Instruction Manual 2013-V3 Serial No: 572-04101 to Band Sawing Machine
DAMAGE CLAIM PROCEDURES VISIBLE DAMAGE AT THE TIME OF DELIVERY: 1. Note damage on carrier’s delivery receipt. Accept the shipment. It can be returned later if repairs are not possible in the field. 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 final.
OPERATOR'S INSTRUCTION MANUAL METAL CUTTING BAND SAW MODEL FIRST SERIAL NO. 2013-V3 572-04101 LAST SERIAL NO. 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. Specifications contained herein were in effect at the time this manual was approved for printing.
TABLE OF CONTENTS MACHINE DIMENSIONS Floor Plan ................................................................ Front View ............................................................... TROUBLE SHOOTING ................................... 16-17 1 2 ACCESSORIES Disc Cutter . ............................................................. 18 Miter No. 2 Cut-Off (Side Mount) . ........................... 18 Rip Fence ................................................................ 18 Heavy Work Slides ......
MACHINE DIMENSIONS INCHES (± .
MACHINE DIMENSIONS (Continued....) A INCHES (± .03) MILLIMETERS (± 1 mm) Work Height FRONT VIEW Dimensions 13" (330.2 mm) 20" (508.0 mm) 24" (609.6 mm) 30" (762.0 mm) B 80.17" (2036.3 mm) 88.17" (2239.5 mm) 91.17" (2315.7mm) 97.17" (2467.
MACHINE FEATURES FRONT VIEW
INSTALLATION LIFTING All the “left”, “right”, “front” and “rear” designations in this manual are as viewed by the operator facing the machine controls on the electrical control box. 1. LOCATION 1. 2. A tapped hole is located on top of the machine's saw head. Screw a forged 3/4-10NC eye-bolt into this hole for lifting purposes. Net weight of the machine is approximately 1250 pounds (567.0 kg). DO NOT lift the machine by its sawing head.
MACHINE ALIGNMENT (Continued....) 3. 4. 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. Add or remove shims under the base pads until the correct post to square clearance is obtained.
OPERATION SAFETY PRECAUTIONS Warning Label - READ and UNDERSTAND USING THE JOB SELECTOR 1. Refer to the Job Selector chart located on the upper bandwheel door. It has information about the recommended band type and pitch, band speeds and cutting rates according to the type of material to be cut and its thickness. It also has a radius guide that shows the minimum radii cuts possible with various saw band widths. 2. To use, find the material to be cut in the first column.
ELECTRICAL CONTROLS 2. The operator can select between "high" and "low" band speed ranges by hold down the shift lever lock and move the transmission gear shift lever: (a) To the left to obtain "high" range speeds -- 550 to 5500 fpm (170 to 1675 m/min); (b) To the right to obtain "low" range speeds -- 30 to 320 fpm (10 to 100 m/min). 1. The following controls are located on the side of the electrical control box: • Disconnect Switch. This switch supplies incoming power to the machine. • Band Speed.
SAW BAND PREPARATION (Continued....) Insert-type saw guides are recommended for maximum band speeds of 1300 fpm (390 m/min) for production sawing, or up to 5000 fpm (1500 m/min) for occasional sawing. Use optional roller saw guides for continuous sawing over 1300 fpm (390 m/min). Information about all DoALL saw bands can be obtained from a DoALL sales representative. Insert-Type Saw Guide Adjustment Saw Band Removal These instructions apply to both the upper and lower insert-type saw guide blocks.
SAW BAND PREPARATION (Continued....) 3. To adjust bandwheel tilt if tracking is not correct: (a) Loosen the tilt lock handle; (b) Turn the tilt adjustment handle until the saw band tracks correctly on the bandwheel tires; (c) Retighten the tilt lock handle. 4. Close both bandwheel doors. POST ADJUSTMENT Adjusting Saw Band Tension. 3. The following are operator tensioning recommendations: • Reduce the recommended band tension when using saw bands with a coarser pitch or lighter gage.
WORKTABLE AND TILT ADJUSTMENT (Continued....) TYPICAL SAWING PROCEDURES Set-Up 1. The machine must be bolted to the floor for table loads over 100 pounds (45.4 kg). 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 Worktable. 2.
TYPICAL SAWING PROCEDURES Continued....) DO NOT feed work so rapidly that saw band twisting or bowing occurs. 2. The diameter of the drilled starting hole is determined by the size of the saw band being used. 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, and the lower bandwheel may become grooved. The chart on the Job Selector shows minimum radii cuts possible with various saw band widths. 4.
LUBRICATION LUBRICATION CHART LUBRICATION POINT NO. LOCATION DESCRIPTION AND SERVICE RECOMMENDATIONS LUBRICATION INTERVAL* RECOMMENDED LUBRICANT 1 Band Tension Screw and Bearing. Clean and apply oil. MONTHLY 2 Post. Clean and apply oil. MONTHLY 3 Upper Bandwheel Slide, Hinge and Tilt Screw. Clean and apply oil. MONTHLY High quality, rust and oxidation-inhibited, medium hydraulic and general purpose industrial oil. 4 Table Trunnion. Oil tilt surfaces.
LUBRICATION DIAGRAM FRONT VIEW REAR VIEW 13
MAINTENANCE REPLACING CROWNED BANDWHEEL TIRES 2. Check often for seal leaks around the shaft. 1. Loosen the worn tire with a screwdriver or other flat tool. 3. Immediately investigate any loud or unusual noises, or rough operating vibration. 2. Stretch the tire if necessary to remove it. 4. Return a faulty transmission to the factory for repair. 3. Clean the bandwheel and install a new tire by stretching it over the bandwheel.
BAND DRIVE BELT (Continued....) 2. To replace the belt: (a) Loosen the screws that mount the drive motor and slide the motor to the left; (b) Slip the old belt from the pulleys and install the new one; (c) Slide the drive motor to the right to tighten the belt so there is very little deflection of the belt; (d) When correct belt tension is acheived, tighten the screws. MIST COOLANT 1. Intermittent coolant stream indicates an air leak. Check all joints. 2.
TROUBLE SHOOTING SAW BAND IS CUTTING INACCURATELY Repair and adjustment procedures should be made by experienced maintenance personnel, or by a DoALL service representative. Reference to the machine's electrical schematic will be helpful. MACHINE WON'T START 1. Make sure the disconnect switch is in the "on" position. 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.
TROUBLE SHOOTING (Continued....) POOR BAND FILING FINISH (If Supplied) 6. Check for faulty material such as heavy scale, inclusions, hard spots, etc. 1. The feed force is too high. 2. File band is not correctly assembled. 7. Check for saw band vibration. 3. The saw band tension setting is too high. 8. Check for chip welding, or for a chipped tooth lodged in the cut. NO COOLANT FLOW (If Supplied) 9. Check for incorrect saw band tension setting. 1. Make sure reservoir is full. 10.
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. DISC CUTTER 1. This attachment can be used to cut internal or external circles from 2-1/2 to 30 inches (63.5 to 762.0 mm) in diameter. To set up the disc cutter: • Place flat washers under the mounting screws.
HEAVY WORK SLIDES (Continued....) 3. Operation procedures are as follows: 2. • Adjust the pulley and cable system for stock width. This is done by: (a) Loosening the two (2) knobs located under the rear mounting bracket; (b) Removing any slack in the workholding chain. When using the work slides, replace the worktable's center plate with a center plate with an attached block to support stock at the sawing point. Heavy Work Slides. WORKHOLDING JAWS 1.
CHIP BLOWER MAGNIFIER 1. The operator can remove chips from the sawing area by using the chip blower. Shop air is used to deliver air to the cutting area. 1. 2. Adjust the flexible hose and nozzle to direct chips away from the sawing area. Magnifing the cutting area may prove helpful during delicate sawing procedures. This is done by placing a magnifing lens around the shade of the worklight. 2. 3.
WORKTABLE OPTIONS (Continued....) 4. Air power feed option can be added to assist in moving the workpiece through the saw band. 5. The handle must be removed for saw band changing. 3. The worktable has a work rest pin that acts as a workstop when inserted into the sawing slot.
UNIVERSAL CALIBRATED WORK FIXTURE (Continued....) 3. Square the back-up bar to the worktable by aligning one (1) movable workstop edge with the T-slot or edge of the table sawing slot. Then: (a) Line up the calibrated bar's "0" mark with the saw band; (b) Tighten the socket head screws so that the back-up bar is firmly anchored to the worktable. 2. Mount the collar on the right T-nut and fasten it to the worktable (against the back-up bar) with the socket head screw.
OPTIONAL SAW GUIDE BLOCKS 1. It is possible to equip the machine with precision, heavy-duty, high speed, insert-type saw guides or roller saw guides. Insert-Type Saw Guides • High speed, heavy-duty saw guide blocks are for band speeds up to 6000 fpm (1830 m/min). Heavy-Duty Saw Guides With Steel or Carbide-Faced Back-Up Bearing. Roller Saw Guides 1. Use roller saw guides for continuous high-speed sawing. They are recommended for continuous sawing at band speeds over 1300 fpm (390 m/ min).
OPTIONAL SAW GUIDE BLOCKS (Contin- 90° Saw Guide Brackets. 2. Type II Roller Saw Guides. 2. Roller saw guides are adjusted as follows: • Select the rollers which match the width of saw band to be used.
DUST SPOUT Joining File Band 1. 1. Place the file band around the bandwheels and insert one (1) end through the table center plate. The band's cutting edges should point downward. File length is 153 inches (3886.2 mm). 2. Hold the yellow lock rivet segment in your left hand.
BAND FILING (Continued....) 2. Lower the post to approximately four (4) inches (100 mm) above the table. Then: (a) Mount and track the polishing band in the same manner as file bands; (b) Tension the polishing band in the same manner as for a 1/16 inch (1.5 mm) wide carbon saw band; (c) Install the special table center plate (larger slot than the standard one). 3. Occasionally rub graphite powder into the polishing fabric to lubricate and increase band life.
