14” SELF-FEED VERTICAL METAL CUTTING BANDSAW INSTRUCTION MANUAL MODEL: KC-914H COPYRIGHT © 2004 ALL RIGHTS RESERVED BY KING CANADA TOOLS INC. IMPORTANT INFORMATION 2-YEAR LIMITED WARRANTY FOR THIS METAL CUTTING BANDSAW KING CANADA TOOLS OFFERS A 2-YEAR LIMITED WARANTY FOR INDUSTRIAL USE. PROOF OF PURCHASE Please keep your dated proof of purchase for warranty and servicing purposes. REPLACEMENT PARTS Replacement parts for this tool are available at our authorized KING CANADA service centers across Canada. For servicing, contact or return to the retailer where you purchased your product along with your proof of purchase. LIMITED TOOL WARRANTY KING CANADA makes every effort to ensure that this product meets high quality and durability standards. KING CANADA warrants to the original retail consumer a 1-year limited warranty as of the date the product was purchased at retail and that each product is free from defects in materials. Warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents, repairs or alterations and lack of maintenance. KING CANADA shall in no event be liable for death, injuries to persons or property or for incidental, special or consequential damages arising from the use of our products. To take advantage of this warranty, the product or part must be returned for examination by the retailer. Shipping and handling charges may apply. If a defect is found, KING CANADA will either repair or replace the product. PARTS DIAGRAM & PARTS LISTS Refer to the Parts section of the King Canada web site for the most updated parts diagram and parts list. KING CANADA TOOLS INC. DORVAL, QUEBEC, CANADA H9P 2Y4 GENERAL & SPECIFIC SAFETY INSTRUCTIONS VOLTAGE WARNING: Before connecting the tool to a power source (receptacle, outlet, etc.) be sure the voltage supplied is the same as that specified on the nameplate of the tool. A power source with voltage greater than that for the specified tool can result in SERIOUS INJURY to the user - as well as damage to the tool. If in doubt DO NOT PLUG IN THE TOOL. Using a power source with voltage less than the nameplate is harmful to the motor. 1. KNOW YOUR TOOL Read and understand the owners manual and labels affixed to the tool. Learn its application and limitations as well as its specific potential hazards. 2. GROUND THE TOOL. This tool is equipped with an approved 3-conductor cord and a 3-prong grounding type plug to fit the proper grounding type receptacle. The green conductor in the cord is the grounding wire. NEVER connect the green wire to a live terminal. 3. KEEP GUARDS IN PLACE. Keep in good working order, properly adjusted and aligned. 4. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. 5. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. Make sure the floor is clean and not slippery due to wax and sawdust build-up. 6. AVOID DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet locations or expose them to rain. Keep work area well lit and provide adequate surrounding work space. 7. KEEP CHILDREN AWAY. All visitors should be kept a safe distance from work area. 8. MAKE WORKSHOP CHILD-PROOF. Use padlocks, master switches or remove starter keys. 9. USE PROPER SPEED. A tool will do a better and safer job when operated at the proper speed. 10. USE RIGHT TOOL. Don’t force the tool or the attachment to do a job for which it was not designed. 11. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties or jewelry (rings, watch) because they could get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. Roll up long sleeves above the elbows. 12. ALWAYS WEAR SAFETY GLASSES. Always wear safety glasses (ANSI Z87.1). Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses. Also use a face or dust mask if cutting operation is dusty. 13. DON’T OVERREACH. Keep proper footing and balance at all times. 14. MAINTAIN TOOL WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. 15. DISCONNECT TOOLS. Before servicing, when changing accessories or attachments. 16. AVOID ACCIDENTAL STARTING. Make sure the switch is in the ‘’OFF’’ position before plugging in. 17. USE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories. Follow the instructions that accompany the accessories. The use of improper accessories may cause hazards. 18. NEVER STAND ON TOOL. Serious injury could occur if the tool tips over. Do not store materials such that it is necessary to stand on the tool to reach them. 19. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other parts that are damaged should be carefully checked to ensure that they will operate properly and perform their intended function. Check for alignment of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other parts that are damaged should be properly repaired or replaced. 20. NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power ‘’OFF’’. Don’t leave any tool running until it comes to a complete stop. 1. If you are not thoroughly familiar with the operation of Bandsaws, obtain advice from your supervisor, instructor or other qualified person. 2. Adjust and position the blade guard before starting the cut. 3. Keep blade guard tight. A loose blade guard will affect sawing accuracy. 4. Make sure that blade tension and blade tracking are properly adjusted. 5. Make sure blade speed is set correctly for material being cut. 6. Always have stock firmly clamped in vise before starting cut. 7) Be sure the blade is not in contact with the workpiece when the motor is started. The motor should be started and you should allow the saw to come up to full speed before bringing the saw blade into contact with the work piece. 8) The saw must be stopped and the electrical supply must be cut off before any blade replacement or adjustment of the blade support mechanism is done, or before any attempt is made to change the drive belts or before any periodic service or maintenance is performed on the saw. SPECIFIC SAFETY INSTRUCTIONS ELECTRICAL INFORMATION WARNING! ALL ELECTRICAL CONNECTIONS MUST BE DONE BY A QUALIFIED ELECTRICIAN. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY! ALL ADJUSTMENTS OR REPAIRS MUST BE DONE WITH THE BANDSAW DISCONNECTED FROM THE POWER SOURCE. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY! POWER SUPPLY WARNING: YOUR BANDSAW MUST BE CONNECTED TO A 110V, 15-AMP, BRANCH CIRCUIT. FAILURE TO CONNECT IN THIS WAY CAN RESULT IN INJURY FROM SHOCK OR FIRE. GROUNDING WARNING: IF NOT PROPERLY GROUNDED, THIS BANDSAW CAN CAUSE ELECTRICAL SHOCK, PARTICULARLY WHEN USED IN DAMP LOCATIONS. TO AVOID SHOCK OR FIRE, IF THE POWER CORD IS WORN OR DAMAGED IN ANY WAY, HAVE IT REPLACED IMMEDIATELY. Your bandsaw must be properly grounded. Not all outlets are properly grounded. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician. This bandsaw must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current, to reduce the risk of electric shock. This bandsaw is equipped with a cord having an equipment-grounding conductor and grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances. WARNING: TO MAINTAIN PROPER GROUNDING OF YOUR BANDSAW, DO NOT REMOVE OR ALTER THE GROUNDING PRONG IN ANY MANNER. 110V OPERATION As received from the factory, your bandsaw is ready to run for 110V operation. This bandsaw is intended for use on a circuit that has an outlet and a plug which looks like the one illustrated in Fig.1. WARNING: DO NOT USE A TWO-PRONG ADAPTOR FOR THEY ARE NOT IN ACCORDANCE WITH LOCAL CODES AND ORDINANCES. NEVER USE IN CANADA. 220V OPERATION If 220V, single phase operation is desired, the following instructions must be followed: 1. Disconnect the machine from its power source. 2. The bandsaw comes with four motor leads that are connected for 110V operation. Reconnect these four motor leads for 220V operation, as indicated in the wiring digrams. 3. The 110V plug supplied with the band saw must be replaced with a CSA listed plug suitable for 220V operation. This plug is illustrated in Fig.2. Contact your authorized service center or qualified electrician to install the plug and to change the connections from 110V to 220V. The bandsaw must comply with all local and national codes after the 220V plug is installed. 4. A bandsaw with a 220V plug should only be connected to an outlet having the same configuration as illustrated by the grounded outlet box in Fig.2. No adaptor is available or should be used for 220V operation. EXTENSION CORDS The use of any extension cord will cause some loss of power. Use the following table to determine the minimum wire size (A.W.G-American Wire Gauge) extension cord. Use only 3-wire extension cords which have 3-prong grounding type plugs and 3-hole receptacles which accept the tool’s plug. For circuits that are further away from the electrical circuit box, the wire size must be increased proportionately in order to deliver ample voltage to the bandsaw motor. Refer to Fig.3 for wire length and size. PROPERLY GROUNDED OUTLET CURRENT CARRYING PRONGS GROUNDING PRONG FIGURE 1 PROPERLY GROUNDED OUTLET CURRENT CARRYING PRONGS GROUNDING PRONG FIGURE 2 LENGTH OF CONDUCTOR 0-25 FEET 26-50 FEET 51-100 FEET WIRE SIZES REQUIRED (AMERICAN WIRE GAUGE) 110V LINES NO.16 NO.14 NO.12 FIGURE 3 WIRING DIAGRAMS & BANDSAW SPECIFICATIONS 110V Wiring Diagram 220V Wiring Diagram FIGURE 4 FIGURE 5 KC-914H Specifications MODEL Height under guides Throat capacity Speeds (S.F.P.M) Blade width (min. - max.) Blade length Table size Table height from floor Motor Voltage Prewired Dimensions (LxWxH) Weight KC-914H 14” 8 1/2” 4 (70, 140, 280, 580) 1/8” - 1” 120” 18 1/2” x 30 1/2” 30” 15 Amp. @ 110V/ 7 Amp. @ 220V 110V/220V, 1 phase, 60 Hz 110V 45” x 33” x 68” 550 LBS GETTING TO KNOW YOUR BANDSAW A B L C P D K J M E F G O H N Getting to know your Bandsaw I FIGURE 6 A-Blade Tension Handle. Used to set the correct blade tension. Also used to remove and install the saw blade. B-Work Light. Illuminates the work table during operations. has independant power source and on/off switch. C-Upper Blade Guide. Should be adjusted so it clears your work by approximately 1/2”. This will ensure maximum blade rigidity. D-”C” Clamp Vise. It is recommended to fasten all workpieces in vise before making any cut. E-Hydraulic Control. Turning this dial counterclockwise unlocks the release lever (H). F-Hydraulic Feed Rate Control. Used to adjust the hydraulic feed rate. G-On/Off Switch. Turns the machine on or off. H-Saw Frame Release Lever. Pull up on this lever to release the saw frame after unlocking it and push down to return the saw frame to its rear most rest position. I-Leveling Foot (4). Adjust hex. bolt position to level the machine on an uneven floor. J-Depth Stop Knob. Locks the depth stop in position. K-Depth Stop. Allows cuts at a predetermined depth. L-Upper Blade Wheel Blade Tracking Adjustment (See Blade Tracking Adjustments). If your saw should get out of adjustment and the blade runs off the wheel or runs back against the lip, loosen the two bottom cap screws on the upper wheel sliding bracket. Turn the set screw in or out to make the blade run approximatey 1/32” away from the lip on the back of the wheel. Retighten the two upper wheel slide cap screws. IMPORTANT: If the blade is allowed to run against the lip on the wheel, it will wear the lip off. M-Lower Blade Guide. This blade guide is fixed to the saw frame. N-Counter Weight & Hydraulic Cylinder. These should be adjusted to allow the frame to travel rapidly but not free fall. This is a safety device and should be kept properly adjusted. O-Table Roller. Allows easy stock positioning. P-Lock Knob for Blade Guide Bar. Used to lock the upper blade guide in position. SET-UP, ADJUSTMENTS & OPERATION Set-up & Installation Caution! Do not install the machine in a damp, humid, dirty or badly lit environment. The bandsaw has been pre-adjusted at the factory. Place the bandsaw on the shop floor. This machine must be installed on a firm, level surface. Adjust the level of the worktable by adjusting the four leveling feet. If the saw will be used to cut long pieces of stock, allow plenty of room for the length of the stock. Cleaning All unpainted surfaces of the machine are treated with a rust proof grease. Clean all rust protected surfaces with a mild solvent. Do not use paint thinner, lacquer thinner, gasoline or mineral spirits; these will damage painted surfaces. Operation General Always wear approved safety glasses when using this machine. Before operating the machine, remove neck tie, rings, watches and other jewelry, and roll sleeves past the elbows. Remove all loose clothing and confine long hair. Non-slip footwear is recommended. Do not wear gloves when operating the bandsaw. 1) Never use the machine if it is missing any guards or other safety devices. 2) Maintain a balanced stance at all times so that you do not fall or lean against the saw blade or other moving parts. 3) Never leave the machine running. Always make sure it has come to a complete stop before the leaving the machine. Controls On/Off Switch (G-Fig. 6) Located on the right side of the control panel. Press this switch to start or stop the machine. Hydraulic Feed Rate Control (F-Fig.6) Located on the bottom left side of the control panel. This dial is the hydraulic cylinder feed control valve. It is used to set the amount of force that is applied to the saw blade, in combination with the couterbalance force. The feed rate is proportional to the opening of the valve. Increasing the valve opening (counterclockwise) increases the feed rate; decreasing the valve opening (clockwise) reduces the feed rate, including a full stop. Blade Speeds (See Speed Chart Fig.7). This bandsaw has four blade speeds. The different speeds are obtained by changing the position of the motor drive V-belt on step pulleys. Change blade speeds as follows: Caution!: Change speeds only when the machine is not running. 1) Disconnect the power cord from the power source to prevent accidental motor start-up. 2) Place the saw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed rate control (E-Fig.6) clockwise. 3) Remove the cabinet side panel (diagram# 173) to expose the V-belt and pulleys. 4) Lift the motor by hand to loosen the belt tension. 5) Select the speed using the blade speed chart fixed on the machine (Fig.7). Put the V-belt in the pulley grooves of the pulley for the desired speed (Refer to Figure 7 for belt locations and the speeds available). 6) Lower the motor to retension the V-belt. FIGURE 7 ADJUSTMENTS & OPERATION Blade Selection This bandsaw is equipped with a saw blade that is adequate for a variety of jobs on a variety of common materials. Refer to Fig. 8 below for the speeds recommended for various materials. These speeds, while appropriate for many common cutting needs, do not encompass the wide variety of special blade configurations (tooth pitch and set) and special alloys for cutting unusual or exotic materials. A coarse blade could be used for a solid steel bar, but a finer tooth blade would be used on a thin-wall steel tube. In general, the blade choice is determined by the thickness of the material; the thinner the materials, the finer the tooth pitch. A minimum of three teeth should be on the work piece at all times for proper cutting. The blade and workpiece can be damaged if the teeth are so far apart that they straddle the work piece. For very high production cutting of special materials, or to hard-to-cut materials such as stainless steel, tool steel or titanium, you can ask your industrial distributor for more specific blade recommendations. The supplier that provides the workpiece material should be able to provide you with very specific instructions regarding the best blade (and coolant or cutting fluid, if needed) for the material or shape supplied. Blade Removal and Installation FIGURE 8 Warning! Use leather gloves when changing the saw blade to protect your hands from cuts and scratches. Use protective eye wear that meets ANSI specifications. Warning! Disconnect the bandsaw from its electrical power source. 1) To remove the blade, place the saw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed stop dial (E-Fig.6) clockwise. 2) Remove the cabinet side panel (diagram# 173) to expose the lower blade wheel. 3) Open the upper wheel cover (diagram# 124) to expose the upper blade wheel. 4) Remove the blade safety guard (diagram# 41) . 5) Turn the blade tension handle (A-Fig.6) counterclockwise until the blade hangs loose. 6) Use leather gloves to prevent cuts and scratches. Pull the blade off the drive wheels and out of the blade guides. Store the removed blade carefully before proceeding. 7) To install the blade, slide the new blade into the blade guides. 8) Place the blade over the bottom wheel. 9) Place the blade over the top wheel. The teeth must point down toward the table. 10) Push the blade so it is seated against the shoulders of the wheels. 11) Turn the blade tension handle clockwise enough to hold the blade firmly in place. 12) Reconnect the saw to its electrical power source. 13) Turn the machine on to allow the blade to position itself. Check and adjust the tracking of the blade. Refer to Blade Tracking Adjustments in this manual. 14) Turn the blade tension handle clockwise to finish tightening the blade. Do not over-tighten the blade; tighten it just enough so it does not slip while cutting. 15) Reinstall the wheel guards and blade covers. The most common causes of your bandsaw not cutting straight are: 1) Blade tension is set too low. 2) The blade is either dull or worn on one side. Blade teeth may have lost their set. 3) The blade is upside down. The teeth must point down toward the table. ADJUSTMENTS & OPERATION Blade Break-In Procedures New blades are very sharp and, therefore, have a tooth geometry which is easily damaged if a careful break-in procedure is not followed. 1) 2) 3) 4) 5) Clamp a section of round stock in the vise. The stock should be two inches or larger in diameter. Operate the bandsaw at low speed. Start the cut with a very light feed rate. When the saw has completed about 1/3 of the cut, increase the feed rate slightly and allow the saw to complete the cut. Keep the feed rate at the same setting and begin a second cut on the same or similar work piece. When the saw has completed about 1/3 of the cut, increase the feed rate while watching the chip information until cutting is at its most efficient rate (refer to Evaluating Cutting Efficiency in this manual). Allow the saw to complete the cut. 6) The blade is now considered ready for use. Controlling the Cut Hydraulic Feed Control The weight of the saw frame provides the force needed to cut through the workpiece. The saw has a hydraulic cylinder which controls the feed rate. The hydraulic feed control circuit consists of a single-acting hydraulic cylinder and a flow-control valve. The feed control cylinder resists motion in the forward direction to control the feed rate. When the cylinder is not locked, the control cylinder offers no resistance when the saw frame is moved backward. The hydraulic feed rate adjust dial on the control panel controls the rate at which the saw frame moves forward. The control knob (needle valve) controls the rate at which the hydraulic fluid is released from the hydraulic cylinder. When the needle valve is closed, the cylinder is locked and the saw frame release lever can not be pushed down to place the saw frame in the rearmost position. With the needle valve slightly open, the cylinder permits slow, or light, force. Opening the needle valve further increases the feed rate and applies more force to the saw blade and the workpiece. The needle valve is adjusted until the bandsaw is operating efficiently. The efficiency of operation is usually evaluated by observing chip formation. (Refer to Evaluating Cutting Efficiency for more information on cutting efficiency). Evaluating Cutting Efficiency Is the blade cutting efficiently? The best way to determine this is to observe the chips formed by the cutting blade. 1) If the chip formation is powdery, then the feed is much too light, or the blade is dull. 2) If the chips formed are curled, but colored - blue or straw colored from heat generated during the cut - then the feed rate is too high. 3) If the chips are slightly curled and are not colored by heat - the blade is sufficiently sharp and is cutting at its most efficient rate. Setting the Vise for Angle Cuts The vise can be adjusted from 0- 45˚. Adjust as follows: 1) Loosen the vise fixing hex. bolt (diagram# 140) and remove the taper pin and nut (diagram# 208) from the vise. 2) Rotate the vise to the desired angle. For accurate cuts, use a variable protractor to set the position of the jaw; align one side of the protractor with one side of the blade. 3) Tighten the hex. bolt on the vise. Setting the Vise for Square Cuts The procedure for setting the vise for square cuts is identical to setting for angle cuts except that a machinist’s square is used to position the vise (Re-install the taper pin and tighten the hex. bolt on the vise). Work Setup Move the bandsaw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed stop dial (E-Fig.6) clockwise. 1) Turn the lock handle (diagram# 129 & 130) counterclockwise enough to fit the stock. 2) Place the workpiece on the worktable. For long work pieces, provide support at the other end. If necessary, provide additional downward clamping to hold the workpiece securely on the worktable. 3) Clamp the workpiece in the vise by turning the lock handle clockwise. Caution! Do not allow the blade to rest against the workpiece when the saw is not cutting. ADJUSTMENTS, OPERATION SERVICE & MAINTENANCE Setting the Blade Guide Bar Height The bandsaw has an adjustable blade guide bar (diagram# 31). The blade guide bar allows you to set the blade guide for varying heights of workpieces. To make accurate cuts and prolong blade life, the blade guide bar and blade guide assembly should be set one inch above the piece to be cut. Adjust the bar position as follows: 1) Place the workpiece in the vise and clamp tightly. 2) Loosen the blade guide bar lock knob (diagram# 25) on the back of the guide bracket (P-Fig.6). 3) Slide the blade guide bar to the desired position. 4) Tighten the blade guide bar lock knob to secure the blade guide bar. Starting the Saw Warning! Never operate the saw without the blade covers in place. Caution! Make sure the blade is not in contact with the workpiece when the motor is started. Do not force the saw through the workpiece. 1) Move the bandsaw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed stop dial (E-Fig.6) clockwise. Workpiece position in vise 2) Clamp the work piece in the vise (Refer to Fig. 9 for examples of how FIGURE 9 different shaped work pieces are clamped in the vise). 3) Be sure that the blade is not in contact with the work piece when the motor is started. 4) Start the motor and allow the saw to come up to speed. 5) Turn the hydraulic feed rate adjust dial (F-Fig.6) clockwise all the way. This closes the hydraulic valve and stops the feed rate. 6) Turn the hydraulic feed stop dial (E-Fig.6) counterclockwise to the ON position. 7) Pull up on the saw frame release lever (H-Fig.6) to release the saw frame. 8) Slowly let the saw feed into the work piece by turning the hydraulic feed rate adjust dial (F-Fig.6) counterclockwise until the proper feed rate is reached. 9) Do not force the cut. Let the weight of the saw provide the cutting force. 10) If the force is insufficient, adjust the counterweight (diagram# 191) position to adjust the amount of force the saw puts on the workpiece. 11) Turn the lock knob on the counterweight counterclockwise to loosen it, slide counterweight into new position and retighten lock knob. 12) At the end of the cut, push down on the saw frame release lever to move the saw frame back to the rearmost position and turn the hydraulic feed stop dial (E-Fig.6) clockwise to lock it. Service and Maintenance Blade Tracking Adjustments Blade tracking has been tested at the factory. Adjustments are rarely required when the blade is used properly and if the blade is correctly welded. If an adjustment is needed, follow these instructions; 1) Move the bandsaw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed stop dial (E-Fig.6) clockwise. 2) Make sure the blade is properly tensioned. NOTE: Keep proper tension on the blade at all times using the blade tension adjustment. 3) Loosen the two bottom cap screws (diagram#18) on the wheel slide (L-Fig.6) using a hex. key. Caution! While performing the following steps, keep the blade from rubbing excessively on the shoulder of the wheel. Excessive rubbing will damage the wheel and/or the blade. 4) Check blade tracking before starting the saw, slowly turn the blade wheel by hand two or three revolutions. Make sure the blade is not touching the shoulder of the wheel and that no blade teeth are touching the blade guides and table. 5) Start the saw. Turn the set screw (diagram# 19) to tilt the upper blade wheel until the blade is touching the shoulder of the upper blade wheel. 6) Set the blade close to the shoulder, but not touching. Turn the set screw so the blade starts to move away from the shoulder of the wheel; then immediately turn the set screw in the other direction so the blade stops; then moves slowly towards the shoulder. Warning! Keep your fingers clear of the blade and wheel to avoid injury. 7) Tighten the two bottom hex. bolts on the upper wheel slide. ADJUSTMENTS, OPERATION SERVICE & MAINTENANCE Blade Guide Bearing Adjustment Proper adjustment of the blade guide bearings is critical to efficient operation of the bandsaw. The blade guide bearings are adjusted at the factory. They should rarely require adjustment. When adjustment is required, readjust immediately. Failure to maintain proper blade adjustment may cause serious blade damage or inaccurate cuts. It is always better to try a new blade when cutting performance is poor. If performance remains poor after changing the blade, make the necessary adjustments. If a new blade does not correct the problem, check the blade guides for proper spacing. For most efficient operation and maximum accuracy, provide 0.001” clearance between the blade and the guide bearings. The bearings will still turn freely with this clearance. If the clearance is incorrect, the blade may track off the drive wheel. Warning! Disconnect the bandsaw from its electrical power source. Caution! Check the blade to make sure the welded section is the same thickness as the rest of the blade. If the blade is thicker at the weld, the guide bearings may be damaged. If required, adjust the guide bearings as follows: 1) The upper and lower blade guides are adjusted the same way. 2) Loosen the 2 blade guide set screws (A-Fig.10) with a hex. key. 3) Position the bearing by turning the eccentric shaft (B-Fig.10). Set the clearance by approximately 0.001”. 4) Retighten the blade guide set screws with the hex. key. 5) Use the same procedure to adjust the other blade guide bearing. 6) When the adjustment is correct, the guide bearings should rotate freely with slight pressure of the finger (blade stopped). FIGURE 10 Cleaning 1. Clean off any oil and grease on the machine surfaces. 2. After cleaning, coat the machined surfaces of the bandsaw with a medium consistency machine oil. Reapply the oil coating at least every six months. 3. Clean up accumulated saw cuttings after use. Lubrication Lubricate the following components at the recommended intervals using the lubricants specified: 1. 2. 3. 4. Upper wheel bushing: six to eight drops of oil each week. Pivot points, shafts and bearing areas: six to eight drops of oil each week. Ball bearings: the bearings are lubricated and sealed, periodic lubrication is not required. Blade guide bearing: the bearings are lubricated and sealed, periodic lubrication is not required. Changing the Drive Motor V-Belt Warning! Disconnect the band saw from its electrical power source. 1. Move the bandsaw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed stop dial (E-Fig.6) clockwise. 2. Remove the cabinet side panel to expose the belt and pulleys. 3. Pivot the motor upwards to loosen the belt. 4. Remove the worn belt. 5. Put the replacement belt in the pulley position for the speed you require. 6. Tighten the belt by lowering the motor downward. 7. Replace the cabinet side panel and unlock the bandsaw frame. SERVICE & TROUBLESHOOTING Chip Brush and Chip Scraper Replacement The purpose of the chip brush and chip scraper is to remove chips from the saw teeth, the saw blade and the lower blade wheel so an excessive amount of chips do not get into the wheel guard section of the saw. With extended use, this brush and/or scraper will become worn and will require replacement. Warning! Disconnect the bandsaw from its power source. 1. Remove the two pan head screws and washers holding the brush (diagram# 83) or scraper (diagram# 98) on. 2. Remove the worn brush or scraper. 3. Install the replacement brush or scraper. 4. Install the two screws and washers. 5. Adjust the brackets, if necessary, so that the brush makes slight contact with the lower blade wheel and the scraper is as close as possible to the saw blade without touching it. Adjusting or Replacing the Counterweight The counterweight (diagram# 191) is located on the base of the saw. It is used to adjust the amount of force the saw puts on the work piece when the hydraulic control cylinder is open. Warning! Disconnect the bandsaw from its power source. 1. Move the bandsaw frame in the rearmost position by pushing down on the saw frame release lever (H-Fig.6) and lock it by turning the hydraulic feed stop dial (E-Fig.6) clockwise. 2. Turn the lock knob on the counterweight counterclockwise to loosen it. 3. Slide the counterweight along the bar to the proper location. 4. Turn the lock knob on the counterweight clockwise to tighten it. Suggested Remedy Probable Cause Problem 6. Blade rubs on the wheel flange. 7. Misaligned blade guides. 8. Cracking at the weld. 1. Clamp work securely. 2. Check the speed/feed appropriate for the material being cut. 3. Check for the recommended blade type. 4. Adjust the blade tension just to the point where the blade does not slip of the wheel. 5. Start the motor before placing the saw blade against the work piece. 6. Adjust the blade tracking. 7. Adjust the blade guides. 8. Use a longer annealing cycle. Premature Blade Dulling 1. 2. 3. 4. 5. 6. 7. 8. 1. 2. 3. 4. 5. 6. 7. 8. Blade is Twisting 1. Blade is binding in the cut. 2. Blade tension is too high. 1. Decrease the feed pressure. 2. Decrease the tension on the blade. Unusual Wear on Side/Back of Blade 1. Blade guides are worn. 2. Blade guide bearings are not adjusted. 3. Blade guide bearing bracket is loose. 1. Replace the blade guides. 2. Adjust the blade guide bearings. 3. Tighten the blade guide bearing bracket. Bad Cuts (Crooked) 1. Work piece is not square with the blade. 2. Feed pressure is too high. 3. Guide bearings are not adjusted properly. 4. Inadequate blade tension. 5. Span between the two blade guides is too wide. 6. Dull blade. 7. Incorrect blade speed. 8. Blade guide assembly is loose. 9. Blade guide bearing assembly is loose. 10. Blade track is too far away from the wheel flanges. 11. Guide bearing is worn. 1. Adjust the vise so that it is square with the blade (Always clamp the work piece tightly in the vise). 2. Lower the feed pressure. 3. Adjust the guide bearing clearance to 0.001” (0.002” max.). 4. Gradually increase the blade tension. 5. Move the blade guide bracket closer to the work piece. 6. Replace the blade. 7. Check the blade speed. 8. Tighten the blade guide assembly. 9. Tighten the blade guide bearing assembly. 10. Adjust the blade tracking. 11. Replace the worn bearing. 1. Blade speed is too high for the feed pressure. 2. Blade teeth are too coarse. 1. Reduce the blade speed. 2. Replace the blade with a finer tooth blade. Excessive Blade Breakage 1. 2. 3. 4. Material is loose in the vise. Incorrect speed or feed. Blade pitch is too coarse for the material. Incorrect blade tension. 5. Saw blade is in contact with the workpiece before saw is started. Bad Cuts (Rough) Blade pitch is too coarse. Blade speed is too high. Inadequate feed pressure. Hard spots in the workpiece. Scale on/in the workpiece. Work hardening of material (especially stainless steel). Insufficient blade tension. Operating the saw without pressure on the workpiece. Use a finer tooth blade. Use a lower blade speed. Decrease the feed speed pressure. Increase the feed pressure. Reduce the blade speed and increase the feed pressure. Increase the feed pressure. Increase the tension to the proper level. Do not run the blade in/on the material at idle.
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