- Senuce Manual ee Parts List MODEL 610 Series Metal Band Cut-Off Machines ( KALAMAZOO KALAMAZOO SAW, INC. Seatuamnon cre KALAMAZOO, MICHIGAN 49007~ - a Revised Mcy. (QUALITY AND INNOVATION SOICE 1887 \7 KALAMAZOO 610 BAND SAW MACHINES Recommended specifications for cutting specific materials with » Hard Edge Flexible Back Metal Cutting Band Saw blades Recommended specifications for cutting specific materials with Hard Edge Flexible Back Metal Cutting Band Saw blades. = = sPeeDs aan =] = = i & & vo = gl pesrecns en | 14s : Wh Soned State 3 bleds on first cut. Steal with 7 iene 2 ‘high tensile strength use lowest speed No. 1. Te ‘thin wall material 2] tose ea ooo fillet ; : ‘at an ile 2 a a Lae 3 eee 2 r, permit faster cutting speeds PLUS longer blode acne : ae ; ly enclosed construction invites the Sow 2 | saa me : tn te! eoveceary sl lie Fe ee] 2 enouund we mented event toh RF Bw ool We ane ser ener emote et of! in ed Imeching. ASK US for partials ond pres. HOW TO OBTAIN GREATER EFFICIENCY AND MAKE BAND BLADES LAST LONGER —=i/eaed cess = <| Teeth ly open. After one square a aie er . Tor given eves of neler Band iy tram ome] [rate 7 F tod” to et any. Jbreakags I Bics [Adjust side guide rollers to te lighier pressure on spring cong toy rt ob San ok, | ends cas a ae tes ( pe pee | a bs tess Jack edge a = G : blode will Jort —— = contact rim of hond [ E= me no te a ee aeraep nse aoc eum ie W3-2-V188 BoeN SHIA ABIVISE BLOCH. of lowe sro. wiMsce ot SEB, cower carcnan rie sree L ye32-mse esnuor «GALE can wer cexnoven MOVING VISE BLOCH 455° k-300 E210 HICH. *- GUIDE ARMS — The guide arms are used to position the roller guide assemblies and can be moved along the yoke of the machine to desired position. In all cases it is recommended that they be placed as close as possible to the work. Be sure that the guide arms are tight. BLADE BRUSHES — Each Kalamazoo Mechine is equipped with blade brishes (SP44) which fit in a bolder which mounts in a bracket attached to the roller guide assemblies. These brushes should be re- placed often to insure cleaning the blade and extending blade life. They are easily replaced. +. VISE* —The model 610 uses K300. These assemblies use a Bronze Vise Cam K32 with a tumble action which precludes using a control rod. One half backward turn of hand wheel opens the nut and per- mits moving vise jaw to be repositioned. ‘The fixed vise jaw of all machines is also adjustable for making cuts up to 45°. To make such changes 1 the model 610 simply loosen the bolt holding this jaw in place and set to the desired position, tightening the bolt to hold the fixed jaw in place. BLADE SPEED SELECTION — All Kalamazoo machines permit a selection of three or four blade speeds. ‘The model 610 provides three — 53, 96 and 160 FPM. The later models 816 and 824 provide four speeds —53, 96, 160 and 266 FPM. The new Models 8C and 1220 provide for the same speeds, ic, 53, 96, 160 and 266 FPM. On model 610, the motor is mounted on a hinge pin which permits lifting the motor to re- lieve belt tension, You can easily change the belt to desired speed. GEAR CASE — The gcar case assembly is the most important assembly of your machine and should be properly cared for. A filler hole is provided on each gear case and itis necessary when lubricating your ma- chine to check your gear case to be sure the case is properly lubricated. The filler hole may be found by lifting the cover of your machine and looking behind the drive wheel. It is important to keep the gear case filled with 600W giease or oil. LUBRICATION — Your machine, like any mechanical instrument, will lat longer if properly Iubri- cated. The following is important: z 7 : EAL Keep the gear case full, 600W cylinder oil. “cB. Repack idle wheel bearing once a year. C. ‘Refill the hydraulic cylinder as needed with light oil SAE No. 10, + _D. Oil pivot bar once a month with No. 10 oil through oil holes or cups. E. Oil the threads of blade tension sere. ' F. Oil vise screw and moving vise jaw occasionally. G. DO NOT OIL ROLLER GUIDE BEARINGS. *Sce following pages for illustrations. Page 2FURTHER OPERATING INSTRUCTIONS 1, BLADE INSTALLATION — Tilt frame; raise covers; place band on wheels, also through guide rollers. ‘Tighten tension screw, making sure back of band is up against shoulder or rim of both band wheels. Next draw tension up so that all slagk is out of the blade. VERY IMPORTANT. After all Slack is out of blade add one full turn of the handle for. proper working tension. Noté: Band wheels are slightly canted so blade will hug rim of band wheel when correctly tensioned. 2. CUTTING — Start motér and lower blade gently by hand into stock before releasing hold. Machine will com- plete cut and automatically shut off. 3. FRAME CONTROL — A hydraulic frame control holds frame suspended and guards against blade breakage by accidental dropping. Close valve before raising frame. Open valve approximately ¥% turn for cutting 14” thick walls; open to approximately 14 turn for cutting 14” walls; open to approximately ¥ turn for ¥” and all larger solids, At approximately 14 or 4 turn hydraulic is wide open. More turns will not increase the downward speed. (No. 10 oil is used.) 4. BRUSHES — Two sets of double opposed brushes are provided on this machine. These are essential to good cutting and should be kept clean. Replace when worn and save blade expense, NOTE: Quarter turn for every third band used and when used twice around, or matted flat, discard and replace with new set of brushes. Pinch open end of brush holders together for best cleaning action. 5. GUIDE ADJUSTMENT — This machine as it Is shipped from the factory is fully adjusted and should require no further adjustment of the roller guides. Guide arms should be kept a distance of approximately 3” from the work. If necessary to change adjustment of side rollers, be sure vise jaws are again squared to blade and side of blade is square to top of machine bed. Caution: Do not oil roller guide bearings. xe 6. SPEED CHANGE —‘The motor is mounted on a hinged bar. scaew Fon Tension on the belt is released by turning inside handle Venticat on bottom screw and changing pulley groove. ADJUSTMENT VISE — The vise is quick acting; by turning left the screw is, disengaged; by turning right the screw is activated. For -eutting on angle up to 45° loosen both cap screws in fixed vise and move forward 2.3 inches and turn to desired —_eccentifics ron ee angle. “HORIZONTAL RADIAL CAUTION: When returning vise to original position be sure GOEREE ee i ie original p e a it is again square with side of blade. ECCENTRICS FoR FINE 8, SPRING TENSION —The spring is properly adjusted for LATERAL GLADE ADJUSTMENT tension. For increasing or decreasing tension due to dulling of blades or weakening of spring turn hand wheel at bot- tom of eye bolt. Only a slight turn is necessary to vary the tension. 9. SELECTION OF BLADES — The proper size blade for this machine is 7’ 5” x 44” and they are available in 10, and 14 teeth per inch. For most practical purposes experience will show that 10 and 14 teeth will handle the greatest part of your cutting. GENERAL— Maintain & Ibs, lift pressure on end of frame. Keep 1 pint of Mobilgear 634 or equivalent in the gear ‘case at all times. BO NOT CUT brass, copper, bronze and aluminum with the same blade that is used for steel or cast iron. Separate blades should be used. 3OPERATING INSTRUCTIONS INSTALLATION — Your Kalamazoo Machine has been fully adjusted at the factory and no further adjust- ‘ment should be necessary. It has been wired in accordance with the red tag hanging on it. Make sure your power source conforms. BLADE — You have received your machine with a hard edge, hard back, carbon steel blade already mounted. It is 44” wide x .025” thick x 7’-5” long. To change blades, raise head slightly and close hydraulic to hold in position. Remove brushes from brackets on guide arms. Lift both covers and move idle wheel to right by turning blade tension handle counter-clockwise until blade can be lifted off. Place new blade around wheels under flanges and insert between guide rollers. Make sure teeth point to right. Tighten blade enough so that it will not fall off wheels by turning tension handle clockwise. Turn motor on. Tighten blade until all vibration or flutter disappears. Then ADD 1 FULL TURN OF TENSION HANDLE. ‘After installing @ new blade and making the first cut, increase the blade tension to the extent of an ad- ditional 4 turn of the tension handle, As tension is added the blade travels up the faces of the band wheels until nearly against the flanges because the wheels are slightly canted or tilted. Replace brushes and close covers. FEED PRESSURE — Feed pressure or head weight may be adjusted with the single extension spring at the rear of the machine. The two knobs at the lower end of the spring extend or shorten the spring. Ex- tending the spring will reduce head weight. Head weight may be determined by hooking a fish or rag scale under the end of the frame and lifting a few inches off the bed. When measured at this point, the head + should weigh 8 Ibs. for a dry machine and 10 Ibs. for a wet machine. When head weight cannot be main- tained and no further adjustment of the spring is possible, it should be replaced. BLADE DRIVE — The motor is mounted on a hinged plate and the amount of belt tension is established by: ‘a nut and spring on the tension rod, When the machine is shipped, the hinged plate is fully tightened against the frame. Before using, adjust for proper belt tension by swinging the motor. Use just enough tension to eliminate flutter from the belt. Three blade speeds are provided through step pulleys. Begin- ning with the smallest step on the motor pulley and progressing to the largest, speeds will be 50, 90 and 155 F.P.M. (see chart for recommended speeds on various materials). To change speeds, push motor forward and change belt. HYDRAULIC — The hydraulic dash-pot cylinder serves to hold the head in the up position and to control the speed of descent of the head. It can be used to slow the descent of the head when sawing thin wall stock to prevent tearing the stock or stripping teeth from the blade. It does not control feed pressure which is determined by head weight. The control knob for the hydraulic cylinder projects from the end of the bed beside the vise hand wheel. Turning the handle counter-clockwise opens the cylinder and turning it clock- wise closes the cylinder. Always keep the cylinder fuil of light oil. BLADE GUIDES —The roller bearing guides on all Kalamazoo machines are essentially the same, the only difference being in the position of the top roller bearing on Model 610. It is IMPORTANT to note that the adjustment facilities given in the eccentric axies on this assembly are not to be used to correct ‘any wear on the blade. The roller guide assemblies are correctly: adjusted at the factory and it is rec- ommended that careful study of their movements be made before adjustment attempted, It is, however important to note that the ($52) eccentric bolts which connect the roller guide holder to the guide arm Page 1are used to square the blade to the bed and to the fixed vise jaw, To adjust these guides it is suggested that the “F” bearings (side roller) be adjusted first to obtain the correct pressure on the blade. They should be tight enough to permit an up and down movement of the blade, not loose, but snug enough to require a little pressure. Next the squareness of the blade should be obtained by placing a combination square biade, or other parallel bar on the bed and using its end, place vertically against the side of the blade to obtain squareness. Next with the head of a combination square against the bandsaw blade bring the blade of the square horizontally up against the fixed vise jaw to determine the squareness. A loose vise jaw may be the cause of bias cutting. Do not lubricate the guide rollers but keep them clean. When the guides are properly adjusted, crooked cuts can only be caused by a worn out blade or improper feed pressure. VISE — A quick counter-clockwise turn of vise handwheel will release jaw for easy positioning. Since cut- ting action is continuous on @ horizontal band saw, it is not necessary to clamp work too tight. Over- tightening will result in short life of the bronze vise nut. BLADE BRUSHES — Each Kalamazoo Machine is equipped with blade brushes (SP44) which fit in a holder Which mounts in a bracket attached to the roller guide assemblies. These brushes should be replaced often to insure cleaning the blade and extending blade life. They are easily replaced. LUBRICATION — Only the two oil holes above pivot bar require lubrication, preferably with a light-weight number 10 or 20 oil. The transmission has approximately one pint of Mobilgear 634 in it and requires no fur- ther lubrication unless in case of leakage. The gibs and slides on the idle wheel assembly should be kept free of dirt and lightly lubricated with oil or grease occasionally. Repack idle wheel bearings once a year. STATE YOUR MACHINE MODEL AND SERIAL NUMBER WHEN ORDERING PARTS Page 2LEGS and BED PARTS K2 Bed K-58 Stock Stop Bar K-17 Pivot Bar Bushings (2 Req'd) KAIF Front Leg K-57 Stock Stop X71 Steel Ballin Stock Stop KIR Rearleg K-54 Stock Stop Collar %-158 Retainer Spring Pp a= tsi @ a ~ ee K-300 MOVING VISE,BLOCK MISC. VISE PARTS K.27 Moving Vise Jaw ASSEMBLY S53 134" Taper Pin No.3 K39_—_ Vise Screw Consisting of: K-31-1 Fixed Vise Block K-22 Vise Screw K-31 Vise Block K169 Vise Screw Adapter Handwheel K-32 Vise Cam Nut wiPin | K-146 Cam Nut Spring K-160 Hardened Vise & Spring K.121 Cam Friction Pin Washers L-31-1 Vise Block Pin K-18 Fixed Vise Jaw (2 Req'd) Page 37A3 TAA KS Kz KA7 Frame Rear Frame Arm (Large) Front Frame Arm (Small) Pivot Bar Pivot Bar Collars (2 Req'd) ka Ko FRAME Tension Screw and Frame K-34. Slide Block Guide (2 Req'd) Rest Bracket K-35. Slide Block Plate Rocker Block K-23 Blade Tension Handle, Slide Block wiScrew Page4N : IDLE WHEEL PARTS «K-78 Idle Wheel K-141 Idle Wheel Spacer (2 Req'd) 5 K.25A Idle Wheel Axle. —_K-158_ Idle Wheel Snap Ring ul K-101 Idle Whee! Bearings (2 Req'd) K-25-1. Idle Wheel Jam Nut DRIVE WHEEL PARTS K-7AA__ Drive Wheel K.25-1 Drive Wheel Lock Nut (For Serial 1 thru P8L596) K-7A Drive Wheel with 1” BoreK-500 K6 K-19 K-36 K-114 K-122 x.123 K124 COMPLETE GEAR CASE ASSEMBLY Consisting of: Main Housing Bronze Gear Barrel Cover Back Cover Large Oil Seal Small Oil Seal (%") Back Cover Shims X-125 K.127 X-128 K.129 K-130 K-130A X131 GEAR CASE PARTS Barrel Shims Worm Shaft Roller Bearing. (2 Req'd) Steel Worm ‘Worm Shatt Long Spacer ~ Worm Shatt Short Spacer — Worm Shatt ¥%" Pipe Plug Page 6 K-132 Drive Axle w/Snap Ring K-133 Drive Axle Roller Bearing Req'd) K-119 Drive Axle Spacer $62 Drive Shatt Key (No. 15) (2 Req'd) $-62A Worm Shatt Key (No. 19) K-77. Drive Axle Snap Ring $-36-1 Small Oil Cup K-115 Top Oil Seal Cover K-117 Oil Seal Cover Shims (For Serial 1 thru P&L596 Use K-132A Drive Axle) i I | | |K-601 S45 bev KABB A qf q K-42 K-44 K421 K-46 X-143 $78 K-91 S76 K-87 K-55 K59 K-48 S-638 HYDRAULIC ASSEMBLY COMPLETE 0 Consisting of oe Upper Cylinder Head ipper Cylinder rs Housing Cylinder wiBottom Piston Rod Ka Piston a a Piston Rod Nut s-45: Frame Connector Casting Frame Connector Bushing _ go. Oil Seal Leather Cup Needle Valve wiJet K-44. Snap Rings (3 Req'd) Piston Washers (2 Req'd) K-9I MISC. HYDRAULIC PARTS 155 Hydraulic Control Rod Hydraulic Pivot Pin re Universal Joint Axvoorrer AN a Sa =—k-149 [ 9A-170 Page 7 9A-170 K-149 K-25 Ko-149 a S78 0 OL 8B KLE. FLT 0. SR K-145 . NAIRPIN COTTER (3 RECD.) K-48 ‘SPRING PARTS Rear Extension Spring Extension Spring Bolt (Dry Machine) Extension Spring Handwheels (2 Req'd) Extension Spring Bolt (Wet Machine)GUIDE ARM ASSEMBLY COMPLETE (Left Hand or Right Hand) K-700R or K-700L Consisting of: K-10AR_— Guide Arm — Right or K-10AL or Left K81 Guide Arm Block K-26 Roller Guide Holder $29 Side Roller Eccentric Axles (2 Req'd) $30 Top Roller Axle $52 Holder Eccentric Screws (2 Req'd) GUIDE ARM PARTS X.153 8A.197 8A.198 K-38 147 X-154 K-96 SP.43 SP-44 Side Roller Washers (2 Rea'd) Side Roller Bearings (2 Rea'a) Top Roller Bearing Guide Arm Tightener Self Locking Nuts (4 Req'd) Top Roller Washer Side Roller Shims (2 Req'd) Brush Holder Only Brush Only Page 8 MOTOR MOUNTING PARTS Motor Plate Motor Plate Pivot Bar Motor Tension Rod Motor Bracket Motor Tension Handwhee! Motor Tension Spring, Hairpin, Cotter (2 Req'd) 33 K37 K.152 K75, Kal71 X151 K.145 Ul ROLLER GUIDE HOLDER ASSEMBLY (Left Hand or Right Hand) K-701 ‘Same as above less Guide:Arm, Tightener and Block. BLADE CLEANING ASSEMBLY COMPLETE ‘SP-41 Consisting of SP-42 Holder Bracket (wi2 ea SP-44 Brushes) SP.438 Brush Holder SP-44 Extra Brush (4 each) somPULLEYS and GUARD PARTS ¢ eee K-14 Moter Pulley K-15. Oriven Pulley K-86 V.Beit ; $-113 Drive or Driven Pulley Key K-61 Pulley Guard - COVER PARTS . K-49. Idle Wheel Cover w/Hinge K-50 Drive Wheel Cover w/HingeELECTRICAL PARTS K.28A Switch Box S-85-1 1 Phase Switch K-84 Switch Box Cover (ph) K:24-1 Switch Shut-ott Rod (1 ph) $-998 Single Phase Cord Set $-99 Single Phase Wire 2 SO K-100 Switch Box Bracket “(OS Me ERS | = | { 7 | A } ; | | COOLANT PARTS : AW-43 Coolant Motor and _-KO-149. Long Spring Hook C7_ Flexible Nozzie w/Fitting : Pump wiCord KC-110 Feed Assembly» KC-8 Valve Clamp wiTightener KC-3__— Main Coolant Pan Consisting of: C9 4x5" Pipe Nipple KC-18 Mounting Block C5 St. ot Hose C10. %4" Pipe Elbow wiGasket (Set of 8) C-6 Hose Clamps (2 Req'd) C-11._ Brass Valve wiNipple Page 10C6A-1222 CK-10AL K.38 K-81 poeeeariae Uae 2 (C610 CONTOUR ATTACHMENT PARTS Adjustable Table Table Support Arm ‘Support Arm Tightener Tightener Block C6A-1220 C6A-1915 C6A-1221 C6A70) Page it Frame Support Rod Frame Support Tightener Frame Support Tightener Block Blade GuardM6A=1030 eee os a: “M6A~I026° MBA=1024: 1025 Pa KF MéA-102 M6A-108 M6A-1016 M6A-1017 M6A-1019 M6A-1020 M6A-1021 ‘M610 KALAMOBILE PARTS Front Leg Rear Leg Rubber Tired Wheel wiShield (2) Wheel Axte (2) Wheel Axle Nut (2) Handle (2) Handle Grip (2) Handle Tube (2) Mea-1022 MéA-1024 M6A-1025 M6A-1026 MEA-1028 M6A-1030 M6A-1031 Page 12 ‘Tube Bracket wiBolts and Set Screws Tube Bracket Key (2) Tube Bracket Spring (2) Tube Bracket Screw (2) Tube Ciamp wiBolt Frame Lock Ring Spring Stud {i eam al INSTRUCTIONS for Converting from Horizontal to Vertical Sawing REFER TO CORRESPONDING NUMBERS ON THIS SHEET 1, Unbott hydraulic cylinder from frame at top and allow cylinder to swing down. 2 Unhook spring from extension spring bolt. Install leg. Block on end of leg slips into front channel of frame and is tightened in position with stud which passes through loose steel block. Leg extends through hole in cover. Raise frame and adjust leg so its end is resting (on the floor when the frame is éxactly vertical. Install saw table with blade passing through slot in table. Note that the table arm fastens to frame > Page 13 . Install blade guard by placing the channel in exactly the same manner as the guide ‘arms are attached. You will find the block into which the stud is screwed already in place with- in the frame channel between the guide arms. at bot: tom over edge of frame. Lower saw table so that it rests on flange at top of guard and tighten stud. (Guard not shown) To reconvert to horizontal position, reverse above procedure, making sure that spring ten- sion is readjusted for 8 Ib. frame weight in ac- cordance with standard 610 instruction sheet. Vwan fi ca en SPECIFICATIONS 6100 610W M6100 6100 CAPACITY Ae om lo” 10” 10” 10” ROUND ... é 6” 6” 6” 6” THROAT (VERTICAL POSITION) Bsn 6" HEIGHT (VERTICAL POSITION) = 6” MOTOR ....... é WeHP. YeHP. HP. YeHP. SPEEDS 50, 90, 155 F.P.M. FLOOR SPACE....... po ernAben aoe | Abra ase ASE Ka, 45x ae HEIGHT TO BED — 22" 22" 22" 22" HEIGHT TO TABLE (VERTICAL POSITION) 32%” VISE SWIVEL TO 45° BLADE SIZE o..ssscssenseennes Yo" x75" x.025" NET WEIGHT . . 184 Ib. 212 Ib. 226 Ib. 200 Ib. SHIPPING WEIGHT 0.0 oe 247 Ib. 275 Ib. 289 Ib. 263 Ib. ‘SELECTION OF BAND SAW BLADES Efficient band sawing depends on many factors: the machine itself, the speed, the material to be cut, its shape and hardness, the selection of the blade, its type and tooth specifications. Below are recommended speed and tooth specifications for cutting materials with Hard Edge Hard Back Metal Cutting Band Saw Blades. Following these recommendations is your guarantee of economical and efficient metal band sawing. MATERIALS iene | seeede MATERIALS — ‘Aluminum Alloys 610 3 High Chrome Steels 2 Aluminum Castings 6.10 3 High Speed Steels 3 ‘Angle Iron, Light u 3 Beams 3 ‘Angle Iron, Heavy 10 3 Machine Steel 3 Brass, Sheets-Rods 10.14 a Malleable Iron 3 Brass Castings, Soft 10-14 a Mone! Metal 1 Brass Castings, Hard 10.14 a Nickel Steet 1 Bronze 10.14 2 Pipe, Iron Soit 3 “Bakelite 10.14 3 Pipe Steel 3 Boiler Tubes 10.14 3 Pipe, Galvanized 2 Cast Iron, Pipe-Solids 6-10 3 Plastics 3 Channel fron 610 3 Steel, less 50 carbon 3 Cold Rolled Steet 10.14 3 Steel, over 50 carbon 2 Copper 10-14 3 Structural Steel 3 Drill Rod 10.14 2 Tubing, Stee! Light 3 Fibre 10.14 2 Tubing, Seamless Heavy 3 ‘We suggest 10 teeth for general purpose; 14 teeth for light or thin wall material. Your machine when delivered was equipped with a Hard Edge, Hard Back Carbon steel band blade. We recommend it for all general purpose sawing. We stock this blade in 10 and 14 teeth per inch. If your machine is equipped for wet cutting, use a good grade of soluble oil and mix not thinner than 10:1. STATE YOUR MACHINE MODEL AND SERIAL NUMBER WHEN ORDERING PARTS Page 14 ; 4 | ;HORIZONTAL BAND SAW APPLICATIONS MANUAL @ _TA, BA, 9A and: 13A Series” (also applies to models 610, 816, 824, 8c, “and 1220), Kalamazoo Saw Divi 508 Harrison Street * Kalamazoo, Ml 49007-2687 Ph ta 1e 616/345-2141 Telex 22-4321 Fax 616/345-3932 a e Quali ration a Backs is INDUSTRIES, me ivisior 06/88CONTENTS INTRODUCTION Page 2 OPERATION INSTRUCTIONS 3 conrroLs 4 peers ea BLADE TRACKING u-16 FEED PRESSURE 17-18 SPECIFICATIONS 20 When ordering parts be sure to state serial number of your machine. Replacement parts can be ordered through your local KALAMAZ00 e Distributor. KALAMAZOO HORIZONTAL BANDSAW APPLICATIONS MANUAL INTRODUCTION ‘The following manual has been prepared to enable the user of the Kalamazoo Horizontal Bandsaw to better understand the machine and receive the maximum benefits from the Kalamazoo Saw. Periodically the user may encounter sawing problems, and this guide will help solve these problems without expensive waste of "down" time. Periodic servicing of any machine is necessary, and this guide will help the average service and/or maintenance individual service the saw with a minimum delay, cost, or confusion. HEREIN YOU WILL FIND: I. General operating instructions and working explanations of how the controls interact. 8 II. Trouble shooting guide listing potential problems, causes, and solutions. III. Adjustments to be made when correcting problems. IV. Specifications.OPERATING INSTRUCTIONS BLADE INSTALLATION - Move idler bandwheel to right until new blade may be placed around wheels under flanges and inserted between guide rollers. ‘Tighten blade until it is just taut and then ADD ONE FULL TURN OF TENSION HANDLE. After about 6 cuts retension the blade. BLADE SELECTION - RAKER SET BLADES ARE RECOMMENDED. Thickness of stock determines number of teeth per inch. Never less than 2-3 should be in contact with the stock if possible and no more than 7, Blades with 8, 10, or 12 TPI are most suitable for all general purpose sawing. Coarser blades produce faster cutting in solid stock and finer blades may be necessary for very thin sections. BLADE SPEED - The following chart is a guide to blade speed selection and is based on dry cutting. Speed should be increased one step if cutting wet. Speed is indicated as belt position in step pulleys with 1 as lowest speed. Lowest speed is obtained with belt in smallest diameter groove of motor pulley. BLADE SPEED MATERIAL ‘Model 7A ‘Model 8A Model 98 ‘Model 138 Carbon Stee! 2 2 2 2 Alloy Steel 2 2 2 2 Tool Stee! 1 2 2 2 Stainless Steel 1 2 2 2 ‘Aluminum 3 4 4 4 Brass 2 3 3 3 Structural 2 2 2 2 FEED PRESSURE - Feed pressure or head weight is determined by weighing the head at the blade tension handle (under the corner of the frame on model 7A) with fish or rag scales. (see diagram) It is adjusted with the counter balance springs. (see feed pressure adjustments, sec. 3) The following table shows desirable frame weights for each model. For dry cutting, use lower of weights. ‘MODEL FRAME WEIGHT - LBS. 7A 710 8A 10-12 9A 10-12 HOA 1214 13 812MAKING CUT - Raise head and close hydraulic. Place stock in vise and clamp. Start motor. Open hydraulic slightly e and lower head GENTLY to start cut. After blade teeth are fully engaged in cut, open hydraulic full for solid stock. In thin wall stock, control downward travel with hydraulic. Machine will stop automatically at the end of cut. UNDERSTANDING THE SAWING CONTROLS FEED PRESSURE Required to make the saw frame move. Required for chip removal Should be "Heavier" on materials with low machinability rating; "lighter" on materials that are more easily machined. Excessive feed pressure leads to early failure of the blade and/or crooked cuts. Increases in feed pressure will normally call for corresponding increases in blade speéd especially in less hard materials. Inadequate feed pressure dulls the blade, as it tends to rub rather than cut. For proper adjustment, see Sec. ITI. BLADE SPEED Controls how quickly the material is being removed. Gece stnetievacentes oleestesaet iia eoan (cece Should not be too fast or the chip load becomes less than optimum and/or the blade may dull prematurely. Any increases in blade speed must call for corresponding increases in feed pressure to maximize chip load, especially in less hard materials. FEED SPEED Controls, (infinitely) how fast the saw frame moves. Should be set so the saw frame moves only as fast as the material is being removed. Should be set for a slow enough approach to the work to ‘avoid damage to the blade upon contact with the work. Can be used to control sawing movement with precision during the thinner portions of light tubing or structurals; helps to avoid plunging. If set too slow chip load will be less than optimum. CHIP LOAD Careful observation of the chip load is very important when sawing. Chips should be nicely curled. chips that show excessive tight curling indicate too much @ feed pressure. Chips that show a lack of any curl indicate feed pressure that is too light. Chips that turn out blue in color indicate too much blade speed and/or too much feed pressure, leading to premature blade failure.PROBLEM Motor will not start Motor will not start and fuses or circuit breaker "blows" Motor overheats, fails to develop full’ power, or heaters trip out often. Coolant motor will not work. TOUBLE SHOOTING GUIDE PROBABLE CAUSE Switch not reset Low voltage or wrong voltage to saw Coil in manual motor starter "open" burned up Open circuit in line, cord, or plug Short in line or plug Short in motor wiring or motor leads Incorrect or faulty fuses or circuit breaker Power line overloaded Undersized wiring to machine or cord length too long. General overloading of Power company's facilities (especially in hot weather) Motor overloaded Fuse blown Transformer burned up Pump switch faulty. Pump impeller "frozen" SOLUTION 7A_- push button on safe-start plug 8A, 9A, 13A - depress toggle on manual starter Check wiring and voltage requirements Replace coil or entire switch 8A, 9A, 13A only Check all wiring and connections. Inspect wiring and connections. Inspect motor leads and connections. Have motor checked. Install correct fuses or circuit breaker. Redistribute load on power line. Replace with properly sized wiring. Request voltage check from the power company. Reduce the load on the motor. Replace fuse. Replace transformer. Check pump switch wiring or replace switch Remove strainer basket beneath the pump and free impeller, Clean out the tank of chips and swarf.TROUBLE SHOOTING GUIDE CONTINUED PROBLEM Coolant motor will not work-continued Broken blades PROBABLE CAUSE Pump defective or burned out Coolant low Worn belts or pulley Feed speed too fast Excessive feed pressure Incorrect blade selection Incorrect blade speed Improper belt tension Excessive feed pressure Improper tracking Incorrect blade speed Improper guide adjustment/alignment Improper blade tension (too tight or too loose) Incorrect blade selection Feed speed too fast Work piece is not properly clamped in vise SOLUTION Replace the pump. Add coolant. Pump must be 3/4 submersed at all times. Replace either. Slow head descent with hydraulic cylinder. Reduce feed pressure, see pages 17-18. See blade selection chart, page 3. See blade speed selection, page 3. See that the motor hangs freely to provide correct tension. Reduce feed pressure, see pages 17-18. Check tracking & adjust, see pages 11-16. See blade speed selec~ tion, page 3. Adjust guides, 16. see page Check blade tension, see page 3. See blade selection, see page 3. Slow head speed descent with hydraulic cylinder. Clamp material securely and make sure it will not move.TROUBLE SHOOTING GUIDE CONTINUED PROBLEM Broken Blades-- continued Teeth strippage Crooked cuts PROBABLE CAUSE Cut off piece binding between blade and stock stop. Dry cutting Improper blade weld or anneal Chips and swarf build up on bandwheels Too many teeth per inch causing overloading of each tooth. Too few teeth per inch Excessive feed pressure Blade speed too slow Cutting rectangular pieces laying flat Piece not secured properly in vise Lack of control of feed speed Hard spots in stock Teeth too fine Excessive feed pressure Guides not properly supporting the blade Improper blade tension SOLUTION Move stock stop out of the way before completing the cut. Use coolant. Inspect blade. If breakage is occurring at or very near the weld, problem is with the weld or annealing of the weld. Clean often and check blade cleaning brush. Use a coarser blade. Use a finer tooth blade. Reduce feed pressure, see pages 17-18. Increase blade speed one step. Sit pieces up on end. Clamp material securely. Adjust feed speed properly, see page 3. Check with your supplier Use coarser blade. Reduce feed pressure, see pages 17-18. Check guides and make appropriate adjustments, see page 16. Review blade tension, see page 3.TROUBLE SHOOTING PROBLEM Crooked cuts -~ continued Poor Blade life Damage to back of blade GUIDE CONTINUED PROBABLE CAUSE Guides too far from the workpiece Blade teeth dull: Improper feed speed control Vise jaws not square with the blade Blade speed too slow Defective blade Flange worn from bandwheels causing "set" of blades to be flattened on one side. Dry cutting Blade speed too fast Feed speed too slow Blade too coarse Material too hard for the blade being used. Feed pressure too light Not using a hardback blade Tracking too hard against the bandwheels Carbide back-up missing on one. SOLUTION Move guides closer to the workpiece. Change the blade. Slow feed speed, page 3. see Loosen vise jaws and set to square with the blade. Increase blade speed, page 3. see Replace blade. Replace bandwheels and check tracing, see pages 11-15. Use a good grade of coolant. Add a coolant attachment to the machine if it does not have one. Reduce blade speed. Increase speed. Use a finer tooth blade. Obtain better quality blades. Increase feed pressure, see page 3. Replace flexible back blade with hardback or weld-edge blade. Check and re-cant band- wheels, see pages 11-15. Replace carbide back-up.TROUBLE SHOOTING GUIDE CONTINUED e PROBLEM _ PROBABLE CAUSE. SOLUTION Increase in cutting time Will not cut Blade comes off the bandwheel Chatter during cut Vise will not clamp work Dull blade Feed pressure too light Wrong blade speed running in direction pointing in. wrong direction. Teeth must point in direction of travel Motor wrong Teeth Hardened material Improper tracking Improper blade tension Blade speed is too fast Blade selection incorrect Bandwheels or pulleys loose Guide arms too close on small diameter pieces Vise nut not seated Worn nut Excessive swarf and chips in assembly. Replace blade. Increase feed pressure, see page 3. See blade speed chart, see page 3. Reverse rotation. Remove blade and twist inside out. Use alloy or weld-edge blades. Check and re-cant bandwheels, see pages 11-15, Increase blade tension. Reduce Speed. Change blade, see sawing guide page 3. Tighten or replace items at fault Moving guide arm to be set 2"-3" from work piece. Especially on new machines or new replace ment nuts, a slight tap with a soft mallet will seat the nut and probably eliminate the problem thereafter Replace nut. Note:\Most wear is caused by over tightening Clean and repla:TROUBLE SHOOTING GUIDE CONTINUED PROBLEM Vise will not clamp work - continued Head feed speed problem Head will not come down, or comes down’ in erratic and jerky manner Head bounces during cut 10 PROBABLE CAUSE _ Broken or missing pins or spring Worn lead ‘screw Elongated hole in vise block Head falls out of control Cannot shut off hydraulic assembly Head descent "mushy" Oil leakage from hydraulic cylinder pirty oil in hydraulic assembly or bind at pivot area. Bad weld in blade ‘Teeth missing on blade Head weight too light Loose pulleys or bandwheels SOLUTION Replace nut assembly Replace lead screw Replace vise block Replace leather cup and seals or entire hydraulic assembly. Replace leather cup, needle valve or entire assembly. Replenish cylinder with light hydraulic oil through two screws in top of cylinder, Replace seals or entire assembly. Replace oil in hydraulic assembly, replace needle valve in hydraulic cylinder or replace entire assembly. OR Add oil to pivot oilers, check to see pivot is free and examine adjusting collar assembly between frame and bed to insure that it has not gotten loose and expanded too far. The collar should be snug not tightly bound. Replace blade Replace blade Add to feed pressure, see page 3. faulty itemsBLADE TRACKING After properly installing and tensioning the blade you should check to see that it is tracking properly at the points shown in figure 1. Referring to figure 2B you can see that when the bandwheels are canted properly the blade is running just nicely against the flange. Improper blade tracking results from excessive cant (fig. 2C) or negative cant (fig. 2A). These conditions can be corrected with the adjusting screws on the rocker block (idle wheel end) and the gearbox (drive wheel end). When it is suspected that tracking is improper, adjustments should be made only after removing the blade guides to make sure that they are not a part of the problem. IDLER WHEEL DRIVE WHEEL, CHECK TRACKING AT ARROWS FIG. 1 NEGATIVE CANT fap wee (CORRECT TRACKING Fig 28 = EXCESSIVE CANT ee 5 WORN FLANGE FIG, 2c, cEDRIVE WHEEL END TRACKING ADJUSTMENT Note which condition must be corrected. Remove all tension from the bandwheels. Locate two hex head bolts under the inside cover, behind the drive wheel (fig. 3). Crack these bolts loose just slightly. Locate two set screws on the gearcase (fig. 4). Looser. the lock nut of each one of these screws, while maintaining set screw position with an allen key. The Adjustment - Adjusting for negative cant - Turn the right hand set screw counterclockwise one fourth turn and tighten lock nut. Turn the left hand set screw clockwise one fourth turn and tighten the lock nut. Tighten the hex head bolts. Tension the blade and check tracking. Repeat the operation if further adjustment is necessary. Adjusting for excessive cant - Turn the left hand set screw counterclockwise one fourth turn and tighten lock nut. Turn the right hand set screw clockwise one fourth turn and tighten the lock nut. Tighten the hex head bolts. Tension the blade and check tracking. Repeat the operation if further adjustment is necessary. Note: After correcting drive wheel cant, be sure to check the opposite end wheel also. 12FIG. 4 MDRIVE WHEEL, HUB) SET SCREW RH) LOCK NUT GEAR CASE 1Bu Tighten the hex head bolts. Tension the blade and check tracking. Repeat the operation if further adjustments are necessary. Adjustment for excessive cant Turn the right hand set screw counterclockwise one fourth turn. Turn the left hand set screw one fourth turn clockwise. Tighten the hex head bolts. Tension the blade and check tracking. Repeat the operation of further adjustments are necessary. Note: After checking wheel cant be sure to check the opposite end wheel. oo / @ © \ ° o LS 4 9 ON esIDLER WHEEL END ADJUSTMENT JA saw Note which condition must be corrected. Remove all tension from bandwheels Locate two socket head screws behind the idler wheel (fig. 5). Adjusting for negative cant Turn the left hand screw one fourth turn counterclockwise. Turn the right hand screw one quarter turn clockwise. Tension the blade and check tracking. Repeat the operation if any further adjustment is necessary. Adjusting for excessive cant Turn the right hand screw one fourth turn counterclockwise. Turn the left hand screw one quarter turn clockwise. Tension the blade and check tracking. Repeat the operation if any further adjustment is necessary. 8A, 9A, 13A Saws Note which condition must be corrected. Remove all tension from the bandwheels. Locate the four hex head bolts on the slide block (fig. 6), on the underside of the head. Crack these bolts loose just slightly. Locate two socket head set screws in the rocker block (fig. 7), behind the idler wheel. Adjustment for negative cant Turn the left hand set screw counterclockwise one fourth turn, Turn the right hand set screw clockwise one fourth turn.16 BLADE GUIDE INSTALLATION & ADJUSTMENTS MODELS 7A, 8A, 9A, & 13A Prior to installing or adjusting the blade guide block assemblies the blade must be in place, properly tensioned and tracking correctly on the bandwheels. Once the blade guide block assembly is attached to the guide arm there are two adjustments to be made: 1. Vertical adjustment - The guide block should be moved up or down in the slotted hole of the guide arm so that there is approximately 1/64" gap between the top of the blade and the carbide insert on the underside of the guide block. Tighten the hex head bolt to lock the guide block assembly to the guide arm. 2. Roller adjustment - The rear roller is mounted on a fixed spindle and not adjustable. ‘The front roller is mounted on an eccentric spindle which allows it to be move laterally to the blade. Loosen the lock nut and adjust the eccentric in a counter-clockwise direction snugly against the blade. Do not tighten the rollers too tightly against the blade or you will cause undue wear on the rollers and risk damaging the blade. ReyFEED PRESSURE e 13AW (Fig. 9) Feed pressure or head weight may be adjusted with the extension springs at the rear of the machine. Extending these springs will reduce head weight. The spring is extended by loosening the lock nut and turning the adjusting nut towards the spring. When you have neared the proper range, the fine adjustment knob may be used to insure equal feed pressure throughout the entire range of travel. The saw head must be fully raised for adjusting these springs. Head weight may be determined by first raising the head a few inches above the bed, hooking a fish or rag scale to the blade tension handle at the end of the frame and letting the head drop. For all normal cutting in solid stock it should be approximately 12 - 14 lbs. for a wet cutting machine and 10-12 lbs. when cutting dry. When all adjustment is exhausted, these springs should be replaced. ADJSTMENT KNOB INC AQJUSTHENT FIG.10 FEED PRESSURE HOAW (Fig. 10) Feed pressure or head weight may be adjusted with the two extension springs at the rear of the machine. The two knobs at the top of the springs extend or shorten the springs. Extending the springs will reduce head weight. Head weight may be determined by raising the end of the frame a few inches above the bed, hooking a fish or rag scale to the tension handle at the end of the frame and letting the head drop. For all normal cutting in solid stock it should thin sections. When the head weight can not be maintained and no further adjustment of the springs is possible, the spring should be replaced.FEED PRESSURE JAW (Fig. 11) Feed pressure or head weight may be adjusted with the single extension spring at the rear of the machine. The two knobs at the lower end of the spring extend or shorten the spring. Extending the spring will reduce head weight. Head weight may be determined by raising the end of the frame a few inches off the bed and hooking a fish or rag scale under the end of the frame and letting the head drop. When measured to this Point the head should weigh 8 lbs. for a dry machine and 10 Ibs. for a wet machine. When head weight can not be maintained and no further adjustment of the spring is possible, it should be replaced. ) seen ne YF sD.usting «wos J Fig. FEED PRESSURE HEAW (Fig. 12) Feed pressure or head weight may be adjusted with the extension spring at the rear of the machine. Extending the spring will reduce head weight. The spring is extended by swinging the cam handle near the top of the spring. The saw head must be fully raised before adjusting cam. Head weight may be determined by raising the end of the frame a few inches above the bed, hooking a fish or rag scale to the blade tension handle atthe end of the frame and letting it drop. For all normal cutting in solid stock, it should be approximately 10-12 lbs. for a wet cutting machine and 8-10 lbs. when cutting dry. When all adjustment is exhausted, move the top spring hook to the higher hole. When all adjustment is exhausted there, the spring should be replaced. 18[Pxc, Model Cutting Capacities @ 90° | Vise Speed Motor Blade | Shipping "roy No. Round | Rectangular |Opening| Range (FPM) | Horsepower | width | Weight (Io,) a — MZAD_ 320 M7AW r Tome | a2 50, 90, 155 HP Ye" 348 TAD. 200 AW. 306 vai 8 stxig%e" | 16" _| 50,95, 160,275 +HP. ye 650 a 8 ‘erx2a" | 2a" 62390 2HP. 7 890. 82 [How s ox tae= | 16" 62-390 HE £ 8 Se Tisaw 13° 13x19" | 20" 65-345 2HP + 1152 ye pea o orxig | 16" 62-390 2HP 7 1100 42 Pisa-sa is igrxtg- | 20" 65-345 2He +r 1420 33 pasa oie) 12 (62 - 390 BHP: ca 1288 2 13A-A 12" 12° x12" 12" 65-345 2HP + 1620 Height [Diameter of Model | to Working Blade Cutting Capacity @ 45° Vertical Capacity Standard Series_| Surtace Blade Used Wheet_[~ Round |Rectangular(hxw)| (hx w) Electricals* 7A a ex 025 x7 x 10" = Pixs (C7AD) 6 x7 116\607 a6 Ea 3 x.082" x 105" 1 © exe (Gw.006) 13° 8A aie 1x 085" 12 1 = exe NA 118723006071 ®A Bie 1x 085" x10 108 1 * ox NA or 13a Bir 17x 085x131 18 1 1x NA 2osres0460/575/60/8 Ansaw | 2518 1x 085" T0107" 14 NA NA NA 13KA 258 1 x008"x 19 18 NA NA NA 208/230/460/60'3 . tage and Overload Protection are standard on all models. sU0ROIWPOdse j @ @ / . a as et AY “ N. 9A mas, ARM TRAVEL ‘5 - f 7 (a | we JBA4 13 FRAME CLOSED 2 HA 4° TI sn ryyue cuoseo Ae I | \ Lan Faas vost _. T T 1 a rhawe cose 9 ATTY TT 7 x : x. - Si. 1 FULT I I s ol i T Wht \ TOT Keo al T i ‘| L | i OW wes eee a2 wes aise we 8 7 eS a 3 2 TO STOCK WIDTH INCHES eA MAX Wise OPENNG MAXIMUM CAPACITY DIAGRAM HORIZONTAL SAWS 90° CUT