Thomas 275 SUPER CUT User manual

THOMAS
USE AND MAINTENANCE MANUAL
275 SUPER CUT
300 SUPER CUT
315 SUPER CUT

Distributed by:
Trick-Tools
80 Truman Road
Pella, IA 50219
Phone:1-877-VAN-SANT
E-mail: [e-mail]
Here at Trick Tools we believe that our customers deserve the best
value in their tool and equipment purchases. We are constantly at
work searching out a variety of high quality, high performance tools
to oer at the best prices possible. Our commitment to you is that
we will not oer “cheap junk” anywhere on our website. You, the
customer, help us to evaluate our products constantly and as soon as
an ongoing quality issue is uncovered we will correct it or disconnue
that product immediately. We hope to earn your connued trust.

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Guarantee
- The Company guarantees that the machine to which this manual refers has been designed and built to comply with safety regulations
and that it has been tested for functionality in the factory.
- The machine is guaranteed for 12 months: the guarantee does not cover the electric motors, electric components, pneumatic
components or any damage due to dropping or to bad machine management, the failure to observe maintenance standards or bad
handling by the operator.
- The buyer has only the right to replacement of the faulty parts, while transport and packing costs are at his expense.
- The serial number on the machine is a primary reference for the guarantee, for after-sales assistance and for identifying the machine
for any necessity.
7.1 - Disk head ................................................................" 8
7.2 - Vice ........................................................................." 8
7.3 - Cutting angle adjustment........................................" 9
7.4 - Changing the disk ..................................................." 9
7.5 - Changing the lubricating coolant pump .................." 9
CHAPTER 8
Routine and special maintenance .............................. " 9
8.1 - Daily maintenance .................................................." 9
8.2 - Weekly maintenance .............................................." 9
8.3 - Monthly maintenance ............................................." 9
8.4 - Six-monthly maintenance ......................................." 9
8.5 - Oils for lubricating coolant ......................................" 9
8.6 - Oil disposal ............................................................." 10
8.7 - Special maintenance .............................................." 10
CHAPTER 9
Material classification and choice of tool.................. " 10
9.1 - Definition of materials ............................................." 10
9.2 - Choosing the disk ..................................................." 10
9.3 - Teeth pitch .............................................................." 11
9.4 - Cutting and advance speed...................................." 11
9.5 - Running in the disk ................................................." 11
9.6 - Disk structure.........................................................." 11
9.7 - Type of disks..........................................................." 11
Tooth shape ..........................................................." 11
Tooth cutting angle ................................................" 11
9.7.1 - Table of recommended cutting parameters................. " 12
9.7.2 - Table of cutting speed according to disk diameter ....... " 12
CHAPTER 10
Machine components ................................................... " 13
10.1- List of spare parts .................................................." 13
CHAPTER 11
Wiring diagrams ........................................................... " 17
CHAPTER 12
Troubleshooting............................................................ " 19
12.1-Blade and cutting diagnosis...................................." 19
12.2-Electrical components diagnosis ............................" 21
CHAPTER 13
Noise tests..................................................................... " 21
CHAPTER 14
Optional ......................................................................... " 22
14.1 - Pneumatic vice ......................................................" 22
14.2 - Connection to the pneumatic system ..................." 22
Plates and labels .......................................................... " 22
Notes .............................................................................. " 23
Contents
Contents ........................................................................ " 2
Ordering spare parts .................................................... " 2
Guarantee ...................................................................... " 2
Machine certification and identification marking ....... " 3
CHAPTER 1
Reference to accident-prevention regulations........... " 4
1.1 - Advice for the operator............................................" 4
1.2 - Location of shields against accidental contact with
the tool ...................................................................." 4
1.3 - Electrical equipment according to European
Standard "CENELEC EN 60 204-1" (1992) ............" 4
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1" (1992) ..........................." 4
CHAPTER 2
Recommendations and advice for use ....................... " 4
2.1 - Recommendationsandadviceforusingthemachine .." 4
CHAPTER 3
Technical characteristics ............................................. " 5
3.1 - Table of cutting capacity and technical details ........" 5
CHAPTER 4
Machine dimensions -Transport - Installation
Dismantling ................................................................... " 6
4.1 - Machine dimensions ..............................................." 6
4.2 - Transport and handling of the machine.................." 6
4.3 - Minimum requirements for the premises
housing the machine .............................................." 6
4.4 - Anchoring the machine..........................................." 7
4.5 - Instructions for electrical connection ......................" 7
4.6 - Instructions for assembly of the loose parts and
accessories............................................................." 7
4.7 - Disactivating the machine......................................." 7
4.8 - Dismantling ............................................................." 7
CHAPTER 5
Machine functional parts ............................................. " 7
5.1 - Operating head......................................................." 7
5.2 - Vice ........................................................................." 7
5.3 - Bed.........................................................................." 8
CHAPTER 6
Description of the operating cycle ............................. " 8
6.1 - Starting up and cutting cycle .................................." 8
CHAPTER 7
Regulating the machine ............................................... " 8
Ordering spare parts
- When ordering spare parts you must state:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER
Without these references WE WILL NOT SUPPLY the spares. See point 10.1 - list spare parts -.

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(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)
Machinecertificationandidentificationmarking
MACHINE LABEL
SUPER CUT
SERIAL NUMBER
TYP
MODEL
YEAR OF MANUFACTURE
via Pasubio, 32 36033 ISOLA VIC. - ITALIA

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This machine has been built to comply with the national and
community accident-prevention regulations in force.
Improper use and/or tampering with the safety devices will
relieve the manufacturer of all responsibility.
1.1 - Advice for the operator
- Check that the voltage indicated on the plate, normally fixed
to the machine motor, is the same as the line voltage.
- Checkthe efficiencyof yourelectricsupplyand earthingsystem;
connect the power cable of the machine to the socket and the
earth lead (yellow-green in colour) to the earthing system.
- When the tool head is in rest position (raised), the toothed
disk must be stationary.
- It is forbidden to work on the machine without its shields (these
are all white, grey or blue in colour).
- Always disconnect the machine from the power socket before
changing the disk or carrying out any maintenance job, even
in the case of abnormal machine operation.
- It is forbidden to disconnect the “man present” device, known
more correctly in the EEC as the “safety switch with hold-
down action”.
- Always wear suitable eye protection.
- Never put your hands or arms into the cutting area while the
machine is operating.
- Do not shift the machine while it is cutting.
- Do not wear loose clothing with sleeves that are too long,
gloves that are too big, bracelets, chains or any other object
that could get caught in the machine during operation; tie back
long hair.
- Keep the area free of equipment, tools or any other object.
- Perform only one operation at a time and never have several
objects in your hands at the same time. Keep your hands as
clean as possible.
- All internal and/or internal operations, maintenance or repairs,
must be performed in a well-lit area or where there is sufficient
light from extra sources so as to avoid the risk of even slight
accidents.
1.2 - Location of shields against accidental
contact with the tool
- Green metal shield screwed onto the disk head.
- Self-regulating mobile blue plastic shield, fitted coaxially with
the fixed shield.
1.3 - Electrical equipment according to European
Standard"CENELEC EN 60 204-1" which as-
similates, with some integrating modifications,
the publication "IEC 204-1"
- The electrical equipment ensures protection against electric
shock as a result of direct or indirect contact. The active parts
ofthis equipmentare housed ina boxto which accessis limited
by screws that can only be removed with a special tool; the
parts are fed with alternating current at low voltage (24 V).
The equipment is protected against splashes of water and
1REFERENCETOACCIDENT-
PREVENTIONREGULATIONS
dust.
- Protection of the system against short circuits is ensured by
means of rapid fuses and earthing; in the event of motor
overload, protection is provided by a thermal probe.
- In the event of a power cut, the specific start-up button must
be reset.
- The machine has been tested in conformity with point 20 of
EN 60204.
1.4 - Emergencies according to European
Standard "CENELEC EN 60 204-1"
- In the event of incorrect operation or of danger conditions, the
machine may be stopped immediately by pressing the red
mushroom button.
NOTE: Resetting of machine operation after each emergency
stop is achieved by reactivating the specific restart
button.
RECOMMENDATIONS AND
ADVICE FOR USE
2.1 - Recommendations and advice for using the
machine
- The machine has been designed to cut metal building
materials, with different shapes and profiles, used in
workshops, turner’s shops and general mechanical structural
work.
- Only one operator is needed to use the machine.
- To obtain good running-in of the machine it is advisable to
start using it at intervals of about half an hour. This operation
shouldbe repeatedtwoor threetimes, after whichthe machine
may be used continuously.
- Before starting each cutting operation, ensure that the part is
firmlygripped inthevice andthat theend issuitablysupported.
- Do not use disks of a different size from those stated in the
machine specifications.
- If the disk gets stuck in the cut, release the running button
immediately, switch off the machine, open the vice slowly,
remove the part and check that the disk or its teeth are not
broken. If they are broken, change the tool.
- Before carrying out any repairs on the machine, consult the
dealer or apply to THOMAS.
2

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0° 90 75 100 x 65
45° DX - SX 80 70 80 x 60
0° 85 70 95 x 60
45° DX - SX 72 65 75 x 60
1050
1100 520 310
1000
1800 CON PIEDISTALLO
170
1080
1100
1800 CON PIEDISTALLO
TECHNICAL
CHARACTERISTICS
3.1 - Table of cutting capacity and technical details
3
275 SUPER CUT 300 SUPER CUT
2-speed three-phase electric motor KW 1,1 ÷ 1,5
1-speed single-phase electric motor KW 1,5
Max. electric absorption KW 1,55
Oil-bath reduction unit i34 : 1
Max. blade diameter mm 275
Min. blade diameter mm 250
Blade rotation speed rpm 41 ÷ 82
Vice opening mm 120
Machine Weight KG 123
Coolant liquid L 5
Working table height with base mm 980
2-speed three-phase electric motor KW 1,2 ÷ 1,6
1-speed single-phase electric motor KW 1,5
Max. electric absorption KW 1,55
Oil-bath reduction unit i34 : 1
Max. blade diameter mm 300
Min. blade diameter mm 250
Blade rotation speed rpm 41 ÷ 82
Vice opening mm 120
Machine Weight KG 125
Coolant liquid L 5
Working table height with base mm 980
520 310
1000
170

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0° 95 82 110 x 70
45° DX - SX 90 80 85 x 70
PEDESTAL PROFILE
SEC. A - A
M8
7055070
690
AA
445 185
630
12
MACHINE DIMENSIONS
TRANSPORT
INSTALLATION
DISMANTLING
4
520 310
1000
170
1100
1800 CON PIEDISTALLO
1080
315 SUPER CUT
4.1 - Transport and handling of the machine
If the machine has to be shifted in its own packing, use a fork-
lift truck or sling it with straps as illustrated.
4.2 - Minimum requirements for the premises
housing the machine
- Mainsvoltage andfrequency complyingwiththe machinemotor
characteristics.
- Environment temperature from -10 °C to +50 °C.
- Relative humidity not over 90%.
4.3 - Anchoring the machine
- Position the machine on a firm cement floor maintaining, at
the rear, a minimum distance of 800 mm from the wall;anchor
it to the ground as shown in the diagram, using screws and
expansion plugs or tie rods sunk in cement, ensuring that it is
sitting level.
2-speed three-phase electric motor KW 1,3 ÷ 1,9
1-speed single-phase electric motor KW 1,5
Max. electric absorption KW 1,95
Oil-bath reduction unit i34 : 1
Max. blade diameter mm 315
Min. blade diameter mm 250
Blade rotation speed rpm 41 ÷ 82
Vice opening mm 120
Machine Weight KG 128
Coolant liquid L 5
Working table height with base mm 980

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1) Cast iron or ferrous materials, composed of metal alone,
are secondary raw materials, so they may be taken to an
ironfoundry forre-smeltingafter havingremovedthe contents
(classified in point 3);
2) electrical components,including thecable andelectronicma-
terial(magnetic cards,etc.),fall withinthecategory ofmaterial
classified as being assimilable to urban waste according
to the laws of the European community, so they may be set
aside for collection by the public waste disposal service;
3) old mineral and synthetic and/or mixed oils, emulsified oils
and greases are special refuse, so they must be collected,
transported and subsequently disposed of by the old oil
disposal service.
NOTE: since standards and legislation concerning refuse in
generalis inastate ofcontinuousevolution andtherefore
subject to changes and variations, the user must keep
informed of the regulations in force at the time of
disposing of the machine tool, as these may differ from
those described above, which are to be considered as
a general guide line.
MACHINE FUNCTIONAL
PARTS
5.1 - Operating head
- Machine part composed of the parts that transmit movement
(motor, reduction unit), the lubricating coolant pump and the
electrical components.
5
5.2 - Vice
- System for gripping material during the cutting operation,
operated with handwheel and fast manual blocking lever.
It is provided with an anti-burr device for blocking the part that
is to be cut.
Fit the components supplied as indicated in the photo:
- part. 1 Screw the lever onto the head and fix it
- part. 2 Fit the bar holding rod
- part. 3 Fix the pedestal firmly onto the base ( optional )
- part. 4 Fit and align the roller carrying arm on the counter-
vice bench.
= L1
= L2
= PE
R = L1
S = L2
T = L3
PE = GND
4.4 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the
customermust fita suitable onefor hisownworking conditions:
1 - WIRING DIAGRAM FOR THREE-PHASE MACHINE -
SOCKET FOR A 16A PLUG
2 - WIRING DIAGRAM FOR THE SINGLE-PHASE SYSTEM
SOCKET FOR A 16A PLUG
4.5 - Instructions for assembly of the loose parts
and accessories
4.6 - Disactivating the machine
- If the sawing machine is to be out of use for a long period, it is
advisable to proceed as follows:
1) detach the plug from the electric supply panel
2) release the head return spring
3) empty the coolant tank
4) carefully clean and grease the machine
5) if necessary, cover the machine.
4.7 - Dismantling
(because of deterioration and/or obsolescence)
General rules
Ifthe machineis tobepermanently demolishedand/orscrapped,
divide the material to be disposed of according to type and
composition, as follows:

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5.3 - Bed
- Support structure for the OPERATING HEAD (rotating arm
forgradual cutting,with respectiveblocking system),theVICE,
the BAR STOP, the material support ROLLER and the housing
for the cutting coolant TANK.
5
4
6
7
6DESCRIPTION OF THE
OPERATING CYCLE
Before operating, all the main organs of the machine must
be set in optimum conditions (see the chapter on
“Regulating the machine”).
6.1 - Starting up and cutting cycle
3
7
1
2
- Ensure that the machine is not in emergency stop condition;
if it is, release the red mushroom button ( 1 ).
- Select the cutting speed on the switch ( 3 ):
position 1 = 41 rpm.
position 2 = 82 rpm.
- Press the start/reset button ( 2 ): its green light will go on.
- Place material to be cut in the vice ( 4 ). Close jaws against
piece, keeping a distance of approx. 3 - 4 mm then clamp
with lever.
- Grip the handle ( 6 ) of the HEAD control arm and press the
button, checking that the disk is turning in the direction
indicated (if not, invert the two phase leads):
and that sufficient coolant is coming out.
The cropper is now ready to start work, bearing in mind that the
CUTTING SPEED and the TYPE of DISC - combined with a
suitable descent of the head - are of decisive importance for
cutting quality and for machine performance (for further details
on this topic, see below in the chapter on “Material
classification and choice of disks”).
- When starting to cut with a new disk, in order to safeguard
its life and efficiency, the first two or three cuts must be
made while exerting a slight pressure on the part, so that
the time taken to cut is about double the normal time (see
below in the chapter on “Material classification and choice
of disks” in the section on
Running in the disk ).
- Pressthe redemergency button( 1 )when thereare conditions
of danger or malfunctions in general, so as to stop machine
operation immediately.
REGULATING
THE
MACHINE
7.1 - Disk head
- If excessive axial play is found on the hinge, it will be sufficient
to tighten the screws ( 7 ), paying attention not to make the
joint too tight.
7.2 - Vice
- The device does not require any particular adjustment.

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7.3 - Cutting angle adjustment
- Release lever ( 1 ), rotate the cutting head and make sure
thatthe wantedcuttingangle perfectlymeetswith thereference
index before locking with the lever ( 1 ).
BEFORE PERFORMING THE FOLLOWING OPERATIONS,
THE ELECTRIC POWER SUPPLY AND THE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.
7.4 - Changing the disk
To change the disk:
- Release the mobile yellow, white or orange guard and turn it back.
- Block a piece of wood in the vice and lean the disk on it.
- Insert the special spanner provided and remove the screw
( 1 ), slackening it in a clockwise direction because it has a
left-handed thread, then slip off the flange that holds the disk.
- Fit the new disk, checking the cutting direction of the teeth,
thenreplace theflange, thescrewand themobile white, yellow
or orange guard.
8ROUTINE
AND SPECIAL
MAINTENANCE
THEMAINTENANCEJOBS ARE LISTEDBELOW,DIVIDED
INTO DAILY, WEEKLY, MONTHLY AND SIX-MONTHLY
INTERVALS. IF THE FOLLOWING OPERATIONS ARE
NEGLECTED, THE RESULT WILL BE PREMATURE WEAR
OF THE MACHINE AND POOR PERFORMANCE.
8.1 - Daily maintenance
- General cleaning of the machine to remove accumulated
shavings.
- Top up the level of lubricating coolant.
- Check the disk for wear.
- Lift the head into a high position to avoid yield stress on the
return spring.
- Check functionality of the shields and emergency stops.
8.2 - Weekly maintenance
- More accurate general cleaning of the machine to remove
shavings, especially from the lubricant fluid tank.
- Clean the filter of the pump suction head and the suction
area.
- Clean and grease the screw and the sliding guide of the vice.
- Clean the disk housing.
- Sharpen the disk teeth.
8.3 - Monthly maintenance
- Check tightness of the screws on the motor, the pump, the
jaws and shields.
- Check that the shields are unbroken.
- Grease the head hinge pin.
8.4 - Six-monthly maintenance
- Change the oil in the reduction unit using oil type GEARCO
85W-140 by NATIONAL CHEMSERACH or MOBIL GLYCOLE
30 or KLUBER SINTHESO 460 EP or an equivalent oil,
proceeding as follows:
- Check continuity of the equipotential protection circuit
2
8.5 - Oils for lubricating coolant
Considering the vast range of products on the market, the user
can choose the one most suited to his own requirements, using
as reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER
IS 8 - 10 %.
7.5 - Changing the lubricating coolant pump
- Takes the pipes of the lubricating-refrigerating system off.
- Removethe fasteningscrewsand replacethelittle pump,being
careful to keep the driving stem centred on the drive shaft
bearing.
1
1- Removethe connectingplug
from the electric box and un-
screw the head moving
lever.
- Drain off the old oil from the
cap at the side ( 1 ).
- Pour in new oil up to the
mark ( 2 ), through the lever
fixinghole, keepingthe head
in a horizontal position.
- Reassemble all the parts.1

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9.1 - Definition of materials
The table at the foot of the page lists the characteristics of the
materials to be cut, so as to choose the right tool to use.
TYPES OF STEEL CHARACTERISTICS
USE I
UNI D DIN F AF NOR GB SB USA AISI-SAE Hardness
BRINELL
HB
Hardness
ROCKWELL
HRB R=N/mm2
Construction
steels Fe360
Fe430
Fe510
St37
St44
St52
E24
E28
E36
----
43
50
----
----
----
116
148
180
67
80
88
360÷480
430÷560
510÷660
Carbon
steels
C20
C40
C50
C60
CK20
CK40
CK50
CK60
XC20
XC42H1
----
XC55
060 A 20
060 A 40
----
060 A 62
1020
1040
1050
1060
198
198
202
202
93
93
94
94
540÷690
700÷840
760÷900
830÷980
Spring steels 50CrV4
60SiCr8 50CrV4 60SiCr7 50CV4 ---- 735 A 50 ---- 6150 9262 207 224 95 98 1140÷1330 1220÷1400
Alloyed steels for
hardening and
tempering and for
nitriding
35CrMo4
39NiCrMo4
41CrAlMo7
34CrMo4
36CrNiMo4
41CrAlMo7
35CD4
39NCD4
40CADG12
708 A 37
----
905 M 39
4135
9840
----
220
228
232
98
99
100
780÷930
880÷1080
930÷1130
Alloyed
casehardening
steels
18NiCrMo7
20NiCrMo2
----
21NiCrMo2
20NCD7
20NCD2
En 325
805 H 20
4320
4315
232
224
100
98
760÷1030
690÷980
Steel for
bearings 100Cr6 100Cr6 100C6 534 A 99 52100 207 95 690÷980
Tool steel 52NiCrMoKU
C100KU
X210Cr13KU
58SiMo8KU
56NiCrMoV7
C100W1
X210Cr12
----
----
----
Z200C12
Y60SC7
----
BS 1
BD2 - BD3
----
----
S-1
D6 - D3
S5
244
212
252
244
102
96
103
102
800÷1030
710÷980
820÷1060
800÷1030
Stainless
steel
X12Cr13
X5CrNi1810
X8CrNi1910
X8CrNiMo1713
4001
4301
----
4401
----
Z5CN18.09
----
Z6CDN17.12
----
304 C 12
----
316 S 16
410
304
----
316
202
202
202
202
94
94
94
94
670÷885
590÷685
540÷685
490÷685
Copper alloys
Special brass
Bronze
Aluminium copper alloy G-CuAl11Fe4Ni4 UNI 5275
Special manganese/silicon brass G-CuZn36Si1Pb1 UNI5038
Manganese bronze SAE43 - SAE430
Phosphor bronze G-CuSn12 UNI 7013/2a
220
140
120
100
98
77
69
56,5
620÷685
375÷440
320÷410
265÷314
Cast iron Gray pig iron G25
Spheroidal graphite cast iron GS600
Malleable cast iron W40-05
212
232
222
96
100
98
245
600
420
9.2 - Choosing the disk
First of all the pitch of the teeth must be chosen, suitable for the
material to be cut, according to these criteria:
- parts with a thin and/or variable section such as profiles, pipes
and plate, need close toothing, so that the number of teeth
used simultaneously in cutting is from 3 to 6;
- parts with large transverse sections and solid sections need
widely spaced toothing to allow for the greater volume of the
shavings and better tooth penetration;
- parts made of soft material or plastic (light alloys, mild bronze,
teflon, wood, etc.) also require widely spaced toothing.
MATERIAL
CLASSIFICATION AND
CHOICE OF TOOL
9
Sincethe aimis toobtainexcellent cuttingquality, thevarious
parameters such as hardness of the material, shape and
thickness, transverse cutting section of the part to be
cut, choice of the type of cutting disk, cutting speed and
con-trol of head descent,must besuitablycombined.These
spe-cifications must therefore be harmoniously combined
in a single operating condition according to practical consi-
dera-tions and common sense, so as to achieve an optimum
condi-tion that does not require countless operations to
prepare the machine when there are many variations in the
job to be performed.The various problems that crop up from
time to ti-me will be solved more easily if the operator has a
good know-ledge of these specifications.
WE THEREFORE ADVISE YOU ALWAYS TO CHOOSE
ORIGINAL SPARE DISKS THAT GUARANTEE SUPERIOR
QUALITY AND PERFORMANCE.
8.6 - Oil disposal
The disposal of these products is controlled by strict regulations.
Please see the Chapter on “Machine dimensions - Transport
- Installation” in the section on
Dismantling .
8.7 - Special maintenance
Special maintenance operations must be carried out by skilled
personnel. However, we advise contacting THOMAS or their
dealer and/or importer. The term special maintenance also
covers the resetting of protection and safety equipment and
devices.

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9.3 - Teeth pitch
As already stated, this depends on the following factors:
- hardness of the material
- dimensions of the section
- thickness of the wall.
Tooth shape
The profile of the toothing depends on the size, shape and
thickness of the section to be cut, either straight or at an angle.
It may also vary according to the pitch, but not so distinctly as
to make this an element for classification.
- Fine toothing is to be chosen for cutting small sections with a
profiled shape and tubular sections with thin walls (2-5 mm
depending on the material).
- Large toothing is suitable for cutting medium and large solid
sections or fairly thick profiled or tubular sections (over 5 mm).
"A" toothing:
normal fine toothing
S (MM) PICTH SHAPE SPEED
up to 2 4 - 6 B
shaped 2
2 ÷ 5 8C
solid 2
5 ÷ 10 8C
solid 1
over 10 8C
solid 1
up to 20 8C
solid 1
20 ÷ 50 10 C
solid 1
"AW" toothing:
finetoothing withalternate side
rake
Added toothing:
disks made in this way are
used for cutting non-ferrous
metals, such as light alloys,
and plastics, and above all in
wood-working. The teeth are
hardmetal (HM)plates brazed
ontothe bodyof thedisk;there
are various types and shapes
and, considering the vastness
of the field, the topic is not
developed further here.
The rake varies especially according to the type of material
to be cut.
Tooth cutting angle
Each tooth has two cutting angles:
- αα
αα
α: front rake angle
- γγ
γγ
γ: rear rake angle
SHARPENING CIRCULAR SAWS
T3 4 5 6 7 8 9 10 12 14 16
p1,3 1,6 2,1 2,5 2,9 3,4 3,8 4,2 5,1 5,9 7,2
d1,5 22,5 33,5 44,5 5 6 7 8
h = 0,2 mm h = 0,3 mm
SS
S
αα
αα
α
γγ
γγ
γ
"B" toothing:
normal large toothing with or
without shaving breaking inci-
sion
"BW" toothing:
large toothing with alternate
side rake
“C (HZ)” toothing:
large toothing with roughing
tooth with rake on both sides,
alternating with a finishing
tooth without rake. The rou-
ghing tooth is 0.15-0.30 mm
higher
9.7 - Type of disks
The disks differ essentially in their constructive characteristics,
such as:
- Tooth shape
- Tooth cutting angle
9.4 - Cutting and advance speed
The cutting speed (m/min) and the advance speed (cm2/min =
area travelled by the disk teeth when removing shavings) are
limited by the development of heat close to the tips of the teeth.
- The cutting speed is subordinate to the resistance of the
material (R = N/mm2), to its hardness (HRC) and to the
dimensions of the widest section.
- Too high an advance speed (= disk descent) tends to cause
the disk to deviate from the ideal cutting path, producing non
rectilinear cuts on both the vertical and the horizontal plane.
9.5 - Running in the disk
When cutting for the first time, it is good practice to run in
the tool making a series of cuts at a low advance speed
(=30-35 cm2/minonmaterial ofaverage dimensions withrespect
to the cutting capacity and solid section of normal steel with
R = 410-510 N/mm2), generously spraying the cutting area
with lubricating coolant.
9.6 - Disk structure
The most commonly used disks are made of extra high speed
steel (HHS) of normal quality (HHS/DMo5) or superior quality
(HHS/Mo5 + Co5) with a treated tooth, which differentiates them
from the former on account of the high value of structural
resistance, greater resistance to seizing, absence of stress in
the mass and a better holding of lubricating coolant during work.

12
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SUPER CUT
9.7.2 - DIAGRAM OF CUTTING SPEEDS ACCORDING TO DISK DIAMETER
9.7.1 - RECOMMENDED CUTTING PARAMETERS
SECTION TO BE CUT (IN MM)
*T mm
Vt m/1'
*T mm
Av mm/1'
Vt m/1'
Av mm/1'
*T mm
Vt m/1'
Av mm/1'
Av mm/1'
*T mm
Vt m/1'
*T mm
Av mm/1'
Vt m/1'
*T mm
Vt m/1'
Av mm/1'
Av mm/1'
Vt m/1'
*T mm
Mild steel R = 350-500 N/mm2
Aluminium and alloys R = 300-300 N/mm2 Tubes and beams 0,025.D R = 300-600 N/mm2 Brass R = 200-400 N/mm2 Titanium and alloys R = 300-800 N/mm2 Tubes and beams 0,05. D R = 300-600 N/mm2 Alloyed brass R = 400-700 N/mm2
KEY
T Tooth pitch in millimetres
Av mm/min Advance in millimetres per minute
Vt m/min Cutting speed in metres per minute
Az Tooth advance
Ng/min Number of revs per minute
Z Number of teeth on the disk
p Tooth depth
Heat-treated steel R = 950-1300 N/mm2
Extra-hard steel R = 950-1000 N/mm2 Hard steel R = 750-950 N/mm2
Semi-hard steel R = 500-700 N/mm2 Grey cast iron Aluminium and alloys R = 200-400 N/mm2 Copper R = 200-350 N/mm2 Phosphor bronze R = 400-600 N/mm2 Hard bronze R = 600-900 N/mm2
Vt m/min
n = g/min
d Diameter of the tooth fillet cone distance
h Tooth protrusion
γFront rake
αRear rake
N/mm Ultimate tensile stress
a-f Flat parts of the cutting edge
Ø Tube diameter or profile width
Austentic stainless steel R = 500-800 N/mm2 Martensiticstainless steel R = 500-800 N/mm2
CUTTING ANGLES
RECOMMENDED LUBRIFICANTS Emulsion - Cutting oil Dry Kerosene
Dry Emulsion Cutting oil Emulsion

13
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SUPER CUT
10 MACHINE COMPONENTS
10.1 - List of spare parts
REFERENCE N° DESCRIPTION REFERENCE N° DESCRIPTION
38 Burr-free plate
39 Grain M8
40 Screw M8
41 Tank filter
42 Screw M6
43 Bar stop rod
44
45
46 Bar stop
48 Screw M8
49 Support tank cover
50 Ring seeger Ø 42 I
51 Tank cover filter
52 Tank cover filter
53 Tank cover
54 Washer
55 1/4" gas tap
56 Coolant tube
57 Oiler Ø 8
58 Return spring connection
59 Head return spring
60 Nut M12
61 Screw M12
62 Head
63 plug
64 Oil level plug
65 Oil drain plug
66 Screw M10
67 Hinge pin
68 Hinge pin washer
69 Hinge pin bush
70 Grain M8
71 Nut M8
72 Nut M16
73 Head lever
74 Head lever handgrip
75 GUK ring nut M25x1,5
76 Worm wheel
1 Machine bed
2 Revolving arm
3 Revolving arm locking pin
4 Revolving arm locking bush
5 Revolving arm locking lever
6 Screw M8
7 Countervice
8 Pin
9 Countervice jaws
10 Burr-free jaws
11 Countervice fixing pin
12 Roller arm
13 Roller
14 Washer M10
15 Vite M10
16
17 Vice
18 Vice jaws
19 Vice jaws washer
20 Screw M12
21 Vice jaws washer
22 Screw M12
23 Grain M8
24 Lever bush
25 Quick lock vice lever
26 Thrust bearing AX 3047
+ CP 3047
27 Quick lock vice lever washer
28 Vice closing handwheel Ø 18
29 Elastic pin Ø 5
30 Washer
31 Screw M8
32
33
34
35 Vice thread
36 Lock vice spring
37 Burr-free transverse plate

14
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N° RIFERIMENTO DENOMINAZIONE
REFERENCE N° DESCRIPTION
N° RIFERIMENTO DENOMINAZIONE
REFERENCE N° DESCRIPTION REFERENCE N° DESCRIPTION
REFERENCE N° DESCRIPTION
77 Ring SM 35-47-7
78 Blade shaft
79 Pin
80 Blade
81 Shaft flange stakes
82 Screw M12
83 Fixed blade guard
84
85
86 Coolant distributor
87 Coolant tube
88 Grain M6
89 Mobile blade guard
90 Ring seeger Ø 60E
91
92
93 Tir rod support
94 Washer
95 Screw M8
96 Mobile guard rod
97 Screw M8
98 Washer
99 Bearing 6301
100 GUK ring nut M17x1
101 Worm screw
102 Spacer
103 Spacer Ø 47
104 Bearing 3204
105 Ring DPSM 25-40-7
106 Head gasket
107 Front motor flange
108 Motor shaft (rotor)
109 Key
110 Washer
111 Stud bolt
112 Nut
113 Motor and stator casing
114
115
116 Rear motor flange
117
118
119 Bearing 6205 2Z
120 Ring seeger Ø 25E
121 Fan
122 Screw M4
123 Fan cover
124 Bearing 609
125 Pump connection box
126
127 Screw M5
128 Coolant pump
129 Washer
130 Screw M6

15
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SUPER CUTSUPER CUT
SUPER CUT

16
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SUPER CUTSUPER CUT
SUPER CUT
LEGENDA
146 Speed switch
147 Reset button
148 Emergency push button
149 Electric components box
LEGENDA
140 Auxiliary relay
141 Remore control switch
142 Fuse carrier
143 Transformer
144 Socket connector
145 Plug connector
142
146 147
148
149
140
143
141
144
145

17
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SUPER CUT
11 WIRING DIAGRAMS
V 230/50 Hz
CIRCUIT DIAGRAM
SINGLE-PHASE
THOMAS
THOMAS

18
SUPER CUTSUPER CUT
SUPER CUTSUPER CUT
SUPER CUT
V 400 / 50 Hz
CIRCUIT DIAGRAM
THREE-PHASES

19
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SUPER CUTSUPER CUT
SUPER CUT
PREMATURE DISK WEAR Wrong running in of the disk
Wrong cutting speed
Unsuitable tooth profile
Wrong tooth pitch
Low quality disk
Insufficient lubricating refrigerant
TROUBLESHOOTING
This chapter lists the probable faults and malfunctions that could occur while the machine is being used and suggests possible
remedies for solving them.
The first paragraph provides diagnosis for TOOLS and CUTS, the second for ELECTRICAL COMPONENTS.
12.1 - Blade and cut diagnosis
12
FAULT PROBABLE CAUSE REMEDY
TOOTH BREAKAGE Too fast advance
Wrong cutting speed
Wrong tooth pitch
Low quality disk
Ineffective gripping of the part in the
vice.
Previously broken tooth left in the cut
Cutting resumed on a groove made
previously.
Insufficient lubricating refrigerant or
wrong emulsion
Sticky accumulation of material on
the disk.
Decrease advance, exerting less cutting
pressure
Change disk speed and/or diameter.
See Chapter
“ Material classification
and choice of disks” and the Table of
cuttingspeeds accordingto diskdiameter.
Choose a suitable disk.
See Chapter “Material classification
and choice of disks”.
Use a better quality disk.
Check the gripping of the part.
Accurately remove all the parts left in.
Make the cut elsewhere, turning the part.
Check the level of the liquid in the tank.
Increasethe flowof lubricatingrefrigerant,
checkingthat thehole andthe liquidoutlet
pipe are not blocked.
Checkthe blendof lubricatingcoolantand
choose a better quality disk.
See Chapter “Material classification
and choice of disks”
in the paragraph
on Running in the disk.
Change disk speed and/or diameter.
See Chapter “Material classification
and choice of disks” and the
Table of
cuttingspeeds accordingto diskdiameter.
Choose a suitable disk. See Chapter
“Material classification and choice of
disks”in the paragraph on
Type of disks.
Choose a suitable disk.
See Chapter “Material classification
and choice of disks”.
Use a better quality disk.
Check the level of the liquid in the tank.
Increasethe flowof lubricatingrefrigerant,
checkingthat thehole andthe liquidoutlet
pipe are not blocked.
CHIPPED DISK Hardness, shape or flaws in the mate-
rial (oxides, inclusions, lack of homo-
geneity, etc..)
Wrong cutting speed
Wrong tooth pitch
Vibrations
Disk incorrectly sharpened
Low quality disk
Reduce the cutting pressure and/or the
advance.
Change disk speed and/or diameter. See
Chapter “Material classification and
choice of disks” and the
Table of
cutting speeds according to disk
diameter.
Choose a suitable disk.
See Chapter “Material classification
and choice of disks”.
Check gripping of the part.
Replace the disk with one that is more
suitable and correctly sharpened.
Use a better quality disk.