Page 1
ZV-3620
Serial No: 565-03101 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
METAL CUTTING BAND SAW
MODEL FIRST SERIAL NO. LAST SERIAL NO.
ZV-3620 565-03101
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.
Specications 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 specications 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, Dart, Tensigage and Zephyr.
PRINTED IN U.S.A.
i
PB-507.5 (2-10)
Page 4
TABLE OF CONTENTS
MACHINE DIMENSIONS
Floor Plan ............................................................... 1
Floor Plan With HMD Hydraulic Table .................... 2
Front View .............................................................. 3
Front View With HMD Hydraulic Table ................... 4
MACHINE FEATURES
Front View .............................................................. 5
Front View With HMD Hydraulic Table ................... 6
Rear View ............................................................... 7
Raer View With HMD Hydraulic Table .................... 8
INSTALLATION
Location .................................................................. 9
OSHA Notice!! ........................................................ 9
Unpacking ............................................................... 9
Cleaning ................................................................. 9
Lifting ...................................................................... 9
Machine Installation and Alignment ........................ 9
Electrical Installation ............................................... 10
Table Alignment (Standard) .................................... 10
Table Alignment (HMD Table) ................................. 11-12
Preparation for Use ................................................ 12
OPERATION
Safety Precautions ................................................. 13
Friction Sawing ....................................................... 13
Machine Controls .................................................... 13-14
Table Controls ......................................................... 14
Band Speed Control ............................................... 15
Saw Band Tension Handwheel ............................... 15
Saw Band Tracking Lever ....................................... 15
Saw Band Preparation ............................................ 15-17
Post Adjustment ...................................................... 17
Spark Guard ........................................................... 17
Worktable and Adjustments .................................... 17-18
Dust Spout .............................................................. 18
Hydraulic Brake ...................................................... 18
Typical Sawing Procedures .................................... 18-19
LUBRICATION
Lubrication Chart .................................................... 20
Lubrication Diagram ............................................... 21
MAINTENANCE
Changing Belt ......................................................... 22
Electric Motors ........................................................ 22
Head Components .................................................. 22
Hydraulic Brake ...................................................... 22
Hydraulic System .................................................... 22-23
Hydraulic Table (Optional) ...................................... 23
Saw Guides ............................................................ 23
Machine Cleaning ................................................... 23
Bandwheel Tire Replacement (Sheet Metal
Bandwheels) ........................................................ 24-25
Bandwheel Tire Replacement (Cast Aluminum
Bandwheels) ........................................................ 25-26
TROUBLE SHOOTING .................................. 27-29
ACCESSORIES
Disc Cutter .............................................................. 30
Rip Fence ............................................................... 30
Worklamp ............................................................... 30
Magnier ................................................................. 30
Chip Blower ............................................................ 30
DBW-15 Buttwelder ................................................ 31
Workholding Jaw .................................................... 31
Secondary Table ..................................................... 31
Hydraulic Tables ..................................................... 31-32
Glide Table .............................................................. 32
Optional Saw Guides .............................................. 32
Extra Work Height .................................................. 32
Hydraulic Band Tension .......................................... 32
Band Lubricator ...................................................... 32
Dust Collector ......................................................... 32
Safety Equipment ................................................... 33
Material Handling Equipment ................................. 33
How to read your serial number:
ii
Page 5
MACHINE DIMENSIONS
INCHES (± .03)
MILLIMETERS (± 1 mm)
FLOOR PLAN
1
A
B
Table Dimensions
Standard
Table
36.25
(920.8)
30.50
(774.7)
Glide
Table
32.63
(828.8)
25.39
(644.9)
Hydraulic
Table
41.00
(1041.4)
32.00
(812.8)
Optional
Page 6
MACHINE DIMENSIONS (Continued....)
INCHES (± .03)
MILLIMETERS (± 1 mm)
FLOOR PLAN With HMD HYDRAULIC TABLE
2
Page 7
MACHINE DIMENSIONS (Continued....)
Work
Height
Dimensions
A B C
20.00" (508.0) 15.50" (393.7) 103.25" (2622.6)
30.00" (762.0) 25.50" (647.7) 113.25" (2876.6)
36.00" (914.4) 31.50" (800.1) 119.25" (3029.0)
42.00" (1066.8) 37.50" (952.5) 125.25" (3181.4)
INCHES (± .03)
MILLIMETERS (± 1 mm)
FRONT VIEW
3
Page 8
MACHINE DIMENSIONS (Continued....)
* "A" and "B" Is Dependent On Work Height Ordered.
INCHES (± .03)
MILLIMETERS (± 1 mm)
FRONT VIEW With HMD HYDRAULIC TABLE
4
Page 9
MACHINE FEATURES
FRONT VIEW
5
Page 10
MACHINE FEATURES (Continued....)
FRONT VIEW With HMD HYDRAULIC TABLE
6
Page 11
MACHINE FEATURES (Continued....)
REAR VIEW
7
Page 12
MACHINE FEATURES (Continued....)
REAR VIEW With HMD HYDRAULIC TABLE
8
Page 13
INSTALLATION
All the “left”, “right”, “front” and “rear”
designations in this manual are as viewed by
the operator facing the machine’s pushbutton
controls.
LOCATION
1. The oor area required for the standard machine is
approximately 81.50 inches (2070.1 mm) in width
by 36.25 inches (920.8 mm) in length. Machine
height for the standard machine is 103.25 inches
(2622.6 mm). Optional tables may require extra
space. Refer to pages 1 thru 4 for further machine
dimensions.
2. Locate the machine to provide adequate space
for your sawing needs. Be sure also to provide
sufcient clearance for: (a) Loading and unloading
of stock; (b) All door openings; (c) Maintenance and
lubrication procedures; (d) Plus any operation of
any machine options, if applicable.
OSHA NOTICE!!
OSHA Regulation 1910.212 (5B).
Machinesdesignedforaxedlocationshall
be securely anchored to prevent walking or
moving.
UNPACKING
LIFTING
1. A tapped hole is located on top of the machine’s
column. Screw a forged 3/4-10NC eye-bolt into
this hole for lifting purposes. An overhead hoist
is recommended. The weight of the machine is
approximately 3500 pounds (1587.6 kg).
DO NOT lift the machine by the sawing
head.
2. Lifting of the HMD hydraulic table can be done by
a fork lift or overhead hoist. Distribute the weight
evenly when lifting. Approximate weight of the table
is 1500 pounds (680.4 kg).
MACHINE INSTALLATION and ALIGNMENT
Drive Motor Installation (When Machine Was Shipped
On Its Side)
1. Install the two (2) motor supports. The supports
have been correctly aligned and doweled at the
factory. Then: (a) Slip in the motor base weldment
into the supports and install cotter pins; (b) Place
the belts around both motor and spindle pulleys; (c)
Adjust the belt tension screw so very little deection
is noticed; (d) Install the belt guard to the machine
frame.
1. In most cases, the machine is fastened to and
shipped on a wooden skid and shipped on its
side.
2. If shipped on its side, tip the machine upright rst
before removing any other shipping materials.
3. 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) Check for other removable brackets, extra
machine parts or supplies which might have been
placed for shipment; (c) DO NOT remove the motor
blocking until the machine is placed in desired
position; (d) Inspect the machine and all parts for
shipping damage. Claim procedures are listed on
this manual’s inside front cover.
CLEANING
1. If necessary, use solvent to remove any rustpreventive coating applied to exposed bare metal
surfaces before shipment.
Drive Assembly.
DO NOT change the location of the motor
or spindle pulley as they have been factory
aligned.
9
Page 14
ELECTRICAL INSTALLATION
Electrical installation must be made by
authorized electrical maintenance personnel
only!
1. Refer to the machine specications plate on the
machine 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. Bring the incoming power leads into the
machine’s electrical box enclosure. Refer to the
electrical schematic if necessary when making the
connections.
Controls on the machine may vary. Some may
not have a Band Stop control in which case
the All Stop pushbutton is used.
3. Turn the disconnect switch on the electrical box to
"ON". Then: (a) Intermittenly push the Band Start
and Band Stop pushbuttons; (b) Check to make
sure the saw band is moving in a downward direction
between the saw guides; (c) Reverse the leads if
saw band movement is incorrect.
Squaring Worktable to Post.
2. Place a good quality, 10 inch (254.0 mm) master
square on the worktable against the post’s back side.
Measure clearance between the post and square
near the bottom of the post. Clearance should be
within 0.007-inch ±0.005-inch (0.18 mm ±0.13 mm)
at the bottom of the post for standard machines.
3. Add or remove shims under the base pads until the
correct post to square clearance is obtained.
Themachinemust beboltedtotheoorfor
worktable loads over 100 pounds (45 kg).
4. The machine is provided with overload protection,
however, the overload relay may kickout if starting
and stopping occurs numerous times in rapid
succession. If this happens, let the relay cool for
a few minutes, then push the overload reset inside
the control box enclosure before restarting the
machine.
TABLE ALIGNMENT (Standard)
1. Place the machine in desired location. Place a level
on the machine table center. Insert leveling screws
into the mounting pads and make nal shimming
adjustments to level the machine in both directions.
Make sure weight bears evenly on all mounting pads.
DONOTboltthe machine to the oor until all
alignment and assembly procedures have been
completed.
Hydraulic Installation (If Required)
1. Connect the hydraulic hoses from the power unit
to the hydraulic valve manifold on the saw column
or the hydraulic power unit. Hoses are numbered
and tagged for correct installation. Referring to the
hydraulic schematic will be helpful when making the
connections.
2. The power unit must be used to check table travel
with the saw band and raise the post.
3. If necessary, ll the hydraulic reservoir. The standard
reservoir is located on the saw column. Machines
with hydraulic options has a hydraulic power unit
located either under the HMD table or behind the
machine column.
• Standard reservoir capacity is 2.8 gallons (10.6
liters) and ten (10) gallons (37.8 liters) for the typical
hydraulic power unit. Both are lled with automatic
transmission uid.
4. Operate all the controls and check for correct
operation. Let the hydraulic system run for several
minutes to remove entrapped air.
10
Page 15
TABLE ALIGNMENT (HMD Table)
1. Place the machine in desired location. Place
a level on the machine table base plate. Insert
leveling screws into the mounting pads and make
nal shimming adjustments to level the machine
in both directions. Make sure weight bears evenly
on all mounting pads. DO NOT bolt the machine
to the oor until all alignment and assembly
procedures have been completed.
2. Remove the saw band according to the instructions
in the "Operation" section in this manual. Then raise
the saw guide post to its highest position.
Hydraulic Installation (If Required)
1. Connect the hydraulic hoses from the power unit
to the hydraulic power unit. Hoses are numbered
and tagged for correct installation. Referring to the
hydraulic schematic will be helpful when making the
connections.
3. Turn the disconnect switch to "ON". Then: (a)
Push the Hydraulic Start pushbutton to activate
the hydraulics; (b) Turn the Post selector switch to
"UP" and raise the post to its highest position; (c)
Move the table to the rear postion by turning the
Table selector switch to "REV" or; move the Table
Feed Control to "REVERSE".
4. Reinstall the saw band. To do this you must lower
the table support bar so a gap is created for the saw
band can slip through.
5. Remove the table slot clamp bar at the edge of
the saw band slot. Then turn the Band Change
Handwheel clockwise (located under the forward
section of the table) to lower the table support bar
until the saw band can slip through the opening.
Reinstall the table slot clamp bar and turn the
handwheel back to its preset stop.
6. Reinstall the saw band according to the instructions
in the "Operation" section of this manual.
2. The power unit must be used to check table travel
with the saw band and raise the post.
3. If necessary, ll the hydraulic reservoir. The reservoir
is located either under the HMD table or behind the
machine column.
• Reservoir capacity is ten (10) gallons (37.8 liters)
for the typical hydraulic power unit and lled with
automatic transmission uid.
4. Operate all the controls and check for correct
operation. Let the hydraulic system run for several
minutes to remove entrapped air.
Table Positioning and Alignment
1. Position the HMD table onto the machine base
making sure the table is setting rmly on the table
base plate of the band saw. Loosely install hex. cap
mounting screws to attach the table to the machine
frame. DO NOT TIGHTEN at this time.
7. After the saw band is installed and tensioned, position
the table as such that the saw band tracks in the
center of the slot. Adjust the leveling screws in the
legs to stabilize the table.
8. Lower the post to just clear the table. Place a
square of known accurarcy on the table against the
throat side of the post and check the post-to-table
squareness. Post should be square to the table to
0.002 inch per inch (0.05 mm per 25 mm). Adjust
the leveling screws in the legs.
9. Place a good quality ten (10) inch master square
on the table against the backside of the saw guide
post. Measure the clearance between the square
and the post near the bottom of the post. Clearance
should be within 0.007 ± 0.005 inch (0.18 ±0.13
mm). Adjust the set screws in the table mounting
pad.
Typical Table Mounting Block.
2. Adjust the table leg leveling screws to roughly level
and square the table to the saw.
Squaring Post to the Table.
11
Page 16
TABLE ALIGNMENT (HMD Table) (Continued....)
10. Add or remove shims under the base pads until the
correct post to square clearance is obtained.
11. With an indicator mounted to the saw guide post,
check table travel by positioning the indicator to
read off of the T-slot in the table. Traverse the table
through its full travel and adjust to achieve from 0
to .015 inch per 30 inches (0 to 0.38 mm per 762.0
mm) of travel.
12. When table and machine are in correct alignment
and level, tighten the mounting screws and then
tighten the jam nuts on the leveling bolts.
PREPARATION FOR USE
1. Remove the pipe plug from on top of the upper
spindle for venting purposes, not the two (2) from
the side and bottom of the spindle.
2. Be sure the hydraulic reservoir is full. Refer to the
Lubrication Chart for recommended uid.
• If necessary, replace the plug on top of the reservoir
with the breather from the box of extra parts.
3. Shop air is required to operate the optional chip
blower or band lubricator. Incoming air supply should
be between 80 and 90 psi (5.6 and 6.3 kg/cm²).
DONOTexceed90psi(6.3kg/cm²).
4. Check the optional band mist lubricator unit for the
proper reservoir level. Refer to the manufacturer
supplied literature for reservoir capacity and
recommended procedures.
5. Make sure all other points listed by the Lubrication
Chart have been properly checked and/or
serviced.
12
Page 17
OPERATION
SAFETY PRECAUTIONS
Warning Label - READ and UNDERSTAND.
FRICTION SAWING
1. The design of this machine makes it ideal for
friction sawing. In friction sawing, momentary
contact between the material being cut and the
fast moving saw band produces enough friction to
heat the material to its softening point. As soon
as it becomes soft, it is cut away by the saw band
teeth. This method cuts many times faster than
conventional methods and cuts many materials that
can not be machined any other way.
2. Keep these important points in mind while friction
sawing:
Roller saw guides are required for friction
sawing.
Attach the spark shield to the post is necessary
for friction sawing. Coolant is not used.
Thicker the workpiece, the faster the band
speed required and heavier the feed force.
Forexample, bandspeedshouldbeatleast
6000fpm(1828.8m/min.)for1/4inch(6.4mm)
thickcarbonsteel;12,500fpm(3810.0m/min.)
for one (1) inch (25.4 mm) thick material.
MACHINE CONTROLS
Depending on options supplied (if any), some
controls may not apply to your machine
application.
1. Band Speed Display. This digital readout displays
the band speed in feet per mimute.
2. Band Speed Control. This control allows the
operator to change the band speed. Turning the
knob clockwise to “increase” the band speed;
counterclockwise to “decrease” it.
13
Page 18
MACHINE CONTROLS (Continued....)
10. Controls for the optional DBW-15 Buttwelder are
described in a seperate instruction manual.
TABLE CONTROLS (If Supplied)
1. Feed Force. This controls the force against the
saw band. Force is indicated on a graduated dial
around the control.
Table Controls.
Typical Machine Controls.
3. Hydraulic Start (Optional). Pushing this illuminated
green button starts the hydraulic pump motor for the
optional band tension and/or hydraulic table.
4. Hydraulic Stop (Optional). Pushing this red button
stops the hydraulic pump motor for the optional
band tension and/or hydraulic table.
5. Post. When the operator turns and holds this
selector switch to the “UP” or “DOWN” position, it
allows the movement of the post. Releasing the
selector switch springs to the “HOLD” position and
stops the post in position.
6. Band Start. Pushing this illuminated green button
starts the band drive.
7. Band Stop. Pushing this red button stops the band
drive.
8. All Stop (Emergency Stop). Pushing this red
mushroom head button stops the band drive motor.
To resume operation, the All Stop button must be
reset by rotating the head of the button clockwise
until the head pops out.
9. The optional Worklight has its own “ON-OFF”
switch on the lamp.
2. Table Feed. This control with "REVERSE", "STOP",
"FEED", and "FORWARD" settings controls table
movement in either direction.
• The "REVERSE" setting moves the table away from
the saw band at a rapid traverse speed.
• The "STOP" setting stops all table movement.
• The "FEED" setting is for sawing and used in
conjunction with the Table Speed Control.
• The "FORWARD" setting moves the table toward
the saw band at a rapid traverse speed.
The "FORWARD" setting is NOT used for
cutting stock.
3. Table Speed Control. When the Table Feed
Control is at the "FEED" setting, the table speed can
be regulated by turning the center knob clockwise
to increase table speed, counterclockwise to
decrease it. Forward speed range is approximately 0
to 8 fpm (0 to 2.4 m/min.); feed rate is approximately
0 to 18 ipm (457.2 mm/min.).
4. Table. Some machines may have a selector switch
with "REV", "HOLD" and "FWD" settings to control
table movement.
• (a) Turn the selector to "REV" (reverse) moves the
table back and away from the saw band; (b) Turn
the selector to "FWD" (forward) moves the table
towards the teeth of the saw band; (c) Turning the
selector to "HOLD" stop table movement in either
direction.
14
Page 19
BAND SPEED CONTROL
1. Speed range can be innitely varied with the Band
Speed control. The speed is shown on an display
located above the control.
4. The back edge of the saw band should just touch
the back-up ange of the saw guide rollers, or the
back-up bearings on insert type saw guides.
5. Close both bandwheel doors.
2. Band speed is changed by turning the Band Speed
control to the desired speed as indicated on the
band speed display.
4. During machine operation, keep the following band
speed precautions in mind:
Adjust the band speed only while the machine
is running.
Always turn the band speed control to “slow”
before stopping the machine.
Always allow the saw band to stop completely
before opening any bandwheel doors.
SAW BAND TENSION HANDWHEEL
1. Saw band tension is adjusted by turning the
handwheel located below the machine’s sawing
head.
2. A scale showing the recommended tension for
various saw band widths is located to the right of the
tension adjustment handwheel near the post. Scale
numbers represent the recommended tensions for
common saw band gages and pitches.
Optional hydraulic band tension is factory set.
DO NOT adjust the handwheel if supplied!
SAW BAND TRACKING LEVER
1. The upper bandwheel can be tilted a maximum of
ve (5) inches (127.0 mm) forward and backward to
help obtain correct saw band tracking. This is done
by the use of the bandwheel tilting lever located
behind the band tension handwheel. A saw band is
tracking properly when the saw band center follows
the center of both crowned bandwheel tires.
2. The following tracking procedures are to be
performed with the band drive motor "OFF": (a)
Open both bandwheel doors; (b) Manually turn
the bandwheels to observe how the saw band is
tracking.
3. Move the bandwheel tilting lever to adjust the
position of the bandwheel; to the left to track the
saw band “IN”; to the right to track the saw band
“OUT”.
SAW BAND PREPARATION
Information about any DoALL saw bands
and their applications can be obtained from
a DoALL sales representative.
Saw Band Selection
1. The standard machine is equipped with a friction
saw band that is 234 inches (5343.6 mm) long. It
will accept saw band widths from 1/16 to one (1)
inch (1.6 to 25.4 mm). Extra work height machines
requires longer saw bands.
2. Optional saw guides that can be used:
• One (1) set of double row, heavy duty ball bearing
saw guide with rollers for one (1) inch (25.4 mm)
wide saw band. Rollers for saw bands 1/4 to 3/4
inch (6.3 to 19.0 mm) are also available.
• One (1) set of insert-type precision saw guide blocks
with inserts for saw bands from 1/16 to 1/4 inch (1.6
to 6.3 mm) wide.
Roller-Type Saw Guide Adjustment-Type III
These instructions apply to both the upper
and lower roller-type saw guide blocks.
1. Select the saw guide blocks and rollers marked
for the width of the saw band to be used. Then:
(a) Place one (1) side roller and one (1) back-up
roller in the upper saw guide block; (b) Switch the
rollers around for the lower saw guide block; (c)
Install the special adaptors onto the post and table
cradle; (d) Then install the saw guide blocks on the
adaptors.
2. After the saw guides are in place, the saw band
should be in place and tensioned. See later in
this section on installation and tensioning the saw
band.
3. Loosen the clamp screws and bring the rollers up to
the saw band, then tighten the screws. The rollers
should be free enough to turn without moving the
saw band.
15
Page 20
SAW BAND PREPARATION (Continued....)
Saw Band Removal
Insert-Type Saw Guide Adjustment
These instructions apply to both the upper
and lower insert-type saw guide blocks.
1. Select the saw guide blocks and inserts marked
for the width of the saw band to be used. Then:
(a) Place the right insert in the right milled slot; (b)
Tighten the insert screw slightly so that the insert
will slide in the slot, yet still hold its correct position
when released.
Positioning the Right Insert.
2. Select the insert gage which matches the size of the
saw band being used. Then: (a) Place the insert
gage in the left slot; (b) Adjust the right insert to t
exactly into the notched end of the gage; (c) Tighten
the right insert screw.
3. Place the left insert in its slot and tighten the insert
lightly. Then: (a) Place the gage edgewise between
both inserts; (b) Lower the left insert until it rests
against the gage; (c) Tighten the left insert screw.
Alwaysuseextremecarewhenhandlingsaw
bands. Wear gloves.
1. Turn the band tension handwheel to release saw
band tension. Then: (a) Open both bandwheel
doors; (b) Open the post and the column saw
band guards; (c) Loosen the knobs holding the
worktable’s sawing slot ller plate and remove it.
2. Carefully slip the worn or broken saw band from
between the saw guides rollers or inserts and table
slot and remove it from around both bandwheels.
Saw Band Installation
Alwaysuseextremecarewhenhandlingsaw
bands. Wear gloves.
1. Remove the old saw band according to the
directions above. Then: (a) Place the new saw
band carefully (teeth facing down and to the front)
through the table slot, around the bandwheels and
between the upper and lower saw guide rollers or
inserts; (b) The center of the saw band should track
along the center of the bandwheel tires.
2. Remove the new saw band’s protective Saw Cap.
Then: (a) Apply the band tension recommended
by the dial located on the front of the column; (b)
Close the post and the column saw band guards;
(c) Replace and secure the worktable’s sawing slot
ller plate.
Saw Band Tension Adjustment
Positioning the Left Insert.
1. Saw band tension is adjusted by turning the
handwheel located below the machine’s sawing
head.
Optional hydraulic band tension is factory set.
DO NOT adjust the handwheel if supplied!
2. A scale showing the recommended tension for
various saw band widths is located to the right of the
tension adjustment handwheel near the post. Scale
numbers represent the recommended tensions for
common saw band gages and pitches.
16
Page 21
SAW BAND PREPARATION (Continued....)
Using theTensigage.
3. A DoALL Tensigage can also be used to check
the band tension. A reading of 2.2 units indicates
correct band tension.
4. Tension may be checked “reading up” or “reading
down”. (a) Fix the Tensigage to a slack saw band
and apply tension to “read up”. (b) To “read down”,
relax tension.
WORKTABLES AND ADJUSTMENTS
1. The standard worktable measures 36.25 by 30.5
inches (920.7 by 774.7 mm). Its load capacity is
500 pounds (226.8 kg) evenly distributed with NO
impact.
Themachinemust beboltedtotheoorfor
table loads over 100 pounds (45.4 kg).
5. A new saw band will stretch as it being used. For
this reason, it is adviseable that the operator checks
the band tension frequently.
6. The following are operator tensioning
recommendations:
• Reduce the recommended band tension when
using saw bands with a coarser pitch or lighter
gage.
• Increase the recommended band tension when
using heavier gage saw bands.
POST ADJUSTMENT
1. Post elevation can be adjusted to accept workpieces
under saw guides with heights varying up to the
limits of the saw depending the work height capacity
(standard capacity is 20 inches (508.0 mm). The
post is positioned with a selector switch located
on the pushbutton control box on the front of the
machine.
2. Always keep the post and upper saw guide as close
as possible to the workpiece and the post band
guard in place at all times when in operation.
SPARK GUARD
1. A spark guard is provided for protection from chips
and sparks. It is installed over the saw guides and
clamped to the place with a wing nut.
Standard Worktable.
2. The worktable can be tilted manually up to 5° left
and 45° right primarily for sawing compound angles.
The amount of worktable tilt is indicated by a pointer
and a trunnion-mounted calibrated scale.
3. To tilt the worktable: (a) Move the table tilt locking
lever located just above the locking handwheel to
the left to loosen; (b) Turn the handwheel located
under the table to desired angle as indicated on the
scale; (c) Move the tilt locking lever to the right to
tighten.
4. The worktable is drilled and tapped on the front side
for attaching accessory equipment. Its removable
table ller plate can be locked in place by two (2)
knobs located under the table.
Optional Secondary Table
1. The xed worktable measures approximately 19.00
by 19.00 inches (482.6 by 482.6 mm) and used for
support of large workpieces.
Optional Hydraulic Table
1. Another optional hydraulic table measures 32 by 41
inches (812.8 by 1041.4 mm) with a table stroke of
16 inches (406.4 mm) and hydraulic actuated table
tilt. See the “Accessories” section of this manual
for operation of this table.
17
Page 22
WORKTABLES AND ADJUSTMENTS
(Continued....)
Optional HMD Hydraulic Worktable
1. The HMD-36 worktable measures 34.00 by 42.00
inches (863.6 mm by 1066.8 mm). Its load capacity
is 1100 pounds (499.0 kg)evenly distributed with NO
impact.
2. The HMD-60 worktable measures 34.00 by 68.00
inches (863.6 mm by 1727.2 mm). Its load capacity
is 2200 pounds (998.0 kg)evenly distributed with
NO impact.
3. Each table has two (2) replaceable wear plates on
both sides of the saw band and four (4) T-slots for
mounting various xtures.
DUST SPOUT
6. Carefully move the stock toward the saw band
and begin the cut. Adjust the band speed as
necessary during the cutting procedure.
• For HMD hydraulic table: (a) Turn the Feed
Force and Table Speed knobs to "0" or low
settings; (b) Position the material to be cut to
the starting point of the cut by moving the Table
Feed control to "FORWARD" and turn the Feed
Force knob until the table is in position; (c) Turn
the Table Feed control to "FEED" and turn the
Table Speed knob slowly to move the saw band
into the workpiece.
7. After the cut has been nished: (a) Turn the Band
Speed control to its lowest speed; (b) Push the
All Stop pushbutton; (c) Remove the piece just
cut from the worktable; (d) Reposition the stock
to begin another cut; (e) Push the Band Start
button and then set the band speed.
1. A dust spout is provided on the right side of machine
frame just below the worktable. If desired, a dust
collection unit can be attached to the spout.
HYDRAULIC BRAKE
1. A disc type, hydraulic wheel brake operates
automatically whenever the saw band should
break.
TYPICAL SAWING PROCEDURES
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.
Procedure
1. Raise the post high enough so that the upper saw
guide can not be damaged while stock is being
loaded onto the worktable.
8. The following are important sawing precautions
which should be observed:
Reduce the feed force when cutting into an
opening to prevent saw band damage.
DO NOT feed work so rapidly that the saw
band twists or bows.
For future reference, keep a record of band
speed, feed pressure, coolant application
settings etc. for successful jobs.
Contour Sawing (Does Not Apply to HMD Tables)
1. Procedures for stock set-up and band speed
adjustment are the same as noted for production
sawing except that: (a) Contour sawing of large,
heavy stock will require the use of a heavy gage
saw band; (b) The operator should consider using
options that make the movement of stock easier for
sawing intricate contours.
2. Load stock to be cut onto the worktable. Clamp
the stock if necessary.
3. If required, tilt the worktable to the desired angle
and lock it in place.
4. Lower the post until the upper saw guide is just
above the stock, but NOT touching.
5. Determine the desired band speed for the
procedure to be undertaken. Then: (a) Push
the Band Start button; (b) Turn the Band Speed
control to the band speed desired.
Starting Hole for Sharp Contour Cutting.
18
Page 23
TYPICAL SAWING PROCEDURES
(Continued....)
Internal Contours
1. To prepare for internal contour sawing: (a) Drill a
starting hole in the stock; (b) Run the saw band
through the hole; (c) Weld the saw band. Insulate
the saw band from contact with the stock or the
worktable will insure a better weld.
Radii Chart.
Typical Internal Contour Sawing.
2. The diameter of the drilled starting hole is determined
by the size of the saw band being used. A hole is
usually drilled in the stockpiece when a sharp corner
is to be cut, as shown in the illustration. However,
a corner may also be by-passed by cutting a curve,
and leaving the remainder to be notched out later.
Use the widest possible saw band for cutting the
curve.
3. Attempting to cut too small a radius with too wide a
saw band will cause binding, saw band breakage
and/or excessive insert/roller wear.
4. Radii chart recommendations are based on sawing
relatively thin stock. Consider these variations: (a)
Use a heavy gage saw band for heavy stock sawing;
(b) Use a narrower than recommended saw band
when sawing stock more than one (1) inch (25.4
mm) thick.
19
Page 24
LUBRICATION
LUBRICATION CHART
LUBRICATION
POINT NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
LOCATION DESCRIPTION AND
SERVICE RECOMMENDATIONS
Roller saw guides (optional). One (1) grease tting
on each roller.
Linear Rail Bearings (HMD Hydraulic Tables Only).
Grease ttings. Quantity of: 8 for HMD-36; 12 for HMD-
60.
Band Tension Screw and Bearing. Clean and apply
oil.
Post. Clean and apply oil. MONTHLY
Upper Bandwheel Slide, Hinge, and Tilt Screw.
Clean and apply oil.
Table Trunnion and Tilt Screw. Apply oil to tilt
surfaces and threads as required.
Miscellaneous: Slides, Hinges, Pivot Points,
Component Parts, Unpainted Surfaces, Optional
Equipment as Supplied, etc. Keep clean and apply oil
as required to to maintain proper function, reduce wear,
and corrosion, etc.
Electric Motors. Band Drive, Hydraulic System Pump. Lubricate (if any) per manufacturer’s recommendations.
Upper and Lower Spindle Bearings. Proper oil level
must be maintained.
Hydraulic Reservoir (Standard). 2.8 gallon (10.6
liter) capacity. Proper oil level must be maintained.
Drain and rell after rst month, every six (6) months
thereafter.
Hydraulic Reservoir (for Hydraulic Table, HMD Table
and/orHydraulicBandTensionOptions). Ten (10)
gallon (37.8 liter) capacity. Proper oil level must be
maintained. Drain and rell after rst month, every six
(6) months thereafter.
Band Mist Lubricator (Optional). Keep lled and
hoses clear.
Oil-Mist Lubricator (For Optional Roller Saw
Guides). Keep lled and hoses clear.
DBW-15 Buttwelder (Optional). Lubricate as required per DBW-15 Instruction Manual.
LUBRICATION
INTERVAL*
DAILY
MONTHLY
MONTHLY
MONTHLY
MONTHLY
CHECK
MONTHLY
CHECK
WEEKLY
CHECK
WEEKLY
CHECK WEEKLY
AS REQUIRED
CHECK WEEKLY
AS REQUIRED
RECOMMENDED
LUBRICANT
Premium quality, multi-purpose, lithiumbased, EP (extreme pressure) grease.
NLGI Grade No. 2.
Union 76, UNOBA EP 2, or equivalent.
High quality, rust and oxidation-inhibited,
medium hydraulic and general purpose
industrial oil.
ISO-VG Grade 68 (Formerly ASTM
Grade No. 315).
Union 76, UNAX RX 68, or equivalent.
High quality #10 spindle oil.
Mobil, Velocite #6, or equivalent.
Multi-purpose automatic transmission
uid.
General Motors Dexron III, or equivalent.
Contact your DoALL sales representative
for the best oils and/or uids for your
application.
DoALL cutting uids and/or oils (AL-
2000).
20
* Lubrication intervals are based on a 8-hour day, 40-hour week.
Lubricate more often with heavier use.
Page 25
LUBRICATION DIAGRAM
REAR VIEW
HMD TABLE OPTION
21
Page 26
MAINTENANCE
CHANGING BELT
1. Belts on the spindle pulley and motor pulley will
stretch during use. This stretch is taken up by
tighten the belt tension screw located below the
drive motor.
2. To replace the belts: (a) Turn the belt tension
screw counterclockwise to relax belt tension; (b)
Remove the old belts.
Hydraulic Brakes.
2. To replace the brake pads: (a) Remove the housing;
(b) Remove the nut and screw or snap ring holding
the brake pad onto the housing; (c) Replace the
brake pads and reinstall necessary hardware (pad
on the piston side “oats” in the opening and is not
attached); (d) Reinstall the housing.
Drive Components.
3. Install the new belts around the spindle pulley and
motor pulley. Then turn the belt tension screw
clockwise to tighten belt so there is very little
deection of the belts at the midpoint between the
pulleys.
ELECTRIC MOTORS
1. Follow the manufacturer’s maintenance instructions
for each electric motor.
HEAD COMPONENTS
1. Wipe oil onto the post occasionally. Then move the
post up and down through the slide block several
times.
2. Oil the upper bandwheel slide and band tension
screw each month.
3. Upper spindle bearings are sealed and lubricated
for life.
HYDRAULIC BRAKES
3. Remove air in the brake lines by loosening the top
screw on the brake cylinder until uid appears.
Repeat the procedure for all brake units.
4. Check the hydraulic reservoir for proper oil level,
add if necessary. Drain, flush, and refill the
reservoir after the rst month, every six (6) months
thereafter.
HYDRAULIC SYSTEM
1. Keep the hydraulic reservoir lled at all times.
Check the reservoir oil level daily by referring to
the sight gage.
2. Drain, clean, rell the reservoir and change the
uid after the rst month of operation; every six (6)
months thereafter. Clean the suction strainer and
keep hoses clear. Automatic transmission uid is
the recommended product.
System Pressure
1. Hydraulic system pressure is correctly set at the
factory and should not require adjustment for a
considerable period of time. On hydraulic systems,
correct system pressure varies between 200 and 300
psi (13.8 and 20.7 bar or 14.1 and 21.1 kg/cm²).
1. Inspect the brake pads occasionally and keep the
pads clean. Do not allow hydraulic uid to drip onto
the brake pads.
22
Page 27
HYDRAULIC SYSTEM (Continued....)
2. To adjust system pressure: (a) Loosen the jam nut
counterclockwise on the adjusting screw; (b) Start
the hydraulic motor by pushing the Hydraulic Start
button; (c) Looking at the pressure gauge, turn the
adjusting screw in (clockwise) to increase pressure,
out (counterclockwise) to decrease it.
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.
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.
HYDRAULIC TABLE (Optional)
Bleeding Air From The System
1. Run the machine for at least 30 minutes or until oil
is warm. Then: (a) Position the adjustable table
stops, located on the side of the table, to give full
table travel; (b) Place the Table Feed Control in
“FORWARD” to move the table cylinder rod to its
extended position; (c) Remove the two (2) jam nuts
and spacer shown in the illustration.
Support the rod end of the table cylinder as
the rod is pulled out of the table bracket.
Be certain to close the bleed port opposite the
end you are bleeding.
3. Allow the cylinder to hang down to provide access
to the bleed port on the top of the rod end cap.
Then: (a) Close the bleed valve on the cap end
of the cylinder; (b) With a container under the
rod end of the cylinder, open the bleed port 2-1/2
turns counterclockwise; (c) Move the Table Feed
Control in “FORWARD” to fully extend the cylinder
rod; (d) Repeat steps 2 and 3 until all air is purged
from the system.
4. Reinstall the table cylinder rod with spacer and jam
nuts, as shown in the illustration. Allow .003 inch
(.076 mm) clearance between the spacer and the
table bracket.
4. See the "Adjustment Summary" for information on
all hydraulic adjustment procedures.
SAW GUIDES
Pivot Back-Up Inserts
1. Reverse pivot back-up inserts for additional wear
life, then replace when all surfaces are worn.
Roller Back-Up Bearings
1. These bearings are sealed and packed for life with
a special lubricant. They can be replaced by: (a)
Removing the snap ring; (b) Pulling out the bearing
and shaft; (c) New bearings are easily installed with
a light press t.
Automatic Mist Lubricated (Optional)
Bleeding Air From the Hydraulic System.
2. Attach a length of plastic tubing to the bleed valve
on the rod end of the cylinder and route it into the
reservoir through the dip stick opening. Next: (a)
Open the bleed valve on the cap end of the cylinder;
(b) Move the Table Feed Control to “REVERSE”
and retract the cylinder.
1. Keep reservoir full and hoses clear. Follow the
manufacturer’s maintenance instructions for the
lubricator.
MACHINE CLEANING
Stop the machine when cleaning the machine
or opening bandwheel doors or covers.
1. Keep the machine and its parts as clean as possible
to prevent excessive wear and damage.
3. Metal chips and other waste materials may
collect around areas such as: saw guides,
table surface, T-slots, bandwheels, slides, etc.
Remove these materials as soon as possible. The
DoALL Company recommends removing chip
collections at least twice per each eight (8) hour
shift, and more often with heavier use.
23
Page 28
BANDWHEEL TIRE REPLACEMENT (Sheet
Metal Bandwheels)
DO NOT drive or hammer against the rim
angeorbandwheelangeatanytime.
1. This procedure requires the following items: (a)
A hammer; (b) A length of steel bar with one end
sharpened (such as a dull chisel); (c) A block of
wood; (d) Five (5) tire installation kits (in extra parts
box); (e) Wrenches for miscellaneous hardware.
The bandwheel assembly may be removed from
the machine if desired, but not necessary.
Tire Installation Kit.
Tire Removal
1. Remove the ten (10) cap screws, nuts and washers
along the rim. Also note the balancing arrow and
mark (or two (2) arrows) on the wheel MUST be
aligned when reinstalled.
3. Put the tire and rim in a vertical position. Next, with
a block of wood held rmly against the inside web
of the wheel rim, strike the block with the hammer
at 12 inch (304.8 mm) intervals until the tire rim is
seperated from the tire.
4. Wipe down the wheel rim with a cloth to remove all
grease and oils.
Tire Installation
1. Put the wheel rim, ange edge down, on a rm, at
surface (saw table makes a good surface). Then
place the new tire on the rim so that it is unifomly
seated on the starting radius of the rim.
2. Mount the ve (5) tire installation kits as follows: (a)
Place the “hooked” end of the clamp over the new
tire; (b) Slide the clamps so the hole lines up with
alternate holes in the rim; (c) Socket cap screws
are then threaded through the holes in the clamp,
rim and then the at clamp bar on the underside of
the rim; (d) Turn the screws until the screw heads
contacts the clamps; (e) Check to see that the tire
is uniformly engaged on the rim as you continue to
turn each cap screw two (2) turns until the tire is fully
engaged onto the rim; (f) Remove all the clamps;
(g) Using the block of wood and the hammer, tap
the edge of the tire until the tire seated against the
rim ange.
Remove Rim and Tire From Bandwheel.
2. Facing the end of the bandwheel, hold the steel bar at
a 45° angle to the face of the tire and approximately
the horizontal center line of the bandwheel. Then:
(a) Strike the bar with the hammer hard enough
to move the tire from its seated position against
the inside rim; (b) Rotate the bandwheel about 12
inches (304.8 mm) and repeat the procedure until
the rim is removed from the bandwheel.
Seating the New Tire onto the Rim.
3. The rim and tire assembly is now ready to be
mounted onto the bandwheel. Next: (a) Place the
rim and tire against the face of the wheel making
sure that the arrow align with the mark on the
rim (they must be in register); (b) Hook the top
edge of the tire over the wheel so that it will be
temporarily self supporting; (c) Place the “hooked”
end of the installation clamp over the rim; (d) Slide
the clamps so the hole lines up with alternate holes
in the rim and wheel; (e) Socket cap screws are then
threaded through the holes in the clamp, rim and
then the at clamp bar on the opposite side of the
wheel; (f) Repeat mounting the clamps at alternate
holes around the wheel.
24
Page 29
BANDWHEEL TIRE REPLACEMENT (Sheet
Metal Bandwheels) (Continued....)
Seating Rim onto the Bandwheel.
4. After the five (5) clamps have been mounted
gradually and uniformly, tighten the screws two (2)
turns each until the rim and tire is seated against
the wheel ange.
5. Remove the tire installation clamps and then insert
the ten (10) cap screws, nuts and washers.
4. Prepare the caulking gun conversion kit as follows:
(a) Insert the adhesive cartridge, nose rst, through
the oval opening of the sleeve until the cartridge
ange ts snugly against the end of the sleeve;
(b) Place the two stem plunger in the back of the
cartridge; (c) Remove the cap from the front end of
the cartridge and replace with the nozzle; (d) Place
the assembled kit into the caulking gun.
Conversion Kit and Caulking Gun.
Tire Installation
BANDWHEEL TIRE REPLACEMENT (Cast
Aluminum Bandwheels)
1. This procedure requires the following items: (a)
A hammer; (b) A length of steel bar with one end
sharpened or a dull chisel; (c) Large pliers; (d)
Caulking gun; (e) An orbital sander; (f) Small brush;
(g) Clamps; (h) Caulking gun conversion kit.
2. Another person may be helpful for this procedure.
3. Remove the bandwheel from the machine.
Tire Removal
1. Cut the tire and loosen the worn tire with a hammer
and chisel or other at tool.
2. Grab the loosened tire with the pliers and pull the
tire off the bandwheel.
3. Using an orbital sander, carefully sand off any
residue from the bandwheel.
1. Lay the bandwheel at onto a heavy table and clamp
if necessary.
2. With the caulking gun, spread the adhesive all
the way around the inside of the tire and on the
bandwheel rim using a brush. Spread evenly to
the edges (100% coverage).
3. Place the tire onto the bandwheel approximately
half way around the rim positioning it on the center
of the rim.
DO NOT remove the center crown of the
bandwwheel or create "at spots" with too
much sanding in one area.
25
Page 30
BANDWHEEL TIRE REPLACEMENT (Sheet
Metal Bandwheels) (Continued....)
Clamp the Bandwheel and Tire Do-ecurely.
4. Clamp a at board on top of the bandwheel to keep
the glued portion of the tire in place. If necessary,
clamp the bandwheel down to the table.
5. With two (2) screwdrivers, stretch the tire over
the bandwheelalways keeping one screwdriver
stretching the tire as you move around the rim until
the tire is placed. The other person can be centering
the tire onto the rim as you go.
6. Before the adhesive sets, clean any excess from
the both edges of the bandwheel with solvent.
7. Working time of the adhesive is approximately
twenty (20) minutes and cure time is 24 hours.
26
Page 31
TROUBLE SHOOTING
Repair and adjustment procedures should be
madebyexperiencedmaintenancepersonnel,
or by a DoALL service representative.
Reference to the machine’s electrical and
hydraulic schematics will be helpful.
MACHINE WON’T START
1. Make sure the disconnect switch is in the “ON”
position.
2. Reset the All Stop pushbutton (rotate clockwise).
3. Make sure the bandwheel doors are closed.
4. Check the fuses/circuit breakers for tripping or faulty
operation.
5. Check the overload reset on the drive motor starter.
Starting and stopping the machine a number of
times in quick succession, or an overload, will trip
the starter overload switch. Locate and correct
the trouble, then push the reset on the overload
switch.
6. Check the transformer for faulty operation.
8. Check for an incorrect saw band tension setting.
SAW BAND IS CUTTING INACCURATELY
1. Check for worn blade teeth. Inserts that are too
wide for the blade will damage the teeth set.
2. Check for scale on the stock.
3. The saw band may be too wide if a radius is being
cut.
4. Check for incorrect saw band or insert alignment.
5. Incorrect band speed is being used.
6. Mist lubricant (if supplied) is not being applied
evenly to both sides of the saw band.
7. Check for an incorrect saw band tension setting.
8. The upper saw guide is not located close enough
to the stock.
9. Check for worn or loosely-adjusted saw guide
inserts.
MACHINE VIBRATION
1. Check for unbalanced bandwheels.
2. Check for worn bandwheel tires.
3. Check for worn or unbalanced band drive belt.
4. Check for an incorrectly shimmed machine base.
SAW BAND VIBRATION
1. Incorrect band speed is being used.
2. Choice of blade pitch is incorrect.
3. Stock is not being clamped rmly to the worktable
and/or by optional vise jaws.
4. Check for worn or improperly adjusted saw guide
inserts (If supplied).
5. Check for a worn saw guide back-up bearing.
PREMATURE BAND BREAKAGE
1. Saw band weld is defective.
2. Feed force and/or band tension is too high.
3. Saw guide inserts or rollers are not guiding the saw
band properly.
4. Band pitch is too course, use ner pitch blade.
5. Band speed is too low.
6. Wrong coolant type is being used.
EXCESSIVE INSERT AND BLADE WEAR
1. Inserts or saw guide rollers are adjusted too tightly
on the saw band.
2. High band speed is causing friction (using roller
saw guides may be adviseable). Increase coolant
volume to better lubricate the saw band.
6. Check for a loose post. Adjust the cover plate if
necessary.
7. Check for a poor weld in the saw band.
3. The back-up bearing may need replacement.
4. Check for incorrect saw band tension setting.
27
Page 32
TROUBLE SHOOTING (Continued....)
NO COOLANT FLOW (If Applicable)
PREMATURE BLADE TEETH DULLING
1. The saw band is not being “broken” in on the rst few
cuts. Reduce the feeding pressure when making
these cuts.
2. Band speed is too high (this causes abrasion).
3. Saw band pitch is too coarse.
4. Too light a feed pressure. Increase if necessary.
5. Coolant is not properly covering the saw band.
6. Check for faulty material such as heavy scale,
inclusions, hard spots, etc.
7. Check for saw band vibration.
8. Check for chip welding, or for a chipped tooth lodged
in the cut.
9. Check for incorrect saw band tension setting.
10. Inserts are incorrect for the width of blade being
used. This allows the inserts to hit the set teeth
(listen for clicking sounds during saw band
operation).
SAW BAND SLIPS OFF BANDWHEEL
1. The upper bandwheel is not aligned properly. The
saw band needs to be tracked.
2. Check for worn bandwheel tires.
3. Check for slippery coolant, or excessive coolant
volume.
1. Make sure reservoir is full.
2. Check for a clogged coolant applicator nozzle.
3. Check for a clogged or kinked coolant hose.
SLUGGISH HYDRAULIC BRAKE OPERATION
1. Check for low hydraulic system pressure or low
reservoir level.
2. Check for air in the hydraulic system.
3. Check for faulty hydraulic pump operation.
4. Check for cold hydraulic oil.
5. Relief valve in hydraulic line is opened too far,
dropping system pressure. See tag on the valve
for correct pressure setting.
6. Brake linings are worn.
7. Check for oil on the brake discs.
LOW HYDRAULIC SYSTEM PRESSURE
1. Check the relief valve for incorrect adjustment or
faulty operation.
2. Hydraulic pump is worn or damaged.
HYDRAULIC BRAKES DRAG
1. Check for air in the lines.
2. Brake pad return spring is broken or damaged.
4. Check for incorrect machine alignment.
5. Incorrect saw guide blocks are being used.
6. Check for incorrect saw band tension setting.
SURFACE FINISH ON WORK IS TOO ROUGH
1. Check for a worn saw guide insert (adjust or replace
if necessary.
2. Band speed is too low or feed force is too heavy.
3. Blade pitch is too coarse.
4. Check for saw band vibration.
5. Check for a poor weld in the saw band.
HYDRAULIC BRAKES DON’T OPERATE
1. Check for faulty brake solenoid valve.
2. Brake pad linings are worn.
3. Brake cylinder o-ring is worn or damaged.
TABLE FEED ROUGH AND ERRATIC
1. Air is in the lines, bleed the lines.
2. Table feed cylinder is damaged or worn.
3. Linear bearing rails are damaged.
28
Page 33
TROUBLE SHOOTING (Continued....)
TABLE FEED PRESSURE TOO LOW
1. Table feed cylinder is damaged or worn.
2. System pressure too low. Adjust pressure.
3. Table feed pressure control valve spring, ball or ball
seat are damaged.
4. Check for leaks in the hydraulic lines and connections.
5. Check for hydraulic pump failure.
TABLE DOES NOT MOVE
1. Check for obstructions.
2. Table feed cylinder is damaged or worn.
3. Make sure the hydrulic pump is on.
29
Page 34
ACCESSORIES
The following are accessories sometimes
used during sawing operations. A DoALL
sales representative can advise you about the
current availability of any accessory.
DISC CUTTER
1. This attachment can be used to cut internal or
external circles from 3 to 36 inches (76.2 to 914.4
mm) in diameter. To set up the disc cutter:
• Place at washers under the mounting screws. Then:
(a) Bolt the mounting bracket to the post; (b) Lower
the post until the upper saw guide is approximately
3/8 inch (10 mm) above the worktable; (c) Loosen
the ne adjustment and arm clamp bolts; (d) Move
the center pin to the approximate distance of the
radius to be cut; (e) Tighten the ne adjustment
clamp bolt.
2. Before attempting a long cut, check to see that the
saw band is not worn on one side. This will cause
stock to wander relative to the rip fence guide bar.
Rip Fence.
WORKLAMP
1. This worklamp illuminates the cutting area and areas
nearby. It is turned “OFF” and “ON” with a switch
on the lamp itself.
Disc Cutter.
• Position the center pin so that it is perpendicular to
the saw band’s cutting edge. To do so: (a) Place
a square against the tip of a sawband tooth; (b)
Loosen the vertical adjustment clamp bolt; (c) Line
up the center pin with the square’s blade edge; (d)
Clamp the vertical adjustment clamp bolt.
• Make final radius adjustments with the fine
adjustment wheel. Then: (a) tighten the arm and
radius arm clamp bolts while making sure the center
pin is square to the table; (b) Adjust the disc cutter
for stock thickness by raising or lowering the post.
RIP FENCE
1. Square this xture during installation so that it is in
line with the worktable sawing slot. When alignment
is correct, secure the adjusting screws in place with
the set screws under the the guide bar on the rip
fence casting.
• Some machines may have a selector switch located
on the pushbutton control box on the front of the
control box enclosure to turn the lamp "OFF" and
"ON".
MAGNIFIER
1. Magnifing the cutting area may prove helpful
during delicate sawing procedures. This is done
by placing a magning lens around the shade of
the worklight.
2 . A protective lens cover should be placed around
the magnier to prevent scratches when not being
used.
CHIP BLOWER
1. A nozzle delivers shop air to the sawing area. The
operator can remove chips and depris from the
sawing area by adjusting the exible hose and
nozzle.
2. Incoming air supply should be betwwen 80 to 90
psi (5.5 to 6.2 bar or 5.6 to 6.3 kg/cm²) is required
to operate this option.
DONOTexceed90psi(6.2baror6.3kg/cm²)
air pressure.
30
Page 35
DBW-15 BUTTWELDER
1. Information covering blade welding, plus operation
and maintenance of the optional DBW-15 Buttwelder
(with ash grinder and blade shear, portable or
machine mounted) are provided in a seperate
instruction manual included with the welder.
WORKHOLDING JAW
1. The workholding jaw is used for off-hand and
contour sawing. The operator can use this option to
guide stock along prescribed contour layout lines.
Hydraulically Powered Worktable.
3. Two (2) adjustable work stops, located on the table’s
left side, limit table travel. The front stop controls
the cut depth, the rear stop minimizes unnecessary
table travel. They can be adjusted by loosening the
lock nuts and slide the work stops to the desired
position.
Workholding Jaw.
2. The workholding jaws can also be used as a xed
angle jaw for manually guided contour sawing.
Be sure to use the correct saw band width
when cutting a radius.
SECONDARY TABLE
1. This xed worktable, located to the left of the main
worktable, measures approximately 19.00 by 19.00
inches (482.6 by 482.6 mm) and used for support
of larger) workpieces.
HYDRAULIC TABLES
Hydraulic Table
1. This optional hydraulic table measures 32 by 41
inches (812.8 by 1041.4 mm) with a table stroke of
16 inches (406.4 mm) and hydraulic actuated table
tilt. It has a seperate hydraulic system and controls
in a remote console.
This hydraulic table reduces work height
approximatelyfour(4)inches(101.6mm).
2. The worktable is drilled and tapped on the right
side to attach accessory equipment. Its removable
center plate can be replaced with optional plates
for various options. The worktable also has two (2)
1/2 inch (12.7 mm) wide T-slots for tool and xture
mounting purposes.
4. The worktable can be tilted up to 5° left and 45°
right primarily for sawing compound angles. The
amount of worktable tilt is indicated by a pointer and
a trunnion-mounted calibrated scale.
5. To tilt the worktable: (a) Use the wrench provided
to reach through the machine frame and under
the worktable to loosen the tilt locknut; (b) Tilt the
worktable manually or use the selector switch to
tilt the table hydraulically until the pointer reaches
desired angle shown on the scale; (c) Tighten the
tilt locknut.
Table Controls
1. These controls, located on a consoleattached to the
front of the column, operate the hydraulic table:
• Table Pressure (Feed Force). This dial permits the
operator to vary workpiece pressure against the saw
band. Feed force can be changed between 0 and
175 psi (0 and 12.1 bar or 0 and 12.3 kg/cm²).
• Table Feed. This valve with “REVERSE”, “STOP”,
“FEED” and “FORWARD” settings controls table
directional movement. “FEED” position is for
sawing, “REVERSE” and “FORWARD” positions are
for table set-up and/or rapid table movement, and
“STOP” stops table movement in either direction.
The "FORWARD" setting is NOT used for
cutting stock.
31
Page 36
HYDRAULIC TABLES (Continued....)
Insert Type Saw Guides
1. Insert type saw guides are designed for lower range
band speeds. See the “Operation” section of this
manual for use and adjustments for these saw
guides.
Roller Type Saw Guides
1. Roller type saw guides are designed for high range
band speeds. See the “Operation” section of this
manual for use and adjustments for these saw
guides.
EXTRA WORK HEIGHT
Table Controls.
• Table Speed. This dial located in the center of the
Table Feed control regulates the table speed. Turn
the dial clockwise to “increase” table feed speed,
counterclockwise to “decrease” it. This operates
in the “feed” position only.
GLIDE TABLE
1. This non-tilting worktable option has a 25.39 by
32.63 inch (644.9 by 828.8 mm) worktable and table
travel of 18.00 inches (457.2 mm). Load capacity
is 250 pounds (113.4 kg).
2. The workpiece is securely clamped to the table.
The operator then holds the handle in front of the
table and manually pushes the table with the workpiece through the saw band. The handle also acts
as a workstop if desired.
DO NOT force workpiece through the saw
band.
1. The factory installed extra work height allows
maximum cutting capacity up to 42 inches
(1066.8 mm). Machines with this option have
an auxiliary post support, plus a slightly different
frame weldment, post guarding, and hydraulic
post cylinder from those shown elsewhere in this
manual.
HYDRAULIC BAND TENSION
1. A factory installed cylinder mounted next to the upper
bandwheel spindle applies the correct tension to the
band and controlled by a selector switch on or near
the control box enclosure.
2. This option eliminates the need to physically climb
up on the machine. This especially helpful with
machines of large work heights.
Optional hydraulic band tension is factory set.
DO NOT adjust the handwheel if supplied!
BAND LUBRICATOR
3. A thumbscrew located in the lower right under the
worktable locks the worktable in place to allow loading and unloading of stock. Loosen the thumbscrew
completely for the worktable to move freely.
4. The handle must be removed for saw band
changing.
OPTIONAL SAW GUIDES
1. The following optional saw guides may be used to
help increase productivity and economy.
Information and availability of all DoALL saw
bands and guides can be obtained from a
DoALL sales representative.
1. For machines without the mist lubricated saw guides,
this option is for lubricating the saw band and sawing
area during the sawing process.
2. See the instructions sent with the unit for information
on operation and adjustments.
DUST COLLECTOR
1. See the literature sent with the unit for information
on installation, operation, maintenance and
adjustments.
32
Page 37
SAFETY EQUIPMENT
1. Your machine may be equiped with safety devices
that keep equipment and operating personnel
protected. Contact your DoALL sales representative
for information on any safety needs such as
shrouding, guards, safety switches, etc.
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.
33
Loading...