protech 500DSA User manual

METAL CUTTING BAND SAW
500DSA/H
INSTRUCTION MANUAL
500DSAH-1020403-R1

- -
1
Table Of Contents Page No
Overall Aspect……………………………………………………………….……….... .... 2
1 Warning ….………………………………………………………………….….….. .. .3
2 Safety rules for all tools ..…………………………………………………………. .... 3
3 Specification …………………….……………………………………………….... .. 6
4 Transportation of machine …………………………………………………..….... ....6
5 Minimum Room Space For Machine Operation ………………………………... .... ..7
6 Make proper tooth selection ……………………………………….………….…. .... ...8
7 BI-Metal speeds and feeds .…………………….………………………………...... ...9
8 Connecting saw to power source ………………………………………………........ ..11
9 Starting and stopping machine (Model：500DSA)……………………………..... .... 12
9 Starting and stopping machine (Model：500DSAH) …………………………..... .... 13
10 Adjusting automatic shut-off limit switch……………..................................... .... ....16
11 Adjusting downward travel of saw arm …………………………………….... .... 16
12 Changing saw blade speeds …………………………………..……...……..….... .. 17
13 Adjusting blade tension …………………………………………………….….. .... 17
14 Adjusting blade guide support arm ………..…..…………………..………...... ..17
15 Adjusting feed rate ……………………….……………………………………...... ...18
16 Adjusting the auxiliary pulling spring of the saw arm ….………….…....... .... ...18
17 Operating cutting angle and adjusting vise .... ……………………………….... ...19
18 Coolant ………………………………………………………………….……........20
19 Adjusting stock advance stop ……………………….………………………....... ..20
20 Adjusting blade guide roller bearings,
carbide blade guides and back-up bearings …………………………….….... ...20
21 Removing and installing the blade ……………………………..…………........ ..21
22 Gear box …………..…………………………………..………………………….... ...22
23 Saw blade brush setting ………………………………………………..……….... ....23
24 Coolant tank and chips container …………………………………………….….... .23
25 Drive belt replacement and proximity sensor adjustment ………………….... .... .23
26 Vise clamping pressure setting ……………………………………………….….... ..24
27 Cutting guide plate adjustment …………………………………………………. .... 24
28 Trouble shooting …………………………………………………………………....25
29 Circuit Diagram ……………………….…………………………………………..28
30 Parts Drawing ……………………………………………………………………….33
31 Parts Lists ……………………………………………………………………………37

- -
2
Overall Aspect
CAUTION
Install saw blade and blade guard
before use. Set proper blade tension
to prevent any danger caused by
damaged saw blade or work piece.
Vise clamping pressure
Control box
Arm Blade adjustable knob
Hand wheel
Vise jaw bracket
Support rod Auxiliary pulling spring
Saw blade brush

- -
3
1 WARNING: FAILURE TO FOLLOW THESE RULES
MAY RESULT IN SERIOUS PERSONAL INJURY
As with all machinery there are certain hazards involved with operation and use of the machine.
Using the machine with respect and caution will considerably lessen the possibility of personal
injury. However, if normal safety precautions are overlooked or ignored, personal injury to the
operator may result.
This machine was designed for certain applications only. We strongly recommends that this
machine NOT be modified and/or used for any application other than for which it was designed. If
you have any questions relative to its application DO NOT use the machine until you contact with
us and we have advised you.
Your machine might not come with a power socket or plug. Before using this machine, please
Do ask your local dealer to install the socket or plug on the power cable end.
ULES FOR ALL TOOLS
A .USER:
(1). WEAR PROPER APPAREL. No loose
clothing, gloves, rings, bracelets, or other
jewelry to get caught in moving parts.
Non-slip foot wear is recommended. Wear
protective hair covering to contain long hair.
(2). ALWAYS WEAR EYE
PROTECTION. Refer to ANSLZ87.1
standard for appropriate recommendations.
Also use face or dust mask if cutting
operation is dusty.
(3). DON’T OVERREACH. Keep proper
footing and balance at all times.
(4). NEVER STAND ON TOOL. Serious
injury could occur if the tool is tipped or if the
cutting tool is accidentally contacted.
(5). NEVER LEAVE TOOL RUNNING
UNATTENDED. TURN POWER OFF.
Don’t leave tool until it comes to a complete
stop.
(6). DRUGS, ALCOHOL, MEDICATION.
Do not operate tool while under the influence
of drug, alcohol or any medication.
(7). MAKE SURE TOOL IS
DISCONNECTED FROM POWER
SUPPLY. While motor is being mounted,
connected or reconnected.
(8). ALWAYS keep hands and fingers away
from the blade.
(9). STOP the machine before removing
chips.
(10). SHUT- OFF power and clean the
BAND SAW and work area before leaving
the machine.
B. USE OF MACHINE:
(1). REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to see
that keys and adjusting wrenches are removed
from tool before turning it “on”.
(2). DON’T FORCE TOOL. It will do the
job better and be safer at the rate for which it
was designed.

- -
4
(3). USE RIGHT TOOL. Don’t force tool or
attachment to do a job for which it was not
designed.
(4). SECURE WORK. Use clamps or a vise
to hold work when practical. It’s safer than
using your hand frees both hands to operate
tool.
(5). MAINTAIN TOOLS IN TOP
CONDITION. Keep tools sharp and clean for
best and safest performance. Follow
instructions for lubricating and changing
accessories.
(6). USE RECOMMENDED
ACCESSORIES. Consult the owner’s
manual for recommended accessories. The
use of improper accessories may cause
hazards.
(7). AVOID ACCIDENTAL STARTING.
Make sure switch is in “OFF” position before
plugging in power cord.
(8). DIRECTIONOF FEED. Feed work into
a blade or cutter against the direction of
rotation of the blade or cutter only.
(9). ADJUST AND POSITION the blade
guide arm before starting the cut.
(10). KEEP BLADE GUIDE ARM TIGHT,
A loose blade guide arm aill affect sawing
accuracy .
(11). MAKE SURE blade speed is set
correctly for material being cut.
(12). CHECK for proper blade size and type.
(13). STOP the machine before putting
material in the vise.
(14). ALWAYS have stock firmly clamped in
vise before starting cut.
(15). GROUNDALL TOOLS. If tool is
equipped with three-prong plug, it should be
plugged into a three-hole electrical receptacle.
If an adapter is used to accommodate
atwoprong receptacle, the adapter lug must be
attached to a known ground. Never removed
the third prong.
C. ADJUSTMENT :
MAKE all adjustments with the power off.
In order to obtain the machine. Precision and
correct ways of adjustment while assembling,
the user should read the detailed instruction in
this manual.
D. WORKING ENVIRONMENT:
(1). KEEP WORK AREA CLEAN.
Cluttered areas and benches invite accidents.
(2). DON’T USE IN DANGEROUS
ENVIRONMENT. Don’t use power tools in
damp or wet locations, or expose them to rain.
Keep work area well-lighted.
(3). KEEP CHILEREN AND VISITIORS
AWAY. All children and visitors should be
kept a safe distance from work area.
(4). DON’T install & use this machine in
explosive, dangerous environment.
E. MAINTENANCE:
(1). DISCONNECT machine from power
source when making repairs.
(2). CHECK DAMAGED PARTS. Before
further use of the tool, a guard or other part
that is damaged should be carefully checked
to ensure that it will operate properly and
perform its intended function check for
alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any
other conditions that may affect its operation.
A guard or other part that is damaged should

- -
5
be properly repaired or replaced.
(3). DISCONNECT TOOLS before
servicing and when changing accessories such
as blades, bits, cutters, etc.
(4). MAKE SURE that blade tension and
blade tacking are properly adjusted.
(5). RE-CHECK blade tension after initial
cut with a new blade.
(6). TO RPOLONG BLADE LIFE
ALWAYS release blade tension at the end of
each work day.
(7).CHECK COOLANT DAILY Low
coolant level can cause foaming and high
blade temperatures. Dirty or week coolant can
clog pump, cause crooked. Cust, low cutting
rate and permanent blade failure. Dirty
coolant can cause the growth of bacteria with
ensuing skin irritation.
(8). WHEN CUTTING MAGNESIUM
NEVER use soluble oils or
emulsions(oil-water mix) as water will greatly
intensify any accidental magnesium chip fire.
See your industrial coolant supplier for
specific coolant recommendations when
cutting magnesium.
(9). TO PRNMT corrosion of machined
surfaces when a soluble on is used as coolant,
pay particular attention to wiping dry the
surfaces where fluid accumulates and does not
evaporate quickly, such as between the
machine bed and vise.
F. SPECTIFIED USAGE:
This machine is used only for general metals
cutting within the range of cutting capacity.
G. NOISE:
A weighted sound pressure level : 80 Db.
H. SAFETY DEVICE:
Interlock switch on cutting area as soon as the
cover of cutting area is open, machine will
stop at once witch the function of this switch.
Do not remove this switch from machine for
any reason, and check it’s function frequently.
Your machine might not come with a power
socket or plug. Before using this machine,
please do ask your local dealer to install the
socket or plug on the power cable end.

- -
6
3 SPECIFICATION
MOTOR 5HP,,( 3Φ)
60Hz 32-96 MPM
105-315FPM
Saw Blade Speed 50Hz 26-80 MPM
85-262FPM
Blade Size(mm) 41 x 1.3 x 5890L
Dimension L x W x H (mm) 3000L x 1270W x 1730H
N.W / G.W (kgs) 1590 / 1800
Packing Measurement 2930L x 1140W x 1981H mm
○(mm/inch) 508 mm / 20”
□(mm/inch) 508 mm x 508 mm /20” x 20”
0°
□(mm/inch) 660 mm x 508 mm /26” x 20”
○(mm/inch) 508 mm / 20”
+ 45°□(mm/inch) 508 mm x 508 mm /20” x 20”
○(mm/inch) 380 mm / 15”
Cutting
Capacity
+ 60°□(mm/inch) 380 mm x 380 mm /15” x 15”
4 TRANSPORTATION OF MACHINE:
Unpacking
1. Transportation to desired location before unpacking, please use lifting jack.(Fig. B)
2. Transportation after unpacking, please use heavy duty fiber belt to lift up the machine.
Fig. B
ALLWAYS KEEP PROPER FOOTING & BALANCE WHILE MOVING THIS MACHINE.

- -
7
Installation:
As this machine weights 1320 kg. It is recommended that the machine shall be transported, with
help of lifting jack.
Transportation Recommendation:
(1). Tighten all locks before operation.
(2). ALWAYS Keep proper footing & balance while moving this machine.
(3). TURN OFF the power before wiring, & be sure machine in proper grounding, Overload &
circuit breaker is recommended for safety wiring.
(4). Tighten 4 bolts to base holes after machine in balance.
(5). CHECK carefully if the saw blade is running in counter-clock wise direction it not reverse
the wiring per circuit diagram then repeat the running test.
(6). KEEP machine always out from sun, dust, wet, raining area.
CLEAIG & LURICATING
(1) Your machine has been coated with a heavy grease to protect it in shipping. This coating
should be completely removed before operating the machine. Commercial degreaser, kerosene
or similar solvent may be used to remove the grease from the machine, but avoid getting
solvent on belts or other rubber parts.
(2) After cleaning, coat all bright work with a light lubricant. Lubricate all points in Fig 1. With
a medium consistency machine oil.
5 MINIMUM ROOM SPACE FOR MACHINE OPERATION

- -
8
6 MAKE PROPER TOOTH SELECTION
For maximum cutting efficiency and lowest cost per cut, it is important to select the blade with
the right number of teeth per inch (TPI) for the material being cut. The material size and shape
dictate tooth selection.
TOOTH
SELECTION
You need to consider:
The width of the cut. That is, the distance in the cut that each tooth must travel from the point it
enters the workpiece until it leaves the workpiece, and
1.The shape of the workpiece.
zSquares, Rectangles, Flats (Symbol : ■)
Locate the width of cut on the chart. (Inches on the outer circle and millimeters on the
inner circle.) Select the tooth pitch on the ring marked with the square shape which aligns
with the width of cut.
EXAMPLE: 6” (150mm) square, use a 2/3 Vari-Tooth.
zRound Sollds (Symbol : ●)
Locate the diameter of your workpiece on the chart. Select the tooth pitch on the ring
marked with the round shape which aligns with the size of stock you are cutting.
EXAMPLE: 4” (100mm) round, use a 3/4 Vari-Tooth.
zTubing, Pipe, Structurals( Symbol : O H ^ )
Determine the average width of cut by dividing the area of the workpiece by the distance
the saw blade must travel to finish the cut. Locate the average width of cut on the chart.
Select the tooth Ditch on the ring marked with the tubing and structural shape which
aligns with the average width you are cutting.

- -
9
EXAMPLE: 4”(100mm) outside diameter, 3”(75mm) inside diameter tubing.
4”(100mm) OD=12.5 sq.ln. (79cm2)
3”(75 mm ) ID = 7.0 sq.ln. (44cm2)
Area = 5.5 sq.ln. (35cm2)
5.5 sq.ln. (35cm2) / 4” (100mm) distance =1.38(35mm) average width
1.38” (35mm), use a 4/6 Vari-Tooth
NOTE: The band speed and cutting rate recommendations presented on this chart are
approximations and are to be used as a starting point for most applications. For exact
sawing parameters’ consult your saw blade supplier.
7 BI-METAL SPEEDS AND FEEDS
These figures are a guide to cutting 4”(100mm) material (with a 314 Vari-Tooth) when using a
cutting fluid.
Increase Band Speed: 15% When cutting 1/4”(6.4mm) material (l0/l4 Vari-Tooth)
12% When cutting 3/4”(19 mm) material (6/10 Vari-Tooth)
10% When cutting 1-1/4”(32 mm) material(5/8 Vari-Tooth)
5% When cutting 2-1/2” (64 mm) material(4/6 Vari-Tooth)
Decrease Band Speed: 12% When cutting 8”(200mm) material(2/3 Vari-Tooth)
BAND SPEEDMATERIAL ALLOY
ASTM NO. FT./MIN M/MIN
173,932 314 96
330,365 284 87
623,624 264 81
230,260,272 244 74
280,264,632,655 244 74
101,102,110,122,172 234 71
1751,182,220,510 234 71
625,706,715,934 234 71
630 229 70
Coppe
r
Alloy
811 214 65
1117 339 103
1137 289 88
1141,1144 279 85
Carbon
Steel
1141 HI STRESS 279 85