PARTS and

INSTRUCTION
MANUAL

MODEL: DBW-15

SERIAL NO: 471-88101 to

BUTTWELDER
 DAMAGE CLAIM PROCEDURES
VISIBLE DAMAGE AT THE TIME OF DELIVERY:

1. Note damage on carrier’s delivery receipt. Accept the shipment. It can be returned later if repairs
are not possible in the field.

2. Request a “damage inspection” from the delivery carrier:

a. The carrier will send his own people or contract an independent agency to make the
inspection.

b. The inspector will request a signature on the report and leave a copy.

c. The carrier “damage inspection” report is not final. If additional damage is found when
repairs are started, contact the carrier for another inspection; or at least give them the
details of the damage.

3. Do not move the equipment from the receiving area and keep all shipping materials until carrier
“damage inspection” report is complete.

4. If possible, take photographs of the damage and keep them for your files. Photos could possibly
prove a claim at a later time.

5. Keep a record of all expenses and be sure they are documented.

6. Repair damage in the field whenever possible. Carriers encourage this to keep expenses down.

7. You have nine (9) months to file a claim.

CONCEALED DAMAGE:

1. You have fourteen (14) days to report damage not noted at time of delivery.

a. Report damage as soon as possible. This makes it easier to prove that it did not happen
at cosignee’s plant.

b. Inspect machine(s) carefully before moving from the receiving area. Again, if machine is
not moved, it is easier to prove your case.

2. Request a “damage inspection” from the delivery carrier:

a. The carrier will send his own people or contract an independent agency to make the
inspection.

b. The inspector will request a signature on the report and leave a copy.

c. The carrier “damage inspection” report is not final. If additional damage is found when
repairs are started, contact the carrier for another inspection; or at least give them the
details of the damage.

3. Do not move the equipment from the receiving area and keep all shipping materials until carrier
“damage inspection” report is complete.

4. If possible, take photographs of the damage and keep them for your files. Photos could possibly
prove a claim at a later time.

5. Keep a record of all expenses and be sure they are documented.

6. Repair damage in the field whenever possible. Carriers encourage this to keep expenses down.

7. You have nine (9) months to file a claim.

 PARTS and INSTRUCTION MANUAL
BUTTWELDER
MODEL FIRST SERIAL NO. LAST SERIAL NO.
DBW-15 471-88101

For your information and future reference, pertinent data concerning your buttwelder
should be written in the spaces provided above. This information is stamped on
a plate attached to the front of your welder. Be sure to provide welder model and
serial numbers with any correspondence or parts orders.

Specifications contained herein were in effect at the time this manual was approved
for printing. The DoALL Company, whose policy is one of continuous improvement,
reserves the right, however, to change specifications or design at any time without
notice and without incurring obligations.

PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATING THE BUTTWELDER!

For Sales, Parts and Service, call 1-888-362-5572

DoALL SAWING PRODUCTS

2375B TOUHY AVENUE
ELK GROVE, ILLINOIS 60007 U.S.A.

The following registered trademarks of the DoALL Company are used in this manual:
DoALL, Carbon, Dart and Imperial Bi-Metal.

PRINTED IN U.S.A. PB-413.4 (9-08)


TABLE OF CONTENTS
WELDER DIMENSIONS ........................... 1 TROUBLE SHOOTING ................................... 10

WELDER FEATURES . ............................. 2 ACCESSORIES

Blade Shear . ........................................................... 11

INSTALLATION

Specifications .......................................................... 3 REPLACEMENT PARTS

Location ................................................................... 3
Unpacking ............................................................... 3 DBW-15 Buttwelder ................................................. 12-13
Blade Shear Installation .......................................... 3 Blade Shear . ........................................................... 14-15
Electrical Installation . .............................................. 3

OPERATION

General Description . ............................................... 4

Preparation For Welding ......................................... 4-5
Making the Weld . .................................................... 5-6
Grinding and Annealing Welded Bands . ................. 6-7

MAINTENANCE

Lubrication ............................................................... 8
Slide Bar Maintenance ............................................ 8
Welder Jaw Maintenance ........................................ 8
Jaw Alignment ......................................................... 8
Jaw Gap Adjustments . ............................................ 8
Weld Upset Force Adjustment ................................. 8-9
Weld Lever Drag Spring .......................................... 9
Maximum Jaw Gap Adjustment ............................... 9
Blade Line-Up Guide Adjustment ............................ 9
Final Jaw Alignment ................................................ 9

How to read your serial number:

ii
WELDER DIMENSIONS
INCHES (± .03)
MILLIMETERS (± 1 mm)

SIDE VIEW
FRONT VIEW (Inside Enclosure)

NOTE: Portable Welder has the

Enclosure and related parts.
SIDE VIEW


WELDER FEATURES

FRONT VIEW REAR VIEW

SIDE VIEW SIDE VIEW

(Inside Enclosure)


INSTALLATION
All the “left”, “right”, “front” and “rear”
designations in this manual are as viewed by
the operator facing the control panel.
SPECIFICATIONS
ELECTRICAL INSTALLATION
Electrical installation must be made by
authorized electrical maintenance personnel
only.

1. This resistance-type buttwelder is capable of

welding DoALL Carbon, Dart, and Imperial Bi-Metal
saw bands from 1/16 to 1 inch (1.6 to 25.4 mm)
wide and 0.025 to 0.035 inch (0.63 to 0.89 mm) in
thickness.

LOCATION

1. There are three (3) primary factors to consider when

choosing the buttwelder's location:

• The operator must have sufficient space foe easy

saw band handling and welding.

• Sufficient space must be allowed so that a coiled Incoming Power Connections.

saw band will not injure persons passing nearby.
• There must be no flammable materials nearby that
might be ignited by sparks from the welder.
UNPACKING
1. Carefully remove the buttwelder from its shipping
box. Then: (a) Remove all packing materials; (b)
Unpack the Blade Shear and band thickness gage;
(c) Place the welder on a table in preparation for
Blade Shear attachment.
2. Inspect the welder for broken or damaged parts.
Refer to this manual's inside front cover for damage
claim procedures.
3. When assembling the blade shear to the welder,
follow the directions on the instruction sheet SE-14
provided with the Blade Shear.
BLADE SHEAR INSTALLATION
1. Mount the Blade Shear to the band sawing machine
or to the portable buttwelder box with the 5/16-
18NC x 3/4 cap screws provided. A bracket is also
provided for mounting the blade shear to the facing
surface of the machine if desired.
Portable Welder
1. Refer to the welder specifications plate on the front
panel to verify that the electrical supply circuit will
meet the voltage/phase/frequency/amperage re-
quirements listed. A basic data plate is reproduced
on this manual’s introductory page.
This buttwelder WILL NOT operate on direct
current (DC).
2. Wiring must conform to local electrical codes. To
continue electrical connections: (a) Route the
customer supplied power source through the back
panel hole in the welder box; (b) Secure with an
appropriate connector (customer supplied); (c)
Attach the ground wire to the ground stud inside
the back panel; (d) Connect line "1" to the top of
the disconnect switch T1; (e) Connect line "2" to
the top of the disconnect switch T2.
Machine Mounted Installation (208V, 230V Only)
1. Bring incoming power from the machine to the back
of the welder. Then: (a) Connect the lines to the
terminals shown in the illustration.
2. For all other voltages, refer to the electrical
schematic furnished with the welder or machine for
proper electrical connections.


OPERATION
GENERAL DESCRIPTION

1. The DoALL Model DBW-15 is a resistance-type

buttwelder. Its two (2) clamping jaws hold the butted
saw band ends together during the welding process.
When the operator presses the Weld Lever, an
electric current flows through the butted saw band
ends. This creates enough heat to soften and join
the band ends.

2. Pressing the Weld Lever also releases a spring

which causes the clamping jaws to force the saw
band ends together (electric current shuts off before
the movable jaw has completed its movement).

3. Final upset or "forging" occurs while the saw band is

still hot, but no longer being heated by its electrical
energy source.
Grind Off Teeth to Insure Weld Area Uniformity.

PREPARATION FOR WELDING

3. If the Blade Shear is not used to cut the saw band,
It is important that both the saw band and
buttwelder be properly prepared for each
welding operation.
Saw Band Preparation
1. Cutting. Cut the saw band to length using the blade
shear (if supplied) to insure that the blade ends are
flat, square and smooth.
both ends must be squared before welding. To do
so: (a) Grind both ends in one operation; (b) Hold
the ends so that teeth point in opposite directions;
(c) Regardless of the grinding angle, both ends
should match perfectly when positioned end to
end.

Grind Blade Ends When Necessary.

Use the Blade Shear to Cut the Saw Band.

4. Cleaning. Use No. 120 grit emery cloth or
equivalent for this operation. Be sure the emery
2. Tooth Spacing. When preparing fine-pitched cloth does not touch the teeth and damage the set of
saw bands, one or more teeth on each side of the teeth sharpness. Sand that part of each saw band
cut must be ground off to insure uniformity of the end that will contact the welder jaws (any dirt, oil,
saw band's weld cross-section area. This willalso oxide or scale that is not removed will prevent good
insure: (a) Proper tooth spacing at the weld area; electrical contact). Oxide must also be removed
(b) Retention of the teeth's set pattern. from Dart saw bands.


PREPARATION FOR WELDING (Continued....)
Buttwelder Prepration
1. Clean the welder jaws. Then: (a) Remove and
clean the lower jaw inserts; (b) Set the Weld Force
selector to the correct position for the width of blade
to be welded; (c) Adjust the Weld Lever position
according to blade width.
2. Both the weld force setting and the initial gap
between welder jaws must be increased in
proportion to the increase in cross-section area of
the blade being welded (force and initial jaw gap
must be increased for thicker blades as well as
wider blades). Greater jaw gap and weld force
allow wider or thicker blades to reach proper welding
temperature.
3. It is difficult to establish recommended jaw gap and
Weld Force settings because so many variables are
involved (such as different blade types, widthe and
gages), in addition to variations between welders.
Settings which provide the best welds for each
width, gage and type of blade should be determined
by experience and noted for future use.
Saw Blade Adjustment
1. For internal sawing purposes, insert the saw band
through a starting hole drilled in the workpiece.
Next: (a) Bring the blade ends together to be
clamped into the buttwelder jaws; (b) Cut out the
old weld if welding a used saw band.
It is recommended that saw bands contain
only one (1) weld.
Preparing For Internal Sawing.

When welding bands which pass through a
workpiece hole, insulating the saw band from
contact with the workpiece or table will insure
a better weld.
2. Place saw band ends between the jaws with the
teeth against the line-up guides attached to the
front edge of the jaws.
Blades 1/8 inch (3.2 mm) or less in width are
too narrow to be clamped correctly when
placed against the line-up guides. Move
these narrow blades back slightly from the
line-up guides, align by eye, and then clamp
in place.
3. Clamp the jaws by moving the handles upward.
Check to be sure that the band edges meet in the
center of the jaw gap without any offset in thickness
or across the width.
4. If contact across the saw band width is not complete,
remove one end and recut it.
A misaligned joint will cause an incomplete
weld.
MAKING THE WELD
Jaw Gap and Weld Force Controls
1. The Weld Force setting and the initial welder jaw
gap must be in proportion to the increase in cross-
section area of the blade being welded. Greater jaw
gap allow wider or thicker blades to reach proper
welding temperature.
2. Greater weld forces produces the same unit pressure
while welding wider or thicker saw bands.
3. The Weld Force selector provides variable control
of the upsetting force. Initial jaw gap is set by
adjusting the Weld Lever position before making
the weld.
Weld Procedures
Always step to one side to avoid welding
sparks.
1. Use a smooth, steady motion (not too fast or slow)
when pressing the Weld Lever and holding it down.
Hold the lever down until the weld has cooled.
2. Release the stationary jaw clamping handle first,
then release the Weld Lever (this will prevent
scouring of the welder jaw surface). The welder
mechanism and electrical switches are automatically
recocked when the Weld Lever is released.
MAKING THE WELD (Continued....)
3. Remove the saw band and carefully inspect the
weld for possible deficiency (see "Weld Inspection"
next page). If the weld is poor, refer to the
"Trouble Shooting" section for possible cause and
solution).
Imperial Bi-Metal and very narrow carbon
saw bands require special treatment to
protect a weld from accidental breakage. It is
recommended that welds in these saw bands
be annealed BEFORE removal for grinding,
and also AFTER grinding as well.
Weld Inspection
1. Inspect the weld carefully immediately after
removing from the welder. Check to see that: (a)
Teeth spacing is uniform; (b) The weld is located in
the center of the gullet.
Weld Characteristics.
2. Major jaw misalignment is easily noted from the
weld appearance. Refer to the "Trouble Shooting"
section if the weld is imperfect.
Band Misalignment.

Welder Jaw Clean-Up
1. It is very important that the welder jaws be kept
clean at all times. That means the jaws and inserts
must be wiped or scraped clean after every weld.
2. Clean welder jaws help insure better welds by: (a)
Holding proper alignment; (b) Preventing flash from
becoming embeded in the saw Band; (c) Preventing
shorts or poor electrical contact.
This buttwelder is designed for intermittent
use. Overheating may occur if repeated
welding takes place during a short period of
time.
GRINDING & ANNEALING WELDED BANDS
Grinding
1. Use the grinding wheel to prepare the saw band for
welding and to remove flash from the weld. Flash
on both sides of the weld must be ground off to
blade thickness (the weld should then pass freely
through the band gage).
2. The grinder switch pilot light is provided as a safety
feature since it may be difficult for the operator to
visually see if the grinding wheel is rotating. The
light glows when the grinder motor is running.
Using the Grinding Wheel.
Keep hands away from the rotating grinding
wheel. The glowing pilot light of the grinder
on-off switch indicates when the grinding
wheel is running.
3. Dress the saw band after welding to remove excess
metal from the weld flash. With the blade teeth
facing outward, grind the welded area down to the
same thickness as the remainder of the band.
Handle the saw band carefully because welds
are brittle before being annealed.
GRINDING AND ANNEALING WELDED BANDS
(Continued....)
4. Grind the weld carefully and observe these
precautions: (a) DO NOT hit the saw band teeth; (b)
DO NOT grind deeper than the saw band thickness;
(c) DO NOT burn or overheat the weld area; (d) DO
remove flash from the saw band's back edge; (e)
DO grind off flash or "stub" teeth projecting beyond
the normal set or height of other teeth; (f) DO check
the weld thickness by passing it through the correct
band thickness gage.

Annealing

1. When a saw band is heated with the buttwelding

process, steel at the point-of-weld "air hardens"
and becomes brittle. The Annealing switch is used
to "anneal" the weld by reheating it (this returns
the saw band to an approximation of its original
condition).

2. Swing the Weld Lever completely upward to the

"anneal" setting (the drag spring will hold the lever
in place). Then clamp the saw band between the
welder jaws and follow the annealing instructions
below.

Overheating will damage blade temper.

Always shade the weld area with your hand
because the desired color may not be visible
with normal lighting conditions.

3. To Anneal Carbon Blades: (a) Push and jog the

Annealing switch until the weld is dull cherry to
cherry red in color; (b) Allow the blade to cool
slowly by decreasing the jogging frequency.

4. To Anneal Dart Blades: (a) Heat the blade slowly

until the first indication of dull red color appears
across the width og the weld area; (b) Cool quickly
by releasing the Annealing switch.

5. To Anneal Imperial Bi-Metal Blades: (a) Jog

the Annealing switch so that the saw band heats
slowly until the weld begins to emit light (dullest
red color); (b) Cool the weld quickly by releasing
the Annealing switch. Follow this procedure
both before and after grinding Imperial Bi-Metal
blades.


MAINTENANCE
All adjustments must be made with the power
off, except where specifically instructed
otherwise.
LUBRICATION
1. Lubricate the weld force selector cam and all
miscellaneous pivot points every six (6) months.
The interval between lubrication may be shortened
or lengthened depending usage and on the amount
of dust and dirt in the area.
2. The grinder motor normally will not require
lubrication for several years.
3. Use Union 76 UNAX-RX 215, ASTM Grade 215 or
equivalent oil on all lubrication points.
SLIDE BAR MAINTENANCE
1. Keep the slide bar clean. Dirt may cause the
movable jaw to stick and "burn out" the weld.
2. Check the movable jaw often for freedom of
movement. If there is binding, remove the jaw, then
clean the slide bar and jaw.
WELDER JAW MAINTENANCE
1. Welder jaws must be kept clean if consistent
results are to be obtained. Excess metal in the
form of incandescent particles is blown out of the
weld during the welding cycle causing a scale or
flash to build on the welder jaws. The welder will
not perform properly unless the jaws are wiped or
scraped clean after each weld.
JAW ALIGNMENT
1. Welder jaws are aligned at the factory and do not
require further adjustment. Replace both welder
jaws if either jaw becomes damaged.
2. Blade line-up guides insure that the saw band's
tooth edge is straight within 0.004 inch (0.10 mm)
per four (4) inches (101.6 mm) when measured two
(2) inches (50.8 mm) on either side of the weld.

JAW GAP ADJUSTMENTS
Final Jaw Gap
1. Final jaw gap shall be 0.075 inch (1.9 mm) with the
weld lever completely depressed (it is factory set).
If the jaw gap becomes noticeably reduced, anew
jaw gap spacer is required.
Jaw Gap at Electrical Cut-Off
Any adjustments involving electrical work must
be performed by a qualified electrician.
1. Jaw gap at the electrical cut-off shall be 0.140 inch
(3.65 mm) with power off. Adjust the elctrical cut-off
as follows: (a) Connect a continuity meter to the
cut-off switch wires; (b) Place a 0.140 inch (3.65
mm) gage between the jaws (the jaws must hold
the gage in place); (c) Loosen the jam nut and turn
the adjustment screw as required to just break the
circuit with a 0.140 inch (3.65 mm) gap; (d) Tighten
the jam nut.
2. Acceptable jaw gap is 0.135 to 0.140 inch (3.42
to 3.65 mm) when the mavable jaw is repeatedly
cycled through the welding motion.
WELD UPSET FORCE ADJUSTMENT
1. Upset force shall be from 10 to 12 pounds (4.5 to
5.4 kg) when measured at the movable jaw with
the Weld Force selector set for the narrowest saw
band width.
2. Approximate location of the weld force spring anchor
is with approximately 1/4 inch (6.3 mm) of thread
visible on the spring anchor.
3. Make the final adjustments in the following manner:
(a) Disconnect the weld lever spring; (b) Disconnect
the weld force spring; (c) Bend the transformer
lead attached to the movable jaw so that when
connected it will urge the jaw to its final jaw gap
position; (d) Reconnect the weld force spring.
4. Attach the spring scale to the movable jaw and
use it to manually pull the jaw to its maximum
open position, approximately 15/32 inch (11.9 mm).
Then: (a) Gradually release pull on the scale and
note the reading when the jaw starts to move; (b)
If the spring scale reading at this point does not fall
within the 10 to 12 pounds (4.5 to 5.4 kg) range, the
weld force spring anchor must be reset.
WELD UPSET FORCE ADJUSTMENT FINAL JAW ALIGNMENT
(Continued....)
1. To check final alignment, make a weld in a 1 inch
5. To reset the spring anchor, disconnect the weld (25.4 mm) wide by 0.035 inch (0.89 mm) gage
force spring and turn the screw as required. Then: Imperial Bi-Metal saw band. The finished weld
(a) Replace the weld force spring and recheck as must be straight within 0.004 inch (0.10 mm) per
described above; (b) Replace the weld force return four (4) inches (100 mm) when measured two (2)
spring. inches (50.8 mm) on either side of the weld.

WELD LEVER DRAG SPRING
1. This spring serves two (2) functions: (a) Its upper
corner acts as a detent to locate the movable jaw
for band annealing purpose; (b) Force exerted by
the spring against the weld lever provides frictional
drag to hold the lever at any of the several required
initial jaw gap settings for welding. This allows the
operator to clamp a blade in the welder or adjust
the upset force selector without disturbing the jaw
gap setting.
2. Follow these procedures in making this weld: (a)
Set the Weld Force selector at its maximum width
position; (b) Set the initial jaw gap by adjusting
the Weld Lever position (it mudt be set to the line
indicating the widest width); (c) Make the final jaw
alignment adjustment required to result in the listed
tolerances.

2. The weld lever drag spring is mounted on the panel

and secured by two (2) screws. It is adjusted by
shimming between the panel and spring (shim as
required to obtain both objectives). The top shim
is usually used to establish detent; the bottom shim
to establish frictional drag. However, shims under
either top or bottom screws will affect function.

MAXIMUM JAW GAP ADJUSTMENT

1. Place the Weld Lever in the "anneal" setting and

the Weld Force selector at its widest position.
Next: (a) Turn the jaw gap adjustment set screw
to obtain 15/32 inch (11.9 mm) jaw gap; (b) Lock
the adjustment set screw in place.

BLADE LINE-UP GUIDE ADJUSTMENT

1. The blade line-up guides maintain tooth edge
alignment of the saw band ends being welded.
Before installing the line-up guides, check their
mounting surfaces as these guides must be in line
within 0.004 inch (0.10 mm) when checked with a
straightedge. The guides are aligned to protrude
0.025 inch (0.63 mm) below the saw band clamping
surface of the welder jaws.

2. Adjust the line-up guides as follows: (a) Loosen

the screws holding the line-up guides to the welder
jaws; (b) Insert a section of 1 inch (25 mm) wide
by 0.035 inch (0.89 mm) gage saw band into the
welder jaws. The saw band must be out of the jaws
(teeth extended in front of the alignment guides) by
at least 3/16 inch (4.8 mm); (c) Place a 0.025 inch
(0.63 mm) shim on top of the saw band, but within
the jaw clamping area; (d) Clamp the welder jaws;
(e) Adjust the band guides to touch the side of the
saw band and lock in place.

TROUBLE SHOOTING
Repair and adjustment procedures should
be made only by experienced maintenance
personnel, or by a DoAll service representative.
Reference to the buttwelder's electrical
schematic and Feld Alignment and Adjustment
Summary will be helpful.
MISALIGNED WELD
1. Cause - Dirt or scale on the welder jaws or blade.
Solution - Clean with No. 120 emery cloth.
INCOMPLETE WELD (Joint Not Complete or
Has "Blow Holes"
1. Cause - Incorrect initial set-up.
Solution - (a) Initial jaw gap (Weld Lever position)
is not set correctly; (b) Weld Force control is not
set correctly.
2. Cause - Improper clamping procedures.
Solution - Refer to the "Saw Blade Alignment"
portion of the "Operation" section.

2. Cause - Blade ends are not cut off squarely. 3. Cause - Defective cut-off switch may not break the
Solution - (a) Shear blade ends properly; (b) circuit at the end of the welding operation.
Replace knives in the Blade Shear. Solution - Replace the weld cut switch.

3. Cause - Jaws or inserts are worn.

Solution - Replace the jaw or inserts.
Incomplete Weld.
4. Cause - Jaws are not aligned correctly.
Solution - Replace the jaws and/or slide bar.

5. Cause - Blade is not clamped correctly.

Solution - Refer to the "Saw Blade Alignment"
portion of the "Operation" section.
Burned Out Weld.

4. Cause - Cut-off switch is not adjusted correctly.

Solution - Refer to the "Jaw Gap at Electrical Cut-
Off" portion of the "Operation" section.
Misaligned Weld.

5. Cause - Jaw movement is obstructed by kinked jaw

MISALIGNED WELD - BLADE ENDS OVERLAP cable or tangled wires..
Solution - Bend the cable or untangle the wires.
1. Cause - The Weld Force control is set foe a wider
blade than that being used.
BRITTLE WELDS
Solution - Adjust correctly.
1. Cause - Incorrect annealing heat.
2. Cause - Jaws are not aligned correctly.
Solution - Bring the weld up to correct color as
Solution - Replace the jaws and/or slide bar.
described in the "Annealing Welded Bands" portion
of the "Operation" section.

2. Cause - Scale or oil on the weld.

Overlapped Weld.
Solution - Clean the weld area properly.

WELD BREAKS WHEN USED

1. Cause - Weld is not annealed correctly.

Solution - Refer to the "Annealing Welded Bands"
portion of the "Operation" section.

2. Cause - Weld has been ground too thin.

Solution - Refer to the "Grinding Welded Bands"
portion of the "Operation" section.

10
ACCESSORIES
BLADE SHEAR
1. This attachment is capable of cutting saw bands
from 1/16 to 1 inch (1.6 to 25.4 mm) wide and 0.025
to 0.035 inch (0.63 to 0.89 mm) in thickness.
2. To sharpen or replace the knife blades: (a) Remove
the retaining rings and pivot pin to remove the upper
knife blade and the four (4) round head screws to
remove the lower knife blades; (b) Grind the cutting
edges to sharpen or replace the blades; (c) Reinstall
the screws, pivot pin and retaining rings.

Blade Shear Features

Mounting

1. The Blade Shear is mounted on the left side of the

welder enclosure (portable welder only) and to the
machine frame if the welder is flush mounted into
the machine.

Operation

1. With the handle in the upright position, place the

saw band with the teeth of the blade against the
squaring edge. This assures that the saw band will
be square with its length.

2. Pull the handle down. Shear will cut from back of

the saw band to the front or teeth edge.

3. To remove an old weld from a saw band, place the

center of the weld between the knife blades and cut
through.

Maintenance

1. Lubricate the eccentric with a general purpose oil

and carefully wipe the knife blades occasionally to
keep the Blade Shear functioning properly.

11
REPLACEMENT PARTS

12

BUTTWELDER ASSEMBLY
INDEX PART DESCRIPTION UNITS
PER NO. NO. ASS’Y. PER NO. NO. ASS’Y.
Ref. DBW-15 Buttwelder Assembly
1 513543 . Buttwelder Enclosure Weldment ........... 1
2 175105 . Safety Switch ........................................ 1
3 199470 . Screw, Pan Hd. Self-Tap #10-24NC x 5/16 4
4 174845 . Side Cover ............................................ 1
5 198906 . Screw, Rd. Hd. Mach. 5/16-18NC x 3/4 2
6 121127 . Nutsert 5/16-18NC (If Supplied) . .......... 2
7 131807 . Blade Shear Assy (See Detail) . ............ 1
8 414365 . Grinder Wheel Guard . .......................... 1
9 198344 . Screw, Button Hd. Soc. #8-32NC x 1/2 4
10 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 2
11 175662 . Escutcheon (Specifications) . ................ 1
12 199400 . Screw, Rd. Hd. Drive #6 x 1/4 . ............. 4
13 175612 . Blade Gauge ......................................... 1
14 414406 . Welder Jaws (Order As A Unit) ............. 1
15 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 4
16 121066 . Line-Up Guide . ..................................... 2
17 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 2
18 173374 . Knob . .................................................... 1
19 1005111 . Grinder Motor Switch ............................ 1
1005113 . Wire Lead Assembly ............................. 1
20 174850 . Anneal Switch ....................................... 1
21 175919 . Handle . ................................................. 1
198410 . Screw, Soc. Set #10-24NC x 1/4 .......... 1
22 513221 . Panel...................................................... 1
23 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 4
24 198344 . Screw, Button Hd. Soc. #8-32NC x 1/2.. 2
25 119880 . Drag Spring . ......................................... 1
26 198344 . Screw, Button Hd. Soc. #8-32NC x 1/2.. 4
27 121067 . Insert Bearing . ...................................... 2
28 198344 . Screw, Button Hd. Soc. #8-32NC x 1/2.. 4
29 038660 . Jaw Insert . ............................................ 2
30 119906 . Pin (If Supplied) .................................... 2
31 315503 . Cam And Handle . ................................. 2
32 018151 . Shoulder Screw . ................................... 2
33 174853 . Knob . .................................................... 2
34 198368 . Screw, Button Hd. Soc. 1/4-20NC x 3/4 2
35 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 4
36 13-006501 . Grinding Wheel ..................................... 1
37 317286 . Retaining Ring ...................................... 1
38 177062 . Fender Washer ..................................... 2
39 199209 . Nut, Hex. Jam 3/8-24NF (Left Hand) .... 1
40 199302 . Washer, Flat 3/8 Wrought (If Supplied) 1
41 107429 . Grommet................................................ 1
42 104770 . Ground Tag............................................ 1
43 175071 . Wire (14” w/.250 Spade)........................ 3
44 199211 . Nut, Brass #10-24NC............................. 3
45 199387 . Washer, Flat #10 Brass w/Teeth ........... 3
46 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 1
47 174062 . Ground Wire (4” w/.250 Ring Terminal
- Both Ends) .......................................... 1
48 174522 . Terminal Block . ..................................... 1
49 198344 . Screw, Button Hd. Soc. #8-32NC x 1/2.. 2
50 415449 . Transformer (208V Only) ...................... 1
415126 . Transformer (All Other Voltages) .......... 1
51 138561 . Fuse Block ............................................ 2
52 175767 . Fuse ...................................................... 2
53 138562 . End Section . ......................................... 1
54 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/4 4
55 199853 . Screw, Pan Hd. Mach. #10-24NC x 1
(Brass) .................................................. 1
56 131959 . Transformer (380V, 400V, 415V) . ......... 1
209573 . Transformer (460V) . ............................. 1
211426 . Transformer (575V) . ............................. 1
13
CODE NO. H1-13.10
INDEX PART DESCRIPTION UNITS
57 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/2 4
58 513545 . Bracket . ................................................ 1
59 177046 . Electric Motor ........................................ 1
60 175720 . Actuator Weldment . .............................. 1
61 104030 . Spring . .................................................. 1
62 175148 . Spring Anchor ....................................... 1
63 199114 . Nut, Hex. Jam 1/4-20NC . ..................... 1
64 315476 . Frame Casting ...................................... 1
65 120796 . Screw, Soc. Hd. Shoulder 1/4-20NC x 3/8 1
66 35-009550 . Tension Adjusting Leve.......................... 1
67 415304 . Switch Mounting Bracke........................ 1
68 198349 . Screw, Button Hd. Soc. 1/4-20NC x 1/ 2 2
69 6-006313 . Insulator ................................................ 1
70 6-006339 . Tension Spring ...................................... 1
71 198360 . Screw, Button Hd. Sco. 1/4-30NC x 7/8 1
72 172925 . Switch ................................................... 2
73 175261 . Jaw Gap Spacer ................................... 2
74 198376 . Screw, Button Hd. Soc. #6-32NC x 3/8 6
75 198429 . Screw, Soc. Set 1/4-20NC x 1-1/4 ........ 1
76 175148 . Spring Anchor ....................................... 1
77 199811 . Screw, Button Hd. Soc. 1/4-20NC x 1-1/2 4
78 315478 . Slide Bar ............................................... 1
79 173063 . Slide Casting . ....................................... 1
80 198638 . Screw, Soc. Set 1/4-20NC x 1-1/4 (Oval
Point) . ................................................... 1
81 199114 . Nut, Hex. Jam 1/4-20NC . ..................... 1
82 316601 . Tension Adjustment Cam (Includes Pin) 1
83 319481 . Actuator Stop Bracket ........................... 1
84 198366 . Screw, Button Hd. Soc. 1/4-20NC x 3/8 2
85 198242 . Screw, Soc. Hd. Cap 1/4-20NC x 1 . ..... 1
86 199114 . Nut, Hex. Jam 1/4-20NC . ..................... 1
Following Not Shown:
175614 . Adjustment Summary . .......................... 1
415127 . Electtrical Schematic . ........................... 1
175615 . Manual on CD ....................................... 1
6-006502 . Tag (Caution) ........................................ 1
004231 . Spring Pin ............................................. 1
176888 . Cable Tie Mount . .................................. A.R.
107637 . Cable Tie . ............................................. A.R.
128968 . Conduit Sub-Assembly (Machine Mounted
Units) . ................................................... 1
For Machine Mounted Units:
Ref. 414276 Welder Mounting Bracket Assembly
1 198008 . Screw, Hex. Hd. Cap 1/4-20NC x 3/4 ... 2
2 199321 . Washer, Lock 1/4 Std. ........................... 2
3 198008 . Screw, Hex. Hd. Cap 1/4-20NC x 3/4 ... 2
4 199321 . Washer, Lock 1/4 Std. ........................... 2
5 199260 . Washer, Flat 1/4 S.A.E. Std. ................. 2
6 199176 . Nut, Hex. 1/4-20NC . ............................. 2
7 315330 . Bracket . ................................................ 1
8 172397 . Bar ........................................................ 1
9 198008 . Screw, Hex. Hd. Cap 1/4-20NC x 3/4 ... 3
10 199321 . Washer, Lock 1/4 Std. ........................... 3
Ref. 409525 Welder Mounting Bracket Assembly
1 198027 . Screw, Hex. Hd. Cap 5/16-18NC x 3/4 4
2 199323 . Washer, Lock 5/16 Std. ......................... 4
3 199122 . Nut, Hex. 5/16-18NC . ........................... 4
4 300705 . Bracket Weldment . ............................... 1
5 198100 . Screw, Hex. Hd. Cap 5/16-18NC x 1 .... 4
6 199323 . Washer, Lock 5/16 Std. ......................... 4
14
 CODE NO. H1-19.0
____________
____________

BLADE SHEAR ASSEMBLY

INDEX PART DESCRIPTION UNITS PER

NO. NO. ASS’Y.
Ref. 131807 Blade Shear Assembly
1 35-008437 . Knife ........................................................................................................ 1
2 35-007558 . Retaining Ring ........................................................................................ 2
3 34-013508 . Knob . ...................................................................................................... 1
4 35-008441 . Eccentric ................................................................................................. 1
5 35-008446 . R.H. Square ............................................................................................ 1
6 35-008438 . Handle . ................................................................................................... 1
7 35-008448 . R.H. Side Plate ....................................................................................... 1
8 35-008447 . L.H. Side Plate ........................................................................................ 1
9 35-008445 . L.H. Square ............................................................................................. 1
10 198012 . Screw, Hex. Hd. Cap 1/4-20NC x 1-1/2 .................................................. 1
11 100016 . Spacer . ................................................................................................... 3
12 199261 . Washer, Flat 1/4 S.A.E. Std. ................................................................... 6
13 199115 . Nut, Hex. 1/4-20NC . ............................................................................... 1
14 199321 . Washer, Lock 1/4 Std. ............................................................................. 1
15 198011 . Screw, Hex. Hd. Cap 1/4-20NC x 1-1/4 .................................................. 2
16 199115 . Nut, Hex. 1/4-20NC . ............................................................................... 2
17 199321 . Washer, Lock 1/4 Std. ............................................................................. 2
18 100015 . Blade ....................................................................................................... 2
19 198865 . Screw, Rd. Hd. Mach. #10-24NC x 1/4 ................................................... 4
20 35-008451 . Pin ........................................................................................................... 1
21 35-008582 . Retaining Ring ........................................................................................ 2

Following Not Shown and Used for Mounting. Select What Applies to Your Machine:

121127 . Nutsert 5/16-18NC .................................................................................. 2

198027 . Screw, Hex. Hd. Cap 5/16-18NC x 3/4 ................................................... 2
199323 . Washer, Lock 5/16 Std. ........................................................................... 2
146720 . Bracket .................................................................................................... 1
198906 . Screw, Rd. Hd. Mach. 5/16-18NC x 3/4 .................................................. 2

15