Then: (a) Thread the adjusting screw inward part
way; (b) Install the adjustable insert; (c) Tighten
the adjustment screw; (d) Replace the left saw band
guard (if removed).

BAND DRIVE/BRUSH BELT REPLACEMENT

Check the status of the band brush belt at

this time also. The band drive belts must
be removed to access the band brush belt.
Consider changing both belts at the same
time.

HYDRAULIC SYSTEM

1. The machine's hydraulic reservoir capacity depends
on machine model. (See Machine Specications

Chart). Check the reservoir oil level daily by referring

to the sight gauge (located on the left side of the
machine behind the control console.

2. Before changing the hydraulic oil: (a) Lower the
saw head completely; (b) Push the Hydraulic Stop
pushbutton; (c) Remove the reservoir drain plug;
(d) Allow the reservoir to drain completely.

3. Drain, clean, rell the reservoir and change the oil
lter after the rst three (3) months of operation;
every six (6) months thereafter. Clean the suction
strainer and ller opening screen when necessary.
Automatic transmission uid is the recommended

product.

System Pressure

1. Hydraulic system pressure is correctly set at the
factory and should not require adjustment for a
considerable period of time.

DC-280NC DC-330NC DC-420NC

System

Pressure

± 10 psi (2 kg/cm²)

System

Pressure

± 10 psi (2 kg/cm²)

425 psi

(30 kg/cm²)

DC-460NC DC-500NC DC-560NC

570 psi

(40 kg/cm²)

425 psi

(30 kg/cm²)

570 psi

(40 kg/cm²)

570 psi

(40 kg/cm²)

640 psi

(45 kg/cm²)

COOLANT SYSTEM

1. To change the band drive belt, open the right
bandwheel door. Then: (a) Undo the guard clips
and remove the screws; (b) Located in the rear of
the machine between the band drive motor and the
gearbox, turn adjustment knob counterclockwise
to relax belt tension; (c) Remove the old belt and
install the new belt by stretching the belt over the
desired speed range set of pulleys.

5. Turn adjustment knob clockwise to tension the belt.

There should very little deection at the center span

of the belt.

6. Flip the cover back up and engage the clips and
install the screws.

1. The machine's coolant reservoir capacity depends
on machine model. (See Machine Specications
Chart). A reservoir level sight gauge is located at
the machine’s right front side.

2. Check the coolant often for signs of contamination

or breakdown. The reservoir and coolant system
should be drained and cleaned thoroughly when the

cutting uid becomes undesirable for further use.

If another type of coolant is to be used, the entire

coolant system must be ushed (use DoALL’s Kleen

Flush).

3. To thoroughly clean the reservoir section below
the conveyor trough, removal of the trough will be
necessary.

32

4. Fill the reservoir with coolant through the tube
breather opening until coolant is above the red line
on the sight gauge.

BAND DRIVE GEARBOX

MACHINE ALIGNMENT

1. Misalignment of the machine’s saw guide arms,
slide bar, saw band, pivot points, gearbox, etc., will
cause inaccurate sawing.

1. Gearbox replacement, repair, adjustment or
alignment should be performed only by a DoALL
service representative.

2. The machine's gearbox reservoir capacity depends
on machine model. (See Machine Specications

Chart). Check the reservoir oil level daily by referring

to the sight gauge.

3. Before changing the gearbox oil, lower the saw head
completely and then stop the hydraulics.(a) Remove
the reservoir drain plug; (b) Allow the reservoir to
drain completely; (c) Remove the tube breather at
the top of the gearbox.

4. Place container under the gearbox and remove the

reservoir drain plug. Allow the reservoir to drain
completely. Then replace the drain plug making
sure the plug is tight and sealed.

5. Fill the gearbox with oil through the tube breather
opening until oil is above the red line on the sight
gauge.

6. Change the oil after the rst three (3) months of

operation; every six (6) months thereafter.

MACHINE CLEANING

1. Keep the machine and its parts as clean as possible
to prevent excessive wear and damage.

2. Use the Flushing Hose as soon as possible to remove
metal chips and other waste materials which may
collect around the saw guides, bandwheels, vises,

slides, sensing arm, etc. The hose has a hand-

operated valve and attaches to the coolant pump.

The DoALL Company recommends using the
Flushing Hose to remove chips at least twice
per each eight (8) hour shift, and more often
with heavier use.

DO NOT attempt any alignment procedures

not covered by this manual. Contact a
DoALL service representative in such cases

because special xtures and techniques may

be required.

BAND BRUSH

1. The band chip brush will wear and lose steel bristles

over time. Check often to be sure the bristles are

removing metal chips from the blade tooth gullets,
but are not touching the bottom of the gullets.

2. Move the brush closer to the blade as normal wear
occurs. Replace the brushes when necessary.

BAND TENSION MEASUREMENT

1. Band tension is factory set.

• Band tension measurement can be made with the
machine’s hydraulics running and by using the Band
Tension selector and a DoALL Tensigage.

2. Tension may be checked "reading up" or "reading
down". To "read up": (a) Fix the Tensigage to a

slack saw band; (b) Apply tension. To "read down":
(a) Fix the Tensigage to a tensioned saw band; (b)

Relax tension.

3. A correct DoALL Tensigage reading depends on
machine model. (See Machine Specications

Chart).

3. Use a shovel, scoop or rake to remove accumulated
metal chips or other waste materials from machine
areas. Be sure the band drive motor is stopped

before cleaning.

Using a Tensigage to Measure Band Tension.

33

WEAR PLATE REPLACEMENT

CLEANING CHIP CONVEYOR

1. The removable vise jaw and vise guide bars must
be replaced before excessive wear causes the
mounting screw heads to become damaged and

makes removal difcult.

Vise Jaw Plates

1. The machine has eight (8) vise jaw wear plates: four

(4) on the front vise jaws and four (4) on the index

vise jaws. All wear plates are mounted with low-head

screws. Be sure the vise jaws are separated and
the machine turned off before trying to replace
the wear plates.

Vise Guide Rails

1. Each of the two (2) vise guide rails for both front

and index vises has eight (8) mounting screws

which must be removed. Replacement requires:
(a) Removing the mounting screws; (b) Pulling the
guide rails toward the left.

BANDWHEELS

1. To clean the chip conveyor, turn the machine off.
Then: (a) Disconnect the hydraulic hoses; (b) Pull
the auger from its cradled position in the base; (c)

Clean the conveyor trough; (d) Clean the reservoir
oor; (e) Reinstall the auger and cover.

1. Occasionally check each bandwheel’s back-up
ange and wheel tread for wear. Saw bands will

not track properly if the taper is worn from the wheel
tread.

2. Replace the entire bandwheel if the rim becomes
badly worn.

3. Ideally, the saw band should be tracking on both
wheels so that the back edge will just lightly contact

the wheel anges, or is not more than 0.005 inch
(0.127 mm) away from the anges.

Bandwheel Flange and Tread.

34

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 schematics will be helpful.

ERROR MESSAGES

1. Follow the prompts when an error message appears.

MACHINE WILL NOT START

1. Check that the disconnect switch is in the “ON”

position.

2. The Emergency Stop pushbutton needs to be reset
(rotate the button head clockwise).

3. See if the main fuses and/or circuit breakers have
tripped or burned out.

4. Make sure both bandwheel doors are closed or any
interlock is engaged.

SAW BAND STALLS DURING A CUT

1. Decrease saw head feeding pressure.

2. Check to see if drive belt tension is adequate to
resist "cogging" underload.

3. Use a Tensigage to check for proper saw band
tension.

4. Check for proper operation of the Band Tension

selector.

BLADE TOOTH GULLETS ARE LOADING

1. Use a coarser pitch saw band.

2. Increase the band speed setting, or decrease the
feed pressure setting.

3. Check for improper coolant application.

4. Check the positioning of the band brush. Replace

the brush, if necessary.

5. Push the motor starter overload reset buttons in

the electrical cabinet. If overload tripping occurs,
locate and correct the problem.

6. Check the control transformer for power.

7. Check the hydraulic motor and wiring.

8. Check the starter, relay coils and contacts for faulty

operation.

9. Have an electrical service person check the continuity
of the starting circuit.

MACHINE STARTS, BUT WON’T CONTINUE
RUNNING

1. The saw band is broken or too long and is activating
the band break proximity switch.

2. Check to see if the bandwheel doors are closed (the

band drive motor will not start unless both doors are
closed).

3. The saw head has not cleared the head down

proximity switch. Push the Saw Head Up button.

SAW BAND SQUEAL

1. The lead-in/exit rollers are: (a) Not contacting the
saw band; or (b) Positioned too tightly against the
saw band.

2. Check for defective lead-in/exit roller bearings.

SAW BAND VIBRATION

1. Check for a dull or damaged saw band.

2. Incorrect band speed or feed pressure setting is
being used.

3. Check for incorrect saw band pitch.

4. Coolant mixture is weak, or incorrect coolant is being

used.

5. Stockpiece is not being rmly clamped by the vise

jaws.

6. Check for worn or improperly-adjusted saw guide

inserts.

4. The out of stock limit switch has been actuated.

7. Check for a worn saw guide back-up bearing or
lead-in/exit roller bearing.

8. Check for incorrect saw band tension.

35

TROUBLE SHOOTING (Continued....)

PREMATURE BLADE TEETH DULLING

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

2. Increase band speed being used and/or decrease
feed force.

3. Check for stock not being held rmly by the vise

jaws.

2. Check for faulty stock: Heavy scale, inclusions,

hard spots, etc.

3. Stock analysis is incorrect. This can result in an
incorrect cutting recommendation.

4. Coolant is not covering the saw band properly.

5. Check for saw band vibration.

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

lodged in the cut.

7. Saw band being used is incorrect.

8. Coolant mixture is too weak, or incorrect coolant is

being used.

9. The saw band is not properly tensioned.

10. Decrease feed pressure to "break in" a new saw
band on its rst few cuts.

BLADE TEETH STRIPPING

4. Check for incorrect adjustment of the saw guide
inserts and carbide back-up guides.

5. Check for insufcient coolant ow.

6. Use a ner pitch saw band.

7. Check for incorrect saw band tension.

SAW BAND IS NOT RUNNING TRUE AGAINST
THE SAW GUIDE BACK-UP BEARINGS (May
Cause Vibration)

1. Examine the carbide back-up bearings. Replace
them if they are chipped or worn more than 0.020-

inch (0.5 mm).

2. Have a DoALL service representative check machine
alignment.

3. Check for worn saw guide pivot bolts.

4. Left saw guide arm is loose, or not positioned close
enough to the stock.

1. Increase band speed or decrease feed pressure.

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

lodged in the cut.

3. Faulty stock is being used: Check for heavy scale,

inclusions, hard spots, etc.

4. Check for a worn, or improperly adjusted band brush.

5. Check for vibration caused by loose vise jaw clamping

against the stockpiece.

6. Check for worn saw guide inserts and/or carbide
back-up bearing.

7. Coolant is not being applied correctly.

8. Check for incorrect saw band tension being used.

9. Saw band pitch may be too coarse for thickness of
the stock section.

SAW BAND BREAKAGE

1. The saw band is being dropped into the stockpiece
due to incorrect saw head feeding rate.

INACCURATE CUT-OFF

1. Check for worn or dull blade teeth.

2. Check for a hard spot in stock being cut.

3. Band brush is not properly cleaning the blade teeth.

4. Increase band speed being used and/or decrease
feed force.

5. Check for dirty coolant. Replace if necessary.

6. Check for crooked stock (this can result in straight,

but not square cuts).

7. Left saw guide arm is loose, or not positioned close
enough to the stock being cut.

8. Saw band pitch choice is incorrect.

9. Check for incorrect saw band tension.

10. Check for incorrect adjustment of inserts, back-up

bearing, or worn pivot bolts.

36

TROUBLE SHOOTING (Continued....)

11. Check machine alignment. Have a DoALL service

representative check and/or adjust machine
alignment.

VISES WON’T TRANSFER and SAW HEAD
STAYS DOWN

1. Check for faulty operation of the head down proximity

switch.

12. Check for coolant not being supplied evenly to both

sides of the saw band.

SURFACE FINISH OF CUT-OFF PIECE IS TOO
ROUGH

1. Check for vibration while sawing.

2. Check for a damaged saw band.

3. Use a ner pitch saw band.

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

5. Check the saw band back-up guides for wear.

Replace them if necessary.

6. Check for incorrect saw band tension.

CUTTING RATE IS TOO SLOW

1. Increase the feed rate.

2. Check to see if the vise solenoid is operating.

3. Check to see if the saw head solenoid is operating..

SAW HEAD WON’T LOWER

1. The feed rate setting is too low.

2. Check the head clear proximity switch for faulty
operation.

3. Check to see if the saw head solenoid is operating.

4. Check for saw head obstruction.

SAW HEAD WILL NOT RAISE, OR RAISES
SLOWLY

1. Check to see if the saw head solenoid is operating.

2. Check for low hydraulic system pressure caused
by blockage, clogged oil lter cartridge, or pinched

hose.

2. Increase band speed and/or feed force.

3. Use a courser pitch saw band.

STOCK FEEDS ERRATICALLY

1. Check for low hydraulic system oil level.

INDEX VISE WON'T MOVE FORWARD

1. Check to see if the vise solenoid is operating.

VISES WON'T TRANSFER AFTER AN INDEX

1. Check for faulty operation of the index forward

proximity switch on the index vise base.

2. Check to see if the vise solenoid is operating.

INDEX WON'T RETURN

1. Check to see if the vise solenoid is operating.

2. Check for incorrect adjustment of the index forward

proximity switch.

SAW HEAD LOWERS ERRATICALLY

1. Bleed air from the head lift cylinder. It may be
necessary to raise and lower the saw head several
times to thoroughly bleed the head lift cylinder.

SAW HEAD WON'T STOP AT THE CORRECT
STOCK HEIGHT

1. Check the stock height sensing arm. Is it positioned

correctly relative to the saw band?

2. Check to see if the sensing arm is properly actuating

the head clear proximity switch.

3. Check to see if the saw head solenoid is operating.

SAW HEAD DOESN'T LOWER FOR REPEAT
CUTS

1. Check to see if the saw head solenoid is operating.

2. Check adjustment of the head clear proximity switch.

3. Check the index forward proximity switch.

37

TROUBLE SHOOTING (Continued....)

SLUGGISH HYDRAULIC OPERATION

1. Check for low hydraulic system pressure or low

reservoir level.

2. Check for air in the hydraulic system.

3. Check for a blocked or clogged hydraulic lter.

4. Check for faulty hydraulic pump operation.

5. Check for cold hydraulic oil.

BAND DRIVE TRANSMISSION GETS HOT

1. Check for low transmission uid level.

2. Check for lubricant leakage.

NUISANCE OVERLOAD TRIPPING

1. Check to see if the overload relays are set too low.

Increase the setting if necessary.

SENSING ARM HANGS UP

1. Check to see if the sensing arm is dirty.

MALFUNCTIONING OPERATING SEQUENCE

1. EPROM memory pack is malfunctioning, or is not

installed or is installed incorrectly.

38

ACCESSORIES

10" (3050.0 mm) ROLLER STOCK CONVEYOR

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
adjunct). The following conveyors are available:

• The ve (5) foot conveyor is standard.

• Optional stock conveyor is ten (10) feet (3050.0 mm)

long by 22 inches (558.8 mm) wide with a weight
capacity of 800 pounds (362.9 kg) per 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.

39