Thomas TRAD 300 AO GT User manual

USE AND MAINTENANCE MANUAL
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34
THOMAS
10/2004
TRAD 300 AO GT

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CHAPTER 7
Regulating the machine ............................................... " 10
7.1 - Blade tension assembly........................................." 10
7.2 - Blade guide blocks................................................." 11
7.3 - Fixed vice..............................................................." 11
7.4 - Feed unit vice ........................................................" 11
7.5 - Sawframe return ...................................................." 11
7.6 - Cutting length ........................................................" 12
7.7 - Changing the blade ..............................................." 12
7.8 - Replacing saw frame return spring ......................." 12
CHAPTER 8
Routine and special maintenance .............................. " 13
8.1 - Daily maintenance ................................................." 13
8.2 - Weekly maintenance ............................................." 13
8.3 - Monthly maintenance ............................................" 13
8.4 - Six-monthly maintenance ......................................" 13
8.5 - Oils for lubricating coolant ....................................." 13
8.6 - Oil disposal ............................................................" 13
8.7 - Special maintenance ............................................." 13
CHAPTER 9
Material classification and choice of tool.................. " 14
9.1 - Definition of materials............................................" 14
9.2 - Selecting blade ......................................................" 14
9.3 - Teeth pitch ............................................................." 14
9.4 - Cutting and advance speed..................................." 15
9.5 - Blade running-in ...................................................." 15
9.6 - Blade structure ......................................................" 15
9.7 - Blade type.............................................................." 15
Shape and angle of tooth ......................................" 15
Set ........................................................................." 16
9.7.1 - Table of recommended cutting parameters................. " 16
CHAPTER 10
Machine components ................................................... " 17
10.1- List of spare parts.................................................." 17
CHAPTER 11
Three-phase electric diagram ..................................... " 23
Hydraulic electric diagram .......................................... " 28
CHAPTER 12
Troubleshooting ............................................................ " 29
12.1- Blade and cut diagnosis ........................................" 29
12.2- Electrical components diagnosis ..........................." 33
CHAPTER 13
Noise tests..................................................................... " 36
Plates and labels .......................................................... " 37
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" ......................." 5
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1" ......................................." 5
CHAPTER 2
Recommendations and advice for use....................... " 5
2.1 - Recommendations and advice for using the machine ." 5
CHAPTER 3
Technical characteristics............................................. " 6
3.1 - Table of cutting capacity and technical details ......." 6
CHAPTER 4
Machine dimensions - Transport - Installation
Dismantling ................................................................... " 6
4.1 - Machine dimensions ............................................... " 6
4.2 - Transport and handling of the machine.................." 7
4.3 - Minimum requirements for the premises
housing the machine .............................................." 7
4.4 - Anchoring the machine..........................................." 7
4.5 - Instructions for electrical connection ......................" 7
4.6 - Instructions for assembly of the loose parts and
accessories............................................................." 8
4.7 - Disactivating the machine......................................." 8
4.8 - Dismantling ............................................................." 8
CHAPTER 5
Machine functional parts ............................................. " 8
5.1 - Operating head or saw frame................................." 8
5.2 - Vice ........................................................................." 8
5.3 - Material advance unit ............................................." 8
5.4 - Bed.........................................................................." 9
CHAPTER 6
Description of the operating cycle ............................. " 9
6.1 - Starting up and cutting cycle .................................." 9
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 of spare parts -
Guarantee
- The Company guarantees that the machine, described in this manual, has been designed to meet safety requirements. As for
machine functionality, inspection has been successful.
- 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.

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(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)
Machine certification and identification marking
MACHINE LABEL
via Pasubio, 32 36033 ISOLA VIC. - ITALIA
MODEL
TYP
SERIAL NUMBER
YEAR OF MANUFACTURE
TRAD 300 AO GT

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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.
- Check the efficiency of your electric supply and earthing system; connect the power cable of the machine to the socket and the
earth lead (yellow-green in colour) to the earthing system.
- When the saw frame is in suspend mode (up) the toothed blade must not move.
- Only the blade section used for cutting must be kept unprotected. Remove guarding by operating on the adjustable head.
- It is forbidden to work on the machine without its shields (these are all white, blue or grey in colour).
- Do not use any artful system or device (for ex. shim) to prevent the vice from locking the workpiece. Do not hold the workpiece with
your hand during the cutting process.
- Do not charge the workpiece from the right to the left-hand side with respect of the machine front.
- Always disconnect the machine from the power socket before blade change or carrying out any maintenance job, even in the case
of abnormal machine operation.
- Always wear suitable eye protection.
- Never put your hands or arms into the cutting area while the machine is operating.
- 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
- Blue, grey right and left hand metal shields, fastened with screws onto the guide blade stationary head ( RIF. A ).
- Metal guard blue or grey fastened on the front with screws to the blade guide fixed head ( Rif. A ).
- Blue or grey metal shield fastened with screws onto the blade guide adjustable head, ensures covering of blade section not used in
cutting operation ( RIF. B ).
- Metal guard white or grey fastened to the saw frame to protect blade drive flywheels ( RIF. C ).
- Blue front metal guard ( RIF. D ).
- Blue rear metal guard ( RIF. E ).
REFERENCETO ACCIDENT - PREVENTION REGULATIONS
1
AB
C
D
E

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1.3 - Electrical equipment according to Euro-pean Standard "CENELEC EN 60 204-1" which
assimilates, 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 of this
equipment are housed in a box to which access is limited by screws that can only be removed with a special tool;the parts are fed
with alternating current (24 V). The equipment is protected against splashes of water and 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 relay.
- In case of power failure or removal of the flywheel guard, 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.
- The accidental or willingly removal of the guard protecting the flywheels or the stock feed unit will cause the stepping in of the
microswitch that actuates all the machine functions.
- In case blade breaks, the band tightening microswitch disconnects all machine.
NOTE:Resetting of machine operation after each emergency stop is achieved by reactivating the specific restart button.
1.5 - Other risks
- As the machine is running, any intervention from the operator within the “dangerous zone” or cutting area must be considered a
risk for his own safety.
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, that must stand as shown in the picture.
- Before starting each cutting operation, ensure that the part is firmly gripped in the vice and that the end is suitably supported.
These figures show examples of suitable clamping of different section bars, bearing in mind the cutting capacities of the machine
in order to achieve a good efficiency and blade durability.
- Do not use blades of a different size from those stated in the machine specifications.
- If the blade does not cut through the material, immediately strike the emergency push-button and switch off the machine. Open
the vice with the handwheel, remove part to be cut ad check that the blade teeth are not broken, If they are, replace tool.
- Check saw frame return spring to ensure proper balancing.
- Before carrying out any repairs on the machine, consult the dealer or apply to THOMAS.
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TECHNICAL
CHARACTERISTICS
3.1 -Table of cutting capacity and technical details
3MACHINE DIMENSIONS
TRANSPORT
INSTALLATION
DISMANTLING
4.1 - Machine dimensions
4
2135
1800
1850

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4.2 - 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 through the special attachments as
indicated by the arrow.
4.3 - Minimum requirements for the premises
housing the machine
- Mains voltage and frequency complying with the machine
motor characteristics.
- Environment temperature from -10 °C to +50 °C.
- Relative humidity not over 90%.
4.4 - Anchoring the machine
- Position the machine on a firm cement floor, maintaining, at
the rear, a minimum distance of 1000 mm from the wall; an-
chor 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.
4.5 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the cus-
tomer must fit a suitable one for his own working conditions:
1 - WIRING DIAGRAM FOR 4-WIRE SYSTEM FOR THREE-
PHASE MACHINE - SOCKET FOR A 20A PLUG
R = L1
S = L2
T = L3
PE = GND
570
1200
POSIZIONE
OPERATORE
P. COMANDI
3000
3000
DIREZIONE
CARICO MATERIALE
Area di operatività della
segatrice

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4.6 - Instructions for assembly of the loose parts
and accessories
MACHINE FUNCTIONAL
PARTS
5.1 - Operating head or saw frame
- Part of the machine consisting of drive members (gearmotor
orvariablespeed motor,flywheels), tighteningandguide (blade
tightening slide, blade guide head) of tool.
5
Fit the components supplied as indicated in the photo:
- Mount the guard protecting the bar feed cylinder.
4.7 - 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)loosen blade
3)release the arch return spring
4)empty the coolant tank
5)carefully clean and grease the machine
6)if necessary, cover the machine.
4.8 - Dismantling
(because of deterioration and/or obsolescence)
General rules
Ifthe machineisto bepermanentlydemolished and/orscrapped,
divide the material to be disposed of according to type and com-
position, as follows:
1)cast iron or ferrous materials, composed of metal alone, are
secondary raw materials, so they may be taken to an iron
foundry for remelting after having removed the contents (clas-
sified in point 3);
2)electrical components, including the cable and electronic ma-
terial (magnetic cards, etc.), fall within the category of mate-
rial classified as being assimilable to urban waste accord-
ing 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 dis-
posal service.
NOTE: since standardsand legislationconcerningrefusein gen-
eral is in a state of continuous evolution and therefore
subject to changes and variations, the user must keep
informed of the regulations in force at the time of dis-
posing of the machine tool, as these may differ from
those described above, which are to be considered as
a general guide line. 5.3 - Material advance unit
- Oleodynamic device for material advance.
5.2 - Vice
- Material clamping system during the cutting operation by
means of an approach handwheel and hydraulic clamping.

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5.4 - Bed
- Structure supporting the SAW FRAME OPERATING HEAD ,
ofthe STOCKFEEDDEVICE, the bedplate houses the cooling
liquidTANK, the CONTROL BOARD, ELECTRICAL PART and
the DEVICE CONTROLLINGTHE AUTOMATIC HYDRAULIC
LOWERING AND RISE OF THE SAW FRAME.
DESCRIPTION OFTHE
OPERATING CYCLE
Before operating, all the main organs of the machine must
be set in optimum conditions (see the chapter on “Regulat-
ing the machine”).
6.1 - Starting up and cutting cycle
- Ensure that the machine is not in emergency stop condition; if
it is, release the red mushroom button ( 1 ).
- Check that the protection devices (guard protecting the fly-
wheels and guard protecting the stock feed unit) are actu-
ated.
- Rotate blade tightening handwheel ( A pag. 10 ) clockwise
until you press the relative microswith ( B pag. 10 ).
- Rotate the main switch ( 3 ) to position 1, press the push
button ( 5 ) and check that the relative green indicator light is
lit.
- MAKE SURE that the hydraulic regulator ( 2 ) is completely
closed to the position 0 ( zero ).
- For starting up the machine refer to the separate instruction
manual on Programming the control unit ( para. 1.1 - page 4);
6
- Check that the pressure gauge, located on the hydraulic unit
reads 28 BAR, if it doesn’t attempt to swap one of the electric
power supply wires (only during installation).
- Adjust the starting position of the saw frame according to the
dimensions of the part to be cut: the blade must be positioned
at about 10 mm from the piece (see chapter 7 paragraph
7.5 ).
- On the standard model, select the cutting speed on commu-
tator ( 4 ):
Position 1 = 33 m/min.
Position 2 = 66 m/min.
- If the machine is equipped with an electronic speed variator
( inverter ), select the most suitable speed according to the
specifications of the workpiece.
N.B.: After switching on the machine through the main switch
and starting the hydraulic pump motor, wait 10 seconds before
starting the cutting cycle.
- see PROGRAMM MANUAL FOR " NC " AUTOMATIC
BANDSAWING MACHINES givingdetailedinstructions onthe
cutting cycle programming.
1
1 2
1
4
3
5
2
Keep away at safety distance from the cutting area as the
machine is running.

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The band saw is now ready to start work, bearing in mind that
the CUTTING SPEED and theTYPE of BLADE - combined with
a suitable lowering of saw frame - are of decisive importance
for cutting quality and for machine performance (for further de-
tails on this topic, see below in the chapter on “Material classi-
fication and blade selection”).
- When starting to cut with a new blade, in order to safe-
guard 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 blade selection” in the section on
Blade running-in ).
- Press the red emergency button ( 1 ) when there are condi-
tions of danger or malfunctions in general, so as to stop ma-
chine operation immediately.
- To reset the machine operation disengage and then engage
the main switch ( 3 ).
A
REGULATING
THE MACHINE
7.1 - Blade tension assembly
The ideal tightening of the blade is achieved by rotating the
blade tightening handwheel ( A ) clockwise until you press the
microswith ( B ).
Note: In case the saw is not used for a period of time, loosen
blade.
Always use blades having the dimensions specified in this
manual.
7
B
28 BAR
CUTTING DIRECTION
CUTTING SPEED VARIATOR ( OPTION )
- To adjust the blade speed rotation at the requested rate
(metersper minute), turn the handwheel located on the control
panel. Each position corresponds to the speed indicated on
the table below:
POSIZIONE
VOLANTINO VELOCITA' m/ 1'
018
123
232
340
450
558
667
777
886
997
10 100

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- This device does not require any special maintenance; keep
vice adjustment screw well greased and perfectly clean.
To adjust proceed as follows:
- Place the part to be cut in cutting position but avoid sudden
contacts with the supporting rollers and adjust the opening of
the fixed vice at 3-4 mm from the part.
- Place the part to be cut in the vice and clamp the part into
place by striking the relative function key ( on the keyboard ).
- Make sure that the bar is resting on the vertical alignment
roller.
- Rotate the handwheel of the carriage vice ( D ) in order to
move the jaw at abt 0.5 - 0.7 mm from the material to be cut.
- Lock the handgrip ( E ).
Note: Maximum performance of the sawing machine is
achieved with material featuring good linearity.
7.3 - Bench vice
- Approach the vice jaw up to 3 - 4 mm from the material to cut.
- Adjust the outfeed conveyor according to the dimensions of
the material being cut (allow 1-2 mm gap).
NOTE: keep clean the vice guide as well as the relevant vice
screw.
7.4 - Feed vice unit
D
E
7.2 - Blade guide blocks
The blade is guided by means of adjustable pads set in place
during inspection as per the thickness of the blade with mini-
mum play as shown in the figure.
In case the blade needs to be replaced, make sure to always
install 0,9 mm thick blades for which the blade guide pads have
been adjusted.In the case of toothed blades with different thick-
nesses adjustment should be carried out as follows:
- Loosen nut ( C ), screw ( B ) and loosen dowel ( D ) widening
the passage between the pads.
- Loosen the nuts ( H ) and the dowels ( I ) and rotate the
pins ( E - G ) to widen the passage between the bearings ( F
).
- Mount the new blade, place the pad ( A ) on the blade and,
loosening the dowel, allow a play of 0,04 mm for the sliding of
the toothed blade; lock the relative nut and screw ( B ):
- Rotate the pins ( E - G ) until the bearings rest against the
blade as indicated in the figure and then secure the dowels (
I ) and nut ( H ).
- Make sure that between the blade and the upper teeth of the
block ( L ) this is at least 0,2 - 0,3 mm of play; if necessary,
loosen the screws that fasten the blocks and adjust accord-
ingly.
☞☞

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7.7 - Changing the blade
- Lift the saw frame in upmost position.
- Loosen the blade with the handwheel, open the guard pro-
tecting the flywheels and remove the movable guard, with-
draw the old worn out blade from the flywheels and from the
blade guide heads.
- Assemble the new blade by placing it first between the bear-
ings and then on the races of the flywheels, paying particular
attention to the cutting direction of the teeth (
blade rotation
diagram page 10).
- Tighten blade and make sure that it perfectly suits inside the
flywheel races and that it actuates the relative microswitch.
- Reinstall the mobile guard, close the guard protecting the fly-
wheels and fasten with the relative clips; check that the safety
microswitch is energized or else when the electric system is
restored the machine will not start.
WARNING: always assemble blades having dimensions speci-
fied in this manual and for which the blade guide heads have be
set: otherwise, see chapter on “Regulating the machine” in
the section on
Blade guide heads.
7.8 - Replacing saw frame return spring
- When performing this operation it is necessary to keep saw
frame up using the lifting device.
- Replace the spring by loosening the upper coupling rod and
releasing it from the lower tie-rod.
BEFORE PERFORMING THE FOLLOWING OPERATIONS,
THE ELECTRIC POWER SUPPLY ANDTHE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.
7.5 - Sawframe return
This system reduces the passive phases of the operating cycle,
in other words to eliminate the idle stroke that takes place when
the size of the material to be cut is much smaller than the
maximumcutting capacity.Practically,youcan adjust the starting
position of the blade in proximity of the material to cut.
- Set the machine in the MANUAL mode;
- Slightly open the regulator controlling the sawframe downfeed.
- Release the handle ( A ).
- Set the cutting speed switch to position '0' (zero).
- By means of the UP and DOWN keys ( K5 - K6 ), approach the
blade up to 10 mm from the material to cut.
- Lock the handle ( A ).
A
This is a mechanical system to set the cutting length.
The display indicates the value where the system must be
adjusted to. This value includes the blade thickness.
Move the feeding system to the extreme right against the bench
vice.Release the handle ( B ) and turn the handwheel ( C ) to
set the cutting length. The counter allows 0,1 mm precision.
Eventually, lock the handle ( B ).
If the cutting length is beyond the mechanical stroke of the
feeding system (500mm), the controller will calculate the length
to be set automatically. In fact, the display will show the value
where the system must be adjusted to and repeat the material
feeding automatically to reach the programmed cutting length.
7.6 - Cutting length
C
B
LENGTH TO SET
AUTOMATICO PGR: 01/50
L = _____ P = _____/ ____
Battuta L = _____mm
+ - RES

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- Check that the blade guide bearings on the heads are perfect
running condition.
- Check the tightening of the screws of the gearmotor, pump
and accident protection guarding.
- Check shields.
8.4 - Six-monthly maintenance
(every 2000 hours)
REDUCTION UNIT
- The worm drive gear box mounted on the machine is mainte-
nance-free guaranteed by its manufacture.
SPEED REDUCER (optional) as per manufacturer's instruc-
tions.
- Replace grease with IP ATINA 0 long life fluid for gears or
ESSO FIBER - GREASE 370, or againTOTAL CALIDRIS 0 or
similar. Moreover, grease bearings with DIN 51825 K-P-F2K
“extreme pressure grease” through the plug.
- Replace oil in the hydraulic unit with SHELL HYDRAULIC OIL
32 or MOBIL DTE 13 or again AGIP OSO 32 or similar.
- Check continuity of the equipotential protection circuit.
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 MINI-
MUM PERCENTAGE OF OIL DILUTED INWATER IS 8 - 10 %.
8.6 - Oil disposal
The disposal of these products is controlled by strict regula-
tions. 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. Also the reset of protective and safety
equipment and devices, of the reducer, the motor, the motor
pump and electric components is to be considered extraordi-
nary maintenance.
RELY ON SKILLED AND QUALIFIED PERSONNEL TO RE-
PLACE OTHER MACHINE MEMBERS SUCH AS REDUCTION
UNIT OR VARIATOR, PUMP MOTOR AND ELECTRICAL
COMPONENTS.
ROUTINE
AND SPECIAL
MAINTENANCE
THEMAINTENANCE JOBS ARELISTED BELOW,DIVIDED
INTO DAILY, WEEKLY, MONTHLY AND SIX-MONTHLY IN-
TERVALS. IF THE FOLLOWING OPERATIONS ARE NE-
GLECTED, THE RESULT WILL BE PREMATURE WEAR
OF THE MACHINE AND POOR PERFORMANCE.
8.1 - Daily maintenance
- Generalcleaning of the machineto remove accumulated shav-
ings.
- Clean the lubricating coolant drain hole to avoid excess fluid.
- Top up the level of lubricating coolant.
- Check blade for wear.
- Rise of saw frame to top position and partial slackening of the
blade to avoid useless yield stress.
- 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.
- Removal of pump from its housing, cleaning of the suction
filter and suction zone.
- Cleaning and greasing of the screws and of the slide guides
of the fixed vice and of the carriage.
- Cleaning with compressed air the blade guide bearings (drain
hole of the lubricating cooling).
- Cleaning flywheel housings and blade sliding surfaces on fly-
wheels.
- Cleaning and greasing of the stock feed carriage guide rods.
8.3 - Monthly maintenance
- Check the tightening of the motor flywheel screws.
- Check the tightening of the transmission flywheel ring nut.
8

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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
Alloyed for
bearings 100Cr6 100Cr6 100C6 534 A 99 52100 207 95 690÷980
Tool steel 52NiCrMoKU
C100KU
X210Cr13KU
58SiMo8KU
56NiCrMoV7C100K
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
steels
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
MATERIAL
CLASSIFICATION AND
CHOICE OF TOOL
9
Since the aim is to obtain excellent cutting quality, the vari-
ous parameters such as hardness of the material, shape
and thickness, transverse cutting section of the part to
be cut, selection of the type of cutting blade, cutting
speed and control of saw frame lowering.These specifi-
cations must therefore be harmoniously combined in a sin-
gle operating condition according to practical considerations
and common sense, so as to achieve an optimum condition
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
time will be solved more easily if the operator has a good
knoledge of these specifications.
WE THEREFORE RECOMMEND YOU TO ALWAYS USE
GENUINESPARE BLADESTHATGUARANTEESUPERIOR
QUALITY AND PERFORMANCE.
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.
9.2 - Selecting blade
First of all the pitch of the teeth must be chosen, in the other
BLADE TEETH SELECTION TABLE
THICKNESS MM Z CONTINUOUS
TOOTH DESIGN Z COMBO TOOTH DESIGN
TILL 1.5 14 10/14
FROM 1 TO 2 88/12
FROM 2 TO 3 66/10
FROM 3 TO 5 65/8
FROM 4 TO 6 64/6
MORE THAN 6 44/6
S = THICKNESS
words, the number of teeth per inch (25,4 mm) 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;
- pieces cut in bundles require combo tooth design.
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

15
TRAD 300TRAD 300
TRAD 300TRAD 300
TRAD 300 AA
AA
AO GTO GT
O GTO GT
O GT
9.7 - Blade type
They differ essentially in their constructive characteristics, such
as:
-shape and cutting angle of tooth
-pitch
-set
Shape and angle of tooth
REGULAR TOOTH: 0° rake and constant pitch.
Most common form for transversal or inclined cutting of solid
small and average cross-sections or pipes, in laminated mild
steel and grey iron or general metal.
POSITIVE RAKE TOOTH: 9° - 10° positive rake and constant
pitch.
positive
Particular use for crosswise or inclined cuts in solid sections or
large pipes, but above all harder materials (highly alloyed and
stainless steels, special bronze and forge pig).
COMBO TOOTH: pitch varies between teeth and consequently
varying teeth size and varying gullet depths. Pitch varies be-
tween teeth which ensures a smoother, quieter cut and longer
blade life owing to the lack of vibration.
SOLID Ø OR L MM Z CONTINUOUS
TOOTH DESIGN Z COMBO TOOTH DESIGN
TILL 30 85/8
FROM 30 TO 60 64/6
FROM 40 TO 80 44/6
MORE THAN 90 33/4
Ø = DIAMETER L = WIDTH
9.4 - Cutting and advance speed
The cutting speed (m/min) and the advance speed (cm2/min =
area travelled by the blade during removal of chip) are limited
by the development of heat close to the tips of the teeth.
- The cutting speed is subordinate to the resistance of the ma-
terial (R = N/mm2), to its hardness (HRC) and to the dimen-
sions of the widest section.
- Too high an advance speed (= lowering of the saw frame)
tends to cause the blade to deviate from the ideal cutting path,
producing non rectilinear cuts on both the vertical and the
horizontal plane.
The best combination of these two parameters can be seen
directly examining the chips.
Long spiral-shaped chips indicate ideal
cutting.
Very fine or pulverized chips indicate lack
of feed and/or cutting pressure.
Thick and/or blue chips indicate overload
of the blade.
9.5 - Blade running-in
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/min on material of average dimensions with re-
spect 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 - Blade structure
Bi-metal blades are the most commonly used.They consist in a
silicon-steel blade backing with electron beam or laser welded
high speed steel (HHS) cutting edge. The type of stocks are
classified in M2, M42, M51 and differ from each other because
of their major hardness due to the increasing percentage of
Cobalt (Co) and molybdenum (Mo) contained in the metal alloy.
distance between teeth
distance between teeth
Another advantage offered in the use of this type of blade in the
fact that with an only blade it is possible to cut a wide range of
different materials in size and type.
COMBO TOOTH: 9° - 10° positive rake.
positive
This type of blade is the most suitable for the cutting of section
bars and large and thick pipes as well as for the cutting of solid
bars at maximum machine capacity. Available pitches: 3-4/4-6.

16
TRAD 300TRAD 300
TRAD 300TRAD 300
TRAD 300 AA
AA
AO GTO GT
O GTO GT
O GT
This set is associated with very fine teeth and it is mainly used
for the cutting of pipes and thin section bars (from 1 to 3 mm).
ALTERNATE SET (IN GROUPS): Groups of cutting teeth right
and left, alternated by a straight tooth.
This set is associated with very fine teeth and it is used for
extremely thin materials (less than 1 mm).
ALTERNATE SET (INDIVIDUAL TEETH): Cutting teeth right
and left.
This set is used for the cutting of nonferrous soft materials,
plastics and wood.
Set
Saw teeth bent out of the plane of the saw body, resulting in a
wide cut in the workpiece.
REGULAR OR RAKER SET: Cutting teeth right and left, alter-
nated by a straight tooth.
Of general use for materials with dimensions superior to 5 mm.
Used for the cutting of steel, castings and hard nonferrous ma-
terials.
WAVY SET: Set in smooth waves.
9.7.1 - RECOMMENDED CUTTING PARAMETERS
STEEL CUTTING SPEED LUBRICATION REMOVAL cm²/min
CONSTRUCTION 60/80 EMULSIFIABLE OIL 40/60
CEMENTATION 40/50 EMULSIFIABLE OIL 20/40
CARBON STEEL 40/60 EMULSIFIABLE OIL 40/60
HARDENING AND TEMPERING 40/50 EMULSIFIABLE OIL 30/50
BEARINGS 40/60 EMULSIFIABLE OIL 15/30
SPRINGS 40/60 EMULSIFIABLE OIL 10/30
FOR TOOLS 30/40 EMULSIFIABLE OIL 6/20
FOR VALVES 35/50 EMULSIFIABLE OIL 20/30
STAINLESS STEEL 30/40 EMULSIFIABLE OIL 6/20
SPHEROIDAL GRAPHITE 20/40 EMULSIFIABLE OIL 6/30
CAST IRON 40/60 EMULSIFIABLE OIL 30/60
ALUMINIUM 80/600 KEROSENE 60/450
BRONZE 70/120 EMULSIFIABLE OIL 40/70
HARD BRONZE 30/60 EMULSIFIABLE OIL 6/20
BRASS 70/350 EMULSIFIABLE OIL 25/80
COPPER 50/720 EMULSIFIABLE OIL ------

17
TRAD 300TRAD 300
TRAD 300TRAD 300
TRAD 300 AA
AA
AO GTO GT
O GTO GT
O GT
REFERENCE N° DESCRIPTION
BEDPLATE UNIT
1 .......................................Bed
2 .......................................Rear cover
3 .......................................Electric box
4 .......................................Electric box cover
5 .......................................Cover
6 .......................................chip collect box
7 .......................................Crugible
8 .......................................Front protection
9 .......................................Rear protection
10 .......................................Vice support
11 .......................................Vice screw
12 .......................................Vice cylinder
13 .......................................Vice handwheel
14 .......................................Vice jaw
15 .......................................Vice
16 .......................................Conveyor jaw
17 .......................................Conveyor rod
18 .......................................Handwheel
19 .......................................Vice screw cover
20 .......................................Antiburr Jaw
21 .......................................Countervice jaw
22 .......................................Countervice
23 .......................................Hinge pin support
24 .......................................Bracket
25 .......................................Spring bush
26 .......................................Cylinder fork
27 .......................................Pin
28 .......................................Saw frame spring
29 .......................................Saw frame spring
30 .......................................Saw frame cylinder
31 .......................................Hinge pin
32 .......................................NILOS ring
33 .......................................Bearing 32007 X
34 .......................................Ring nut M 35
35 .......................................Eccentric bush
36 .......................................Bearing 32007 X
37 .......................................Ring NILOS
SAW FRAME UNIT
70 .......................................Rear saw frame
71 .......................................Front saw frame
72 .......................................Blade tension slide
73 .......................................Pin
74 .......................................Microswitch
75 .......................................Plate
76 .......................................Blade tension guide block
77 .......................................Blade tension pin
78 .......................................Spring
79 .......................................Blade tension handwheel
MACHINE COMPONENTS
10.1 - List of spare parts
10
80.....................................
81.....................................
82..................................... Ring nilos 32006 XAV
83 ..................................... Spacer ring
84..................................... Bearing 32006 X
85 ..................................... Transmission flywheel
86..................................... Ring nut M 30
87..................................... Screw TE M 12
88..................................... Washer
89 ..................................... Motor flywheel
90..................................... Bearing 6208 2RS
91 ..................................... Key
92 ..................................... Key
93..................................... Motor flywheel shaft
94 ..................................... Reduction unit
95 ..................................... Electric motor
96 ..................................... Bracket
97..................................... Screw TE M 12
98 ..................................... Bush
99..................................... Sping couple blade
100 ................................... Cooling distributor
101 ................................... Coupling
102 ................................... Cooling liquid cock
103 ................................... Coupling
104................................... Microswitch
105................................... Knob
106 ................................... Saw frame cover
107................................... Knob
108 ................................... Bracket
109 ................................... Coupling
110 ................................... Blade guide adjustable rod
111 ................................... Short eccentric pin
112 ................................... Long eccentric pin
113 ................................... Bearing 608 2RS
114 ................................... Blade guide adjustable cover
115 ................................... Fixed blade guide pad
116 ................................... Movable blade guide pad
117 ................................... Movable blade guide block
118 ................................... Additional protection
119 ................................... Fixed blade guide block
120 ................................... Fixed blade guide block
121 ................................... Cleaning brush
122................................... Support
123 ................................... Bearing 626 2RS
124................................... Bush
REFERENCE N° DESCRIPTION

18
TRAD 300TRAD 300
TRAD 300TRAD 300
TRAD 300 AA
AA
AO GTO GT
O GTO GT
O GT
REFERENCE N° DESCRIPTION
FEEDING SYSTEM
201.................................... Support
202.................................... Screw
203.................................... Carriage guide rod
204.................................... Support
205.................................... Bush
206.................................... Roller
207....................................
208.................................... Supprt plate
209.................................... Block
210.................................... Carriage countervice cylinder
211.................................... Carriage countervice jaw
212.................................... Microswitch cam
213.................................... Microswitch
214....................................
215.................................... Support
216.................................... Pin
217.................................... Bearing 6200 2RS
218.................................... Roller
219.................................... Scraper ring 40/50/4
220.................................... Bush GLISSA 40/50/40
221.................................... Carriage
222.................................... Adjustable screw
223.................................... Guide nut
224.................................... Measuring system body
225.................................... Bearing 30203 X
226.................................... Support
227.................................... Bearing 30203 X
228.................................... Pulley
229.................................... Ring nut M 17x1
230.................................... Cogged belt 270 L
231.................................... Belt cover
232.................................... Ring nut M 17x1
233.................................... Pulley
234.................................... Ring
235.................................... Support
236.................................... Handwheel
237.................................... Measuring system SIKO
238.................................... Bearing 6003 2RS
239.................................... Adjustable shaft
240.................................... Handwheel
241.................................... Carriage vice jaw
242.................................... Carriage vice guid nut
243....................................
244.................................... Screw support plate
245.................................... Adjustable screw
246.................................... Handwheel
247.................................... Carriage vice
248.................................... Handwheel
249.................................... Adjustable screw
250.................................... Support
251.................................... Support
252.................................... Avance Cylinder
253.................................... Cylinder protection
REFERENCE N° DESCRIPTION
254.................................... Washer
255.................................... Bearing 6002 2RS
256.................................... Vertical roller
257.................................... Roller protection
258.................................... Nut
259.................................... Washer
260.................................... Bearing 6002 2RS
261.................................... Pin
262.................................... Rod protection
263....................................
264.................................... Microswitch
265.................................... Microswitch

19
TRAD 300TRAD 300
TRAD 300TRAD 300
TRAD 300 AA
AA
AO GTO GT
O GTO GT
O GT
BEDPLATE UNIT
1
2
3
4
5
6
7
8
9
10
11
12
13
15
14 16 17
18
19
20
21
22
23
32
31
27
28
30
24
25
33
26 25
29
34
36
35 37
42
38 39
41
40
43 44

20
TRAD 300TRAD 300
TRAD 300TRAD 300
TRAD 300 AA
AA
AO GTO GT
O GTO GT
O GT
SAW FRAME UNIT
ZOOM - 1
ZOOM - 2
70
71
72
73
74
75 76 77
78
79
82
83
84
85
86
82 84
87
88
89
90
91
92
93
94
95
96
97
98
98
97
99
100
101
102
103
101
104
105
106
107
108
109
110
111
112 113
114
115
116
113 112 115
116
111
117
118
119
120
121
122123
124