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OPERATOR'S INSTRUCTION MANUAL

METAL CUTTING BAND SAW

PB-482.5 (7-13)

PRINTED IN U.S.A.

The following registered trademarks of the DoALL Company are used in this manual:

DoALL, Imperial Bi-Metal, Kleen-Kool, Polypac, Power-Cut and Tensigage.

MODEL FIRST SERIAL NO.

LAST SERIAL NO.

C-4100NC

524-97116

524-11322

524-13338

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. The DoALL Company, whose policy is one of continuous

improvement, reserves the right, however, to change specifications or design

at any time without notice and without incurring obligations.

DoALL SAWING PRODUCTS

2375B TOUHY AVENUE

ELK GROVE, ILLINOIS 60007 U.S.A.

PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATING THE MACHINE!

For Sales, Parts and Service, call 1-888-362-5572

For general information, visit our web site at:

www.doallsawing.com

Summary of Contents for C-4100NC

Page 1: ...C 4100NC Serial No 524 97116 to 524 11322 524 13338 to Band Sawing Machine Instruction Manual ...

Page 2: ...e nine 9 months to file a claim 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 carrie...

Page 3: ...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 approvedforprinting TheDoALLCompany whosepolicyisoneofcontinuous improvement reserves the right however to change specifications or design at any time without notice and without incurring o...

Page 4: ...ode Only 25 26 Minimum Bar End Split Front Vise 26 Vertical Guide Roller 26 Hydraulic System 26 Coolant System 26 Chip Removal 26 28 Idler Wheel Motion Detector 28 Typical Operating Procedures 28 30 LUBRICATION Lubrication Chart 32 Lubrication Diagrams 33 MAINTENANCE Replacing Saw Guide and Back Up Inserts 34 Adjust or Replace Saw Band Lead In Exit Rollers 34 Band Drive Belt Replacement 34 Hydraul...

Page 5: ...1 MACHINE DIMENSIONS FOOT PAD LAYOUT ...

Page 6: ...2 MACHINE DIMENSIONS Continued INCHES 03 MILLIMETERS 1 mm FLOOR PLAN 5 Foot Index Option ...

Page 7: ...3 MACHINE DIMENSIONS Continued INCHES 03 MILLIMETERS 1 mm FRONT VIEW ...

Page 8: ...4 MACHINE DIMENSIONS Continued INCHES 03 MILLIMETERS 1 mm SIDE VIEW 5 Foot Index Option SIDE VIEW Standard ...

Page 9: ...5 MACHINE FEATURES TOP VIEW FRONT VIEW ...

Page 10: ...6 MACHINE FEATURES Continued PROXIMITY SWITCH LIMIT SWITCH LOCATIONS Before machine number 218 limit switches in parenthesis were used instead of proximity switches FRONT VIEW SIDE VIEW ...

Page 11: ...ear designations in this manual are as viewed by the operator facing the control console LOCATION 1 The floor area required by the standard machine is 111 inches 2819 4 mm in width by 82 50 inches 2095 5mm inlength Machineheight withthesaw headfullyraised is90 00inches 2286 0mm Refer to pages 1 thru 4 for further machine dimensions 2 Locate the machine to provide sufficient clearance for a Materia...

Page 12: ...d bearing surfaces are to be co planar within 0 030 inch 0 76 mm T I R or 0 0008 inch per inch 0 02 mm per mm mearsured from the plane of the saw band to the outboard roller The tensioned saw band between the saw guides is to be perpendicular to the fixed vise jaw faces within 0 000 to 0 002 inch 0 000 to 0 050 mm at maximum saw guide arm spacing 5 Afterthemachinehasbeenleveled installanchoring sc...

Page 13: ...ectrical supply b Interchange two 2 of the L1 L2 or L3 leads to the disconnect switch c Restore power and perform Step 4 again 7 As soon as hydraulic motor rotation is correct jog the Hydraulic Start and Hydraulic Stop buttons severaltimestomakesurethehydraulicandcoolant pumps are primed Then allow the machine to run for several minutes to remove entrapped air Electrical Connections to Disconnect ...

Page 14: ... Now move the Saw Head Control selector joystick to UP and raise the saw head to its maximum heigh 2 Open both bandwheel doors and find the ends of the Saw Cap Pull the cap off of the saw band If the cap is pinched onto the bandwheel relax the band tension by turning the Band Tension selector switch to OFF The cap now should come off After removal check to be sure that the saw band rides properly ...

Page 15: ...eel which is two 2 inches 50 8 mm thick the Job Selector recommends using a An Imperial Bi Metal saw blade with 10 6 blade pitch b Band speed of 315 fpm 90 m min and c A cutting rate of 13 square inches per minute 79 square centi meters per minute Job Selector recommendations are a general guide for correct power sawing on a prop erly maintained DoALL saw They are based on cutting five 5 inch 127 ...

Page 16: ...ics a The All Stop button is reset turn clockwise b Disconnect switches on the control console and band drive enclosure are ON 5 Hydraulic Stop Pushing this red button turns off the hydraulic pump coolant pump chip conveyor and band drive motors CONTROL CONSOLE Electrical Controls 1 Band Cycle Start Push this green button to start the band drive motor The button will be illuminated when the band d...

Page 17: ...til it pops up b Push the Hydraulic Start and Band Start buttons in sequence Ifthemachinewasoperatingin AUTO modebefore the All Stop button was pushed a Reset the Emergency Stop button by turning the button head clockwise until it pops up b Push the Hydraulic Start button c Position the stock as necessary d Clamp both index and fixed vises e Push the Auto F6 button f Push the Band Cycle Start butt...

Page 18: ... actual bandspeedtimerequiredforthelastcutisdisplayed which is updated at the end of each cut 4 Most screens have instructions on the screen to assist in entering information Do not push two 2 or more buttons at the same time Screens 1 SCREENS F1 When both the variable frequency drive disconnect and the control enclosure disconnects are ON push Hydraulic Start The displaywilllightupandshowtheiniti...

Page 19: ...provideextraclampingarea Operatingsequence is as follows When the cut has been completed the index vise jaws open the index moves to the required dimension and transfers the stock b INDEX REAR This is the shortest cycle time and is preferred for most operations when not using the nesting fixture or variable vise pressure Operating sequence is as follows While a cut is being made the index vise wit...

Page 20: ...d due to longer closing time resulting from variable vise pressure etc and is used with the nesting fixture Entry range is from 3 to 9 99 seconds AFixed Vise Delay of 3 seconds is suggested for the first time user Index Vise Delay This allows time allotted for the index vise jaws to clamp before index movement is allowed due to longer closing time resulting from variable vise pressure etc and is u...

Page 21: ... 99 jobs To end a run list enter job 0 c RUN LIST B A second list of up to ten 10 jobs Jobs from run list A may be programmed into run list B If the run list is pre programmed and the operator wants to repeat the run list sequence but skip over one or more jobs the operator must go to the job library and program the number of cuts to zero for the jobs to be skipped To enter a job into the job libr...

Page 22: ...in the top two 2 rows identified as LIST A and LIST B then a Move the flasher through the lists with the UP DOWN LEFT or RIGHT arrow keys to the desired position b Enter a job number c press key to accept and advance to the next field or press ENTER twice or CLEAR to quit Job Screen Display 3 of 6 F4 If less than ten 10 jobs are entered in a list a zero must be entered in the position following th...

Page 23: ...peeds beyond this range 6 AUTO F6 Automatic Cycle On Off Pushing this button initially selects the automatic operating mode and lights the LED Display window When the button is pushed again the AUTO mode is turned OFF and individual MANUAL machine operations such as machine set up positioning material etc are activated 7 CUT TIME F7 See F4 Screen 6 of 6 Pushing this button permits the operator to ...

Page 24: ...ANUAL operating mode to increase or decrease index rate of travel along the index section when the INDEX FWD or INDEX REV buttons are activated When creep speed is active LED is lit the index vise does not go to full speed after two 2 seconds It will always stay at the creep speed setting ApasswordmustbeenteredtoclearJobsorDones The password is the same as the model number of the saw i e 305 3300 ...

Page 25: ...nter data OTHER CONTROLS Variable Vise Pressure Controls 1 The two Variable Vise Pressure control valves positionedtotherightoftheelectricalcontrolpanel are used to adjust vise clamping force against materials which cannot tolerate full vise clamping pressure examples are thin walled tubing pipe light structurals etc This control can be used with or without the optional Nesting Fixture Clamping pr...

Page 26: ...by operating the machine without these guards attached THEY ARE THERE FOR YOUR PROTECTION Saw Guide Insert Adjustment 1 Loosen the adjustment screw turn counterclockwise on each saw guide arm Then a Remove the old saw band b Replace the saw band c Tighten the insert adjustment screw turn clockwise to the fixed stop Saw Band Removal Always use extreme care when handling saw bands DO NOT attempt to ...

Page 27: ... is correct a Turn the Band Tension selector to ON b Move the left saw guide arm to the desired position c Tighten both saw guide insert adjustment screws 5 Reposition the band brush and tighten the clamp screw brush bristles should clean the blade teeth gullets but not contact the bottom of the gullets Then a Closebothbandwheeldoors b Jogthebanddrivemotor c Openeachbandwheel door to make certain ...

Page 28: ...the stock s top left corner during the saw head s raising and lowering arc This applies for all stock widths between 3 1 2 and 16 inches 88 9 and 406 4 mm Both saw guide arms must clear the loaded stock and vise jaws as the saw head raises and lowers This is important when cutting maximum height rectangle stock FEED FORCE ADJUSTMENTS 1 Feed force is the pressure exerted by the workpiece against th...

Page 29: ...ation To lift the saw head off the limit switch and resume operation the operator must a Move the Saw Head Control selector to UP b Push the Hydraulic Start button Sensing Arm 1 The sensing arm works in conjunction with the head clear proximity switch 3 or 2 PRS to assure that the saw head has raised sufficiently above existing stock so that automatic indexing or manual stock positioning can be ac...

Page 30: ...the Lubrication section of this manual for recommended oils COOLANT SYSTEM Coolant Selection 1 The main cause of tooth failure during band machining is excessive heat build up Using the proper cutting fluid reduces the heat generated during operation It also helps the machine take full advantage of its high speed steel saw bands Literature describing these and other coolant types is available from...

Page 31: ... to the opening at the machine s right side where chips empty into a customer supplied container Band Brush 1 A covered hydraulic motor driven band brush is located near the band drive wheel During machine operation the brush bristles should be positioned so that the tips clean chips from the blade teeth gullets but do not contact the bottom of the gullets DO NOT allow metal chips to accumulate on...

Page 32: ... F11 buttons OperatingNotes a Thesawheadmustberaised completely to allow complete opening of the vise jaws or to accomodate a stockpiece wider than the piece previously clamped b If the saw head is not completely raised the vises will open just slightly wider than for the previous stockpiece 4 Load the stock to be cut onto the feed conveyor rollers near the fixed vise jaws and position for a crop ...

Page 33: ...tic cycle a Move the Saw Head Control selector to HOLD this will stop saw head fall and saw band b Push the Auto button toswitchmachineoperationtothe MANUALmode c To resume cut after interuption move the Saw Head Control selector to DOWN AUTO and then push the Band Cycle Start button 10 After the cut has been completed the saw band will shut off with the saw head in the down position Next a Raise ...

Page 34: ... done to insure cut accuracy 4 The operator can push the Job button then edit or enter jobs while the automatic cycle is running The operator CANNOT edit the job being cut while the machine is running 5 The operator may interrupt a job at any time and return later to complete it 6 The operator can also set all DONES to 0 this sets the quantity done to 0 for all of the jobs DO NOT remove any cut of...

Page 35: ...31 LUBRICATION NEXT 2 PAGES ...

Page 36: ...oils Coolant Reservoir 20 gallon 75 7 liter capacity Drain clean and refill whenever coolant becomes undesireable for further use Clean the mesh screen at the same time 9 AS REQUIRED Lubrication intervals are based on a 8 hour day 40 hour week Lubricate more often with heavier use Hydraulic System Ten 10 gallon 37 8 liter capacity Check fluid level daily and keep the reservoir full Drain change th...

Page 37: ...33 LUBRICATION DIAGRAM FRONT VIEW SIDE VIEW REAR VIEW LEFT SIDE ...

Page 38: ... fixed spindles rollers a Raise the saw head until the saw band is above the front movable vise jaw b Shut the machine and disconnect switch off c Move the left saw guide arm to the closest approach to the right saw guide arm 2 Insert a straightedge gage and clamp the inserts in Position the bearing blocks so that the fixed splindle rollers bear evenly on the straightedge gage 3 Loosen the set scr...

Page 39: ...cups used in DoALL hydraulic systems are compatible ONLY with hydraulic oils having an aniline point between 215 and 230 F 102 and 111 C 2 If hydraulic oil having an aniline point not falling within the above range is used the seals may either swell or shrink and harden This causes machine malfunction and leakage HYDRAULIC SYSTEM Continued DOALL hydraulic fluid with an aniline point of approximate...

Page 40: ...ing a Tensigage to Measure Band Tension WEAR PLATE REPLACEMENT 1 The removeable vise jaw and vise guide bars must be replaced before excessive wear causes the mounting screw heads to become damaged and makes removal difficult Vise Jaw Plates 1 Themachinehaseight 8 visejawwearplates four 4 on the front vise jaws and four 4 on the index visejaws Allwearplatesaremountedwithlow head screws Be sure the...

Page 41: ... 1 To clean the chip conveyor turn the machine off Then a Disconnect the hydraulic hoses b Pull theconveyorfromitscradledpositioninthebase c Clean the conveyor trough d Clean the reservoir floor e Replace the conveyor and cover ...

Page 42: ...e head down promimity switch 2 PRS or 2 LS Move the Saw Head Control selector to UP 4 The out of stock limit switch 6 PRS or 6 LS has been actuated SAW BAND STALLS DURING A CUT 1 Decrease saw head feeding pressure 2 Check to see if drive belt tension is adequate to resist cogging underload 3 Use a Tensigage to check for proper saw band tension 4 Check for proper operation of the Band Tension selec...

Page 43: ...e to incorrect saw head feeding rate 2 Increase band speed being used and or decrease feed force 3 Check for stock not being held firmly by the vise jaws 4 Check for incorrect adjustment of the saw guide inserts and carbide back up guides 5 Check for insufficient coolant flow 6 Use a finer pitch saw band 7 Check for incorrect saw band tension SAW BAND IS NOT RUNNING TRUE AGAINST THE SAW GUIDE BACK...

Page 44: ...AD STAYS DOWN 1 Checkforfaultyoperationoftheheaddownproximity switch 2 PRS or 2 LS 2 Check to see if Solenoid 2 is energized 3 Check to see if Solenoids 8 and 11 are operating SAW HEAD WON T LOWER 1 The feed rate setting is too low 2 Check the head clear proximity switch 3 or 2 PRS for faulty operation 3 Check Solenoids 1 and 12 for incorrect operation 4 Check for saw head obstruction SAW HEAD WIL...

Page 45: ...mp operation 5 Check for cold hydraulic oil BAND DRIVE TRANSMISSION GETS HOT 1 Check for low transmission fluid level 2 Check for lubricant leakage NUISANCE OVERLOAD TRIPPING 1 Check to see if the overload relays are set too low Increase the setting if necessary SENSING ARM HANGS UP 1 Check to see if the sensing arm is dirty MALFUNCTIONING OPERATING SEQUENCE 1 EPROM memory pack is malfunctioning o...

Page 46: ...ide rollers are effectively used to help maintain correct positioning of long stock on the fedd table and or conveyor 2 These can be installed between the interface plate and conveyor or between conveyors if more than one is supplied 3 For nesting fixture an additional vertical roller is mounted to the index roller bed rail to provide another laterally adjusted vertical roller the roller on the fi...

Page 47: ...oundstockisimportantbecause sawbandbreakagemayoccurifroundnestedpieces slip or spin during sawing 3 Slippage can also be prevented by using polyurethane wear plates on the moveable vise jaws on both index and front vises 4 Two 2 workable round stock stacking methods are showninthenextillustration usingthesamenumber of rounds in each row usually provides the best sawing results although the alterna...

Page 48: ...er on illustration 1 Two Green LED s indicate zero or the center of the display These LED s are always on 2 Vertical line of Green LED s indicate the machine s normal operating range Only one at a time is lighted 3 Amber LED s indicate a caution region These LED s remain on and flash if there is a condition which remains for a period of time seconds This is intended to caution the operator that a ...

Page 49: ... mm in length instead of the standard 24 inches 609 6 mm All other operations and data remain the same LASER LINE OPTION To avoid eye damage DO NOT stare into the laser beam 1 A laser devise is used to emit a line on the material to be cut This line shows the approximate spot where the cut will take place 2 The devise is controlled by a selector switch with ON and OFF settings and is located on or...

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