DoAll TF-2025M Instruction Manual

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Page 1

TF-2025M

Serial No: 543-99101 to

Instruction Manual

Band Sawing Machine

Page 2

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.

Page 3

OPERATOR'S INSTRUCTION MANUAL

UNIVERSAL TILT-FRAME BAND MACHINE

MODEL FIRST SERIAL NO. LAST SERIAL NO.

TF-2025M 543-99101

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

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 and Tensigage.

PRINTED IN U.S.A. PB-486.4 (2-10)

Page 4

TABLE OF CONTENTS

MACHINE DIMENSIONS

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

Front View .............................................................. 2

Side View ................................................................ 3

MACHINE FEATURES

Front and Side Views ............................................. 4

Head Assembly ....................................................... 5

Proximity/Limit Switch Locations ............................ 6

INSTALLATION

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

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

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

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

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

Floor Installation and Alignment ............................. 7

Electrical Installation ............................................... 7-8

Hydraulic Installation .............................................. 8

Coolant Installation ................................................. 8-9

Preparation for Use ................................................ 9

OPERATION

Safety Precautions ................................................. 10

Using the Job Selector ........................................... 10

Cutting Capacity ..................................................... 11

Control Console ...................................................... 11-14

Saw Band Preparation ............................................ 14-15

Post Adjustment ...................................................... 16

Feed Force Adjustments ......................................... 16

Saw Head Approach Rate ...................................... 16

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

Hydraulic System .................................................... 17

Chip Removal ......................................................... 17-18

Idler Wheel Motion Detector ................................... 18

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

LUBRICATION

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

Lubrication Diagram ............................................... 21

MAINTENANCE

Replacing Saw Guide and Back-Up Inserts ........... 22

Hydraulic System .................................................... 22-23

Coolant Ststem ....................................................... 23

Machine Cleaning ................................................... 23

Machine Alignment ................................................. 23

Brush Adjustments .................................................. 23

Wear Plate Replacement ........................................ 23

Bandwheels ............................................................ 24

Cleaning Optional Chip Conveyor .......................... 24

Head Angle Display Calibration .............................. 24

TROUBLE SHOOTING .................................. 25-27

ACCESSORIES

Roller Stock Conveyors .......................................... 28

Vertical Guide Rollers (For Conveyors) .................. 28

Nesting Fixture ....................................................... 28-29

Chip Conveyor W/Coolant Reservoir ...................... 29

Mist Lubricator ........................................................ 30

Outboard Vise (Right Hand Vise) ........................... 30

Lift Rollers ............................................................... 30

Laser Line Option ................................................... 30

Fixed Head (Non-Tilting) ........................................ 30

3° Head Cant .......................................................... 30

How to read your serial number:

Page 5

MACHINE DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

FLOOR PLAN

Page 6

MACHINE DIMENSIONS (Continued....)

INCHES (± .03)

MILLIMETERS (± 1 mm)

FRONT VIEW

Page 7

MACHINE DIMENSIONS (Continued....)

INCHES (± .03)

MILLIMETERS (± 1 mm)

SIDE VIEW

Page 8

MACHINE FEATURES

FRONT VIEW

SIDE VIEW

Page 9

MACHINE FEATURES (Continued....)

HEAD ASSEMBLY

Page 10

MACHINE FEATURES (Continued....)

PROXIMITY/LIMIT SWITCH LOCATIONS

REAR VIEW

HEAD

TOP VIEW

Page 11

INSTALLATION

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

designations in this manual are as viewed by the operator looking directly at the teeth of the saw band.

LOCATION

1. The floor area required by the machine is approximately 105.00 inches (2667.0 mm) in width by 91 (2311.4) inches (4567.3 mm) in length. Machine height for the machine is 107.65 inches (2734.3 mm). Refer to pages 1, 2 & 3 for further machine dimensions.

2. Locate the machine to provide adequate space for your sawing needs. Be sure also to provide:

(a) Sufcient clearance for loading and unloading

of stock; (b) Coolant tray installation; (c) Head tilt; (d) Door openings; (e) Maintenance and lubrication procedures; (f) Operation of any machine accessories.

3. Provide ample space for roller conveyors and/or

other material handling equipment if supplied.

OSHA NOTICE!!

LIFTING

NEVER lift the machine by its sawing head.

1. There is three (3) forged 3/4-10NC eye-bolts for

lifting purposes. Two (2) are located in front on the corners of the machine base and one (1) located in the rear center near the head pivot pillow block.

2. Using chains attached to the eyes-bolts, it is recommended that lifting and transporting of the machine be done with an overhead hoist. Net weight is approximately 7200 pounds (3265.9 kg).

3. The hydraulic power unit (aproximately 600 pounds (272.2 kg) and conveyors (if supplied as optional equipment) can be lifted and transported by overhead hoist, fork lift, or by other means that provides adequate safety precautions.

FLOOR INSTALLATION and ALIGNMENT

1. While the machine is suspended by the overhead hoist, thread the provided leveling screws into each machine base foot and attach the jam nuts. Slowly lower the saw into desired position.

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. Carefully remove all protective covers, strapping,

hold-down brackets, crating, etc., but DO NOT remove the head support bracket until the machine is placed in desired location. Then: (a) Remove all bolts which fasten the machine to the shipping skid;

(b) Check around the machine for other removable

brackets, extra machine parts or supplies which might have been placed there for shipment; (c) Inspect the

machine and all parts for shipping damage. Claim

procedures are listed on this manual’s inside front cover.

CLEANING

2. Just prior to touching the ground, place a cast iron foot pad under each of the leveling bolts. Lower the saw completely onto the foot pads.

3. Place a level on the machine vise wear plate bed.

Insert leveling screws into the mounting pads and

make nal adjustments to level the machine in both

directions. Make sure weight bears evenly on all mounting pads.

4. After the machine has been leveled, install anchoring screws through the base pad holes next to the leveling screws.

5. Remove the protective shipping bracket installed to connect the saw head to the base frame during shipping.

6. Install optional roller stock conveyor(s) if supplied.

These do not attach to the machine and should

beanchoredtotheoorseparately.

1. If necessary, use solvent to remove rust-preventive coating applied to exposed bare metal surfaces before shipment.

Page 12

ELECTRICAL INSTALLATION

Electrical installation must be made by

authorized electrical maintenance personnel only.

7. 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).

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. A basic data plate is reproduced on this manual’s introductory page.

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

3. Power is connected to the main enclosure located

the rear of the machine.

4. The fol l o win g ar e im p ort a n t di sco n nec t precautions:

The disconnect must be "ON" 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.

5. Turn the disconnect switch on the electrical cabinet to "OFF". Then: (a) Loosen the screws at the right 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.

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

hole into 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). DO NOT bring the power cable

through any holes in the back wall. These are for installation of future accessories.

8. Place the operating shaft and operating handle of

the disconnect switch in the "OFF" position. Then:

(a) Close the electrical cabinet door and secure its

screws; (b) Now turn the electrical supply and the disconnect switch to "ON" (no action will occur until the Hydraulic Start button on the control console has been pushed).

DO NOT start machine hydraulics until the

following “Hydraulic Installation” procedures have been performed.

HYDRAULIC INSTALLATION

1. Position the hydraulic power unit behind and to the

right of the machine.

2. Check the hydraulic reservoir uid level in the power unit. Capacity is 20 gallons (75.7 liters). If

the reservoir level is low (or empty): (a) Check to see that the reservoir’s drain plug is installed tightly; (b) Fill with multi-purpose automatic transmission

uid.

3. Connect the hydraulic lines between the machine

and power unit by matching tags on hoses to connection points on the power unit. Refer to the hydraulic schematic if necessary.

4. Remove the orange coupling guard between the hydraulic pump and motor and turn the coupling to assure free movement.

5. Prime the hydraulic pump by jogging the Hydraulic Start and Hydraulic Stop pushbuttons. Check the

rotation of the hydraulic pump motor as indicated on the arrow label.

Electrical Connections to Disconnect Switch.

6. If hydraulic pump motor rotation is reversed: (a) Turn the disconnect switch 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 5 again.

7. As soon as hydraulic pump motor rotation is correct, jog the Hydraulic Start and Hydraulic Stop pushbuttons several times to make sure the hydraulic pump is primed. Then allow the machine to run for several minutes to remove entrapped air. Also check for any hydraulic leaks at this time.

Page 13

COOLANT INSTALLATION

1. Install the coolant pump by attaching it to the mounting bracket inside the coolant tray with screws provided.

Coolant Installation.

2. From the rear, slide the coolant tray between the

deector shields all the way in and under the saw

head with the coolant pump to the rear of the machine.

3. Fill the coolant reservoir with 20 gallons (75.7 liters)

of oil or cutting uid recommended by the Lubrication Chart. DO NOT let coolant spill over the tray and

ontotheoor.

 Thecoolantpumpintakemustbesufciently

submergedforcoolantowtoreachallareas

in the coolant system.

PREPARATION FOR USE

1. Check to be sure all safety guards, covers and doors are in place, closed and/or secured.

2. Remove the protective Saw Cap from the saw band

by opening the upper bandwheel door and carefully pull the cap off the saw band. Then closed the bandwheel door.

3. Check to see that all other points listed by the Lubrication Chart have been properly checked and/or serviced.

Page 14

OPERATION

SAFETY PRECAUTIONS

Warning Label - READ and UNDERSTAND.

USING THE JOB SELECTOR

1. Refer to the Job Selector chart on the front panel of the control console for information about the recommended blade pitch, band speed, and cutting rate. This information is listed according to type of material to be cut and its thickness. The Job Selector also has a checklist for proper machine operation and saw band break-in procedures.

Job Selector recommendations can be adjusted

to meet special sawing requirements and are a general guide for correct cut-off sawing on a properly-maintained DoALL saw. They are based on cutting annealed, scale-free stock using a Imperial Bi-Metal saw blade.

Job Selector.

Page 15

CUTTING CAPACITY

1. The standard machine's cutting capacity is:

2. Left Vise. This selector switch with "OPEN", "HOLD"'

and "CLAMP" settings operate the vise on the left

side (inboard side) of the saw band.

• At 0° tilt: 20 inches (508.0 mm) wide by 25 inches (635.0 mm) high for rectangular stock; 20 inches (508.0 mm) diameter for round stock.

• At 45° tilt: 20 inches (508.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; 17 inches (431.8 mm) diameter for round stock.

• At 60° tilt: 20 inches (508.0 mm) wide by 11 inches (279.4 mm) high for rectangular stock; 11 inches (279.4 mm) diameter for round stock.

2. Cutting capacity may vary with addition of accessories

and will be noted when applicable.

Vise Capacity

1. The vise maximum opening is 20.50 inches (520.7 mm).

• Weight limit for the vise bed is approximately 1000 pounds (453.6 kg); 500 pounds (226.8 kg) for each half evenly distributed with no impact.

Saw Band Recommendations

• The "OPEN" setting opens the vise jaws; the "CLAMP" setting closes the vise jaws; and "HOLD"

stops vise jaw movement, it does not clamp material.

• This vise must be clamped to start the band drive.

3. Saw Head Control. Use this selector switch

with "REV" (reverse), "HOLD" and "FWD/AUTO" ("FORWARD/AUTO") settings to regulate the

direction of saw head movement.

• Rotating the selector to "FWD/AUTO" or forward

moves the saw head forward or towards the sawing area.

• Rotating the selector to "REV" or reverse moves the saw head back or away from the sawing area.

• Turning the selector switch to "HOLD" stops all saw feed motion.

4. Right Lift Roller (Optional). This selector switch operates the right hand (outboard) lift roller in the

"UP" or "DOWN" positions.

1. A high-speed DoALL Imperial Bi-Metal Super

Silencer saw band with protective Saw Cap is

supplied with the machine. Band length is 209

inches (5308.6 mm); width is 1-1/4 inches (31.7

mm); recommended gage is 0.042-inch (1.1 mm); kerf is 0.085-inch (2.2 mm).

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; (b) Using correct

band speed, feed force and cutting uids during

operation; (c) Removing scale from stock before sawing; (d) Keeping the protective Saw Cap over blade teeth until installation time.

Consult your DoALL sales representative for

complete information about saw bands and their applications.

CONTROL CONSOLE

5. Right Vise (Optional). This selector switch with

"OPEN", "HOLD"' and "CLAMP" settings operate

the vise on the right side (outboard side) of the saw band.

• The "OPEN" setting opens the vise jaws; the "CLAMP" setting closes the vise jaws; and "HOLD"

stops vise jaw movement.

Make sure the vise jaw is opened wide enough

when moving material through the vises.

6. Head Rapid Approach. Used in conjunction with the Saw Head Control selector switch, pushing and holding this pushbutton accelerates the rate of speed the saw head moves towards the sawing area.

• This pushbutton is active only when the Saw Head

Control selector is in the "FWD/AUTO" position. The

band drive does not have to be "ON" to operate.

7. Laser. This selector switch turns the line-up laser "ON" and "OFF".

Electrical Controls

1. Left Lift Roller (Optional). This selector switch

operates the left hand (inboard) lift roller in the "UP"

or "DOWN" positions.

To avoid eye damage, DO NOT stare into the

laser beam.

Page 16

CONTROL CONSOLE (Continued....)

Typical Pushbutton Panel.

8. Post. This selector switch with "DOWN", "HOLD",

and "UP" settings regulate post movement.

• (a) Rotating the selector to "DOWN" lowers the post; (b) The "UP" position raises the post; (c) The "HOLD" position stops post movement.

When the saw head is rotated, make sure the

post is positioned to clear the material. Failure to do so will result in damage to the post.

9. Operation. This selector switch with "MANUAL" and "AUTO" settings determines the machine's operating mode. Make your selection before starting the band drive motor.

• Placing the selector to "MANUAL" will stop all

machine functions at the head forward position following the completion of each cut.

• Placing the selector in "AUTO" permits a full cycle

mode following the completion of cuts; (a) The saw band drive motor will stop; (b) The saw head will return behind the vise jaw; (c) Hydraulics will remain on.

10. Head Angle Display. This displays the angle of the saw head in degrees from vertical.

• When the saw head is tilted to the left, the display shows a "-" or negative angle; when tilted to the right, no sign is shown or positive angle.

11. Head Angle Rapid. Used in conjunction with the Head Angle selector switch, pushing and holding this pushbutton accelerates the rate of speed the saw head moves while rotating the saw head.

12. Head Angle. This selector switch with "-", "HOLD", and "+" settings regulate the direction of head tilt and shows the angle in degrees on the display above.

Head Angle Orientation.

• Turn the selector to "-" or left causes the head to pivot to the left or negative direction.

• Turn the selector to "+" or right causes the head to pivot to the right or positive direction.

• Turn the selector to "HOLD" stops head movement in either direction.

13. Band Speed Display. This display shows the factory-set band speed in feet per minute or meters per minute.

14. Band Speed. Turn this knob to adjust band speed

between 50 and 400 fpm (15 to 122 m/min.).

Rotate clockwise to "increase" the band speed; counterclockwise to "decrease" it.

Page 17

CONTROL CONSOLE (Continued....)

15. Chip Conveyor (Optional). This selector switch with "REVERSE", "OFF", and "FORWARD" settings operate the optional motorized chip conveyor.

• Turning the selector to the "FORWARD" position moves the chip conveyor belt to the rear of the saw and deposits the chips into a container. This is the normal operating position and recommended that it is in the "FORWARD" position during sawing procedures.

• Turning the selector to "REVERSE" moves the chip conveyor belt towards the front of the machine. Use this setting only to clear a temporary situation.

• The center position turns the chip conveyor "OFF".

16. Band/Cycle Start. Push this green button to start the band drive motor. The button will be illuminated when the band drive motor is operating. Allow the motor to accelerate to operating speed before starting a cut.

20. Hydraulic Stop. Pushing this red button turns off the hydraulic pump.

21. Emergency Stop. Pushing this red mushroom head pushbutton stops all machine motors (band drive, hydraulic pump, coolant pump and optional chip conveyor) simultaneously. To reactivate machine motors:

• If the machine was operating in manual mode before the Emergency Stop button was pushed: (a) Reset the Emergency Stop button by turning the button head clockwise; (b) Push the Hydraulic Start and Band/Cycle Start buttons in sequence.

• If the machine was operating in automatic mode before the Emergency Stop button was pushed: (a) Reset the Emergency Stop button by turning the button head clockwise; (b) Push the Hydraulic

Start button; (c) Position the stock as necessary; (d) Clamp both index and xed vises; (e) Push the Auto (F6) button; (f) Push the Band/Cycle Start

button.

Other Controls

• The following conditions must exist before pushing the Band/Cycle Start button: (a) The Emergency

Stop pushbutton is reset (turn the button head clockwise); (b) Hydraulics must be on; (c) All doors

and covers/guards must be closed or in place; (d) A saw band must be installed and the Band Tension selector must be at “ON”; (e) The vise(s) must be clamped.

17. Band/Cycle Stop. Push this red button to stop the band drive motor.

18. Coolant. Four position selector switch with "AUX", "OFF", "BAND ON", and "ON" settings.

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

"ON" allows the ood coolant system to operate

without the band drive motor running; (c) "AUX" is used for the optional cutting lubrication system; (d) "OFF" turns off either system.

19. Hydraulic Start. Push this green button to start the hydraulic pump motor (the button will be illuminated when the hydraulics are operating). The hydraulic pump motor must be on to operate any machine functions.

1. Band Tension. This selector switch with "OFF", "HOLD" and "ON" settings is used when changing saw bands. The control is located on the rear side of the column and accessed from the left side.

• 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 pressures the cylinder and establishes band tension required for cutting. DO NOT operate the band drive motor unless band tension is on.

• The Band Tension selector must be "ON" before the saw head will traverse.

Hydraulic Control Panel

1. Variable Vise Pressure. This control valve and gauge 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.).

• Before starting the hydraulics, the Emergency Stop pushbutton must be reset (turn clockwise).

• Clamping pressure is set by loosening the lower

locking knob, then turn the upper adjusting knob until the desired pressure is shown by the indicator gauge. Turn the knob clockwise to "increase" pressure;

counterclockwise to "decrease" pressure.

Page 18

CONTROL CONSOLE (Continued....)

Typical Hydraulic Control Panel.

2. Head Approach. This valve regulates the saw head’s forward rate. Turn the knob counterclockwise to “increase” the velocity; clockwise to “decrease” it.

3. Coolant. This valve regulates coolant ow to

the upper saw guide and ushing hose. Turn the

valve counterclockwise to “increase” coolant ow; clockwise to “decrease” the ow.

4. Feed Force. This valve and gauge are used to regulate the amount of pressure being placed by the saw band against the workpiece. Turn the knob clockwise to “increase” pressure; counterclockwise to “decrease” the force desired as shown on the gauge. The valve’s lower locking knob helps maintain the setting.

Optional Material Handling Controls

1. Conveyor Speed. This selector switch with "LOW" or "1" and "HIGH" or "2" settings regulate the speed of the conveyor(s).

• When the selector is in the "LOW" or "1" position, the conveyor maximum speed is reduced to about 30%.

4. Conveyor Speed/Direction. This two position joystick allows the operator to adjust the conveyor

speed and direction of material owing through the

machine.

• The Infeed and/or Outfeed Conveyor Enable selectors must be "ON" for this control to operate.

• Moving the joystick to the right will convey the material to the rear of the machine; moving the joystick to the left will convey the material forward on the system.

• The rate of travel in either direction is controlled by how far the joystick is moved from center. The farther from center, the faster the rate of travel.

SAW BAND PREPARATION

Saw Band Recommendations

1. A high-speed DoALL Imperial Bi-Metal Super

Silencer saw band with protective Saw Cap is

supplied with the machine. Band length is 209

inches (5308.6 mm); width is 1-1/4 inches (31.7

mm); recommended gage is 0.042-inch (1.1 mm); kerf is 0.085-inch (2.2 mm).

2. Infeed Conveyor Enable. This selector switch with "ON" and "OFF" settings allows the operator to turn the power off or on to the conveyor. This is used in conjunction with the Conveyor Speed/Direction control.

3. Outfeed Conveyor Enable. This selector switch with "ON" and "OFF" settings allows the operator to turn the power off or on to the conveyor. This is used in conjunction with the Conveyor Speed/Direction control.

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; (b) Using correct

band speed, feed force and cutting uids during

operation; (c) Removing scale from stock before sawing; (d) Keeping the protective Saw Cap over blade teeth until installation time.

Page 19

SAW BAND PREPARATION (Continued....)

Saw Guide Insert Adjustment

Consult your DoALL sales representative for

complete information about saw bands and their applications.

Blade Guards

1. The machine has several guards for operator safety and protection. All guards must be in place before

any sawing procedure is started.

2. Post Guard. This guard is hinged and attached to the upper saw guide and extends up towards the bandwheel.

3. Post Bellows. Mounted in the right side of the upper saw guide and also extends up towards the bandwheel.

4. Column Guard. This guard is mounted on the head column and located between the bandwheels.

5. Cover Guard. This guard with a interlocked door is located in the left rear of the machine.

DO NOT defeat the purpose of any guard

or safety devise. They are there for YOUR PROTECTION!

1. L o o s e n t h e a d j u s t m e n t s c r e w ( t u r n counterclockwise) on each saw guide. Turn the insert adjustment screw clockwise until tight and

then back off 1/4 turn. This applies to both upper

and lower saw guides.

Saw Band Removal

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

bands. Wear gloves.

1. Before removing the saw band, set the machine to the following conditions: (a) Hydraulics are "ON"; (b) Band drive motor is "OFF"; (c) Coolant is completely shut off; (d) Saw head is vertical and completely retracted.

2. Turn the Band Tension selector switch to "OFF". Then: (a) Open the upper bandwheel; (b) Open the hinged post guard; (c) Loosen the saw guide insert adjustment screws; (d) Carefully remove the old, worn or broken saw band from between the saw guide inserts and both bandwheel; (e) Carefully work the saw band out from the column guard and dispose the saw band immediately.

Saw Band Installation

Saw Guides

1. The upper and lower saw guides both have zeroclearance, carbide-faced, spring-loaded inserts. The inserts provide support necessary to help maintain sawing accuracy. Back support is provided by the pivoting carbide back-up inserts.

Typical Saw Guide.

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

bands. DO NOT attempt to change saw bands while the band drive motor is running.

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

2. Carefully position the saw band around the drive

and idler bandwheels with the saw band's back edge

resting against each bandwheel's rear ange. Then:

(a) Maneuver the saw band into the column guard; (b) Turn The Band Tension selector switch to "ON"

to apply just enough tension to hold the saw band in position, then turn the selector to "HOLD".

3. Slip the saw band between the saw guide inserts by twisting it 90° so the blade teeth are facing the front of the machine and pointing downward. Then:

(a) Turn each saw guide insert adjustment screw clockwise until tight and then back off 1/4 turn; (b) Remove the protective Saw Cap from the saw

band; (c) Close the hinged post guard and then the bandwheel door; (d) Turn the Band Tension selector switch to "ON" to apply full tension to the saw band.

Page 20

SAW BAND PREPARATION (Continued....)

4. Push the Band/Cycle Start button and run at a very low speed to check for proper band tracking

against the each bandwheel rear ange.

POST ADJUSTMENT

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.

1. Post and upper saw guide height is regulated by

the Post selector switch on the control panel.

2. Sawing results will generally be more satisfactory if the post and upper saw guide are kept as close as possible to the material being cut. Doing so helps reduce saw band vibration and contributes to more accurate sawing.

When the saw head has been tilted, make

sure the post and saw guide will clear the material.

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.

2. Proceed as follows when it becomes necessary to

modify solid section sawing recommendations: (a) Measure the thinnest stock section to be cut; (b) Apply the corresponding percentage factor from the chart below; (c) Use a high band speed, but never

exceedthemaximumspeedrecommendedfor

stock sections of the same size.

SECTION FACTOR TO APPLY THICKNESS TO MINIMUM CUTTING RATES GIVEN BY JOB SELECTOR*

Up to 3/16 inch 40%

(0 to 4.8 mm)

3/16 to 3/8 inch 50%

(4.8 to 9.5 mm)

3/8 to 5/8 inch 60%

(9.5 to 15.9 mm)

5/8 to 1 inch &over 70%

(15.9 to 25 mm & over)

*Based on 5 inch (127.0 mm) solids.

Cutting Rate to Thickness Relationship.

SAW HEAD APPROACH RATE

• 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.

• Feed force adjustments are not necessary for changing stock cross-sections. A balancing valve enables the saw band to maintain a uniform cutting rate.

1. After the stock has been positioned for cutting and the Saw Head Control selector is placed at the

"FWD/AUTO" setting, the saw head's approach

(traversing) rate is regulated by the Head Approach valve.

2. Correct head approach 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.

3. To move the saw head if the band drive motor is not running: (a) Place the saw in "MANUAL" operating mode; (b) Move the Saw Head Control

selector to "FWD/AUTO"; (c) Make the desired Head Approach valve setting; (d) There must be some Feed Force setting.

Page 21

COOLANT SYSTEM

CHIP REMOVAL

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.

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 the control panel.

• To a ushing nozzle for washing parts or cleaning

areas of the machine.

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

"ON" or "BAND ON"; (c) Turning the coolant valve on the control panel clockwise until uid completely shrouds the saw band.

1. Metal chips should be removed from the work area as soon as possible. They can be washed or scraped into the right front pan opening, or scooped out with the supplied shovel-rake.

DO NOT shovel or rake chips while the saw

band is running.

Band Brush

1. A band brush powered by the lower bandwheel and removes metal chips from the saw band. 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.

DONOTstartcuttinguntilcoolantisowing

adequately. Dry cutting will greatly reduce blade life.

3. Check the coolant level if ow is stopped or reduced. Drip pan capacity is 20 gallons (75.7 liters). Chip

conveyor option has a capacity of 50 gallons (189.2 liters).

HYDRAULIC SYSTEM

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) Traverse the sawing head; (c) Clamp or unclamp the vises; (d)

Position stock manually.

2. The machine's hydraulic reservoir has a 20 gallon (75.7 liter) capacity. Refer to the Lubrication section of this manual for recommended oils.

Chip Removal Points.

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, 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.

Page 22

CHIP REMOVAL (Continued....)

Shovel-Rake

1. Accumulations of metal chips can be removed from the machine with the shovel-rake.

DO NOT use the shovel-rake while the saw

band is running.

6. Tilt the saw head to desired setting and align for a good cut angle.

Correct Starting Cut Angle.

7. Adjust the post until it is just clears the material.

Combination Shovel-Rake.

Band Wiper

1. A wiper located at approximately the ten (10) o'clock position from the lower bandwheel removes coolant residue from the moving saw band before it reaches the upper bandwheel.

Carriage Brush

1. A brush located on the lower front side of the saw head removes chips and depris from the head carriage bearing rails as the saw head is traversing.

IDLER WHEEL MOTION DETECTOR

1. This safety devise located in front of the lower bandwheel stops the machine if the saw band should break or stall in the workpiece. Always determine the cause of the stoppage and correct it before attempting to resume operation.

TYPICAL OPERATING PROCEDURES

When the saw head has been tilted, make

sure the post and saw guide will clear the material.

8. Select the coolant ow desired for your application.

Make sure to cover both sides of the saw band.

9. Select "MANUAL" or "AUTO" on the Operation selector switch.

10. Using the Feed Force and Head Approach controls to make initial settings. Watch closely as the saw head moves forward and make any adjustments that may be needed.

11. To begin the cut: (a) Move the Saw Head Control

selector to "FWD/AUTO"; (b) Push the Band/Cycle Start button. The band drive will come up to speed and the saw head will feed to begin the cut. The vise must be clamped for the machine to start.

12. The operator may adjust band speed, coolant ow, approach rate, and/or feed force at any time during

the sawing process.

1. To start the machine: (a) Make sure the main disconnect switch is turned "ON"; (b) Turn the Emergency Stop button clockwise to reset (if necessary); (c) Push the Hydraulic Start button. This will start the hydraulic pump motor.

2. Move the post and saw guide up all the way to clear the material when loading.

3. Load the stock to be cut onto the vise bed and position for clamping by the vise jaws.

4. Clamp the vise(s).

5. Move the Saw Head Control selector to " FWD/ AUTO" and position the saw band just behind the vise, then move the Saw Head Control selector to the "HOLD" setting.

13. After the cut has been completed, the saw band will shut off with the saw head in the forward position if in "MANUAL" operating mode; the saw head will retract when in "AUTO" operating mode. Hydraulics will remain "ON".

14. Retract the saw head by moving the Saw Head Control selector to "REV" (move the selector to "HOLD" when the desired saw head position is reached). Then unclamp the vise(s) and remove the cut-off piece.

Page 23

TYPICAL OPERATING PROCEDURES

(Continued....)

Operating Notes

1. To interrupt a cut in either manual or automatic cycle: (a) Move the Saw Head Control selector to "HOLD" (this will stop saw head movement); to resume cut after interuption, move the Saw Head

Control selector to "FWD/AUTO" and then push

the Head Rapid Approach pushbutton.

2. When pus hing the Head Rapid Approach pushbutton, the saw head will move forward at a rapid speed until it reaches the "feed zone". The

Feed Force then engages as the cut begins.

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.

Page 24

LUBRICATION

LUBRICATION CHART

LUBRICATION

POINT NO.

LOCATION DESCRIPTION AND

SERVICE RECOMMENDATIONS

Vise Movable Jaw Slides/Gibs. Four (4) grease ttings. 1 for each gib. Add two (2) for Optional Outboard Vise.

Band Tension Slide. Clean and apply grease.

Bandwheel Bearings. One (1) grease tting each

bandwheel.

Head Carriage Linear Bearing (Older machines). Four

(4) grease ttings.

Current machines are sealed for life.

Head Pivot Pillow Blocks. Two (2) grease ttings.

Insert Adjustment Screws. Oil the threads.

Post. Clean and apply oil.

Miscellaneous: Vise Slides, 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.

Electric/Hydraulic Motors. Hydraulic Pump, Coolant, Drive and Optional Chip Conveyor.

Coolant Reservoir (Drip Pan). 20 gallon (75.7 liter) capacity. Chip Conveyor (Optional). 50 gallon (189.2 liter) capacity.

Drain, clean and rell whenever coolant becomes undesireable for further use. Clean the mesh strainer at the

same time.

LUBRICATION

INTERVAL*

WEEKLY

MONTHLY

INSERT CHANGE

MONTHLY

AS REQUIRED

Lubricate per manufacturer's recommendations.

CHECK DAILY/

AS REQUIRED

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, 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 - (Power-Cut).

RECOMMENDED

LUBRICANT

Band Mist Lubricator (Optional). Keep reservoir lled

and hoses clear.

Hydraulic Reservoir. 20 gallon (75.7 liter) capacity.

Check oil level daily and keep the reservoir full. Drain, change the lter element and rell after the 1st month;

every six (6) months thereafter.

Contact your DoALL sales representative

CHECK DAILY/

AS REQUIRED

CHECK DAILY/

AS REQUIRED

* Lubrication intervals are based on a 8-hour day, 40-hour week. Lubricate more often with heavier use.

for the best oils and/or uids for your

application.

DoALL cutting uids and/or oils.

Multi-purpose automatic transmission

uid.

General Motors Dexron III, or equivalent.

Page 25

LUBRICATION DIAGRAMS

TOP VIEW

HEAD VIEW

Page 26

MAINTENANCE

REPLACING SAW GUIDE AND BACK-UP INSERTS

These instructions can be used to replace

saw guide inserts and back-up inserts on both upper and lower saw guides.

The band drive motor must NOT be running

when replacing saw guides and back-up inserts.

1. Loosen the insert adjustment screw on each saw guide. Then: (a) Remove the saw band; (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 at head screw and

remove the rear insert.

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

3. Before changing the hydraulic uid: (a) Retract

the saw head completely; (b) Push the Hydraulic Stop button; (c) Remove the reservoir drain plug; (d) Allow the reservoir to drain completely.

System Pressure

1. Hydraulic system pressure is correctly set at the factory and should not require adjustment for

a considerable period of time. Correct system

pressure is 1000 ±25 psi (68.9 ±1.7 bar.)

2. Pressure is adjusted by turning the screw extending outward from the hydraulic reservoir. Consult

a DoALL service representative if assistance is needed.

Pump Repair & Replacement

Typical Saw Guide Assembly .

2. Thoroughly clean the saw guide and inserts area. Then: (a) Reverse the carbide back-up insert (if worn); (b) Replace the rubber back-up insert if it has deteriorated (this will help prevent coolant leakage)

3. Install the new inserts. Then: (a) Thread the adjusting screw inward part way; (b) Reinstall the saw band between the inserts; (c) Tighten the adjustment screw; (d) Back off the adjustment screw 1/4 turn.

HYDRAULIC SYSTEM

1. Keep the reservoir lled at all times. Capacity is 20 gallons (75.7 liters). Check the reservoir oil level

daily by referring to the sight gauge.

1. DO NOT attempt to repair the hydraulic pump. Return it to the factory for repair or replacement. Be sure to specify the correct pump model and serial numbers when returning the unit.

2. Following a new pump installation: (a) Jog the Hydraulic Start and Hydraulic Stop buttons several times; on for two (2) seconds, off for three (3) seconds until the pump is primed; (b) Check for proper pump rotation while jogging; (c) Review wiring connections if the pump rotates in the wrong direction.

After the pump has been primed, run it

for several minutes while operating the machine’s controls to purge entrapped air from the pump and system. Check for oil leaks while the system is being operated.

Seals & Cups

1. Seals and cups used in DoALL hydraulic systems are compatible ONLY with hydraulic oils having an aniline point between 215° and 230° F. (102° and

111° C.).

2. If hydraulic oil having an aniline point not falling within the above range is used, the seals may either swell or shrink and harden. This causes machine malfunction and leakage.

Page 27

HYDRAULIC SYSTEM (Continued....)

BRUSH ADJUSTMENTS

 DOALLhydraulicuidwithananilinepointof

approximately221°F.(106°C.)willnotcause

deterioration of component seals.

COOLANT SYSTEM

1. The machine’s coolant drip pan has a 20 gallon (75.7 liter) capacity.

2. Check the coolant often for signs of contamination

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

cutting uid becomes undesireable 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 drip pan section below the saw head, removal of the drip pan may be necessary.

MACHINE CLEANING

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

Band Brush

1. The band 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 Wiper

1. A wiper located at approximately the ten (10) o'clock position from the lower bandwheel removes coolant residue from the moving saw band before it reaches the upper bandwheel. Adjust or replace the brushes when necessary.

Carriage Brush

1. A brush located on the lower front side of the saw head removes chips and depris from the head carriage bearing rails as the saw head is traversing. Adjust or replace the brushes when necessary.

WEAR PLATE REPLACEMENT

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, 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 when necessary.

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

before opening machine doors or covers.

Combination Shovel-Rake.

MACHINE ALIGNMENT

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

1. The removeable vise jaw and vise bed wear plates 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 two (2) vise jaw wear plates, one (1) on each jaw. 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 Bed

1. The inboard and outboard tables has three (3) vise bed wear plates each. When no rollers are supplied, there is two (2) each. All wear plates are mounted

with at head screws.

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.

Page 28

BANDWHEELS

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.

5. Push the Display Zero pushbutton. The Head

Angle Display will read 0°. The saw head is now perpendicular to the vise table. Reinstall the back panel on the operator control console panel support.

Typical Bandwheel Flange and Tread.

CLEANING OPTIONAL CHIP CONVEYOR

1. To clean the optional chip conveyor, turn the machine off. Then: (a) Disconnect the coolant hoses; (b)

Pull the conveyor out from its cradled position in the base; (c) Clean the conveyor trough; (d) Clean out the chip box and the reservoir oor; (e) Replace

the conveyor.

HEAD ANGLE DISPLAY CALIBRATION

1. If some unusual event or a repair has been made, it will be necessary to calibrate the saw head angle display.

2. Calibration procedures are as follows: (a) Remove the back panel from the operator control console panel support; (b) Note the location of a pushbutton on the bottom of the operator panel. This is the Display Zero pushbutton.

3. Tilt the saw head until it is against one of the physical

stops. Push the Display Zero pushbutton. The Head Angle Display will read 0°.

4. Move the saw head towards the vertical until the Head Angle Display reads 60.5°.

Page 29

TROUBLE SHOOTING

Repair and adjustment procedures should

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

personnel, or by a DoAll representative. Reference to the machine's electrical and hydraulic schematics will be helpful.

MACHINE WILL NOT START

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

position.

2. Reset the Emergency Stop pushbutton (rotate the button head clockwise).

3. Check the main fuses/circuit breakers and control circuit fuse/circuit breaker.

4. Make sure the bandwheel door and/or the index

guard door are closed.

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.

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.

SAW BAND SQUEAL

1. Coolant is not covering the saw band properly.

2. Check for worn or improperly-adjusted saw guide

inserts.

SAW BAND VIBRATION

1. Check for a dull or damaged saw band.

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

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 tension limit switch (3 LS).

2. Check to see if the bandwheel door and/or the cover

guard door are closed (the band drive motor will not start unless both doors are closed).

SAW BAND STALLS DURING A CUT

1. Decrease saw head feeding pressure.

2. Increase band speed and/or head approach rate.

3. Check for low hydraulic pressure.

4. Check for pinching of saw band in the material due

to crooked stock. Use wider set saw band.

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.

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

8. Bandwheel bearings are badly worn or damaged.

PREMATURE BLADE 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 an incorrect cutting recommendation.

4. Coolant is not covering the saw band properly.

5. Check for saw band vibration.

Page 30

TROUBLE SHOOTING (Continued....) SAW BAND IS NOT RUNNING TRUE AGAINST

THE SAW GUIDE BACK-UP BEARINGS (May

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. Check for saw band vibration.

10. Decrease feed pressure to "break in" a new saw

band on its rst few cuts.

Cause Vibration)

1. Examine the carbide back-up bearings. Replace them if they are chipped or worn more than 0.020inch (0.5 mm).

2. Have a DoALL service representative check machine alignment.

3. Check for worn saw guide pivot bolts.

4. Saw guides are loose, or not positioned close enough to the stock.

BLADE TEETH STRIPPING

INACCURATE CUT-OFF

1. Increase band speed or decrease feed pressure.

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

lodged in the cut.

1. Check for worn or dull blade teeth.

2. Check for a hard spot in stock being 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 fed into the stockpiece due to incorrect saw head feeding rate.

2. Increase band speed being used and/or decrease

feed force.

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. Saw guides are loose, or not positioned close enough to the stock being cut.

8. Saw band pitch choice is incorrect.

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

bearing, or worn pivot bolts.

10. Check machine alignment. Have a DoALL service representative check and/or adjust machine

alignment.

11. Check for coolant not being supplied evenly to both

sides of the saw band.

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

jaws.

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.

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.

Page 31

TROUBLE SHOOTING (Continued....)

SLUGGISH HYDRAULIC OPERATION

4. Increase band speed being used and/or decrease

the feed rate.

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

Replace them if necessary.

6. Increase ow of coolant to the cutting area.

7. Feed force may be too high if using a new saw band.

CUTTING RATE IS TOO SLOW

1. Use a coarser pitch saw band.

2. Increase band speed and/or feed force.

VISES WON’T OPEN OR CLAMP

1. Check for mechanical obstructions.

2. Check for faulty operation of Solenoids 11 and 12 for xed vise; Solenoid 22 and 23 for outboard vise

option.

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.

3. Check control panel selector switch settings.

SAW HEAD DOESN'T TILT

1. Check for faulty operation of Solenoids 5 and 6.

2. Check adjustment of the head rear proximity switch

(3 PRS).

SAW HEAD WON’T TRAVERSE

1. The head approach rate setting is too low.

2. Vise(s) must be clamped.

3. Check the head rear proximity switch (3 PRS) for faulty operation.

4. Check for saw head obstruction.

5. Check Solenoids 7 and 8 for incorrect operation.

SAW HEAD TRAVERSES ERRATICALLY

1. Bleed air from the saw head feed cylinder. It may be necessary to move the saw head back and forth several times to thoroughly bleed the saw head feed cylinder.

Page 32

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 adjunct). The following conveyors are available:

• Stock conveyor ve (5) feet (1524.0 mm) long by

22 inches (558.8 mm) wide with a weight capacity of 750 pounds (340.2 kg) per roller.

• Stock conveyor ten (10) feet (3048.0 mm) long by 22 inches (558.8 mm) wide with a weight capacity of 750 pounds (340.2 kg) per roller.

Vertical Guide Roller For 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 8 to 20 inches (203.2 to 508.0 mm) wide, and from 1.38 to 10.25 inches (34.9 to 260.3 mm) high.

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 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 (For Conveyors)

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

2. Vertical nesting clamp cylinders are mounted to the machine’s inboard and optinal outboard vise tables. The cylinders operate simultaneously with the regular vise clamping cylinders.

A negative (-) angle tilt ot the saw head is NOT

permitted with the left hand (inboard) Nesting

Fixture.NOtiltingisallowedwithbothinboard andoutboardnestingxtures.

 Thehydraulically-operatedNestingFixturecan

also be used with the Variable Vise Pressure control.

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.

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

Page 33

NESTING FIXTURE (Continued....)

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).

Rod End Hose Position.

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.

Vise Adjustment

1. Stack stock to be cut between the machine’s vise jaws. Then: (a) Turn the Vise(s) selector(s) to

"CLAMP"; (b) Center the nesting xture’s vertical

clamping cylinder.

CHIP CONVEYOR W/COOLANT RESERVOIR

1. This option has a conveyor belt and reservoir located under the saw head and slides in and out from the rear for cleaning or servicing.

2. The chip conveyor motor operates simultaneously with the hydraulic pump motor. The conveyor belt moves slowly at the bottom of the reservoir. Its movement carries metal chips to the opening at the rear of the machine where chips empty into a customer-supplied container.

3. A mesh screen lters the coolant before returning

to the reservoir for reuse.

4. A sight gage mounted on the rear of the reservoir for viewing coolant level.

5. The chip conveyor has a 50 gallon (189.2 liter)

capacity with a oat switch to indicate low coolant

level.

Nesting Fixture Vise Adjustments.

2. 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 outboard

vise cylinders to achieve relatively equal release.

3. Move the the vise's rod end hose(s) to indicated position.

Chip Conveyor With Coolant Reservoir.

Page 34

MIST LUBRICATOR

1. The mist lubricator has a reservoir mounted in the rear of the machine with a nozzle unit mounted above and left of the lower bandwheel near the band wiper.

2. See the literature sent with your machine on recommendations and operation of the mist lubricator unit.

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

FIXED HEAD (NON-TILTING)

1. This factory installed option does not allow tilting of the saw head.

3° HEAD CANT

OUTBOARD VISE (Right Hand Vise)

1. The outboard vise is mounted on the right side of the saw band and used for job requirements where more clamping or holding power is needed.

2. A selector switch on the control panel operates the

vise in the same fashion as the left vise with "OPEN", "HOLD" and "CLAMP" settings.

Make sure the vise jaw is opened wide enough

when moving material through the outboard vise.

LIFT ROLLERS

1. The lift roller is used to help manually feed the material along into the cutting area. This roller can be mounted on either side of the saw band.

2. A selector switch on the control panel operates the

lift roller (left and/or right hand) with "UP" or "DOWN"

settings.

1. This factory installed option tilts the saw head forward three (3) degrees from vertical for easier and faster cutting of structural and other certain materials.

Contact a DoALL sales representative for

information on all your cutting applications.

MATERIAL HANDLING EQUIPMENT

1. Special material handling equipment can enhanced

the performance of your machine. Contact your

DoALL sales representative for information on any material handling needs that could increase your productivity.

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 by a selector switch with "ON" and "OFF" settings and is located on or near the control panel. Turn the laser "OFF" when not in use.

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

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

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

enhance the line.