Thomas 275 SUPER CUT Manuel utilisateur

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: sales@trick-tools.com

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

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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.

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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

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

7055070

690

445 185

630

MACHINE DIMENSIONS

TRANSPORT

INSTALLATION

DISMANTLING

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.

5.2 - 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.

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

- 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

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- 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

Ce manuel convient aux modèles suivants

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