Brobo TNF 115 2 Series User manual

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BROBO GROUP (AUST) PTY. LTD.
8 Fowler Rd, Dandenong South
Victoria 3175, AUSTRALIA.
☏ + 61 3 9794 8751 📧 [email protected]
🖷 + 61 3 9794 8792 www.brobo.com.au
PRODUCT AND MAINTENANCE MANUAL
MANUAL NON-FERROUS CUTTING SAW
MODEL No. TNF 115 (SERIES 2)
___________________________________________________________________________________________
 Precision Drilling Machines  Tapping Machines  Multi-Head Drills  Tool Grinders 
 Tool Post Grinders  Machine Vices  Special Production Equipment 
 Accessories  Riveting Machines  Pedestal Grinders  Metal Cutting Saws  Linishers 
YOUR BROBO DISTRIBUTOR IS:
A.C.N. 098 264 316
A.B.N. 42 098 264 316

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OPERATING MANUAL FOR BROBO GROUP
MANUAL NON-FERROUS CUTTING SAW TNF115
TECHNICAL SPECIFICATION
CHAPTER 1: Installation of the Machine
1.1 Unpacking & Handling the Machine
1.2 Parts Checklist
1.3 Minimum Requirements
1.4 Anchoring the Saw
1.5 Connection to Power Source
CHAPTER 2: Safety & Accident Prevention
2.1 Operation of the Machine
2.1.1. Noise Level
2.1.2. Power Supply
2.2 General Requirements
2.3 Advice for the Operator
2.4 Machine Safety Devices
2.4.1. Reference Standards
CHAPTER 3: Main Functions & Operation of the Machine
3.1.1. Cutting Head
3.1.2. Saw Safety Guard & Locking System
3.1.3. Saw Handle (with ‘Dead Man’ Trigger Switch)
3.1.4. Power Switch & Clamp Switch
3.1.5. Pneumatic Vice Clamp
3.2 Preparation for Operation
3.3 Operation Recommendations
CHAPTER 4: Drawings, Layouts, Assembly & Spare Parts
4.1.1 Main Dimensions
4.1.2 Assembly Drawings
4.1.3 Electrical Drawings
CHAPTER 5: Adjustments for the Saw Unit
5.1 Changing the Blade
5.2 Adjusting the Head Tilt
5.3 Cutting & Feeding Speeds
5.4 Lubricator Adjustment
5.4.1 Lubricating Oil Precautions – Health Hazard Information
CHAPTER 6: Maintenance & Selection of Consumables
6.1 Role of the Operator
6.2 Maintenance Requirements
6.3 General Maintenance of Functioning Components
CHAPTER 7: Appendix
i. Hazard/Risk Assessment
ii. Workplace Health & Safety Policy

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TECHNICAL SPECIFICATION
STANDARD FEATURES
 Mitering 45° left, straight 90° & 45° right with rapid adjustment bumpers
 45° Compound Mitering
 Automatic Lubrication
 Vertical & horizontal pneumatic clamping
 400mm TCT blade
 Two feed roller conveyors (3m long each).
 3m Adjustable length stop
 Trigger Switch (DMT) to activate the machine
BLADE SIZES
Blade Type: TCT Tungsten Carbide-Tipped
Blade RPM: r 3190 rpm
Blade RPM Max 4800 rpm
Blade Diameter D 400 mm
Bore d 30 mm
Tooth Width S 3.6mm
Body Thickness s 2.8mm
Tooth Geometry: TFZ N Triple chip tooth alternating with flat tooth
with negative hook angle
Number of Teeth z 120
CHARACTERISTICS:
Cutting of aluminium profiles & mouldings, plastic boards, brass
Suitable for angle cutting & cross cutting
MOTOR
Power: 1.5 kW
Rpm 2800 rpm
V Single Phase, 240V TNF115-240
3 Phase, 415V TNF115-415
PNEUMATIC
Air pressure 6-8 bar
Air Consumption 2.2 l/min
DIMENSIONAL SPECIFICATIONS
Base Dimensions 670 mm x 540 mm
Table Working Height 870 mm
Dimensions L x W x H 670 x 850 x 1700 mm
Packaged L x W x H 1140 x 1140 x 1700 mm
Roller Conveyor 300 x 30 x 20 mm
WEIGHT
m 167 Kg

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CUTTING RANGE CHART
90˚ 100 mm
45˚ 100 mm
90˚ 100 mm
45˚ 100 mm
90˚ 100 x 190 mm
45˚ 100 x 130 mm

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CHAPTER 1 - Installation of the Machine
1.1. Unpacking & Handling the Machine
Upon receiving the Brobo Group TNF115 Series 2, the machine should be standing upright & positioned centrally
on top of a wooden pallet. While the machine is situated on the pallet, position the forklift arms under the pallet
between the runners, keeping in mind that the machine is head heavy. Move the entire unit to an accessible area
as close as possible to the final location.
Carefully remove the wooden frame surrounding the saw unit (Figure 1). Once completed, proceed by elevating the
machine away from the pallet base using a sling harness wrapped around the cutting head of the saw. Ensure that
the floor is as level as possible before finally positioning the machine to the desired location.
FIGURE 1. Handling of Cutting Saw Unit
WARNING – HEAD HEAVY MACHINES
The metal sawing machines are heaviest where the saw heads are fitted & as such, care must
be taken while relocating or moving the machines.

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1.2. Parts Checklist
Along with the saw unit, check that the following accessories, packed "loose", are included as follows:
A. STANDARD ACCESSORIES
1) 1  Saw Blade
2) 1  Operating Manual
B. OPTIONAL ACCESSORIES
Part Number Description
9311270 Standard Adjustable Length Stop (600mm)
9501450
9501470
‘Brobo-Rule’ Series Manual Micro-Adjustment Length Stop
 Available in 3.0m or 6.0m lengths
 Field Kit includes rail, tape, micro-stop & extension arm.
9501210
Roller Conveyor
 68 Kg Steel Rollers
 3000mm x 305mm
 150mm pitch
9504320 Adjustable Stand (610mm – 1016mm)
9540330 Stand V Type Roller
9540340 Stand Flat Roller
- Additional Blade(s) - Custom to Client Requirements
1.3. Minimum Requirements
For the machine to function correctly, the room in which the saw unit is to be installed must be in the vicinity of, &
satisfy the following conditions:
 415/240V Power Supply
 Ambient Temperature - From -10
 C to +50  C.
 Relative Humidity: Not more than 90%.
 Lighting: More than 500 LUX.
WARNING – OPERATING VOLTAGE VARIATION
Each saw model has an inbuilt safety system to protect it against voltage variations. However,
for the machine to perform efficiently, ensure that the saw unit operates within
 10% limits of the
recommended voltage of the motor.

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1.4. Anchoring the Saw
Prior to anchoring the saw unit, take into considerations the requirements mentioned in Section 1.3 & Section 2.2,
& other aspects regarding the usage of the machine such as accessibility to cut parts & safe access for the operator.
The base of the fabricated stand (if applicable), in which the saw head rests on, is anchored to the floor by 4  M12
bolts. For added stability, it is strongly recommended that the machine stand is fastened to the floor by using loxins
(not provided).
Required Working Area
It is recommended that A & B is more than 1.5m
Figure 2. Saw TNF115 S2 Length Stop with Conveyor

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1.5. Connection to Power Source
Before connecting the machine to the power supply, check that the socket is not connected in series with other
machines. This condition is critical for the ideal operation of the saw unit.
Single & Three Phase
a) Single phase machines are provided with three pins, 15 amps rated plugs & leads for connection to 240V,
50Hz power supply in Australia.
Figure 3.1 Connection 3 pins – 1 Phase
b) Three phase machines
Figure 3.2 Connection for “5-CORE” Wire System with Neutral – 3 Phase
c) Check the power supplied & motor specifications before plugging in the machine. Check the terminal
connection on dual voltage motor terminal box & connect it accordingly to the corresponding voltage supply.
d) If the dual motor is requested, the motor is always connected to the higher voltage, unless otherwise
specified prior to the order being placed.
Active = Brown VOLTAGE MAIN VOLTAGE
Neutral = Light Blue 240V/1 PH 240V
Earth = Green/Yellow

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CHAPTER 2 - Safety & Accident Prevention
The Brobo Group TNF115 Series 2 has been designed & manufactured in accordance with Australian Standards.
It is HIGHLY RECOMMENDED that the instructions & warnings contained in this chapter be carefully followed for
correct usage of the machine.
2.1. Operation of the Machine
The Brobo Group TNF115 Series 2 is specifically designed to cut non-ferrous metal cross sections with solid or
thin-walled profiles. Other types of material & machining are not compatible for use with the specifications of the
saw. This machine involves a high-speed blade rotation; therefore extreme caution is required when
operating the device.
The employer is responsible for instructing the personnel who, in turn, are obliged to inform the operator of any
accident risks, safety devices, noise emission & accident prevention regulations provided for by national &
international laws governing the use of the machine. The operator must be fully aware of the position &
functions of all the machine’s controls.
All those concerned must strictly adhere to ALL instructions, warnings, & accident prevention standards in
this manual.
The following definitions are those provided for by the EEC DIRECTIVE ON MACHINERY No. 98/37/CE:
 Danger Zone - any zone in and/or around a machine in which the presence of a person constitutes a
risk for the safety & health of that person.
 Person Exposed - any person finding him or herself, either completely or partly in a danger zone.
 Operator - the person or persons are given the responsibility of installing, operating, adjusting,
maintaining, cleaning, repairing, & transporting the machine.
WARNING – UNAUTHORISED MODIFICATIONS/REPLACEMENTS/USE
The manufacturer declines any responsibility whatsoever, either civil of criminal, in the case of
unauthorised interference or replacement of one or more parts or assemblies on the machine,
or if accessories, tools & consumable materials used are different from those recommended by
the manufacturer, or if the machine is inserted in a plant system & its proper function is altered.

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2.1.1. Noise Level
The noise level of an idling saw has been measured to be below 85 dBA. This complies with the Australian
Occupational Health & Safety (Noise) Regulations 1992.
Please note that peak impulse noise levels will be experienced due to variables including blade characteristics, type,
& condition. This will also vary accordingly depending on the size & type of sample being cut. Under these
circumstances, management should make available to the operator(s) the appropriate hearing protection equipment
as prescribed under the above-stated act.
ALLUMINIUM
IN VACUM
Medium value of the sonorous level measured Lmp= 75,1 dB (A)
Value of the sonorous level in the working position measured Lmp= 81,3 dB (A)
Factor of environmental correction K= 1 dB (A)
Medium value of the correct sonorous level Lpc= 74,1 dB (A)
Value of sonorous level in the correct working position Lpc= 80,3 dB (A)
LOADED
Medium value of the sonorous level measured Lmp= 86,3 dB (A)
Value of the sonorous level in the working position measured Lmp= 91,1 dB (A)
Factor of environmental correction K= 1 dB (A)
Medium value of the correct sonorous level Lpc= 85,3 dB (A)
Value of sonorous level in the correct working position Lpc= 90,1 dB (A)

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2.1.2. Power Supply
The 415/240V power supply requirements for this machine are of a high level & unauthorized interference and or
inadequate maintenance could result in a situation that could put the operator at risk. A qualified electrical engineer
should always be assigned to maintain & repair the system.
International Protection Rating code (Ingress Protection): IP54
First Digit: Solid - Level 5: Protected from limited dust ingress.
Second Digit: Liquid – Level 4: Protected from water spray from any direction.
2.1.3. Compressed Air Supply
The saw needs to be connected to the air supply via the regulator located at the back right hand side of the cabinet
prior to operating the saw.
Various functions of the saw are carried out via the use of 6 bar compressed air.
During these operations, situations would arise where machine parts & materials are clamped together & would
potentially pose a serious safety issue to an inexperienced operator. Operators should be thoroughly instructed
about these hazards.
Only a qualified electrician should carry out regular maintenance of this system.
2.2. General Requirements
Lighting
Insufficient lighting during the operation of the saw unit would constitute a safety hazard for the people concerned.
For this reason, the user of the machine must provide adequate lighting in the working area to eliminate areas of
shadow, whilst also prevent dazzling illumination sources
(Reference standard ISO 8995 - 2002 ‘Lighting of Indoor Workplaces’).
Connection
Check that the power supply cables, compressed air supply (if applicable) & coolant system complies with, & are
operating within the acceptable range of the saw capabilities.
Faulty, damaged or worn components must be replaced immediately.
Earthing Systems
The installation of the earthing system must comply with the requirements stated in the:
IEC Standards Part 195: Earthing & Protection Against Electric Shocks 1998.
Position of the Operator
The user controlling the machine saw operations must be positioned as shown in figure 5 below.
Figure 5. Correct Position for Operating Saw Unit

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2.3. Advice for the Operator
Protective eyewear or goggles must be worn at all times while attending & operating the metal
saw.
Do not attempt to operate the machine unless all safety guards are in operation.
The guard must fully cover the blade when the head is in the uppermost position.
Ensure that hands & arms are kept clear of the cutting zone when the machine is operating.
Do not wear loose clothing with long sleeves & oversized gloves, bracelets, necklaces or any
other loose object that may become entangled in the machine’s blade during cutting. Long hair
must be tied back or placed in a hair net.
Always disconnect the power supply to the machine before carrying out any maintenance
work or adjustments. This includes cases of abnormal operations of the machine.
Any maintenance work performed on the hydraulic, pneumatic or coolant systems must be carried
out only after the pressure in the system has been released.
The operator MUST NOT conduct any risky operations or those not required for the cutting in course
(e.g. remove swarf shavings from the machine while cutting).
Never move the saw while the machine is operating.
Always keep the workplace are as clean as possible.
Remove equipment, tools or any other objects from the cutting zone.
Support the workpiece on both sides of the machine to prevent it falling or jamming during the
cutting cycle.

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Ensure that the specimen being cut is secured firmly in the vice clamps & the machine has been
correctly set. Figure A show some examples of how to correctly clamp different specimen profiles.
Before commencing the cut, be sure the vice(s) is securely clamped & the machine set-up is correct.
Figure A. Correct Clamping of Cutting Specimens
Do not use cutting blades of different sizes to those recommended to the machine’s
specifications. Always follow safe practices & inspection procedures when installing blades
(Please refer to section 5.1 Changing the Blade).
When cutting very small specimens, ensure that the workpiece is not dragged behind the back
fence support, where it could get lodged behind the blade.
If the blade jams during a cut, activate the emergency stop function immediately. Do not
continue forcing the blade through. This could damage the blade, the specimen or be a cause for
potential injury to the operator.
Always turn off the machine before carrying out any repair work. Consult the Brobo Group
Engineering Department in the country in which the machine was initially purchased.

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2.4. Machine Safety Devices
This product & maintenance manual is not purely intended as a guide for the usage, operation, & maintenance of
the saw unit in a strict production environment; it is instead an instrument to providing information on how to use the
machine correctly & safely. The following standards listed in section 2.4.1, which are applicable to the Brobo Group
TNF115 Series 2, are those specified by the EEC Committee that governs the safety of machinery, health & safety
at work, personal protection & safeguarding of the work environment. In addition, the saw also complies with the
Australian Standards regarding the safeguarding & general requirements for electrical equipment.
2.4.1. Reference Standards
MACHINE SAFETY
 EEC Directive No. 98/37/CE - Machines Directive
 EEC Directive No. 91/368 - 94/68 - Amends sections of EEC Directive No. 98/37/CE relating to machine
safety
 EEC Directive No. 73/23 - Low Voltage Directive
 AS4024.1 - 1996 - Safeguarding of Machinery
HEALTH & SAFETY AT WORK
 AS3100 - 2002 - General Requirements for Electrical Equipment
 OH. & S. 1995.81/1995 - Compliance References
 EEC Directive No. 80/1107; 83/477; 86/188; 88/188; 88/642 - Protection of workers against risks caused
by exposure to physical, chemical & biological agents in workplace
 EEC Directive No. 73/23 & Special EEC Directives No. 89/654; 89/655 - Improvements in health & safety
at work

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CHAPTER 3 - Main Functions & Operation of the Machine
3.1.1. Cutting Head
As the name suggests, the cutting head is the focal area where most of the specimen cutting takes place. Thus,
correct saw blade selection such as size, number of teeth & tooth pitch are all critical factors that determine the
overall performance & quality of the final cuts. In addition, the use of correct saw blade provides minimum burr to
the workpiece while maximising the safety to the operator during each cutting procedure.
To adjust cutting table angles by pulling the quick release knob at middle of the clamping table
3.1.2. Saw Safety Guard & Locking System
The primary purpose of the saw safety guard is to protect the user
from the spinning blade. It also functions as a safety device to protect
the operator from any broken tooth, swarf or high-velocity particles
that might be dislodged by the cutting process.
During the use of the machine do not remove the guard & make sure
that they are in correct working order.
The saw is held in the safety rest position by a locking system &
assisted back to its rest position by a return spring
Figure 7. Saw Safety Guard & Locking System
Figure 6. Main Function
Motor Location (dark blue)

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3.1.3. Saw Handle (with ‘Dead Man’ Trigger Switch)
In the rest position (with the arm lifted) the blade is completely covered by the yellow
guard which can be activated for cutting by pulling the release handle & lowering the
head.
3.1.4. Power Switch & Clamp Switch
Power Switch turns on & off power supply.
Turn the knob clockwise to ON position to turn on the machine
Clamp Switch to activate the clamper to secure the movement of the
workpiece. Turn the knob clockwise to clamp the workpiece
3.1.5. Pneumatic Vice Clamps
Pneumatic Vice Clamps use air-actuated cylinders to operate the
clamping action. They are ideal for quick clamping in repetitive
production operations, and yet are portable & economical to use on short
run jobs with temporary fixturing.
Clamp Adjustment: Adjustment is done by first releasing the levers &
then moving the cylinder holders to the left or right or moving the
cylinders backwards & forwards. The cylinders & the holders themselves
move independently from each other.
Figure 11.
Vice Clamp
Figure 8. Saw Handle with “Dead Man” Trigger Switch
Figure 9.
Power Switch
(Currently at Off position)
Figure 10. Clamp Switch

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3.2. Preparation for Operation
The following procedure is recommended for the correct cutting using the Brobo Group TNF115 Series 2
PROCEDURE
Using a non-flammable & toxic free solvent, clean the machine to remove any corrosion protective coating prior to
use.
1) Ensure that both the air & electric power systems are turned on, where applicable. The electrical power
source must be available before any pneumatic functions will operate.
2) Place the cutting specimen you wish to cut into the vice clamps. Manually adjust the clamps so that the
jaws are clamped firmly to the workpiece. With a pneumatic vice, manually adjust the clamps to a clearance
of 3 - 7mm. (For correct clamping of material, please refer to section 2.3 Advice for the Operator). NOTE -
The vice clamps advance with an approximate 10mm pneumatic stroke to apply a clamping pressure of 6
bar (87 psi).
3) Position the vice clamps & component as close to the blade as possible without interfering with the travel of
the blade or guard. Vice relocation is required whenever the head angle is altered.
4) For pneumatic vices, set the vice clamping pressure from the pressure regulators located on the main control
unit door. If for any reason this pressure is not available on a continuous basis, the regulator on the air
service unit must be set slightly below the available line pressure, & the safety low-pressure indicator valve
needs to be reset to correspond with the newly available pressure. The need to change the pressure is
necessary to allow for lighter materials with hollow cross sections to be cut without deforming the walls
thicknesses.
5) To initiate the cutting process
 Vice jaws automatically close & apply clamping pressure.
 Position blade to commence cutting through component, pulling the handle at Trigger Switch to cut &
maintaining a constant forward feed cutting rate until the end of the stroke.
 Return saw cutting head to the initial rest position.
 Vice clamps release workpiece
Note: The clamps must be close in order to active the saw blade
6) The machine is ready for the next cutting cycle.
WARNING – SAFETY GEAR
Protective clothing, safety glasses and gloves should always be worn while loading parts,
operating the machine, or undertaking any maintenance work on the saw.
WARNING - BLADE JAMMING
If the saw blade jams during a cut, engage the EMERGENCY STOP immediately. Remove the
part, check that the blade is not damage and if need be, replace the blade.

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3.3. Operation Recommendations
 Select the correct saw blade with the correct tooth pitch & form to suit the material to be cut to provide
minimum burr & maximum blade lifespan.
 Use the smallest diameter blade & coarsest pitch that is practical within the required speed & material
limitations.
 Generally, use a tooth pitch to give 2 - 4 teeth engagement with the material during cutting.
 Ensure that sufficient coolant is flowing over the cutting teeth.
 The rate of feed affects the quality of the final cut & blade life. This varies also by the material & cross-
sectional dimensions.
 When manually feeding the saw head, keep in mind to maintain a steady, continuous pressure, thus
avoiding work hardening on the cutting piece. Avoid ‘forcing’ the blade through the material as this might
damage or break the blade.
 As a rule of thumb the softer the component, the faster the rate of speed. Note that for non-ferrous
materials such as brass, copper, aluminium etc. require much faster speeds than Ferrous Metal Cutting
Saws
CHAPTER 4 - Drawings, Layouts, Assembly & Spare Parts

540
670
1700
870
NOTE
MINIMUM 600MM ALL
AROUND SAFE SPACE FOR
OPERATING ZONE
TNF 115 S2 MAIN
DIMENSIONS
TITLE:
A4
SHEET 1 OF 4 SCALE:NTS
ISSUED DATE 07.02.2019
DRAWN BY ANH
BROBO GROUP
Address : 8 Fowler Rd, Dandenong VIC 3175
https://brobo.com.au/