DoAll TF-2525 Instruction Manual

DoAll TF-2525 Instruction Manual

Universal tilt-frame band machine

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INSTRUCTION
MANUAL
MODEL: TF-2525
SERIAL NO: 356-76101 to 356-01282
Also Applies To Machines With A
"Tf-25SA" Designation.
BAND SAWING MACHINE

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Summary of Contents for DoAll TF-2525

  • Page 1 INSTRUCTION MANUAL MODEL: TF-2525 SERIAL NO: 356-76101 to 356-01282 Also Applies To Machines With A “Tf-25SA” Designation. BAND SAWING MACHINE...
  • Page 2 DAMAGE CLAIM PROCEDURES VISIBLE DAMAGE AT THE TIME OF DELIVERY: Note damage on carrier’s delivery receipt. Accept the shipment. It can be returned later if repairs are not possible in the field. Request a “damage inspection” from the delivery carrier: The carrier will send his own people or contract an independent agency to make the inspection. The inspector will request a signature on the report and leave a copy. The carrier “damage inspection” report is not final. 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. Do not move the equipment from the receiving area and keep all shipping materials until carrier “damage inspection” report is complete. If possible, take photographs of the damage and keep them for your files. Photos could possibly prove a claim at a later time.
  • Page 3 PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATING THE MACHINE! For Sales, Parts and Servce, call1-888-362-5572 DoALL SAWING PRODUCTS 2375B TOUHY AVENUE ELK GROVE, ILLINOIS 60007 U.S.A. The followng regstered trademarks of the DoALL Company are used n ths manual: DoALL, Imperal B-Metal, Polypac and Tensgage. PRINTED IN U.S.A. PB-331.5 (12-07)
  • Page 4: Table Of Contents

    TABLE OF CONTENTS MACHINE DIMENSIONS LUBRICATION Lubrication Chart ............ Floor Plan ............... Lubrication Diagram ..........Front View .............. Side View ..............MAINTENANCE MACHINE FEATURES Replacing Saw Guide and Back-Up Inserts ... Hydraulic System ............ 24-25 Front and Rear Views ..........Coolant Ststem ............Side View ..............Machine Cleaning ........... Head Assembly ............Machine Alignment ..........Brush Adjustments ..........INSTALLATION Wear Plate Replacement .
  • Page 5: Machine Dimensions

    MACHINE DIMENSIONS INCHES (± .03) MILLIMETERS (± 1 mm) FLOOR PLAN...
  • Page 6: Front View

    MACHINE DIMENSIONS (Continued..) FRONT VIEW...
  • Page 7: Side View

    MACHINE DIMENSIONS (Continued..) Dmensons INCHES (± .03) MILLIMETERS (± 1 mm) 25" (635.0 mm) 4" (101.6 mm) 103.00" (2616.2 mm) 30" (762.0 mm) 9" (228.6 mm) 108.00" (2743.2 mm) Work Heght 36" (914.4 mm) 15" (381.0 mm) 114.00" (2895.6 mm) 40" (1016.0 mm) 19" (482.6 mm) 118.00" (2997.2 mm) SIDE VIEW...
  • Page 8: Machine Features

    MACHINE FEATURES REAR VIEW FRONT VIEW...
  • Page 9: Side View

    MACHINE FEATURES (Continued..) SIDE VIEW...
  • Page 10: Head Assembly

    MACHINE FEATURES (Continued..) HEAD ASSEMBLY...
  • Page 11: Installation

    INSTALLATION All the “left”, “rght”, “front” and “rear” DO NOT use compressed ar for cleanng degnatons n ths manual are as vewed by purposes as ths may force drt and deprs the operator facng the machne's control nto the machne's workng parts. console.
  • Page 12: Electrical Installation

    ELECTRICAL INSTALLATION Place the operating shaft and operating handle of the disconnect switch in the OFF position. Then: (a) Close the electrical enclosure door and secure Electrcal nstallaton must be made by its screws; (b) Now turn on the electrical supply and authorzed electrcal mantenance personnel the disconnect switch (no action will occur until the only. Hydraulc Start button on the control console has been pushed). Refer to the machine specifications plate on the saw head frame to verify that the electrical supply circuit DO NOT start machne hydraulcs untl the will meet the voltage/phase/frequency/amperage...
  • Page 13: Coolant Installation

    COOLANT INSTALLATION Fill the coolant reservoir with 20 gallons (75.7 liters) of oil or cutting fluid recommended by the Lubrication Chart. DO NOT let coolant spll over the tray and onto the floor. The coolant pump straner/screen must be sufficiently submerged for coolant flow to reach all areas n the coolant system. Check for coolant leaks and tighten any fittings if necessary.
  • Page 14: Operation

    Refer to the Job Selector chart on the top panel sawng on a properly mantaned DoALL saw. of the control console for information about the They are based on cuttng annealed, scale-free,...
  • Page 15: Cutting Capacity

    CUTTING CAPACITY • In the "set-up" setting, the saw band does not run while the saw head travels forward or in reverse through its stroke. The saw head must be in the fully The standard machine's cutting capacity is: retracted position for such pre-sawing operations as tilting the head or post movement is allowed. • At 0° tilt: 25 inches (635.0 mm) wide by 25 inches (635.0 mm) high for rectangular/square stock; 25 • In the "manual" mode, the saw head travels forward inches (635.0 mm) diameter for round stock. to complete the cut, then the sawing head and saw band movement will stop. • At 45° left tilt: 25 inches (635.0 mm) wide by 17 inches (431.8 mm) high for rectangular stock; 17.25 • During "auto" mode, all appropriate selector switches inches (444.5 mm) diameter for round stock. must be set at the "automatic" setting. Coolant, band speed and feed rate must be set and the workpiece •...
  • Page 16 CONTROL CONSOLE (Continued..) Typical Pushbutton Panel. Approach Rate. This selector switch with "normal" • The "reverse" or "forward settings are used during and "heavy duty" settings allows a choice of head manual operation. Turn the selector to "auto-off" approach rate toward the material to be cut. The before putting the machine into automatic cycle "heavy duty" setting is a slower than "normal" travel operation. rate and used when cutting large, tough material. 10. Tlt. This selector switch with "left", "hold", and Coolant. Four position selector switch with "aux", "right" settings regulate the direction of head tilt "off", "band on", and "on" settings.
  • Page 17 CONTROL CONSOLE (Continued..) See the "Accessories" section of this manual on controls for the Varable Vse Pressure and Nestng Fixture options. 3. Band Tenson. This selector valve with "tension", "release" settings and a center position for "hold" Hydraulc Control Panel is used when changing saw bands. The control is located on the rear side of the column and accessed 1. Band Speed. This keylock adjustment valve allows from the left side. the operator to set and maintain infinitly variable band speed between 60 and 300 fpm (18 and 90 m/min.). •...
  • Page 18: Saw Band Preparation

    CONTROL CONSOLE (Continued..) Contact your DoALL sales representatve for complete nformaton about saw bands and ther applcatons. Infeed Conveyor Enable. This selector switch with "on" and "off" settings allows the operator to turn Blade Guards the power off or on to the conveyor. This is used in conjunction with the Conveyor Speed/Drecton The machine has several guards for operator control. safety and protection. All guards must be n place before any sawng procedure s started.
  • Page 19: Post Adjustment

    SAW BAND PREPARATION (Continued..) Maneuver the saw band into the column guard. Then: (a) Carefully position the saw band around the drive and idler bandwheels with the saw band's back edge resting against each bandwheel's rear flange; (b) Move the Band Tenson selector switch to "tension" to apply just enough tension to hold the saw band in position, then move the selector to the center position to "hold". Slip the saw band between the saw guide inserts by twisting it 90° using the supplied saw band twist tool so the blade teeth are facing the front of the machine and pointing downward. Then: (a) Turn the adjustment screw two (2) full turns clockwse to provide correct pressure against the saw band; (b) Remove the protective Saw Cap from the saw Saw Guide Insert Components.
  • Page 20: Head Reverse Rate

    HEAD REVERSE RATE When tilting the head to the left, the LCD will display the angle with a minus (-) sign in front of the value. When tilting to the right, there will be no sign in front Located on the left side of the control console, this of the value. valve is used to regulate the reversing speed of the saw head. Turn the knob counterclockwse Elmnate any electromagnetc radaton from to “increase” the reversing velocity; clockwse to such thngs as rado transmtters, walke- “decrease” it. The valve’s lower locking knob or set talkes, etc.
  • Page 21: Band Feed Adjustments

    VISE ADJUSTMENTS (Continued..) • Certain work-hardening materials will require a moderately heavy initial Band Feed valve setting to assure immediate penetration of blade teeth. The fixed vise jaw distance from the saw band can Light feeds on these materials may cause the be adjusted by: (a) Loosening the lock screw; (b) blade to slide over the stock resulting in saw band Slide the fixed vise to desired position;...
  • Page 22: Coolant System

    For example: If Feed Force is set to obtain a given cutting rate Contact your DoALL sales representatve for with fluid temperature at 50° F. (10° C.), the rate complete nformaton about the use of coolants will increase substantially when fluid warms up to and ther applcatons.
  • Page 23: Typical Operation Procedures

    Load the stock to be cut onto the roller table or Flushng Hose as soon as possible. use controls for the material handling equipment if supplied to move stock into position. The DoALL Company recommends usng the Flushng Hose to remove chps at least twce To move the stock into position for clamping by the per each eght (8) hour shft, and more often vise jaws: (a) Turn the hand crank on the outside wth heaver use.
  • Page 24 TYPICAL OPERATING PROCEDURES For future reference, keep a record of band speed, feed rate, feed force and coolant (Continued..) applcaton settngs for successful jobs. After the cut has been completed, the saw band will shut off with the saw head in the forward position. Next: (a) Retract the saw head by moving the Feed selector to "reverse" (move the selector to "hold" when the desired saw head position is reached); (b) Turn the Vse selector (and Nesting Fixture(s) if supplied) to "open"; (c) Remove the cut-off piece either by means of the hand crank for the table rollers, or by use of controls for material handling equipment if supplied.
  • Page 25: Lubrication

    LUBRICATION Next 2 Pages...
  • Page 26: Lubrication Chart

    Drain, clean and refill whenever coolant becomes CHECK DAILY/ lubricant. undesireable for further use. Clean the mesh strainer at the AS REQUIRED same time. DoALL cutting fluids and/or oils. Multi-purpose automatic transmission fluid. Perferred. High quality, rust and oxidation-inhibited, Hydraulic Reservoir. 20 gallon (75.7 liter) capacity. Check CHECK DAILY/ medium hydraulic and general purpose oil level daily and keep the reservoir full.
  • Page 27: Lubrication Diagram

    LUBRICATION DIAGRAM REAR VIEW POWER UNIT LOWER HEAD - REAR VIEW...
  • Page 28: Maintenance

    — be very careful not to drop or lose the front nsert when t falls from Pressure is adjusted by turning the screw extending the assembly; (c) Loosen the screw and remove outward from the hydraulic pump. Consult a DoALL the rear insert. representative if assistance is needed. Pump Repar & Replacement DO NOT attempt to repar the hydraulc pump.
  • Page 29: Coolant Ststem

    If another type of coolant is to be used, the entire Move the brush closer to the blade as normal wear coolant system must be flushed (use DoALL’s Kleen occurs. Replace the brushes when necessary. Flush). Band Wpers Contact your DoALL sales representatve for complete nformaton about the use of coolants Band wipers, located at approximately the ten and ther applcatons.
  • Page 30: Bandwheels

    BANDWHEELS Occasionally check each bandwheel’s back-up flange and wheel tread for wear. Saw bands will not track properly if the taper is worn from the wheel tread. Replace the entire bandwheel if the rim becomes badly worn. Remove the bandwheels every six (6) months to clean them and surrounding areas. At the same time, clean the drive wheel ring gear and pinionbefore appling lubricant. Typical Bandwheel Flange and Tread. On older machines, both bandwheels may have replaceable front flanges to help keep the saw band correctly positioned.
  • Page 31: Trouble Shooting

    TROUBLE SHOOTING BLADE TOOTH GULLETS ARE LOADING Repar and adjustment procedures should be made only by experienced maintenance personnel, or by a DoAll servce representatve. Use a coarser pitch saw band. Reference to the machne's electrcal and hydraulc schematcs wll be helpful. Increase the band speed setting, or decrease the feed pressure setting. MACHINE WILL NOT START Check for improper coolant application.
  • Page 32 Examine the carbide back-up bearings. Replace Coolant mixture is too weak, or incorrect coolant is them if they are chipped or worn more than 0.020- being used. inch (0.5 mm). Check for saw band vibration. Have a DoALL service representative check machine alignment. 10. Decrease feed pressure to "break in" a new saw band on its first few cuts. Check for worn saw guide pivot bolts.
  • Page 33 TROUBLE SHOOTING (Continued..) The feed rate setting is too low. Check for incorrect adjustment of inserts, back-up bearing, or worn pivot bolts. Operaton selector must be in "set-up". Check machine alignment. Have a DoALL service Check the head rear limit switch (5 LS) for faulty representative check and/or adjust machine operation. alignment. Check for saw head obstruction.
  • Page 34: Accessories

    ACCESSORIES NESTING FIXTURE The followng are accessores sometmes used durng sawng operatons. A DoALL This optional feature is designed for high-production, sales representatve wll be happy to advse multiple sawing of stacked bars, rounds and tubing. you about the current avalablty of any Its jaws have the capacity to hold stock from 5 to accessory. 24 inches (127.0 to 609.6 mm) wide, and from 5 to 25 inches (127.0 to 635.0 mm) high. VARIABLE VISE PRESSURE Vertical nesting clamp cylinders can be mounted 1.
  • Page 35: Roller Stock Conveyors

    NESTING FIXTURE (Continued..) Round Stock Stacking Methods. Pieces should be stacked as closely together as possible. Metal chips lodged in open spaces between individual pieces will affect cutting accuracy. For Best Nestng Cuttng Results Total stack width should be no more than five (5) to six (6) inches (127.0 to 152.4 mm).
  • Page 36: Workstop

    ROLLER STOCK CONVEYORS (Continued..) Workstop arm positioning is done either manually, or by a control panel selector switch. The woskstop is moved to desired length as indicated on a scale • Powered stock conveyor five (5) feet (1524.0 mm) on the conveyor and then locked into place. or ten (10) feet (3048.0 mm) long with a weight capacity of 750 pounds (340.2 kg) per roller. VERTICAL GUIDE ROLLERS Powered conveyors allow speeds variable up to 50 fpm (15.2 m/min.) and are regulated with selector switch having "forward", "reverse" and "hold"...
  • Page 37: Laser Line Option

    LASER LINE OPTION If the indicator dot moves during cutting, this signifies that something (dull or improper blade, overfeeding, etc.) is causing the blade to twist. The operator To avod eye damage, DO NOT stare nto the can see graphically the direction of twist and take laser beam. appropriate action to correct the problem before several bad parts are produced. A laser devise is used to emit a line on the material to be cut. This line shows the approximate spot Number in text refers to identical number on where the cut will take place.
  • Page 38: Medium Torque Drive

    NESTING FIXTURE (Continued..) REINFORCING LEGS (Heavy Work Support) Two Red LED's (on side of the display at the top Two (2) reinforcing legs (or jacks) are mounted under and bottom) flash when the indicator moves beyond the roller table weldment. These legs increase the the amber region. This indicates that the amber table support capacity to 10,000 pounds (4536 kg). region has been exceeded. Under this condition, the A bumper plate and bumper bracket are mounted operator does not know the approximate magnitude on the lower portion of the sawing head to prevent of the error. the head from hitting the legs. Red LED's at the extremes of the display are The head CAN NOT be tlted when the unlighted when the deflection is reduced.

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