Instruction Manual 2013-V Serial No: 571-04101 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-V 571-04101 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 printed on a label or stamped on a plate attached to your machine. Be sure to provide machine model and serial numbers with any correspondence or parts orders.
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....) INCHES (± .03) MILLIMETERS (± 1 mm) A 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 (255 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 1. The following controls are located on the side of the electrical control box: • Disconnect Switch. This switch supplies incoming power to the machine. • Start. Push this green button to start the band drive motor. • Stop. Push this red mushroom head button to stop the band drive motor. This button latches down when pushed and must be released or reset before the machine can be operated. To release or reset, rotate the button head clockwise until the head pops up.
SAW BAND PREPARATION (Continued....) Saw Band Removal Always use extreme care when handling saw bands. Wear gloves. Insert-Type Saw Guide Adjustment 1. 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.
SAW BAND PREPARATION (Continued....) 3. 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. 2.
TYPICAL SAWING PROCEDURES WORKTABLE AND TILT ADJUSTMENT (Continued....) Set-Up 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.
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 Variable Pulley. One (1) oil cup. 2 Band Tension Screw and Bearing. Clean and apply oil. MONTHLY 3 Post, Optional Post Elevating. Clean and apply oil. MONTHLY 4 Bandwheel Slides, Hinge and Tilt Screws. Clean and apply oil. MONTHLY High quality, rust and oxidation-inhibited, medium hydraulic and general purpose industrial oil. 5 Table Trunnion.
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.
VARIABLE PULLEY 1. Remove, wash and clean the variable speed pulley with solvent every six (6) months. Then: (a) Check to see that the pulley's center sheave is free to shift sideways; (b) Check the pulley for scoring which could damage the belts. 2. Bearings are lubricated from an oil cup in the shaft end. DO NOT over-lubricate. This will cause oil to coat the belts and pulley and will cause slippage. 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. 2. Make sure the bandwheel doors are closed. 3. Check the main fuses and control circuit fuses and/or circuit breakers for faulty operation. 4. 5. 6.
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. HMD Hydraulic Table 1. This factory-installed hydraulic-powered worktable has a 36 inch (914.4 mm) or a 60 inch (1524.0 mm) stroke instead of the standard table. The HMD-36 table's working surface is 34 by 42 inches (863.6 by 1066.8 mm). The HMD-60 table's working surface is 34 by 68 inches (863.6 by 1727.2 mm). 2.
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.
UNIVERSAL VISE (Continued....) 2. Set-up by clamping the vise jaws into the worktable's right T-slot and the cut-off gage into the left T-slot. DBW-15 BUTTWELDER 1. Information covering blade welding, plus operation and maintenance of the optional DBW-15 Buttwelder (with flash grinder and blade shear) are provided in a seperate instruction manual. 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.
OPTIONAL SAW GUIDE BLOCKS (Continued....) 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.
