Javerty Endres [Company Ltd. eer 135 Agus Svea Gratanhin a Vetote usta PO Box 22 Grehentan 2192 ‘Tir 4 99588 7488 Fac: 612 9583 6614 «_ Eh fo@ brese.coma Vie wrtronacom as Model $3500 {Floor Standing [7 Steam ed accessories. ‘Adjustable length ‘op, feed rolet | attachment, toor Sand ane tigger vite Important IMPORTANT °°" robo Waldown Machine Address robo Waldown Machine sropo, Waldow Borne Toot are worartea fo Weve teem cera fronths [from dote of Schase) against failure, : Erignase). against tale, g ucnase) 80%! Coinph DatePuchosed. Bebe Was cone, fol taully motores, oog oa Ho! faulty: materials ong workmanship, provided Moctine i fo faulty moreno 20g Wore ie al been : ~ hat the goodshave not been ate Pr any conor of pocvel 8 Masel 9 Oe / eee tnd oe e improper use. ond 7 ‘of the manual relating fo satlety 8 { pee Se Ors yar, fhal he oe Sate sector orine machine, reve accep! hake ! Bre ae wan: 12 rons nage wi MEME ee eahcng neh wa tes Sarog pcre. i nas warty cor mut be eked THIRSTY SSpiobe ees10. 1". 12, 13. 14 15. 16, 1”. 18 19. 20, 21. OPERATING MANUAL FOR BROBO WALDOWN CIRCULAR SAWS - ALL MODELS STEEL CONTENT SPECIFICATION/CAPACITY SHIPPING & CONTENTS: NOISE LEVELS & SAFETY INSTRUCTIONS INSTALLATION - MECHANICAL (STANDARD & SEMI AUTO) (A) BENCH MODEL (STANDARD ONLY) (8) FLOOR MODEL (STANDARD & SEMI AUTO) INSTALLATION - ELECTRICAL (STANDARD & SEMI AUTO) PREPARATION : FOR OPERATION (STANDARD & SEMI AUTO) OPERATION (STANDARD ONLY) OPERATING RECOMMENDATIONS (STANDARD & SEM! AUTO) NUMBER OF TEETH SELECTION TABLE MAINTENANCE (STANDARD & SEMI AUTO) PARTS LIST (ALL STD MODELS) SAW GEARBOX ASSEMBLY - EXPLODED VIEW MANUAL VICE ASSEMBLY - EXPLODED VIEW DUAL CLAMP VICE ASSEMBLY ~ EXPLODED VIEW AIR VICE PERFORMANCE AIR VICE ASSEMBLY - EXPLODED VIEW WIRING DIAGRAM 8 PH, 1 PH, 50 HZ, 60HZ (STD.ONLY) AIR CIRCUIT AUTO START - SINGLE VICE AIR CIRCUIT AUTO START - DUAL VICE ‘SEMIAUTO COLD SAW FEATURES & OPERATION SEMI-AUTO PARTS LIST EXTENSION i 2 13 7 8 19 20 2t 23 24 25 Jeaue Date ~ October 2001 PIN 9354640 weet eer rae err ETeEeeT ee ES |a 1.) SPECIFICATION / CAPACITY Standard Blade Sizes: 0.0, Thickness Bore Size No. of teeth a {General purpose recommendation 300 2.5 40 160 only, see blade selection charton 350 2.5 40 180 page 11 for more detail) 4003.0 40 200 a Drive Pin Holes : 300/815/850 - 2.x 8.5mm x55P.C.D. 400 = 2.x 10.5mm x64P.C.D. a Worm-gear drive Ratio : 3001318/350/400 1:89 reduction q Sound level: 85-90 dBA Maximum STANDARD MOTORS: Model Phase Voltage Hz RPM kw 00/816/a50/400 4 2400-50 140047 a 3 41550 1400/2800 1.5/2.2 3 415 80 7oM400 1.4/1.8 3 220 60 B50N700 1.1/1.5 a 3 440 60 850/1700 1.44.5 3 220 60 170018400 4.1/1.5 2 440 60. 1700/3400 1.5/2.2 1 230. 60 1700017 Table 4. Spindle with 60 Hz moto: AL ELECTRIC BLADE SPEEDS MOTOR 8315 ‘$350 ‘$400 Phase_[Frequency| RPM RPM FTIMIN RPM FT/MIN RPM FT/MIN |. 3 60, 850 26 84 26 3 25 106 13 60 3700 52 186. 52 186 52 212, 3 60] 2400 08 34 403 370) 103 224} Table 2. Spindle RPM range with 5 rs. ELECTRIC BLADE SPEEDS MOTOR $300 $360 $400 | [Phase [Frequency | RPM RPM MIN RPM, MIMIN RPM. MiMiN 350 700 21 20 21 23 24 27 1/3 [50 1400) a2 0 42 aT a2 53 350 2800, 8580 65, 33 85 1061.) SPECIFICATION / CAPACITY cont, VICE CAPACITY Vice opening (Mex.) (Mechanical or Pneumatic) 300/318/350/400 Machine : 134 mm (145 mm without weerplate) CUTTING RANGE. MODEL ‘$3006 ‘$3500, $4008 NF350C, Cutting Range Oo = 30 118 130 710 (Dimensions in mm) 45° 85 +10 120 110 {hese specifications are [=F 90° 80x80 400 x 100 10x 110 05x 105 for new blades oniy! aso] 75x75 85 x 85 95x95 85 x85 Cutting dimensions wit “Frey 90° 1 76 x 105 85x 135 00x 135 90x 135 reduce with 45] 80x85 75x95 100 x 95 85 x95 re-sharpening of blades. “I @ age 50 60 60 105 MODEL '$300C $3500 $4008 NF350C, Cutting Range Oo 312 ae 516 4 Ee (Dimensions in inches) 45° 33/6" 456 4aiine 45ne" {hese specications are 90° | “S18 xo 1 exe TSE x4 Se axa for new blades oniy! 45° Bx 328x331" | 334'x334" | 39/"x3318" Cutting aimensions wi Tea] 80° axa SOR XESNE | a xs SNe [31S Se reduce with 4s s4ex2ue | ays 34 a'xsae | 33/8" x3 314" re Se = memes Wee Pe Gee aeD Sewers ee Se NOTE: Above figures are based on e full size blade being used and capacities will reduce as blade's diameter reduces by resharpening, ae. WEIGHTS: UN-PACKED PACKED 300/315/380/400 Machine 436Kg. (300 tp.) 467 Ko. r Coolant tank complete 17 Kg, (42 Ib.) 17 Kg, ze Sheetmetal stand 300 - 400 28 Kg, (62 Ib.) 28 Kg. a Air vice (each) 17 Kg. (38 Ib.) 17 Kg. Semi-auto Machine complete 245 Kg. (538 tb.) 323 Kg, 22 \2) SHIPPING & CONTENTS. Your machine (300 - 400 SERIES) is shipped in a cartonipallet or crate. ‘A fabricated stand is packed separately for the floor model. ‘The carton/pailet or crate contains the following items which are packed "loose", a. Standard Accessories 1. Saw blade (standard or as specified with order) 2. Service kit, 3. Manual. b. Optional Accessories - $300 - $315 - $360 - $400 Series 4, Stock support (A) Roller (B)_Hexhead screw M10 x 25 and washers (2 off) 2, Length stop and bar 3, Second mechanical vice 4, Pneumatic type single vice arrangement (Factory fitted) 5. Pneumatic type dual vice arrangement (Factory fitted) 8, Extra blades - to customer's specification 7. "Dead-man” trigger (DMT) switch attachment (Factory fitted) ‘© Trigger Switch | ‘A ‘dead man type trigger switch | enables instant switching at the ‘operators control, therefore increasing the efficiency and salety ofthe saw. Baa ea hm Mm me | =) i | | SS —_ Ss Ss = ES Be3.) 2 Donot operate this machine unless ali safety guards are placed andthe linka -4- NOISE LEVELS & SAFETY INSTRUCTIONS PLEASE ENSURE YOU READ THIS INFORMATION PRIOR TO USING THE MACHINE! he Noise level of an idling Brobo Waidown cold saw fited with Waldown) has been measured to be below 80 dB (A). This i¢ and Safety (Noise) Regulations 1992, 2 180 tooth blade (as supplied by Brobo beiow the Australian Occupational Health Only TRAINED OPERATORS should be permitted to operate this machine Before the machine is Sene, arehuly reed the “Machine Operating Manual", especially the “Safety instructions". Supervision must ensure both the operator and themeeives underwent the machine's correct method of operating before it is used by the operator 1-1. HIGH VOLTAGE POWER - 415/240 VOLT; The power supply to this machine is of a high level and unauthorised Gsequate maintenance could result in ¢ situation that could put the opcrsto electrical engineer should be assigned to maintainvrepal the system 1.2. AIR SUPPLY - COMPRESSED AIR - 600 kPa (SEMI-AUTOMA Various functions of this machine are carried out vie functions, situations will occur where machine pens this time that incorrect operator action could result interference and or F at risk A qualified out by @ qualified person, 108 is attached correctly, The guard must fully cover the blade when the head isin the uppermost postin Be not piace hands and arms into or near the cutting ares when the machine Is running, Be not place hands or fingers into or near the clamping area when clamping or starting the machine, Benet load or unlosd the machine while the blade is running, 8. Always wear eye protection when attending and operating this machine 9. Keep the cutting area clear of t 10. 14. Disconnect the electrical power Do_not wear loose clothing, long sleeves, gloves, Confine long hair in an appropriate hair net of cap. Support the work piece on both si cycle. Jewellery or any other item that may be caught. (des of the machine to prevent i falling or jamming during the cutting ‘ols and other foose objects, and keep the floor area clear of liquid spillage and excessive swart Before starting to cut, be sure the vice(s) are securely clamped and the machine Set-up is correct, when performing maintenance work on the machine or making acjustments other than those necessary for the normal operation of tne machine, 12. Always follow safe practices and inspection procedures when installing blades. (Refer Blade Mounting on Page 8.) 13. Ifa coolant hose fails or there is excessive water splashed onto the olectrical equipment, ensure that 14, 16, Power to the machine is isolated, before attempting to repair Excessive continual repetitive use of a manual cold saw can lead 1o muscle faiguelstrin, * ERR ePoropriate breathing equipment is used if cuting objects thet produce toxic fumes andlor OSESIvE dust. Also note that some coolant solutions may cause allergic reactions to some peoplea i — a aE ES CR a 3) 4) -5- NOISE LEVELS & SAFETY INSTRUCTIONS cont. 16. During use, the saw gearbox may become quite hot. Do not touch the gearbox, as buming may result if contact is prolonged, ATTENTION 17. DO_NOT ALLOW MACHINE (GEARBOX) TO RUN IDLE IN THE UPRIGHT REST POSITION FOR MORE THAN 3 MINUTES. OTHERWISE, DAMAGE CAN OCCUR TO THE BEARINGS AND DRIVE SYSTEM, ALWAYS OPERATE THE MACHINE SAFELY. BE CAREFUL !! INSTALLATION - MECHANICAL Ensure that the machine (whether bench or floor mounted) has adequate lighting and ventilation. A. inch IF the machine is @ bench model, bolt the machine to the bench by using four (4) only suitable length of M12 screws (not supplied) ‘Tapped holes pattern and centre distances - refer Figure 1 for 300/315/350/400 machines [rey ge ream IE a 4-4 eae an aaa l PROVIDE 4 HOLES 316 "0 CLew@ Wiz Bos-6- 4) INSTALLATION - MECHANICAL contd. B). Floor Model 1, Unpack fabricated stand and allocate space for installation taking into consideration handy stock feeding and safe access for the operator, ete. 2 The febricated stand is either an angle iron construction, (installstion dimensions - see Figure 2, for 300/315/350/400 machines) or @ sheatmetal Cabinet for 300/315/350/400 manual machines, (installation dimensions - see Figure 3.) 660 (26") WITHOUT LENGTH STOP (OR CONVEYOR INSTALLED . 25 Fie (24 oe a") 530 (20,97) fo eee FRONT OF MACHINE. Figure 3, 3. Semi auto models installation alm, see Figure 4, below. > 560 (22) sr | : a 446.(17.5) aaa K avo.es ais | oa toa FRONT OF MACHINE 58 (2.2" r (20.9° im 1 1 i i a 4 aresCEES SS en eee eh ft aim i mM mw i 4) INSTALLATION - MECHANICAL cont. SAW BLADE MOUNTING 4 6 10, {tis strongly recommended the machine base be fastened to the floor by using loxins, Hole pattem and centre distances of the stand see Figures 1,2,3,4 on pages 5&6. Unpack machine and bolt it to the top of the stand with bolts provided. Hex. head M12 x 28,(300/815/350/400 machines). Remove piestic plug and screw operating handle to the saw head end tighten lack ‘ut, if the operating handle is fitted with the deadman switch, the trigger must be facing upward. Connect electrical plug (8 pin type) to connector at the rear of the control box and secure the screw, Release the strap holding the saw head in a fixed position for shipping purposes (200131 6/850/400 machine only) - strap may be discarded. Hold dawn strap doas ot apply to SA models, as the power-pack unit provides the lacking action. f flows: a WARNING: MAKE SURE POWER IS DISCONNECTED !! b. Release outer guard linkage and raise outer guard to gain access to the spindle nose, ¢. Loosen spindle screw (LH THREAD); and remove counterplate. 4. Clean the face of the spindle, blade counterplate and the mounting surfaces of the blade. Place the blade onto the spindle hub end align with the drive pinholes, @ —_ Refit the counterplate with the drive pins passing through the pinholes of the blade into the main spinal. f. Rotate blade back against the drive pins (counter-clockwise) and finger tighten spindle screw. 9. Tighten spindle screw with 14 mm hexagonal wrench, h. Lower the outer guard and re-connact guard linkage. If optional devices are supplied - mount stock support and roller on either side of the clamping table. Normally stock should feed from left to right, but it can also ‘feed from right to left if required. (See installation page 6, B-1) Fit length stop bar and iength stop by securing with screw provided. The bar should be able to rotate,5a.) INSTALLATION - ELECTRICAL ‘The electrical installation should be carried out by a qualified anid authorised person, Single Phase and Three Phase 3 Single phase machines are provided with three pin 1S amp rated plugs and leads for connection to 240V, 50 Hz power supply iri Australia, ». Three phase machines should be fitted with sultable approved four pin plugs (ie. Three phases and earth) (not supplied). NOTE: Check power supplied and motor specifications before plugging in machine, Check ferminal connection on dual voltage motor terminal box and connect it accordingly to the Corresponding voltage supply. (See also electrical circuit drawing). {i gual Voltage motor is requested, the motor is alwavs connected to the higher votage, Unless specified when order is placod. Check direction of spindle rotation. It has to correspond (follow) to the direction of the arrow ‘on the guard, This is a clockwise rotation viewing the machine from the left, Ensure that all electrical leads and cables (inluding supply leads) are maintained in good condition, and replaced if cut, sliced or damaged in any way. 5b.) INSTALLATION - AIR Semi automatic machines alr supply (Max Bar = 116 PS. filtered compressed air) Should connect through a 1/4" BSP female fting, located on the rear side of the stanc. 6.) PREPARATION : FOR OPERATION 7 Clean the machine to remove the corrosion protective coating by using @ solvent, The ‘solvent should be non-flammable and toxin free. NOTE : Wear protective glasses/gloves. 2, Check that the gearbox is filled with oil to centre of the sight glass window when the head is in horizontal position. Use an extreme pressure industrial gear ol, of ISO VG 220 viscosity, conforming to AGMA SEP, US Stee! 224 or API GL-2 specifications to which 1% Ragigal Molyodenum disulphide has been added (Refer to maintenance section) Machines are shipped with gearbox filled and tested, 5. _ Mix the coolant by adding soluble cutting oil to water at a ratio of 1 part soluble oll to 20 Paris water. Stir constantly until well mixed and then add it to the machine coolant tank. Approximate volume required is 6 litres. Ensure tank is located under the chip pan funnel Note: Ditirent brands of soluble cutting oll may retuir efferent mix ratios as spectied by the respective manufacturer, and frothing may occur i these ratios are not adhered to. YOUR SAW MACHINE IS NOW READY FOR USE .. RPRRFEREORRP RPE RRP SEHR eee ees7.) OPERATION ANGLE CUTTIN a. _Tosetthe sew head to the angle of cut required. Loosen the socket nead cap torent {item 60 on the left & right back fences - see diagram on page 13/15) that clamp the table, and then rotate the head to required angle. “The shot-pin has positive locations at 80 deg and 45 deg right and left. Tighten the clamping screws. b, Adjust head depth stop to allow saw blade to cut fo meximum depth. NOTE : (Failing to do £0, could cause severe damage tothe rotary table, he blade, cr both). “The depth stop is located under the saw head pivot arm. c. Position the vice(s) as close tothe blade as possible without interfering with travel of blade or guard. \Viee reposition is required whenever head angle is changed. ‘ndvance vice jaw by the leadscrew handle to epproximately 1 mm fram the work piaea, then rotate quick action lever clockwise. ajst postion of vce jaw with leadscrew to ensure positive clamping of wortpiens ‘with quick eo tmiaking sure lover does nok interfere wih down stroke of the cutting head guarc. Check the workpiece is clamped securely. i «_sppanworplece on both sds ofthe easrine to oven rater roping when te vices are released (ie. when optional vice is provided) A fe. tfalength stop is being used, make sure stop bar is net in contact with the material during the cutting operation. Ifthe length stop is left in contact with the ‘material jamming and blade breakage may occur. i f. Switch the machine to the desired speed. go. ‘Single phase machines have one speed. = Where the deadman trigger switch option fs fitted, blade rotation is achieves Py pressing the trigger switch at the end of the handle. 8.) OPERATING RECOMMENDATIONS, 4, Select the correct saw blad with the correct tooth pitch and form to sult the material to be cat to provide minimum burr and maximum blade tifetime. Lise the smallest diameter biade and coarsest pitch that's practical within the required speed and material limitations. Generally use @ tooth pitch to give 2-4 teeth engagement wih the material during cutting, (Refer to Page 11 Teeth Selection Table) Be sure that sufficient coolant is lowing to the cutting teeth. Do not alow machine (gearbox) fo run ide in the upright rest position for more than 3 . minutes, Otherwise damage can occur to the drive system. 2 Therate of feed affects the quality f the cut and blade fe, and is effected by tho material and orass-section dimensions. a eee tem steady pressure tet the blade cut atthe best rate - DO NOT PULL. Too HARD!8.) -10- OPERATING RECOMMENDATIONS contd, 3. 5. When cutting stainless steel or high carbon steel (Brinnel hardness above 200), the siowest ‘Speed machine should be used together with a cobalt type high speed steel blade. DO NOT dwell ot hesitate while in the cut. Maintain a steady, continuous pressure, thus avoiding “work hardening". Generally speaking, the softer the material, the faster the rate of speed. Blacle speed selection depends on the material being cul.Use the slow speeds for hard, tough materials and higher speeds for soft, ductiie materials. NOTE: Non-ferrous materieis (brass, copper, aluminium) require much faster speeds than provided on this machine. If these are the majority of materials cut, you should use our NF Series Machines. The back jaw wear plates on the 300-400 machines are to be fitted in the following manner: 7 For angle cutting, the wear plates should be fitted as follows to provide the maximum support on one side and clearance on the other. p BweRrweenrteHrRrteRPeWTtEREeFrEreEARFTtrtEaFTErtrtEieEi ] a a 4 em i a me -1t- 1UMBI ETH ION Ty BLADE MATERIAL - AISI M-Z High Speed Stee! 62-64 Rc hollow ground VAPOUR TREATMENT - Blue Oxide Coating for ‘+ Greater durability, + Better coolant conveyance to the cutting edge, + Reduces gailing or "pick-up" on the sides of the biade, * Reduces brittleness of the steal TOOTHFORMS- —_ Teeth are beveled on alternate sides - up to 180 teeth, or High-rolling, low-finishing teeth, "tripie-chip" - above 180 teeth “These charts are a guide only to assist in selecting and ach machines. Consideration must be given to: «Material, softfnerd, ferrousinon-ferrous. © Shanpening of the blade is critical. Skilled saw sharpening is recommended. + Aggressive feed is not essential. tt accelerates blade weer and can cause lock-up and blade breakage. ‘+ Feutting non-ferrous metals, ensure rake angles are correct. ‘+ IFhaving difficulty selecting appropriate blades, contact Brobo Waldown Ply. Ltd. for assistance, ‘+ Tubing wail thickness sizes below are the maximum recommended. ng the most efficient cutting action on your ‘The cutting of square tube creates its own unique conditions. Our experience has shown that selecting 2 tooth number to suit @ similar size of round tubefwall thickness combination, and then reducing the tooth quantity by one group (i.e. 20 teeth), a satisfactory cutting action can be achieved. Hollow Tube Blade Selection Chart WATERIAL OUTSIDE] __ WALL BLADE DIAMETER (MM) AND NUMBER OF TEETH DIAMETER THICKNESS: 300 [ss 350 400, 20 3 380, 780. 220 | __240 2. 240 240 260. 340 4 300) 320 250) 400, a 4 7 60. 80, 3 460 160] 80 200. gus 220220 4 300, ‘0 0 5 120 1401 a 140 760 3 160. 780 fer a gone 220220 4 300) 320 Eo 5 440 140. 4 460160 EY 180 7200 2 7200. 200 1 280 300) 5 x 140) 140 zm: a 760, 70. 3 x 200 | 780. 2 x 220 220 { x 300 ‘340 ia. 5 x x 120 140. — 4 x x 760 160. 3 x x 180-480 gee eee. x "200 220 i x x 300. 340.9). 10.) ~42- NUMBER OF TEETH SELECTION TABLE cont. id Material Blad lection Chai MATERIAL WETER (MM) DIAMETER 300 315, 350 10, 280 1 7280 280, 20 180. 1 160) 200, 30 140, 7140. 160 40. 120 320140 5 30 80. 80 400 a 60, Xx Xx 20 ‘These charts are issued as a guide only. As many factors can and do effect the cutting performance of both-the saw blade and the sawing machine, Brobo Weldown Ply. Ltd, will net accept responsibility of biade and/or machine breakages, or unsatisfactory cutting performance of both the blade and/or the machine, MAINTENANCE Lubricate the saw head pivot shaft and rotary table regularly (after every 40 hours operation or weekly) with an NLGI 2 extreme pressure grease. Change the oil after the first 25 hours operation and after each 300 hours of operation. Use an extreme pressure industrial gear oil, of ISO VG 220 viscosity, conforming to AGMA SEP, US Steel 224 or AP! GL-2 specifications to which 1% colloidal molybdenum disulphide hes been edded. Required quentity to refill is approximately 1 litre for the 300/350/400 gearboxes, Gearbox oil is available from BROBO WALDOWN PTY.LTD., in 2 Litre packs - Part Number: 2501090, Filling point is the handie ber mounting threaded hole. Change coolant as required (whenever the coolant starts to get dirty or emits a foul odour), Use @ premium quality sokible cutting oil. Oil is available from BROBO WALDOWN: PTY. LTD. in 2 litre packs - Part Number: 9301570, The air supply for the semi automatic machines andior pneumatic air vice(s) should be Checked regularly. It should not contain condensed water and the filter should be drained frequently! EEEFERFEEE See eee ee