DoAll TF-2525 Instruction Manual

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Page 1

MODEL: TF-2525

INSTRUCTION

MANUAL

SERIAL NO: 356-76101 to 356-01282

Also Applies To Machines With A “Tf-25SA” Designation.

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-2525 356-76101 356-01282

Also applies to machines with "TF-25 SA" designation.

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, call1-888-362-5572

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, Polypac and Tensigage.

PRINTED IN U.S.A. PB-331.5 (12-07)

Page 4

TABLE OF CONTENTS

MACHINE DIMENSIONS

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

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

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

MACHINE FEATURES

Front and Rear Views ............................................. 4

Side View ................................................................ 5

Head Assembly ....................................................... 6

INSTALLATION

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

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

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

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

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

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

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

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

Coolant Installation ................................................. 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 ...................................................... 15

Head Reverse Rate ................................................ 16

Head Tilt Adjustments ............................................. 16

Miter Meter ............................................................. 16

Roller Table ............................................................. 16

Vise Adjustments .................................................... 16-17

Band Feed Adjustments ......................................... 17

Coolant System ..................................................... 18

Hydraulic System .................................................... 18

Chip Removal ......................................................... 18-19

Typical Operation Procedures ................................ 19-20

LUBRICATION

Lubrication Chart .................................................... 22

Lubrication Diagram ............................................... 23

MAINTENANCE

Replacing Saw Guide and Back-Up Inserts ........... 24

Hydraulic System .................................................... 24-25

Coolant Ststem ....................................................... 25

Machine Cleaning ................................................... 25

Machine Alignment ................................................. 25

Brush Adjustments .................................................. 25

Wear Plate Replacement ........................................ 25

Bandwheels ............................................................ 26

Chip Conveyor ........................................................ 26

Miter Meter ............................................................. 26

TROUBLE SHOOTING .................................. 27-29

ACCESSORIES

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

Filler Plates ............................................................. 30

Nesting Fixture ....................................................... 30-31

Roller Stock Conveyors .......................................... 31-32

Workstop ................................................................ 32

Vertical Guide Rollers ............................................ 32

Mist Lubricator ........................................................ 32

Right Hand Vise ...................................................... 32

Lift Rollers ............................................................... 32

Laser Line Option ................................................... 33

Fixed Frame (Non-Tilting) ....................................... 33

Extra Work Height .................................................. 33

Band Twist Indicator ............................................... 33-34

Medium Torque Drive ............................................. 34

Saw Band Modication ........................................... 34

Head Travel Indicator ............................................. 34

Reinforcing Legs (Heavy Work Support) ................ 34

How to read your serial number:

Page 5

MACHINE DIMENSIONS

INCHES (± .03)

MILLIMETERS (± 1 mm)

FLOOR PLAN

Page 6

MACHINE DIMENSIONS (Continued....)

FRONT VIEW

Page 7

MACHINE DIMENSIONS (Continued....)

INCHES (± .03)

MILLIMETERS (± 1 mm)

25" (635.0 mm) 4" (101.6 mm) 103.00" (2616.2 mm)

Dimensions

Work Height

30" (762.0 mm) 9" (228.6 mm) 108.00" (2743.2 mm)

36" (914.4 mm) 15" (381.0 mm) 114.00" (2895.6 mm)

40" (1016.0 mm) 19" (482.6 mm) 118.00" (2997.2 mm)

SIDE VIEW

Page 8

MACHINE FEATURES

REAR VIEW

FRONT VIEW

Page 9

MACHINE FEATURES (Continued....)

SIDE VIEW

Page 10

MACHINE FEATURES (Continued....)

HEAD ASSEMBLY

Page 11

INSTALLATION

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

deignations in this manual are as viewed by the operator facing the machine's control console.

LOCATION

1. The oor area required by the machine with allowance

for 45° left and right head tilt is approximately 95.50 inches (2425.7 mm) in width by 107.00 inches 2717.8 mm) in length. Standard machine height is 103.00 inches (2616.2 mm). Refer to pages 1, 2 and 3 for further machine dimensions.

2. Locate the machine to provide adequate space for

your sawing needs. Be sure to provide sufcient

clearance for: (a) Loading and unloading of stock; (b) Door openings, head tilting and power unit placement; (c) Maintenance and lubrication pr ocedure s; (d) Operation of the machine accessories, if applicable.

3. Provide ample space for roller conveyors and/or

other material handling equipment.

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. Carefully remove all protective covers, strapping,

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

Check around the machine for other removable

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

damage. Claim procedures are listed on this

manual’s inside front cover.

DO NOT use compressed air for cleaning

purposes as this may force dirt and depris into the machine's working parts.

LIFTING

NEVER lift the machine by its sawing head.

1. Use of an overhead hoist with chain hooks is recommended to lift and transport the machine into

its nal position. Net weight is approximately 6200

pounds (2812.3 kg).

2. Place the chain hooks into the base openings (there

is three (3) openings on each side). Be sure to pad areas where the chains may rub and damage machine surfaces.

3. The hydraulic power unit, conveyors and/or

material handling equipment (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. Place the machine in desired position and then

remove the head support bracket that connects the saw head to the machine frame. Remove the two (2) carriage brackets located in the rear of the machine behind the electrical control box enclosure.

2. Place a level on the machine roller table bed. Insert the 3/4-10NC 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.

3. Position the roller conveyors and/or material

handling equipment and attach if necessary to the machine frame. Adjust the leveling screws so that the conveyor rollers are in the same plane as the table rollers and weight bears evenly on all legs.

CLEANING

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.

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.

8. Place the operating shaft and operating handle of

the disconnect switch in the OFF position. Then:

(a) Close the electrical enclosure door and secure

its screws; (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 “Hydraulic Installation” procedures have been performed.

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

3. Power is connected to the electrical enclosure

located in the rear of the machine.

4. The f ollowin g are i mportan t disco n n e ct precautions:

The disconnect must be on before the machine

will operate. Turning off the disconnect will shut down the machine.

The enclosure door must be closed and the

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

5. Turn the disconnect switch on the electrical enclosure 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 enclosure. 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.

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 or other uid recommended on the Lubrication Chart.

3. Connect the hydraulic lines between the machine

and power unit by matching tags on hoses to connection points on the machine. 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. Push the Hydraulic Start pushbutton and turn the Band selector switch to "run". The saw band should

be running in a downward direction between the saw guides.

6. If the saw band direction is incorrect: (a) Turn the disconnect switch to "OFF" and remove power at the source of electrical supply; (b) Interchange any two (2) of the L1, L2, or L3 leads to the disconnect switch; (c) Restore power and perform Step 5 again.

Electrical Connections to Disconnect Switch.

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).

7. As soon as the saw band movement is correct, jog the Hydraulic Start and 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. 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 strainer/screen must be

sufciently submerged for coolant ow to

reach all areas in the coolant system.

2. Check for coolant leaks and tighten any ttings if

necessary.

PREPARATION FOR USE

1. Check to be sure all safety guards, covers and doors

are in place or closed.

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. If desired, rotate the

bandwheel to help in removal of the Saw Cap and

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 top 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 reference notes about band speed, feed force, etc.

Typical Job Selector.

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, solid material using a Imperial Bi-Metal saw blade.

Page 15

CUTTING CAPACITY

1. The standard machine's cutting capacity is:

• At 0° tilt: 25 inches (635.0 mm) wide by 25 inches

(635.0 mm) high for rectangular/square stock; 25

inches (635.0 mm) diameter for round stock.

• At 45° left tilt: 25 inches (635.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; 17.25 inches (444.5 mm) diameter for round stock.

• At 45° right tilt: 25 inches (635.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; 17 inches (431.8 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(s) maximum opening is 25.50 inches (647.7 mm).

• In the "set-up" setting, the saw band does not run while the saw head travels forward or in reverse through its stroke. The saw head must be in the fully retracted position for such pre-sawing operations as tilting the head or post movement is allowed.

• In the "manual" mode, the saw head travels forward to complete the cut, then the sawing head and saw band movement will stop.

• During "auto" mode, all appropriate selector switches

must be set at the "automatic" setting. Coolant, band

speed and feed rate must be set and the workpiece must be correctly positioned for the cut. When the Cycle Start button is pushed, the saw head travels forward to complete the cut, the saw band stops and the saw head retacts to the rear limit switch. To start the next cut, reposition the workpiece, start the saw band and push the Cycle Start button.

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

CONTROL CONSOLE

Electrical Control Panel

1. Hydraulic Start. Push this black button to start the hydraulic pump motor. The hydraulic pump motor must be on to operate the machine.

2. Cycle Start. Push this black button to start the automatic sawing cycle when the Operation selector is in the "auto" setting.

3. Operation. This selector switch allows the operator to choose "set-up", "manual" or "auto" mode.

• Before the machine can resume operation, the Emergency Stop pushbutton must be reset (turn the button head clockwise until it pops up).

5. Post. This selector switch with "down", "hold", and "up" settings regulate post movement.

• The "hold" position stops post movement.

When the saw head is tilted, make sure the post

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

Control Console.

Page 16

CONTROL CONSOLE (Continued....)

Typical Pushbutton Panel.

6. Approach Rate. This selector switch with "normal" and "heavy duty" settings allows a choice of head approach rate toward the material to be cut. The "heavy duty" setting is a slower than "normal" travel rate and used when cutting large, tough material.

7. 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.

• Older machines had the Coolant selector switch with "off" and "normal" settings located on the side of the rear electrical enclosure. Turning the selector to "normal" activates the coolant pump and allows the operator to control volume with the valve on the left front of the machine.

8. Vise. This selector switch with "open" and "close" settings controls the clamping and unclamping of the left hand vise. It also simultaneously controls the right hand vise with the left vise when suplied.

Make sure the vise jaw is opened wide enough

when moving material through the vise jaws.

• The "reverse" or "forward settings are used during manual operation. Turn the selector to "auto-off" before putting the machine into automatic cycle operation.

10. Tilt. This selector switch with "left", "hold", and "right" settings regulate the direction of head tilt and operates ONLY when the Operation selector switch is in the "set-up" position and the sawing head retracted fully.

• Turn the selector to "left" or "right" causes the head to pivot in that direction. Turn the selector to "hold" will stop head movement when the desired angle is reached.

11. Band. This selector switch with "stop" and "run" settings regulates the starting and stopping of the band drive motor.

• Hydraulics must be running before the band drive motor can be started.

Other Controls

1. Chip Conveyor. This selector switch with "off" and "on" settings operate the optional motorized chip conveyor.

2. Laser. This selector switch turns the line-up laser "on" and "off".

9. Feed. Use this selector switch with "rev" (reverse), "fwd" (forward) and "auto-off" settings to regulate the direction of saw head movement.

To avoid eye damage, DO NOT stare into the

laser beam.

Page 17

CONTROL CONSOLE (Continued....)

3. Band Tension. This selector valve with "tension", "release" settings and a center position for "hold" 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 “release” lowers the upper bandwheel and enables saw band removal or installation.

• The center position or “hold” setting stops bandwheel movement and allows the operator to position the saw band over the bandwheels.

• The “tension” setting raises the upper bandwheel and automatically provides correct band tension.

DO NOT operate the band drive motor unless

band tension is on.

• The Band Tension selector must be at the "tension" position before the saw head will traverse.

8. See the "Accessories" section of this manual on controls for the Variable Vise Pressure and Nesting Fixture options.

Hydraulic Control Panel

1. Band Speed. This keylock adjustment valve allows

the operator to set and maintain innitly variable band speed between 60 and 300 fpm (18 and 90 m/min.).

Refer to the data plate to the left of the valve for equivalent band speeds which can be reached with different valve settings. Turn the knob clockwise to “increase” the band speed, counterclockwise to “decrease” it.

• When setting band speed, the operator should try to obtain a vibration free speed level. Vibration while cutting generally indicates a need for a lower speed. If the vibration is severe, retract the saw head slightly from the stock, then adjust the band speed and resume cutting.

4. Coolant. There is two (2) valves that regulate

coolant ow to various areas of the machine. One

valve is located to the left and below the control

console and regulates coolant ow to the upper

saw guide. The other valve is located under the step on the left side of the machine base near the

coolant pump and regulated the coolant ow to the

band drive motor and chip pan area.

• Turn either valve counterclockwise to “increase”

coolant ow; clockwise to “decrease” the ow.

5. Feed Rate. This valve is used to regulate the linear travel of the sawing head towards the workpiece and is located on a bracket attached to the left side of the control console. Turn the knob counterclockwise to “increase” feed rate; clockwise to “decrease” the rate. The valve’s lower locking knob or set screw helps maintain the setting.

6. Head Reverse Rate. Also located on the left side of the control console, this valve is used to regulate the reversing speed of the saw head. Turn the knob counterclockwise to “increase” the reversing velocity; clockwise to “decrease” it. The valve’s lower locking knob or set screw helps maintain the setting.

Typical Hydraulic Panel.

2. Band Feed. This control valve is used to adjust the saw band's feed force against the workpiece. Feed

force is servo-maintained and innitly adjustable between 0 and 22 ipm (0 and 558.8 mm/min.). Turn

the knob clockwise to “increase” the band feed, counterclockwise to “decrease” it. The valve’s

lower locking knob or set screw helps maintain the setting.

3. Band Feed Gauge. This indicator gauge located directly above the Band Feed valve registers the amount of pressure being directed against the workpiece.

Material Handling Controls

7. Miter Meter. The unit, mounted below the Feed Rate and Head Reversing Rate controls, has a

LCD window displaying the direction and degree of head tilt. Push the button or rotate the thumbscrew

to turn the "power" to the unit on.

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%.

Page 18

CONTROL CONSOLE (Continued....)

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.

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.

Contact 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.

• Post Guard. This guard is attached to the bandwheel door and extends up towards the bandwheel.

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

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.

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

5. Workstop. This selector switch with "up", "down' and "adjust" settings control the position of the optional workstop.

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 209.5

inches (5321.3 mm); width is 1-1/2 inches (38.1

mm); recommended gage is 0.050-inch (1.3 mm).

• Older machines had a band width of 1-1/4 inches

(31.7 mm) with a gage of 0.042-inch (1.1 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.

Typical Saw Guide.

Saw Guide Insert Adjustment

1. Loosen the adjustment screw at least two (2) turns counterclockwise on each saw guide. Then: (a) Remove the saw band (see below); (b) Turn the insert adjustment screw clockwise until it touches the xed insert and then back two (2) full turns; (c) Replace the saw band (see below); (d) Turn the adjustment screw two (2) full turns clockwise to provide correct pressure against the saw band.

Page 19

SAW BAND PREPARATION (Continued....)

Saw Guide Insert Components.

2. This applies to both upper and lower saw guides.

Saw Band Removal

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

bands. Wear gloves.

2. Maneuver the saw band into the column guard. Then: (a) 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; (b) Move the Band Tension selector switch to "tension" to apply just enough tension to hold the saw band in position, then move the selector to the center position to "hold".

3. Slip the saw band between the saw guide inserts by twisting it 90° using the supplied saw band twist tool so the blade teeth are facing the front of the machine and pointing downward. Then: (a) Turn the adjustment screw two (2) full turns clockwise to provide correct pressure against the saw band;

(b) Remove the protective Saw Cap from the saw

band; (c) Close the the upper bandwheel door; (d) Move the Band Tension selector switch to "tension" to apply full tension to the saw band.

4. Turn the Band selector switch to "run" and operate at a very low speed to check for proper band tracking

against the each bandwheel rear ange.

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; (e) Position the post at the midrange height.

2. Move the Band Tension selector switch to "release". Then: (a) Open the upper bandwheel door; (b) Loosen the band brush bracket screw and move the brush aside; (c) Loosen the saw guide insert adjustment screws two (2) full turns counterclockwise; (d) Carefully remove the old, worn or broken saw band from between the saw guide inserts and both bandwheels; (e) Carefully work the saw band out from the column guard and dispose the saw band immediately.

Saw Band Installation

 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; (b) Wiper with clean rag.

Band Tension Adjustment

1. Located on the rear side of the column and accessed from the left side, band tension is hydraulically applied and maintained.

DO NOT operate the band drive motor unless

band tension selector is in the "tension" position.

POST ADJUSTMENT

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.

The post can be lowered only when the saw

head is fully retracted.

When the saw head has been tilted, make sure

the post and saw guide will clear the material and/or the vise jaws.

Page 20

HEAD REVERSE RATE

1. Located on the left side of the control console, this valve is used to regulate the reversing speed of the saw head. Turn the knob counterclockwise to “increase” the reversing velocity; clockwise to “decrease” it. The valve’s lower locking knob or set screw helps maintain the setting.

2. It can also be used to withdraw the saw band from its kerf during a binding or jamming situation To do so: (a) Turn the Band selector to "stop" if the saw band is stalled; (b) Turn the Feed selector to "auto-off"; (c) Turn the Head Reverse Rate knob clockwise to the minimum rate and move the Feed selector to "reverse".

3. Very gradually increase the head reversing rate by turning the control knob counterclockwise to allow the carriage to slowly retract and withdraw from its kerf.

HEAD TILT ADJUSTMENTS

2. When tilting the head to the left, the LCD will display

the angle with a minus (-) sign in front of the value. When tilting to the right, there will be no sign in front of the value.

Eliminate any electromagnetic radiation from

such things as radio transmitters, walkietalkies, etc. which may affect the angle data shown on the display.

ROLLER TABLE

1. Material is supported on the table by four (4) rollers on each side of the saw band. Rollers have sprockets and are chained together for ease of moving material into cutting position. Material movement is done by means of a hand crank (hand crank is also used for

chip conveyor) that ts onto a tting on the far right

or far left roller.

1. The saw head can be tilted up to 45° left or right for angular sawing and controlled by a selector switch on the pushbutton panel. Tilt angle is indicated by the Miter Meter, or on older machines, a protractor scale and pointer located on the rear right side of the roller table behind the sawing head.

2. The sawing head must be in the fully retacted position in order to tilt the head. (a) Turn the Operation selector to "set-up"; (b) Turn the Feed selector to "reverse" to fully retract the head; (c) Turn Tilt selector to "left" or "right" as desired and then turn to "hold" when desired angle is achieved as indicated on the Miter Meter, or the protractor scale and pointer.

When the saw head is tilted, make sure the

post and upper saw guide is positioned to clear the material and/or vise jaws. Failure to do so will result in damage to the post.

MITER METER

1. This angle measuring devise is mounted to a bracket on the left side of the control console. The battery operated unit has a "power on" thumbwheel or button

and a LCD readout window to display the tilt angle

of the saw head.

Roller Table.

2. Maximum table support weight is 6000 pounds (2721.6 kg) evenly distributed with no impact.

VISE ADJUSTMENTS

1. The 12.50 inch high (317.5 mm) vise jaws are mounted on the left side of the saw band and controlled by a selector switch on the pushbutton panel.

2. To adjust the movable jaw: (a) Lift up and hold the locking lever; (b) Slide both the vise jaw and vise lock toward the workpiece; (c) Locate the pin into the nearest hole in the vise slide bar by releasing the locking lever; (d) Turn the Vise selector switch to "close".

Page 21

VISE ADJUSTMENTS (Continued....)

3. The xed vise jaw distance from the saw band can

be adjusted by: (a) Loosening the lock screw; (b) Slide the xed vise to desired position; (c) Tighten the lock screw.

• Certain work-hardening materials will require a

moderately heavy initial Band Feed 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 Band Feed 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.

• Band feed adjustments are not necessary for changing stock cross-sections. A servo 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.

Movable Vise Jaw With Vise Lock.

When the saw head is tilted, make sure the

post and upper saw guide is positioned to clear the material and/or vise jaws. Failure to do so will result in damage to the post.

BAND FEED ADJUSTMENTS

1. Band feed is the pressure exerted by the workpiece against the saw band's cutting edge. It is controlled hydraulically and regulated with the Band Feed valve. Turn the valve clockwise to "increase" pressure, counterclockwise to "decrease" it. The valve’s lower locking knob or set screw helps maintain the setting.

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

• Turn the Band Feed valve to a low setting if the correct band feed 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.

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

Cutting Rate to Thickness Relationship.

Page 22

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.

Contact your DoALL sales representative for

complete information about the use of coolants and their applications.

Coolant Application

1. Coolant is applied as follows during sawing:

• A valve located below and left of the control panel regulates: (a) The ow to the saw band and cutting area through the saw guide inserts; (b) To a ushing nozzle for washing parts or cleaning areas of the machine.

• A valve located under the step on the left side of the machine base near the coolant pump regulates: (a) A nozzle for removing chips and cooling the band drive motor located below and to the right of the lower bandwheel; (b) A ushing nozzle to keep chips moving off the pan onto the chip conveyor.

2. Coolant flow is started by: (a) Pushing the Hydraulic Start button; (b) Turning the Coolant

selector to "on" or "band on"; (c) Turning the coolant valves counterclockwise until uid is owing and completely shrouds the saw band.

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

adequately. Dry cutting will greatly reduce blade life.

3. The machine will function through a wide range

of hydraulic uid temperatures, although ideal

temperature range is between 90° and 130° F. (32°

and 55° C.). Machine functions may be sluggish

ifoperatedwithuidtemperaturebelow70°F. (21°C.).

4. The operator should check the cutting rate closely

as uid temperature rises. Feed force changes will be necessary as the uid warms. For example: If

Feed Force is set to obtain a given cutting rate

with uid temperature at 50° F. (10° C.), the rate will increase substantially when uid warms up to 100° F. (38° C.).

CHIP REMOVAL

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.

2. Metal chips removed by the band brush fall into the coolant reservoir. These should be removed frequently by turning the hand crank operated chip conveyor (hand crank is also used for roller table).

3. Drip pan capacity is 20 gallons (75.7 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.

Page 23

CHIP REMOVAL (Continued....)

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.

Band Wipers

1. A wiper located at approximately the two (2) and ten (10) o'clock position from the lower bandwheel removes coolant residue from the moving saw band before it reaches the lower and upper bandwheels.

2. A set of wipers are also used to wipe the saw band before entering the cutting area. These wipers are located on top of the saw guide inserts on the upper saw guide block.

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.

Combination Shovel-Rake.

TYPICAL OPERATING PROCEDURES

2. Push the Hydraulic Start button and turn the Operation selector to "set-up". Then: (a) Retract

the sawing head completely by turning the Feed selector to "reverse" and then to "auto-off" when the head has reversed; (b) Turn the Vise selector (and NestingFixture(s) if supplied) to "open" and unclamp the vise; (c) Raise the post and saw guide by turning the Post selector to "up" and then to "hold" when the saw guide has been raised enough to clear the stock and/or vise; (d) Turn the Band selector to "stop".

3. Load the stock to be cut onto the roller table or use controls for the material handling equipment if supplied to move stock into position.

4. To move the stock into position for clamping by the vise jaws: (a) Turn the hand crank on the outside table roller until desired length is achieved; (b) Lift up and hold the locking lever; (c) Slide both the vise jaw and vise lock toward the workpiece; (d) Locate the pin into the nearest hole in the vise slide bar by releasing the locking lever; (e) Turn the Vise selector (and NestingFixture(s) if supplied) to "close".

• Operating Note: If a workstop is supplied, set the workstop to desired length, move the material until it contacts the workstop and then turn the Vise selector (and NestingFixture(s) if supplied) to "close".

5. Turn the Tilt selector to the desired cutting angle and then to "hold" after the saw head is at the correct setting shown on the Miter Meter, or the protractor scale.

6. Turn the Post selector to "down" and then to "hold" when the post and saw guide are at a position just

above material and/or vise.

7. Turn the Operation selector to "manual'. Then: (a) Turn the Coolant selector to "band on" (or "normal' on some older machines); (b) Turn the Band selector to "run"; (c) Turn the Band Speed and Band Feed valves to initial settings; (d) Turn the Coolant valve on and adjust so that the saw band is shrouded with coolant.

Manual Operation

1. These procedures assume that the following machine conditions exist: (a) The machine has been properly installed and aligned; (b) The band drive motor is off; (c) The proper saw band has been installed, is correctly tracked and tensioned; (d) All lubrication procedures have been carried out.

8. Turn the Feed selector to "forward" and then the Head Approach selector to "normal". Next, watch

closely as the saw head moves forward and make any adjustments to band speed, band feed, coolant

volume, head approach and/or feed rate settings

as needed.

Page 24

TYPICAL OPERATING PROCEDURES

(Continued....)

9. After the cut has been completed, the saw band will shut off with the saw head in the forward position. Next: (a) Retract the saw head by moving the Feed selector to "reverse" (move the selector to "hold" when the desired saw head position is reached); (b) Turn the Vise selector (and NestingFixture(s) if supplied) to "open"; (c) Remove the cut-off piece either by means of the hand crank for the table rollers, or by use of controls for material handling equipment if supplied.

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.

Automatic Operation

1. Follow Steps 1 through 6 in the "Manual Operation" section.

For future reference, keep a record of band

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

2. Turn the Operation selector to "automatic'. Then: (a) Turn the Coolant selector to "band on" (or "normal' on some older machines); (b) Turn the Band selector to "run"; (c) Turn the Band Speed

and Band Feed valves to initial settings; (d) Turn the Coolant valve on and adjust so that the saw band is shrouded with coolant.

8. Turn the Feed selector to "forward" and then the Head

Approach selector to "normal". Next: (a) Push the Cycle Start button; (b) Watch closely as the saw

head moves forward and make any adjustments to band speed, band feed, coolant volume, head

approach and/or feed rate settings as needed.

9. After the cut has been completed, the saw band will stop running and the saw head will retract until it trips the head reverse limit switch, then stops.

10. Next: (a) Turn the Vise selector (and Nesting Fixture(s) if supplied) to "open"; (b) Remove the cut-off piece either by means of the hand crank for the table rollers, or by use of the material handling equipment controls if supplied; (c) If another cut is to be made, move the stock into desired cutting position, clamp the vise and then push the Cycle

Start button.

DO NOT remove any cut-off pieces until they

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

Page 25

LUBRICATION

Next2Pages

Page 26

LUBRICATION

LUBRICATION CHART

LUBRICATION

POINT NO.

LOCATION DESCRIPTION AND

SERVICE RECOMMENDATIONS

Rear Drive Shaft Bearing. One (1) grease tting.

Upper Bandwheel Bearing. One (1) grease tting.

Drive Pinion Shaft Bearings. Two (2) grease ttings.

Carriage Support Guide Bearings. Eight (8) grease

ttings.

Rear Head Pivot Pillow Block. One (1) grease tting.

Work Stop (Optional). Five (5) grease ttings.

Movable Vise Jaw Slide(s). Clean and apply oil.

Saw Guide 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.

LUBRICATION

INTERVAL*

MONTHLY

3 MONTHS

AS REQUIRED

WEEKLY

INSERT CHANGE

MONTHLY

AS REQUIRED

RECOMMENDED

LUBRICANT

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

NLGI No. 2.

Union 76, UNOBA EP 2, or equivalent.

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

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

Union 76, UNAX RX 68, or equivalent.

Transmission. 3.25 gallon (12.3 liter) capacity. Keep full.

Drain and rell every 6 months or when required.

Electric/Hydraulic Motors. Hydraulic Pump, Coolant Pump, Band Drive.

Coolant Reservoir (Drip Pan). 20 gallon (75.7 liter) capacity.

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

same time.

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.

High quality, EP (extreme pressure) multi-

CHECK

MONTHLY

Lubricate (if any) per manufacturer’s recommendations.

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.

purpose gear oil.

S.A.E. Grade No. 90.

Union 76, MP Gear Lube 90 or equivalent.

Premium quality, saw band coolant and

lubricant.

DoALL cutting uids and/or oils.

Multi-purpose automatic transmission

uid. Perferred.

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

ISO-VG Grade 46 (Formerly ASTM Grade No. 215).

Union 76, UNAX RX 46, or equivalent.

Page 27

LUBRICATION DIAGRAM

REAR VIEW

LOWER HEAD - REAR VIEW

POWER UNIT

Page 28

MAINTENANCE

It is strongly recommended that repair

procedures be performed by experienced

maintenance personnel, or a DoALL service representative who is trained to repair and service your machine.

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. Note that the upper and lower saw guide inserts are NOT interchangable and care must be taken when ordering new ones.

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 — be very careful not to

drop or lose the front insert when it falls from the assembly; (c) Loosen the screw and remove

the rear insert.

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.

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 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 pump. Consult a DoALL

representative if assistance is needed.

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.

Pump Repair & Replacement

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 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.).

Page 29

HYDRAULIC SYSTEM (Continued....)

MACHINE ALIGNMENT

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.

 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).

Contact your DoALL sales representative for

complete information about the use of coolants and their applications.

MACHINE CLEANING

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

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

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.

BRUSH ADJUSTMENTS

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 Wipers

1. Band wipers, located at approximately the ten (10) and two (2) o'clock positions from the lower bandwheel, remove coolant residue from the moving saw band before it reaches the upper and lower bandwheel. Adjust or replace the wipers when necessary.

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 with heavier use.

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.

WEAR PLATE REPLACEMENT

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 one(1) vise jaw wear plate 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. There is one (1) vise bed wear plate on each side of the saw band. All wear plates are mounted with low-head screws.

Page 30

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. Remove the bandwheels every six (6) months to clean them and surrounding areas. At the same time, clean the drive wheel ring gear and pinionbefore appling lubricant.

Typical Bandwheel Flange and Tread.

4. On older machines, both bandwheels may have

replaceable front anges to help keep the saw band correctly positioned. Replace these anges when

there is signs of wear.

CHIP CONVEYOR

1. Metal chips removed from the saw band during operation fall into the machine's coolant reservoir. They are gathered and removed by a hand operated conveyor which carries the chips up a chute and deposits them in a container placed under the chip opening.

2. The furnished roller table hand crank can also be

used to operate the chip conveyor by tting it over the

extended shaft located at the front right side of the machine base. Turn the crank counterclockwise to remove the chips.

MITER METER

1. A message "LoBat" may appear in the LCD display's

upper left corner. This indicates that battery voltage has dropped below the level required for accurate

readings. Carefully pry the top cover off and replace

the 9V battery.

Page 31

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.

MACHINE WILL NOT START

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

position.

2. The Stop (Emergency Stop) pushbutton must be reset (turn the button head clockwise until it pops out).

3. Check the main fuses (F1, F2, F3) and control circuit

fuse (F4).

4. Make sure the bandwheel door is closed.

5. Reset the motor starter overloads/protectors in the

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

6. Check the control transformer for power.

7. Check the hydraulic motor and wiring.

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.

MACHINE RUNS NOISILY

1. Check for low hydraulic oil reservoir level.

2. Check for air in the hydraulic system.

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

pump suction screen.

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 (1 LS).

2. Check to see if the bandwheel door is closed (the

band drive motor will not start unless the door is closed).

SAW BAND STALLS DURING A CUT

1. Decrease saw head feeding pressure.

2. Increase band speed and/or decrease head

approach rate.

3. Check for low hydraulic pressure.

4. Check for faulty hydraulic pump operation.

5. Hydraulic pump to motor alignment is incorrect.

6. Check the hydraulic pump motor coupling. May

need to be tightened.

7. Make sure all lubrication points have been serviced.

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.

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

to crooked stock. Use wider set saw band.

6. Check for worn or improperly-adjusted saw guide

inserts.

Page 32

TROUBLE SHOOTING (Continued....)

SAW BAND BREAKAGE

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.

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.

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. 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.

7. Band tension is too high.

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 0.020inch (0.5 mm).

9. Check for saw band vibration.

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

band on its rst few cuts.

BLADE TEETH STRIPPING

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.

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.

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 or feed rate.

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.

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

8. Saw band pitch choice is incorrect.

Page 33

TROUBLE SHOOTING (Continued....)

SAW HEAD WON’T TRAVERSE

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.

12. Band tension may need adjustment.

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 inserts for wear.

Replace them if necessary.

1. The feed rate setting is too low.

2. Operation selector must be in "set-up".

3. Check the head rear limit switch (5 LS) for faulty operation.

4. Check for saw head obstruction.

5. Check for faulty operation of Solenoid 9 and 10.

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.

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.

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.

VISE(S) WON’T OPEN OR CLAMP

1. Check for mechanical obstructions.

2. Check for faulty operation of Solenoid 8.

3. Check control panel selector switch settings.

SAW HEAD DOESN'T TILT

1. Check for faulty operation of Solenoid 1 and 2.

2. Check for mechanical obstructions.

3. Check control panel selector switch settings.

4. Check for faulty hydraulic pump operation.

NO COOLANT FLOW

1. Make sure reservoir is full.

2. Check for a clogged coolant screen.

3. Check for a clogged or kinked coolant hose.

4. Check for a clogged or damaged coolant control

valve.

5. Check for faulty coolant pump and/or motor.

NO BAND TENSION

1. Check band tension adjustment valve setting. Should

be at the "tension" setting.

2. Check for mechanical obstructions.

3. Check for improper saw band length.

4. Check for damaged or worn band tension cylinder,

or leaking hose connections.

Page 34

ACCESSORIES

The following are accessories sometimes

used during sawing operations. A DoALL sales representative will be happy to advise you about the current availability of any accessory.

VARIABLE VISE PRESSURE

1. This control valve and gauge, located attached to the right side of the control console, 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.).

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 5 to 24 inches (127.0 to 609.6 mm) wide, and from 5 to 25 inches (127.0 to 635.0 mm) high.

2. Vertical nesting clamp cylinders can be mounted on either side of the saw band or on both sides if desired. The cylinders operate independent of the regular vise clamping cylinders.

The saw head CAN NOT be tilted toward the

NestingFixture.

Typical Variable Vise Pressure Controls.

2. 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.

FILLER PLATES

1. This optional feature is designed to keep short cutoff pieces from falling between the table rollers. To

prevent stock from hanging up on the ller plates,

the top surface of the plates should be 0.015 inch (0.38 mm) below the plane of the two (2) nearest rollers to the saw band.

Nesting Fixture.

NestingFixtureControls

1. NestingFixture(L.Hand/orR.H.). A selector valve lever with "open" and "clamp" settings controls

vertical clamping action of the nesting xture. It is

located directly above the control console.

 Thehorizontalvise(s)mustbeclampedrst

beforethenestingxtureisclamped.

Page 35

NESTING FIXTURE (Continued....)

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.

For Best Nesting Cutting Results

1. Total stack width should be no more than ve (5)

to six (6) inches (127.0 to 152.4 mm).

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

Nesting Fixture Controls.

2. Variable Clamping Pressure and Gauge. This control valve is used to adjust vertical vise clamping force against materials which cannot tolerate full vise clamping pressure (examples are thin-walled tubing, pipe, light structurals, etc.).

• 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.

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. Sl ippag e can als o be pr event ed by using polyurethane wear plates on the front movable vise jaw(s).

4. 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).

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

4. Apply as much coolant as possible while cutting.

5. Replace wear plates on the moveable vise jaw and

nesting xture’s vertical clamping jaw when they

become worn.

6. Adjust the conveyor’s vertical guide rollers (if supplied) 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.

ROLLER STOCK CONVEYORS

1. Your machine can be equipped with many varieties of roller stock conveyors for long stock to enter

and/or exit the cutting area. Some examples of

conveyors are:

• Idler stock conveyor ve (5) feet (1524.0 mm) or ten

(10) feet (3048.0 mm) long with a weight capacity of 750 pounds (340.2 kg) per roller.

Page 36

ROLLER STOCK CONVEYORS (Continued....)

• Powered stock conveyor ve (5) feet (1524.0 mm)

or ten (10) feet (3048.0 mm) long with a weight capacity of 750 pounds (340.2 kg) per roller.

Powered conveyors allow speeds variable up to 50 fpm (15.2 m/min.) and are regulated with selector

switch having "forward", "reverse" and "hold" settings or similar settings. See the "Operation" section for descriptions of other conveyor controls that may be supplied.

• Idler and/or powered extension conveyor ten (10)

feet (3048.0 mm) long can be used with any of the conveyors above.

Conveyor Attachments

1. Both idler and powered conveyors can be equipped with drip pans mounted underneath the rollers to catch dripping coolant and allow it to drain back to the machine reservoir.

2. Filler plates can also be placed between the conveyor rollers to prevent short cut-off pieces from

falling through unto the drip pans or the oor.

2. Workstop arm positioning is done either manually, or by a control panel selector switch. The woskstop is moved to desired length as indicated on a scale on the conveyor and then locked into place.

VERTICAL GUIDE ROLLERS

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

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

3. The vertical roller is adjusted along the guide rail

and clamped to the rail to laterally conne stock

when the vise jaws are opened.

MIST LUBRICATOR

1. The mist lubricator has a reservoir mounted in the rear of the machine with a nozzle unit mounted near the upper saw guide to help lubricate the cutting area.

Installation

1. To install a roller stock conveyor: (a) Position the assembled conveyor(s) left and/or right 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 plates.

2. 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.

3. 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.

WORKSTOP

1. Some conveyors may be equipped with manually positioned, hydraulically controlled workstop which travel along a rail at the conveyor edge. This workstop can provide stock cut-off lengths from 35

inches (889.0 mm) to ve (5) or ten (10) feet (1524.0

or 3048.0 mm).

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

RIGHT HAND VISE

1. The right hand 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. This vise operates in sync with the left hand vise.

Make sure the vise jaws are opened wide

enough when moving material through the vises.

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 or near the control panel

operates the lift roller (left and/or right hand) with

"up" or "down" settings.

Page 37

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. If the indicator dot moves during cutting, this signies

that something (dull or improper blade, overfeeding, etc.) is causing the blade to twist. The operator can see graphically the direction of twist and take appropriate action to correct the problem before several bad parts are produced.

 Numberintextreferstoidenticalnumberon

illustration.

1. Two Green LED's indicate zero or the center of the display. These LED's are always on.

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.

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

FIXED FRAME (NON-TILTING)

1. This factory installed option does not allow tilting of the saw head. It features a bracket that extends from the rear of the column to the machine base frame.

EXTRA WORK HEIGHT

1. The factory installed extra work height allows maximum cutting capacity up to 40 inches (1016.0 mm). Machines with this option have a slightly different frame weldment, post and post guarding from those shown else where in this manual. However, machine operation does not change.

2. Vertical line of Green LED's indicate the machine's normal operating range. Only one at a time is lighted.

3. Amber LED's indicate a caution region. These

LED's remain on and ash if there is a condition

which remains for a period of time (seconds). This is intended to caution the operator that a potentially out-of-range condition may occur and corrective action should be taken.

BAND TWIST INDICATOR

1. The Band Twist Indicator gives the operator a graphic indication of the twist of the saw band from a true cut (direction of twist and its approximate magnitude).

• The Band Twist Transducer is mounted on the left saw guide arm.

The Band Twist Indicator reduces height

capacity by two (2) inches (50.8 mm).

2. The unit presents both "manual" and "automatic" operating options. In "manual", it functions only as a visual indicator. During "automatic", the band drive motor shuts off if the twist is greater than the approximate predetermined amount.

Band Twist Indicator.

• The operator can still see the approximate magnitude of the twist by observing the single amber LED which

is still lighted when the ashing LED's are off.

• If the machine is running with the Man Auto selector at "man", a situation could occur which causes a

deection into the amber region. The operator is

able to correct the condition -- perhaps by reducing feed force, etc. -- and the indicator will return to the

green region (the amber LED's will still be ashing

as a caution to the operator. These conditions are remembered until the machine is turned off or the

Reset button is pushed.

Page 38

NESTING FIXTURE (Continued....) REINFORCING LEGS (Heavy Work Support)

4. Two Red LED's (on side of the display at the top

and bottom) ash when the indicator moves beyond

the amber region. This indicates that the amber region has been exceeded. Under this condition, the operator does not know the approximate magnitude of the error.

5. Red LED's at the extremes of the display are

unlighted when the deection is reduced. This may

allow the operator to see what is happening as the conditions change.

6. Zero control allows the operator to position the display where desired. Normally this would be in the center of the display as indicated by the two Green LED's which are always on.

7. Sensitivity control allows the operator to set the full scale of the display -- "1" is the least sensitive to twist and "10" is the most sensitive. The actual values depend on the calibration of the device.

8. Man - Auto. This selector permits the operator to select "manual" operation (machine operation is not interrupted by the band twist monitor), or "automatic" (the saw band is stopped when the red LED's are lighted).

1. Two (2) reinforcing legs (or jacks) are mounted under the roller table weldment. These legs increase the table support capacity to 10,000 pounds (4536 kg). A bumper plate and bumper bracket are mounted on the lower portion of the sawing head to prevent the head from hitting the legs.

The head CAN NOT be tilted when the

reinforcing legs are in place.

9. Reset. Push the button to turn off the ashing indicators, etc.

MEDIUM TORQUE DRIVE

1. Some machines are equipped with this optional band drive which provides band speeds from 50 to

300 fpm (15 to 91 m/min.). This drive alternative is

recommended for applications which involve cutting structural materials.

SAW BAND MODIFICATION

1. This optional feature allows the machine to operate with a 1.25 inch (31.7 mm) wide saw band. There is slight difference in saw guides, bandwheels and inserts, but all machine functions and operations remain the same.

HEAD TRAVEL INDICATOR

1. This device is used along with a stop watch to determine the saw head's forward travel rate. Located on the machine frame above the chip conveyor chute, it has two (2) measurement dials: (a) The lower dial measures head travel in tenths of an inch; (b) The upper, larger dial measures head travel in thousandths of an inch.