Instruction Manual 3613-V3 Serial No: 568-04101 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 3613-V3 FIRST SERIAL NO. 568-04101 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 ................................... 18-19 ACCESSORIES 1 2 Disc Cutter . ............................................................. 20 Miter No. 2 Cut-Off (Side Mount) . ........................... 20 Rip Fence ................................................................ 20 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
MACHINE FEATURES (Continued....
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 1. Foot Switch. Does not apply to this machine. • Laser (Optional). This control turns the optional laser line generator "OFF" and "ON". 2. Hydraulic. Not applicable when plugged. 3. Mist Lube (Optional). This switch turns the optional band mist lubricator "OFF" and "ON". 4. Band Start/Stop. Push this upper green portion of the button to start the band drive motor. Push the lower red portion of the button to stop the band drive motor. 2.
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). One (1) set of steel saw guide inserts for saw bands 1/4 to 1/2 inch (6.3 to 12.7 mm) wide. Information about all DoALL saw bands can be obtained from a DoALL sales representative.
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. • The idler bandwheel has tilt knobs instead of handles but the procedure is still the same. 4. Close all bandwheel doors. POST ADJUSTMENT 1. Adjusting Saw Band Tension. 3.
WORKTABLE AND TILT ADJUSTMENT 1. 2. The standard worktable measures 26 by 26 inches (660.4 by 660.4 mm). Its load capacity is 500 pounds (226.8 kg) evenly distibuted with NO impact. The machine must be bolted to the floor for table loads over 100 pounds (45.4 kg). During operation, chips and other depris may accumulate around such machine areas as saw guides, worktable surfaces, bandwheels, slides, etc. Remove this debris as soon as possible.
TYPICAL SAWING PROCEDURES Continued....) 9. The following are important sawing precautions which should be observes: DO NOT feed work so rapidly that saw band twisting or bowing occurs. Reduce the feed force when cutting into an opening to prevent saw band damage. For future reference, keep a record of band speeds, coolant application, etc. and other settings for successful jobs. Contour Sawing 1.
LUBRICATION NEXT 2 PAGES 13
LUBRICATION LUBRICATION CHART LUBRICATION POINT NO. LOCATION DESCRIPTION AND SERVICE RECOMMENDATIONS LUBRICATION INTERVAL* 1 Band Tension Screw and Bearing. Clean and apply oil. MONTHLY 2 Post, Optional Post Elevating and Gears. Clean and apply oil. MONTHLY 3 Upper Bandwheel Slide, Hinge and Tilt Screws. Clean and apply oil. MONTHLY 4 Table Trunnion. Oil tilt surfaces. MONTHLY 5 Transmission Shift Linkage and Interlock. Clean and apply oil as required.
LUBRICATION DIAGRAM FRONT VIEW REAR VIEW 15
MAINTENANCE REPLACING CROWNED BANDWHEEL TIRES TRANSMISSION 1. Loosen the worn tire with a screwdriver or other flat tool. 1. 2. Stretch the tire if necessary to remove it. 3. Clean the bandwheel and install a new tire by stretching it over the bandwheel. Drain, flush, and refill the transmission yearly. Fill to the bottom of the check plug opening with oil recommended by the Lubrication Chart. INSERT-TYPE SAW GUIDES Back-Up Inserts 1.
MIST COOLANT (Continued....) 3. Keep the mist applicator nozzle and filter clean. If the center nylon coolant tube needs replacing, remove the entire applicator tube. Insert new nylon tube and trim off excess flush with nozzle. Make sure all joints are sealed and tight after applicator tube is reinstalled. 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. 2.
TROUBLE SHOOTING SAW BAND IS CUTTING INACCURATELY Repair and adjustment procedures should be made by experienced maintenance personnel, or by a DoALL Center representative. Reference to the machine's electrical schematic will be helpful. MACHINE WON'T START 1. 2. Make sure the disconnect switch is in the "ON" position. Reset the All Stop pushbutton (rotate the button head clockwise). 3. Make sure the bandwheel doors are closed. 4. Check the circuit breakers for tripping and/or blown fuses. 5. 6.
TROUBLE SHOOTING (Continued....) 5. The feed force is too high. 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). 4. TRANSMISSION WILL NOT STAY IN GEAR 1.
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 1. 2. 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. 2. Adjust the flexible hose and nozzle to direct chips away from the sawing area. 3. The air supply connection is located on the left side of the machine on the drive compartment wall. Incoming air supply should be between 80 and 90 psi (5.6 and 6.3 kg/cm²).
WORKTABLE OPTIONS (Continued....) Set-Up HMD Hydraulic Table 1. Position the workstops located on the left side of the worktable to limit travel. The front stop controls cut depth; the rear stop minimizes unnecessary travel. Stops are positioned by: (a) Loosening the locknuts; (b) Sliding the stops to the desired position; and (c) Tightening the locknuts. 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.
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 1. This option is located just below the worktable on the right side of the machine frame near the lower saw guide and attached to a collection system for disposal of chips and other waste materials. • Longer file guides permit filing seven (7) inch (177.8 mm) thick stock with a 1/4 inch (6.3 mm) file band, or eight (8) inch (203.2 mm) thick stock with 3/8 inch (9.5 mm) and 1/2 inch (12.7 mm) file bands. 3.
BAND FILING (Continued....) 3. 2. Lower the post to approximately four (4) inches (101.4 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 (1.6 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.
