TM-9-3405-210-14-and-P

TM-9-3405-210-14-and-P
TM 9-3405-210-14&P
TECHNICAL MANUAL
OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE
MANUAL INCLUDING REPAIR PARTS LIST
FOR
SAW, BAND, METAL CUTTING
MODEL 2614-1
(DO ALL COMPANY)
(NSN 3405-00-542-1328)
HEADQUARTERS, DEPARTMENT OF THE ARMY
JULY 1981
WARNINGS
When welding, step to one side to avoid welding sparks.
When grinding the welded band, keep hands away from rotating grinding wheel. Because it may be
difficult to see if the wheel if rotating. a pilot light is provided. This light is on when thegrinder motor is
running.
Disconnect electric power to the welder before making adjustments.
TM 9-3405-210-14&P
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 31 July 1981
Technical Manual
No. 9-3405-210-14&P
OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE
MANUAL INCLUDING REPAIR PARTS LIST
FOR
SAW, BAND, METAL CUTTING
MODEL 2614-1
(DO ALL COMPANY)
(NSN 3405-00-542-1328)
REPORTING OF ERRORS
You can help improve this manual. If you find any mistakes or if you know of a way
to improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2,
located in the back of this manual direct to: Commander, US Army Armament
Materiel Readiness Command, ATTN: DRSAR-MAS Rock Island, IL 61299.
A reply will be furnished directly to you.
NOTE
This manual is published for the purpose of identifying an authorized commercial manual for the use of
the personnel to whom this band saw is issued.
Manufactured by: Continental Machines, Inc.
Savage, Minnesota 55378
for:
DoALL Company
254 N. Laurel Avenue
Des Plaines, II. 60016
Procured under Contract No. DAAAO977-C-7006
This technical manual is an authentication of the manufacturers’ commercial
literature and does not conform with the format and content specified in AR 310-3.
Military Publications. This technical manual does, however, contain available
information that is essential to the operation and maintenance of the equipment.
i /(ii blank)
INSTRUCTIONS FOR REQUISITIONING PARTS
NOT IDENTIFIED BY NSN
When requisitioning parts not identified by National Stock Number, it is
mandatory that the following information be furnished the supply officer.
1 -
Manufacturer's Federal Supply Code Number - 18056
2 - Manufacturer's Part Number exactly as listed herein.
3 -
Nomenclature exactly as listed herein, including dimensions, if
necessary.
4 -
Manufacturer's Model Number - Model 2614-1
5 -
Manufacturer's Serial Number (End Item)
6 -
Any other information such as Type, Frame Number, and- Electrical
Characteristics, if applicable.
7 -
If DD Form 1348 is used, fill in all blocks except 4, 5, 6, and
Remarks field in accordance with AR 725-50.
Complete Form as Follows:
(a] In blocks 4, 5, 6, list manufacturer's Federal Supply Code
followed by a colon and manufacturer's
Number - 18056
Part Number for the repair part.
(b)
Complete Remarks field as follows:
(nomenclature of repair part)
Noun:
NSN: 3405-00-542-1328
For:
Manufacturer: Continental Machines, Inc.
for
DoAll Company
Mode: 2614-1
Serial: (of end item)
Any other pertinent information such as Frame Number,
Type, Dimensions, etc.
T A B L E
Chapter 1
INSTALLATION
Location . . . . . . . . . . . .
Lifting Instructions . . . . . . . .
Unpacking . . . . . . . . . . .
Electrical Installation . . . . . . .
Alignment . . . . . . . . . . .
Machine Dimensions . . . . . . .
Preparation for Use . . . . . . . .
OSHA Regulation . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
O F
C O N T E N T S
Chapter 4
MAINTENANCE
Page
1
1
1
1
1&3
2
4
4
Head Assembly
Replacing Wheel
Electric Motor .
Transmission . .
. . 17
.
17
.
18
.
18
Chapter 5
TROUBLESHOOTING . . . . . . . .
19 & 20.
Chapter6
ACCESS0RIES
Chapter 2
OPERATION
Use of Job Selector Dial . . . . . . . .
Adjusting Saw Guides . . . . . . . . .
Band Installation . . . . . . . . . . .
Machine Controls Location . . . . . . .
Band Tensioning . . . . . . . . ...
Tracking the Band . . . . . . . . . .
Elevating Saw Guide & Post . . . . . .
Work Table . . . . . . . . . . .
Adjusting Table Tilt . . . . . . . . .
Using Band Speed Controls . . . . . . .
Contour Sawing Procedures . . . . .
Variable Weight Power feed . . . . . .
Chip Removal . . . . . . . . . . . .
Welding Saw Bands . . . . . . . . . .
Safety Precautions . . . . . . . . . .
Chapter 3
LUBRICATION
. . . . . . . . .
Tires . . . . . . . .
. . . . . . . . . .
. . . . . . . . .
5
6
6
7
8
8
9
10
10
10
11
12
13
13
15
. . . . . . . . . 15 & 16
Disk Cutting Accessory. .
.
. . . .
.
Side-Mounting Vitering Accessory ...
Rip Fence
.........................
Hydraulic Contour Feed. . . . . . . . . . . . . . . . . .
Work Magnifier . . . . . . . . . . . . . . . . . .
Mist Coolant. . . . . . . . . . . . . . . . . . . . . .
Supply Cabinet. . . . . . . . . . . . . .. . . . . . . . . . .
Heavy Work Clamps . . . . . . . . .
Heavy Work Slides . . . . . . . . . .
Screw Feed . . . . . . . . . . . . .
Workholding Jaw(s) . . . . . . . . . . . . . . . .
Air-Powered Worktable . . . . . . . . . . .
21
22
22
23
24
25
25
26
26
27
27
28
(For Air-powered Table Only)
Contour Sawing Attachment . . . . . .
Table Extension Bars . . . . . . . . .
File Adapter Plate . . . . . . . . . .
Ball Transfer Strips . . . . . . . . . .
Universal Vise . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Speed Clamp . . . . . . . . . . . . . . . . . . . . . . .
Calibrated Work Fixture . . . . . . . . . . . . . . . . . . . . . . . .
Protractor Work Stop & Aligning Gage . .
29
30
30
30
31
31
32
33
Machine Specifications
All Purpose Cut-Off, Ripping &
Mitering Attachment
Heavy Parralel Work Clamp Assy
Ratchet Table Feed Assy
Shifter Assy
Transmission Assy
Workholding Jaw Assy
Welder Attachment
i
APP
A
B
C
D
E
F
G
H
CHAPTER
1
I N S T A L L A T I O N
LOCATION
Place the machine so that any overhead light will strike the table over the operator’s right shoulder
when he is in position for cutting. The machine should be centrally located for your cutting needs.
‘Provide sufficient clearance around the machine for handling large pieces of material.
LIFTING INSTRUCTIONS
A 3/4 in. NC tapped hole is provided in the upper surface of the machine head. Use a forged 3/4-10
NC eye-bolt screwed into this hole for lifting the machine. Net weight of Model 2614-1 is approximately 2500 Ibs.
UNPACKING
(1)
Remove rear drive housing. Carefully remove all protective coverings, strapping, and the
skid. Unfasten the hold down bracket for the power feed weight.
(2)
A rust-preventive coating has been applied to all exposed bare metal surfaces. Remove
this coating with solvent. Inspect the machine for broken or damaged parts.
ELECTRICAL INSTALLATION
Bring the leads of the line circuit to the electrical enclosure on the machine column. Refer to the
wiring diagram furnished with the machine.
Jog the start button intermittently and open the door over the lower band wheel. Check to see if
the wheel is turning clockwise. If it is turning counterclockwise, reverse any two of the connections.
Overload protection is provided. Under ordinary conditions this will be ample protection. If the
machine is started and stopped a number of times in rapid succession, the overload relay may kick
out. Let the relay cool for a few minutes before starting the machine again.
ALIGNMENT
Before the machine is bolted into position, or whenever the machine is moved, the alignment should
be checked and the machine shimmed.
(1)
Place machine in desired location. Use 1/4 in. spacers between the floor and the base
mounting pads of the machine.
(2)
Shim under the pads as required until the machine is level and bears evenly on all pads.
Uniformity of bearing can be checked by tapping on the spacers with a bar or hammer.
1
(3)
Remove table center plate and post saw guard.
Install a 1-inch wide saw band and apply correct band tension.
(4)
Clamp or hold a straight edge to the front face
of the post and the face of the lower saw guide
keeper block.
(5)
The post should be parallel with the machined
saw guide mounting recess in the lower keeper
block. As shown in the sketch, this parallelism is checked by placing a spacer block
(ground to exactly 0.250" thickness) in the
keeper block. Then place an accurate straight
edge against this spacer block and the post.
Using a feeler gage, check the clearance and
parallelism of the post to the straight edge.
A clearance of 0.004" or less is required.
(6) Adjust the gap by adding shims (to increase
gap) or removing shims (to decrease gap) under
only the mounting bolt location shown in drawing.
(7)
Replace table center plate and post saw guard.
(8)
Loosen table tilt trunnion lock nut with the
wrench furnished with the machine. Square the
table to the post and check as shown above.
Tighten the trunnion lock.
(9)
If necessary, adjust the tilt angle pointer to zero.
(10) The back of the band should be just touching
the saw guide back-up insert. Adjust upper
wheel tilt, if necessary, so that band is positioned and will track properly. (See Tracking the Band in Operation Chapter).
SQUARE TABLE TO POST AND
TIGHTEN TABLE TILT LOCK
3
PREPARATION FOR USE
(1)
Check the transmission oil level and fill if necessary. See Lubrication, Chapter 3.
(2)
Check to see if all other points listed in the Lubrication Chart, Chapter 3, have been
serviced.
NOTICE!!!
OSHA Regulation No. 1910.212 (B) - Machines designed for a fixed
location shall be securely anchored to prevent walking or moving.
4
C H A P T E R
2
O P E R A T I O N
F-FLOOD M-MIST N-NONE
TO USE THE JOB SELECTOR, FOLLOW THESE STEPS:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Turn the dial until the material to be cut is directly below the window in the cover
(see above).
Locate the recommended pitch and blade type listed next to the work thickness.
If a radius is being cut, locate the correct blade width on the radius chart. Having
determined the width, pitch and tooth type, refer to a saw blade specification table
to determine the gage and set.
Locate the recommended band speed for the work thickness and blade type used.
Note the recommended feed force to be used for the work thickness.
Note the recommended method of coolant application (if your machine is equipped
with drip or spray coolant applicators).
This completes the choice of blade and sets up requirements for the job. However,
these recommendations can be adjusted to meet particular requirements.
NOTE
Job selector recomnendations are for average straightline sawing
and manual contour sawing of work less than one inch thick.
5
HOW TO ADJUST INSERT-TYPE SAW GUIDES
(1)
(2)
Select the set of inserts marked for the width of saw band being used,
Place the right-hand insert in the milled slot and tighten the screw lightly so that while
the insert will slide in the slot, it will still hold its position when released,
(3)
(4)
Select the proper insert gage for the gage of saw band being used.
Place the gage in the opposite slot and adjust the insert so that it meets the two gaging
edges. Then tighten the insert securely in place.
Place the left-hand insert in the slot and tighten the screw lightly.
Place the gage edgewise between the two inserts. Then bring the left-hand insert down
so that it rests against the gage. When the gage is removed, the gap left will be the
proper thickness for the saw band.
(5)
(6)
BAND INSTALLATION
(1)
Open the band wheel doors.
(2)
Unlock and open the bar which crosses the table saw slot, just below the front edge
of the table.
(3)
Remove saw band guard from post.
(4)
Using the gloves to handle the band, place it carefully over the wheels and
between the saw guide inserts.
(5)
Replace band guard, close and lock the bar over the table slot and close the
wheel doors.
6
Model 2614-1 showing location of all operation and alignment controls.
7
BAND TENSIONING
It is essential that the saw band be correctly tensioned in order to obtain maximum accuracy and
cutting rate.
Band tension is applied by tuning the removable handcrank located below the saw heed. Tighten
the band to the proper tension indicated on the band tension indicator on the machine column.
The figures on this scale are recommended tensions and are based on the most common gages and
pitches used. When using bands with coarser pitch or lighter gage, reduce tension. Increase the
tension when using heavier bands.
A new band may stretch slightly as it is being used. It is important to check the tension of the
band so that it does not become too slack.
TRACKING THE BAND
To facilitate tracking the band on the wheels, the upper wheel is tiltable in and out, as
well as adjustable up and down.
(1) With the wheel doors open, jog the start/stop pushbuttons and observe how
the band tracks.
8
(2)
Adjust upper wheel tilt until the band tracks properly. The tilt and lock controls
are located on the wheel hub. To adjust wheel tilt, first loosen the lock which is
located between the tilt adjusting knob and the wheel (see drawing below). Then
turn the tilt knob until the back edge of the band just touches the saw guide backup inserts.
(3)
When the band is tracking correctly, tighten the tilt lock.
Adjust upper wheel tilt until band tracks correctly.
POSITIONING UPPER SAW GUIDE and POST
Post elevation is adjusted manually with the handwheel located on the side of the saw
head. Always keep the post and saw guide as close as possible to the workpiece. This
will provide maximum support for the saw band and increase accuracy. The band guard
should be locked in place at all times during sewing.
9
WORK TABLE
The 30" X 30" heavy duty table has a removable center disk. Accessories can be bolted to
tapped mounting holes provided on the front and side edges of the table.
ADJUSTING TABLE TILT
Table tilt is used primarily when sawing compound angles. To tilt the table, use wrench provided
and loosen lock located below table. Tilt table manually until it is at desired angle. The amount
of table tilt (maximum -5º left, and 45º right) is shown by pointer and calibrated
scale mounted on trunnion.
Front sectional view of the work table and its mounting assembly.
USING BAND SPEED CONTROLS
The transmission gear shift control is used to select one of three transmission speed ratios low,
high, or medium. Band speeds within each range can be varied gradually by the speed change
control which changes the position of the variable pulley. Band speed is shown in feet per
minute (FPM) for each range on the speed indicator dial.
(1) Always allow the machine to come to a complete stop before shifting gears. If the
gears are not in a position to mesh,start and stop the machine intermittently until
they do. Do not attempt to force the shift control into place.
(2) Before stopping the machine, always turn the variable speed control to slow. An
interlock mechanism prevents shifting gears when the variable pulley is in its high
speed position.
10
CONTOUR SAWING PROCEDURES
Use hand feed or screw feed (accessory) for sawing intricate contours. The variable weight power
feed can be used for contour sawing of large, heavy parts. When cutting into an opening, reduce
the feed force to prevent damage which might result when the blade enters the opening suddenly.
Do not feed the work so rapidly that the saw band twists or bows. Follow the recommendations
on job selector for band speed and feed pressure.
A hole is usually drilled when there is a sharp corner to be cut, but this is not always true. A
corner may be by-passed with a curve and the remainder notched out later. To saw an internal
contour, first drill a starting hole, then run the saw band through the hole and weld. If the contour
is a radius, use the disk cutting accessory.
The diameter of the drilled starting hole is determined by the size of the saw band. The widest
possible saw band is used for the curve to be cut, but attempting to cut too small a radius with
too wide a saw bend will bind the band and cause the lower wheel tire to become grooved.
See the radii chart for minimum radii possible with various saw band widths. Use a heavy gage
blade for contour sawing of heavy workpieces.
For sawing an internal contour, the
band must be cut, run through a
starting hole in the workpiece, and
then welded. NOTE: When welding
band which passes through hole in
workpiece - be sure to insulate it
from contact with workpiece or
table. This will insure a better weld.
(Machine model shown is not necessarily
the specified model. For welding iIlustration only.)
The recommendations in the radii chart are based
on sawing relatively thin stock. Use a narrower
saw band than recommended when sawing stock
more than one inch thick.
11
VARIABLE WEIGHT POWER FEED
(1)
The variable weight power feed is a feed assist which allows the operator to use both
hands to guide the work while it is being pulled into the saw band.
(2)
The main mechanism for this system is contained within the machine. A weight on
a beam pulls the work holding chain which, in turn, pulls the work into the blade.
The chain and cable pulley system permits rotating the work to follow curved layout
lines while still using power feed.
12
(3)
Position of weight on beam determines both rate and force of feed. This position is
set by a hand wheel on side of machine. The beam is raised initially by a pedal on
front of machine.
(4)
The weight-type feed system exerts 0 to 80 Ibs. maximum feed force against blade.
Heavy feed force should be used when sawing with wide saw bands. Lighter feed
forces are required when using narrower bands.
(5)
Feed force less than 10 Ibs. is achieved by partially restraining pedal. Lighter feed
forces are also required if workpiece is significantly thicker. Example: 1/4 in. band
in 1 in. thick 1020 HRS use maximum feed force; but in 6 in. thick 1020 HRS use
light feed force.
(6)
On large work where cut is longer than 10-in. maximum feed distance, the weight
is brought back into position by pressing pedal into notch at bottom of its stroke
and then taking up slack in work-holding chain.
When not in use, the foot pedal should be left in the upper position.
The workholding jaw is used to guide
the work. The power feed chain can
be looped around the workholding
jaw as shown here.
CHIP REMOVAL
A removable chip drawer is provided below the lower wheel.
Remove the drawer and clean out when necessary. A wheel brush, mounted above the lower
wheel, cleans chips from the wheel tire.
WELDING SAW BANDS
Complete instructions covering blade welding and operation and maintenance of the welder
are given in the separate welder instruction manual.
13
SAFETY PRECAUTIONS
TO AVOID POTENTlAL HAZARDS, OBSERVE THESE PRECAUTIONS
WHEN OPERATING OR SERVICING THIS MACHINE-OPERATOR MUST:
CLOSE DOORS, REPLACE ALL COVERS AND SAFETY GUARDS BEFORE OPERATING MACHINE.
WEAR SAFETY GLASSES.
WEAR GLOVES WHEN HANDLING SAW BAND.
DO NOT WEAR GLOVES WHEN OPERATING MACHINE.
SET SAW GUIDES AS CLOSE TO WORK AS POSSIBLE.
CLOSE SAND WHEEL COVERS BEFORE TENSlONlNG BAND OR STARTING THE MACHINE.
DISCONNECT ELECTRICAL SUPPLY BEFORE REMOVING PANELS OR DRIVE COVERS.
USE A FIXTURE TO FEED WORK PIECE AND KEEP HANDS AWAY FROM MOVING SAW BAND.
AVOID CONTACT WlTH COOLANT. ESPECIALLY GUARD YOUR EYES.
STEP TO ONE SIDE AND AWAY FROM WELDING UNIT BEFORE WELDING A SAW RAND.
INSTALL FRlCTlON BAND AND PLASTIC SPARK SHIELD BEFORE FRICTION SAWING
USE A DUST COLLECTOR WHEN SAWING GENERATES DUST.
MAKE SAFETY THE RULE AND FOLLOW SAFE SHOP PRACTICES.
ALWAYS CONSULT THE OPERATOR S MANUAL PRIOR TO SERVICING.
14
C H A P T E R
3
L U B R I C A T I O N
LUBRICATION
POINT NO.
LOCATION DESCRIPTION and
SERVICE RECOMMENDATIONS
LUBRICATION
INTERVAL *
1
Variable Pulley. 1 oil cup.
2
Post. Post Elevation Screw and Gears.
Clean and apply oil.
MONTHLY
3
Table Trunnion. Oil tilt surfaces.
MONTHLY
4
Transmission. 1 quart capacity. Proper
oil level must be maintained. Drain and
refill yearly or when required.
AS REQUIRED
5
Transmission Shift Linkage and Interlock.
Clean and apply oil as required.
AS REQUIRED
6
Speed Change Screw and Linkage. Clean
and apply oil
CK. MONTHLY/
AS REQUIRED
7
Miscellaneous, Hinges. Pivots, etc. Clean
and apply oil
CK. MONTHLY/
AS REQUIRED
8
Accessory Equipment as Supplied. Keep
clean and apply oil as required to maintain proper function and reduce wear,
corrosion, etc.
CK. MONTHLY
9
Air Compressor. (optional item)
Proper oil level must be maintained;
drain and refill every three months.
Keep crankcase and air intake filter
clean.
WEEKLY
RECOMMENDED
LUBRlCANT
High quality, rust and oxidation
inhibited, medium hydraulic and
general purpose industrial oil.
ASTM Grad. No., 215.
High quality, rust and oxidation
inhibited, medium hydraulic and
general purpose industrial oil.
ASTM Grade No. 315.
CHECK WEEKLY
(For 80° F. and above)
High quality. rust and oxidation
inhibited, medium hydraulic and
general purpose industrial oil.
ASTM Grade No. 465.
Premium quality, multi-purpose,
lithium base, EP (extreme pressure) grease.
NLGI Grade No. 2.
10
Band Tension Screw and Bearing.
3 grease fittings.
11
Air Pump, Remove air intake filter and
while pump is in motion, feed lubricant
into opening. Keep air filter clean.
CK. MONTHLY/
AS REQUIRED
12
Electric Motor
Lubricate as required per manufacturer’s recommendations.
13
DBW-15 Welder.
Lubricate as required per DBW-15 Instruction Manual.
14
Mist Coolant Tank. (optional item)
1 quart capacity. Keep filled.
CHECK DAILY/
AS REQUIRED
3 MONTHS
Dry, powdered lubricating graphite
(natural or manufactured).
Premium quality, sew band
coolant and lubricant.
cutting fluids and/or oils.
* Lubrication intervals are based on an 8 hour day, 40 hour week. Lubricate more often when required.
15
2
7
10
13
3
5
4
6
12
1
11
16
C H A P T E R
4
M A I N T E N A N C E
HEAD ASSEMBLY
Wipe oil on the post occasionally and run the post up and down through the slide block several
times. The upper wheel slide and band tension screw are lubricated by grease fittings. The
wheel bearings are sealed and lubricated for life at assembly.
If it is necessary to adjust the band tension indicator, first loosen the set screw clamping the wire
leading to the indicator. Then take all slack out of the band with the band tension control. Adjust
the indicator pointer to zero and lock the linkage arm to the wire. A more accurate calibration can
be obtained by using a band tension measuring instrument.
REPLACING WHEEL TIRES
When the tires are completely worn out, replace them by loosening the tire with a screw driver or
other flat tool and stretching it until it can be taken off. Scrape the wheel clean, and apply new
cement before installing a new tire.
WHEEL BRUSHES
Check the wheel brush occasionally.
If it worn so that it is no longer
contacting the wheel face, loosen the
adjusting screws and move the brush
up to the wheel. Replace as needed.
ELECTRIC MOTOR
Main Drive Motor - Follow the manufacturer’s instructions (see tag attached to motor).
17
Rear view of Model 2614-1 drive compartment.
TRANSMISSION
Drain, flush and refill after first month and at least every six months, thereafter. Fill to top
of fill pipe, but do not overfill. Use an ASTM Grade No. 315 industrial oil (see Lubrication
Chapter). Check for seal leaks around shafts.
Any rough operation, vibration, loud or unusual noises should be investigated immediately.
It is recommendad that the transmission be returned to the factory for repairs. Installing a
new transmission correctly is extremely important because of the careful alignment involved.
If the shifter plate has been removed for any reason, do not attempt to operate lever.
18
C H A P T E R
5
TROUBLESHOOTING
MACHINE WILL NOT START:
(1)
(2)
Check main fuses and control circuit fuse.
Check reset on band drive motor starter (if used). Starting and stopping the machine a
number of times in quick succession or an overload will trip the starter heater. After
locating and correcting the trouble, push in the reset button. If the heater relay has
been set for automatic operation, it will not be necessary to push the reset button, but
only to wait for the relay to cool.
(3) Check transformer.
SEVERE MACHINE VIBRATION
(1)
(2)
(3)
(4)
Band wheels not balanced.
Variable pulley components not balanced.
Variable drive belts are unbalanced.
Machine not resting evenly on floor.
SAW BAND VIBRATION (while sawing)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Incorrect band speed.
Incorrect choice of saw band pitch.
Incorrect choice of coolant.
Incorrect feed pressure.
Work piece not firmly clamped to table.
Worn or improperly adjusted saw guide inserts.
Worn saw guide backup bearing.
Special support not used under work when using Heavy work clamp.
NO COOLANT FLOW:
(1)
(2)
(3)
Coolant applicator nozzle jammed.
Coolant hose clogged or kinked.
Coolant reservoir empty.
SURFACE FINISH ON WORK TOO ROUGH:
(1)
(2)
(3)
(4)
(5)
Saw guide inserts worn. Readjust.
Saw band speed too low.
Saw band pitch too coarse.
Feed too heavy.
Vibration.
19
SAW BAND TEETH STRIPPING: (usually caused by chip welding)
(1)
(2)
(3)
(4)
Saw band pitch too coarse for thin work section.
Work not held firmly to stop vibration.
Feed pressure too high.
Band speed too low.
PREMATURE DULLING OF SAW BAND TEETH:
Not breaking in saw band on first few cuts. Reduce feed pressure and speed on first
cuts.
(2) Band speed too high, causing abrasion. Reduce speed.
(3) Saw band pitch too coarse.
(4) Wrong type coolant or no coolant used.
(5) Feed pressure too light. Increase feed.
(6) Coolant not covering saw band.
(7) Cutting rate too high.
(8) Faulty material such as heavy scale, inclusions, hard spots, etc.
(9) Material analysis incorrect.
(10) Saw band vibration.
(11) Chipped tooth lodged in cut.
(12) Chip welding.
(13) Operator’s error.
(14) Inserts too large for blade width, allowing inserts to hit set teeth.
(1)
MOTOR RUNS BUT BAND DOES NOT MOVE:
(1) Broken drive belts or belts off pulleys.
(2) Over-oiling of variable pulley, excess oil has coated pulley and belts.
(3) Drive belt tension too low.
(4) Wrong size drive belts.
(5) Band tension incorrect.
(6) Transmission bad.
BAND SLIPS OFF WHEELS:
(1)
(2)
Upper wheel not aligned correctly, band does not track on center of wheel tire.
Too much coolant used or wrong type coolant used, causing band to slip off wheel
tires.
(3) Initial machine alignment wrong. See Chapter 1.
20
C H A P T E R
6
A C C E S S O R I E S
DISK CUTTING ACCESSORY
The disk cutting accessory is used for cutting of true circles, either internally or externally,
of any diameter from 2-1/2 in. to 30 inches. This attachment is bolted to the post with
the cap screws and washers furnished.
( 1)
(2)
(3)
(4)
(5)
(6)
Place flat washers under screws and bolt bracket (see drawing) to post.
Lower post until saw guides are approximately 3/8 in. above table.
Loosen bolts on fine adjustment and arm clamps and move center pin to approximate
distance or radius to be cut. Tighten bolt on fine adjustment clamp.
The center of centering pin must be directly in line with cutting edge of saw band.
To accomplish this, place a square against side of saw slot with blade of square against
tip of saw tooth. Loosen vertical adjustment clamp bolt and !ine up centering pin
with edge of square’s blade; then clamp tight.
Make final radius adjustments with fine adjustment wheel and tighten arm clamp bolt.
Tighten bolt on the radius arm clamp, making sure center pin is square to table.
Adjust unit for work thickness by raising or lowering saw guide post.
21
SIDE-MOUNTING MITERING ACCESSORY
Set up this attachment as shown in the drawing, making sure that the mitering bar
is in even contact with the table surface. Use a combination square in the table slot
as a basis for alignment and setting the mitering bar at various angles.
When not in use, swing the attachment up, to the right and around on the slide rod
so that it hangs below the table.
RlP FENCE
To set up this accessory be sure to square
the fence so that it is in line with the table
slot. Also make sure that the machine is
in proper alignment as described in the
Installation Chapter.
In making a long cut, check to be sure
that the saw band used is not worn on one
side. This will cause the work to wander
relative to the rip fence guide.
22
HYDRAULIC CONTOUR FEED
Hydraulic-controlled contour feed provides power feeding for all types of contour
sawing, and is controlled by a handwheel and control valve on the table. This is a
factory installed attachment.
As shown above, the power feed guide roller bar is drawn by a hydraulic cylinder.
The valve which controls the hydraulic pressure varies the rate of feed from 0 to
15FPM. When the pointer of the valve handle (shown in sketch) is turned to the
right, the feed increases up to a maximum speed of 15FPM. The hydraulic feed
reverses when the control valve handle is turned to the returned position. The
handle should always be in the stop position when the hydraulic feed is not in
operation.
Use the contour control handwheel to turn the work and follow contours while it
is being pulled into the saw band.
A. SETUP
(1) Check all hydraulic connections. Fill hydraulic tank with 2-1/2 gallons of
ESL anti-wear hydraulic oil.
(2) Put control valve in stop position and start hydraulic pump motor. Be sure
motor is running so that rotation is in same direction shown by arrow on motor.
This may be changed by reversing leads to machine.
(3) Move guide roller bar conected to piston rod back and forth by turning control
valve handle from feed Position to return position until system is completely filled with oil and free of air pockets. The hydraulic system is then
ready for operation.
23
(4) With control valve handle in stop position, place chain around contour control sprocket at rear of table, (as shown in sketch) and then loop chain around
two horizontal rollers at ends of guide roller bar.
(5) With guide roller bar in extreme reverse position, take up all slack in chain and
connect ends together, using quick lock provided. The power feed is then
ready for operation.
B. OPERATION
(1) Always be sure there is enough hydraulic oil in tank. Check oil level with dip
nick provided.
(2) Clean tank and oil filter every six months. Oil filter is located inside of tank and
may be serviced by removing cover plate at front end of tank.
(3) If hydraulic pressure drops, dirt may be lodged in relief valve or relief valve spring
may be weak. The relief valve is set at 100 pounds pressure at factory. To increase pressure, remove the cap on top of relief valve and turn adjustment screw
clockwise. Check pressure with a pressure gage. If pressure is high enough and
pulling power is still low, cylinder piston cups may have to be replaced.
(4) If control valve does not operate properly, there may be dirt between disk and
face of valve. If so, valve should be taken apart and faces cleaned or lapped if
necessary.
(5) Bumpy or uneven feed is caused by air in cylinder. This air may be removed by
running piston rod back and forth for full length of cylinder a number of times.
This condition usually occurs when a new machine is installed and started for
first time, or when system has been drained, cleaned and refilled with oil.
WORK MAGNIFIER
The plastic-constructed magnifier is
light-weight and easily mountable to
the machine’s worklamp reflector
with a single locking bolt and nut.
A snap-on protective lens cover
prevents scratching or damage when
the magnifier is not in use.
24
MIST COOLANT
THE SYSTEM: Mist coolant is delivered from the coolant tank mounted on the back
of the head to a drip applicator valve which has a sight glass. Next, the coolant
enters a manifold where it is directed into a nylon tube which passes through the
center of the flexible air tube. The air and coolant are mixed at the end of the
applicator tube nozzle to form a fine mist.
THE APPLICATION: Regulate the mist by adjusting the drip applicator valve and
counting the drops visible through the sight glass. A normal adjustment to produce
a fine mist would be about one drop of coolant per second. Direct the mist stream
on a metal surface to check for a fine, consistent mist. If the mist stream is intermittent, with spurts of coolant, there is probably an air leak somewhere at the
manifold. Check all joints. Bend the mist applicator tube to direct a mist stream
on the blade teeth and work.
COOLANTS TO USE: The mist applicator is
designed to work properly with
coolants such as POWER-CUT HD-600,
Kleen-Kool, and POWER-CUT No. 360.
If other coolants are used, such as wax
based coolants, clogging may occur.
MAINTENANCE: Clean the nozzle and coolant tank when necessary. If the nylon
center tube is replaced, disassemble and
replace the nylon tube, make sure all
joints are sealed and tight, coil the applicator tube a few times, then trim off the
excess nylon flush with the end of the
nozzle.
SUPPLY CABINET
The supply cabinet provides
for orderly, safe storage of
saw band coils, welded saw
bands, file bands, as well as
the component parts and
accessories when they are
not being used on the
machine.
Saw bands may be looped
into a triple coil, but the
file bands should be hung
over the appropriate hanger
in one loop.
25
HEAVY WORK CLAMPS
The heavy work clamps are used for contour sawing of particularly heavy materials, as
well as for sawing stacked parts to produce multiple parts in one operation. These clamps
have a bail bearing base and have a standard clamping capacity of four inches.
A special center block provided which should be inserted in the table center and sawed to
leave a path or kerf for the saw blade to travel in. It is important that this center support
be used when cutting stacked parts since it will prevent the bottom pieces from bending
downward or vibrating which will cause excessive wear on the saw band. Clamp the four
work holding clamps on the material and square the work with the blade through the use
of the table tilting device.
Each clamp is provided with gear teeth which mesh with the power feed chain.
HEAVY WORK SLIDES
Heavy work slides permit easy movement of heavy parts which would be difficult
to feed into saw band. The slide bars contain ball bearings and have a separate center
block to support the material at the
point of cutting.
Insert the special center support in the
table center disk. The center block
should then be sawed so that the path,
or kerf, is made for the band to travel
in. This will allow a solid contact between the work and feed table surface
at the sawing point.
26
SCREW FEED
The screw feed accessory is used for precision contour sewing of heavy work. The
1/2" thread screw has a hardened
point. The swivel is mounted in a hole in
a bracket attached to the able front The
screw is quickly adjusted to any point within a 12-inch movement simply by lifting
the knob in the top of the-swivel.
WORKHOLDING JAW(s)
The workholding jaw can be used with or without its handles attached. It should be used
with screw feed accessory and also as a fixed-angle jaw for manually guided contour
sawing.
A workholding jaw, with adjustable angle (0º to 90°) jaws, is also available.
27
AIR POWERED WORKTABLE
This accessory replaces the standard 30" x 30" worktable, variable weight power feed,
and workholding jaw. It also reduces the machine’s work height to thirteen inches.
The air powered worktable is a heavy, ribbed cast-iron table, 26-1/2 x 33-1/2 inches,
with two 1/2 inch T-slots for tooling purposes. It has a 12 inch feed stroke and is operated at 80 psi on shop air. Mechanical stops are provided to limit table travel if desired. The table can also be tilted 6º left or 45º right, and locked in place for angle
cutting. A removable center plate is provided. This can be replaced with special plates
for filing or polishing. A pin work rest inserted into a hole on the table top acts as a
work stop. A squaring bar fits into a table slot to hold the workpiece during production sawing.
When the workpiece has been setup the table using either the pin work rest inserted
into the table top or the squaring bar inserted in a table slot resting against the pin rest,
move the table manually until the cut is started. Press the air control lever, located on
the left front of the table, enough to obtain the feed force desired. When the lever is
released, the feed force returns to zero and the table can be moved easily forward or
backward for loading or fixturing.
ADJUSTING TABLE STOPS
The work stops are located on the left hand edge of the table. They are adjusted by
loosening the lock nuts and sliding the stops to the desired position. Set the front
stop to control duplication of cut depth and the rear stop to minimize table travel.
ADJUSTING TABLE TILT
Table tilt is used primarily when sawing compound angles. To tilt the table, loosen
the lock nut with the wrench provided and tilt the table manually until it is at the
desired angle. The amount of table tilt, maximum 6º degrees left and 45º degrees
right, is shown by the pointer and calibrated scale mounted on the trunnion. Next,
lock the table in position.
28
CONTOUR SAWING ATTACHMENT & PROCEDURES (Air powered table only)
The contouring attachment permits the operator to guide a workpiece through intricate contours
by means of a single handwheel controlling a gear train, sprocket, chain and holding fixture. The
control handwheel at the right front of the table drives the sprocket and chain which turns the
work being cut.
The sprocket work holding fixture will take round workpieces to 11-1/4 in. diameter or rectangle shapes
to 8 x 11 inches. Place workpiece in center of fixture, hook holding chain into chain connectors
and tighten clamp screw to hold work solid. Place drive chain around sprocket at rear of table and
work fixture. Connect chain with quick lock provided, shortening chain loop enough to bring work
into sawing position with table in forward position.
Do not feed the work so rapidly that the saw band twists or bows. Follow recommendations on,
job selector for band speed, feed pressure and coolant application.
29
TABLE EXTENSION BARS
(Air powered table only)
The table extension bars provide adjustable
outboard support for plate of flat stock
larger than the table. The bars can be locked
in any position in the table T slots. Studs at
the ends of the bars serve as backstops for
straight or irregular pieces at any angle.
FILE ADAPTER PLATE (Air powered table only)
By using this file adapter plate, accurate filing of small work is possible. It also acts as a
safety device, since it prevents jamming of the work between the table slot and the face of
the file band.
(1)
Remove the table center plate and install
the special file adapter plate around the
file band.
(2)
Loosen the flat head screws in the top
plate and adjust to within 1/16 in. of the
cutting surface of the file band. Tighten
the flat head screws.
DETACHABLE BALL TRANSFER STRIPS (Air powered table only)
For a large or heavy workpiece, use the ball transfer
strips. The two center strips should be attached to
the table with screws as shown here. The other
strips can be moved about as required during sawing.
NOTE: Using the ball transfer strips reduces work
height capacity 1-1/2 inches.
30
UNIVERSAL VISE (Air powered table only)
With this accessory, the operator can rapidly clamp and unclamp work by means of a leveroperated eccentric. The universal vise applies positive work holding pressure needed for
accurate production cut-off work. The angle of cut-off is accurately adjusted from 0 to 45
degrees by means of a pointer and protractor. The table T slots allow quick and easy
removal of the vise. An adjustable cut-off gage assembly mounts in a T slot on the left
side of the table to allow duplicate cut-off operations for production runs.
The universal vise jaws are
clamped in a table T slot and
set at the desired angle. The
cut off gage is mounted in the
left-hand T slot.
MACHINE SPEED CLAMP (Air powered table only)
The machine speed clamp is specifically designed to hold fiat or odd-angle work to the machine
table. The clamp is held on the table by means of a 1/2 inch T-bolt in the table slot. The
clamp head is self-aligning; it automatically adjusts to the angle of the workpiece surface. The
capacity of this clamp is 0 to 8 inches (0 to 200 mm), and the approximate maximum clamping
pressure at 4 in. is 1000 Ibs. The cam action handle is provided with a quick release operated
by thumb pressure.
The machine speed clamp
mounts in the table T slot.
The clamp head automatically
adjusts to the shape of the
workpiece .
31
THE UNIVERSAL CALlBRATED WORK FIXTURE (Air powered table only)
The universal work fixture is clamped to the table and holds the workpiece in position while
it is moved into the saw band. The foot switch may be used if desired. Use the following
procedure for setting up the fixture.
A.
Set up for straight cut-off.
(1)
The fixture bar is bolted to the table with T nuts and socket head cap screws. Place bar
on table at required distance from band and loosely install nuts and screws.*
(2)
Square bar to table by lining up one edge of movable stop with one edge of table slot.
Next tighten the two socket head screws.
After work fixture has been set up, a kerf can be sawed into bar 1/16 in. to 1/8 in. deep.
This will allow cutting completely through workpiece. Set adjustable table stops to
prevent sawing deeper into work bar upon completion of cut.
(3)
Square the bar to the table T slots.
Setting up the fixture for angle sawing
B.
Set up for angle cut-off.
(1)
(2)
(3)
Remove right hand T-nut and socket head screw from bar. Loosen left hand screw.
Turn bar to desired angle and tighten left hand screw.
Mount collar (behind bar) loosely on T nut with socket head screw. Bring collar up
snugly against bar and tighten screw.
•
If necessary, align zero mark on scale with saw band, then zero the pointers.
32
PROTRACTOR WORK STOP AND ALIGNING GAGE (Air powered table only)
(1)
(2)
(3)
(4)
To set up, lock T-shaped slide on bottom of base plate in table T-slot.
Set stop on table slide bar in a position that will prevent saw band from sawing into
miter head.
Adjust miter head for angle cutting by releasing clamp stud. The protractor plate is
calibrated to 45 degrees.
Adjust gage rod to control length of cut by loosening thumb screw and sliding rod
to its correct position. Turn selector switch on control panel to straight ( if
SERVO-CONTOUR is used).
Protractor work stop.
This accessory is
especially adapted
For production cut-off
and angle cut-off
operations.
33(34 blank)
PARTS
MANUAL
APPENDIX A
A-l
INDEX
FICHE NO. A-35
CLASS Contour
MODEL
PAGE NO. DESCRIPTION
C-1-47
Final Assembly
Air Compressor
C-8-57
Air Pump & Chip Blower
C-8-54
Bandfiler
C-7-26
Band Polisher
C-7-26
Band Tension Indicator
C-2-55
Blade Shear
H1-19.0
Chip Brush
C-1-47
Coolant Assembly (Mist Type)
C-8-64
C-10-7
Cutoff Attach. #1 All Purpose
Cutoff Attach. #2 Side Mount
C-10-28
Disc Cutter
C-10-2
C-1-56
Door Handles & Latches
C-5-66
Drive Assembly
H1-20.0 Etching Pencil
C-7-26
Filing Fixture for Small Parts
C-2-75
Head Assembly
Head Sub-Assembly
C-2-76
C-10-38
Heavy Work Clamps
C-10-23
Heavy Work Slides
C-8-104
Job Selector
Lamp Assembly
C-8-8
Magnifier Lamp Mounted
C-8-8
C-10-15 Magnifier (Machine Mounted)
C-5-83
Motor Base Assembly
C-5-84
Motor Base Assembly (Mist Coolant)
C-2-76
Post Elevating Mechanism
C-10-20
Ratchet Feed
C-10-6
Rip Fence
1 of 2
C-7-18
Saw Guides, Insert Type
C-7-20
2 of 2
Saw Guides, Insert Type
C-7-19
Saw Guides, Roller Type
Saw Lubricator
C-10-29
Screw Feed
C-5-90
Shift Sub-Assembly
C-4-39
Shifter Assembly (Transmission)
C-5-105 Speed Indicator
C-3-78
1 of 3
Table Assembly (Air Feed)
2 of 3
C-3-79
Table Assembly (Air Feed)
C-3-80
Table Assembly (Air Feed)
3 of 3
C-3-80
Table Cylinder (Air Feed)
C-3-52
Table Trunnion Assembly
C-9-107
Table Supports
Transmission Assembly
C-4-38
C-5-90
Varible Assembly
C-5-91
Varible Bracket
Varible Speed Pulley (10")
C-5-92
CM-4-124 Varible Pulley Oiler (Attach.)
C-9-14
Weight Feed Assembly
1 of 2
C-9-15
Weight Feed Assembly
2 of 2
C-5-93
Wheel Assemblies (Lower & Upper)
Work Holding Jaws
C-10-16
2614-1
A-2
SERIAL NO. 364-76101
FIRST SERIAL
ALL
ALL
ALL
ALL
ALL
ALL
See Buttwelder
ALL
A L L
A L L
ALL
A L L
A L L
A L L
See Buttwelder
ALL
ALL
ALL
ALL
ALL
ALL
ALL
A L L
ALL
A L L
A L L
A L L
A L L
A L L
A L L
A L L
A L L
See Coolant
ALL
ALL
ALL
ALL
ALL
ALL
ALL
A L L
ALL
ALL
ALL
A L L
ALL
ALL
A L L
ALL
ALL
ALL
ALL
A-2
TO
FRAME NO.
LAST SERIAL
DWG. P.LIST
A-3
A-4
A-6
A-5
A-8
A-7
A-9
A-10
A-9
A-10
A-12
A-11
F-10
F-9
A-4
A-3
A-13
A-14
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
B-10
F-11
F-12
A-9
A-10
B-11
B-12
B-13
B-14
C-2
C-1
C-4
C-3
C-6
C-5
C-8
C-7
C-7
C-8
C-10
C-9
C-12
C-11
C-14
C-14
B-14
B-13
D-2
D-1
D-3
D-4
D-5
D-6
D-8
D-7
D-9
D-10
D-11
D-13
E-1
E-3
E-5
E-7
E-9
E-9
E-11
E-13
F-1
D-13
F-3
F-5
F-7
F-9
F-11
F-13
G-1
D-12
D-14
E-2
E-3
E-6
E-8
E-10
E-10
E-12
E-14
F-2
D-14
F-4
F-6
F-8
F-10
F-12
F-14
G-2
FICHE NO.
H-2
H-2
FINAL ASSEMBLY
MODEL FlRST MACH LAST MACH
2614-1 364-76101
C-1-47
A-3
PRINTED IN U.S.A.
CODE NO.
C-1-47
FINAL ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
CATALOG
NO.
504940
094-066792
091-990135
090-234147
090-040973
105-045207
090-000084
090-179029
094-061413
093-048437
090-185000
091-403295
093-045250
095-049391
093-048445
091-982462
094-065950
091-086017
091-991158
091-990200
091-993212
090-168428
105-021018
090-022716
091-984229
095-048286
095-049482
095-048278
094-065950
090-278847
090-166844
090-177957
090-060641
090-122359
091-993204
091-988691
095-48294
093-020568
091-292730
091-993964
135-044287
091-318071
095-053310
097-322727
091-990192
095-0475O2
094-014610
091-187039
094-044765
090-412636
091-988667
095-049896
093-048767
091-092940
DESCRIPTION
Final Assembly
. Cover
. Ser. Truss Hd. Mach. #10-24NC x 1/4
. Upper Door Latch Assembly (See Detail)
. Air Hose
. 90º Street Elbow
.Hose
. Hose Clamp
. Worklight (See Detail)
. Upper Saw Guide Assembly (See Detail)
. Upper Saw Guide Holding Screw
. Saw Band
.BandTag
. Table & Trunnion Assembly (See Detail)
. Lower Saw Guide Assembly (See Detail)
. Ser. Soc. Hd. Cap 1/4-2ONC x 1-3/4
. Chip Baffle
. Plug Button
. Nut, Hex. 1/4-20NC
. Ser. Truss Hd. Mach. 1/4-20NC x 1/2
. Washer, Lock 1/4 Std
. Handle Assembly
. Door Latch (See Detail)
. Spacer
. Ser.Soc.Set1/4-20NCx1/4
. Weight Feed Assembly (See Detail)
.C h i p B o x
. Drive Assembly (See Detail)
. Lower Wheel Cover Sub-Ass’y.
. Wheel Brush Ass’y
. . Brush
. . Brush Holder
. Bracket
. Rubber Grommet
. Washer, Lock #10-Std
. Ser. Rd. Hd. Mach. #10-24NC x 1/2
. Rear Cover Sub-Assembly
. Escutcheon (Mach. Specs.)
. Escutcheon (Pat. No’s.)
. Ser. Rd. Hd. Drive #2 x 3/16 Type U
. Plug Button
. Blade Shear Assembly
. Electrical Assembly (See Detail)
. DBW-15 Buttwelder Assembly
. Ser. Truss Hd. Mach. 1/4-2ONC x 3/8
. Frame Assembly
. Job Selector Assembly (See Detail)
. Cover
. Escutcheon (Caution)
. Name Plate
. Ser. Rd. Hd. Mach. #10-24NC x 5/16
. Head Assembly (See Detail)
. Column
Saw
Guard
. Shim
A-4
UNITS PER
ASS’Y .
1
8
1
1
1
A.R.
2
1
1
2
2
1
1
1
2
1
1
2
10
8
1
1
2
1
1
1
1
1
1
1
1
2
2
4
4
1
1
1
6
2
1
1
1
10
1
1
1
1
1
3
1
1
A.R.
A-5
CODE NO.
AIR COMPRESSOR
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
PART
No.
400895
118639
118640
118601
118602
118603
118604
118605
118606
118641
118642
118607
118608
118609
118610
118611
118612
118613
118614
118615
118616
118617
118618
1186l9
120943
118626
118627
118623
118624
118625
118628
118630
118631
118632
118633
118634
118629
118636
118637
118638
400835
401957
37252
198027
199262
199122
199323
2103
35-847
2004
C-8-57
CM-8-32
Z-7-8
UNITS PER
ASS’Y .
Air Compressor
. Breather Assembly
. Replacement Felt
. Cylinder
. Stud Breather
. Breather Valve Bumper
. Breather Valve
. Bearing CUP
. Bearing Cone
. 6" Pulley For x-2 Comp
. 8"Pulley For X-2 Comp
. Bearing Carrier
. Bearing Plate Gasket
. Connecting Rod Assembly
. Connecting Rod Bolt Wire
. Oil Pan
. Oil Pan Gasket
. Oil Drain Plug
. Connecting Rod Bolt
. Connecting Rod Bolt Lockwasher
. Bearing Cup
. Bearing Cone
. Crank Shaft
. Bearing Carrier
. Piston Compressor Ring
. Suction Valve Spring
. Suction Valve Bumper
. Piston Pin Assembly
. Piston
. Head Gasket
. Socket Valve Bumper Gasket
. Cylinder Head
. Suction Valve Seat
. Discharge Valve Bumper
. Intercooler Gasket
. Discharge Valve Spring
. Valve
. Discharge Valve Guide
. Discharge Valve Guide
. Oil Gauge Assembly
. Air Compressor (6"Pulley)
. Air Compressor (8"Pulley)
. Adapter Plate Weldment
. Screw, Hex. Hd. Cap 5/16-18NC x 3/4
. Washer, Flat 5/16 Std.
. Nut, HEX 5/16-18NC
. Washer, Lock 5/16 Std.
. Relief Valve
. Service Tee
. Barbed lnsert
A-6
1
1
1
1
2
1
1
1
USE
ONE
1
2
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
use
one
1
4
4
4
4
1
1
1
C-8-54 CM-8-35
A-7
PRINTED IN U.S.A.
CODE NO.
2/68
C-8-54
CM-8-35
AIR PUMP ASSEMBLY
INDEX
NO.
**Ref.
**Ref.
*1
2
3
4
5
6
7
8
*9
*10
11
*12
*13
14
*15
* 16
17
18
*19
20
**NOTE:
*NOTE:
DESCRIPTION
PART NO.
S-11002
42708
5-11316
5-11405
5-11319
Comm.
Comm.
5-11104
Comm.
35-6736
6073
4097
Air
Air
.
.
.
.
.
.
.
.
.
.
4658
35-6735
17902
Stk.#008
5-11510
35-3647
14-14528
5-11517
17-13521
8386
2004
.
.
.
.
.
.
.
.
.
.
UNITS PER
ASS'Y.
Pump Ass’y
Pump Ass’y
Pulley
Bearing
Vane
Screw, Hex. Hd. Cap 1/4-20NC x 3/4"
Washer, Lock 1/4 I.D. Shakeproof
Air Pump Rotor
Screw, Soc. Set 1/4-2ONC x 1/2"
Air Pump Body
Air Hose (1612-1)
Air Hose (1612-U, 3012-U, 3613-1,
1612-0)
Wire Insert
Air Pump Cover
Hose Clamp.
Hose.
Breather
90º Elbow (1612-U & 3012-U)
Close Nipple (1612-U & 3012-U)
Reducer
Street Elbow 1/4 Std
Nipple (1612-U & 3012-U)
Hose Nipple
When replacing complete ass’y #42708, order complete
ass’y #5-11002.
One starred items are not part of Air Pump Ass’y.
A-8
1
1
3
4
4
1
2
1
1
1
1
1
2
AR
1
2
1
1
1
1
1
A-9
Band Filing & Polishing Assemblies
INDEX PART
NO.
NO.
Ref.
7645
1
198748
2
3
Ref.
12046
12045
44780
Ref.
111948
Ref.
132773
Ref.
404994
Ref.
48532
Ref.
401438
Ref.
Ref.
4
44781
45597
27487
27490
5
34096
34099
27488
27491
6
34097
34103
27489
27492
7
8
9
34098
34104
27417
27418
34095
34094
27420
27421
34093
34092
27419
27422
34091
34090
6-09314
6-09313
198680
198699
10
199315
UNITS PER
ASSY
DESCRIPTION
Small Parts Filng Assy. (1612, 1612-0,
1612-H, 1612-1, 2013, 2013-1, 2013-0,
2013-10, 2012-A, 2012-1A, 2012-AT
2012-1AT, 2612-H 2612-1, 3612, 3613-0
3612-H, 3613-1
. Screw, Fl. Hd. Mach. #10-24NC x
3/8
2
1
.Small Part Plate
1
.Center Plate
Band Filing Assy. (1612, 1612-0, 1612-H,
1612-1, 1613-2, 1612-3, 2013, 2013-1,
2013-0, 2013-10, 2012-A, 2012-1A
2012-AT, 2012-1AT, 2612-2H, 2613-3,
3612-H, 3613-1, 3612-3, 6013-3)
Band Filing Assy (1612, 1612-0, 1612-H,
1612-1, 1612-3, 2013 2013-1, 2013-0,
2013-10, 2012-A, 2012-1A, 2012-AT,
2012-1AT, 3612-H, 3612-3)
Band Filing Assy. (1612,1612-0,2013,
2013-1, 2013-0, 2013-10, 2012-A, 2012-AT,
2612-H. 2612-1, 3612, 3613-01
Band Filing Assy. (1612, 1612-0, 2013,
2013-1, 2013-0, 2013-10, 2012-A, 2012-AT,
2612-H, 2612-1, 3612. 3613-O)
Band Filing Assy. (1612-3, 2612-2H,
2613-3, 3612-3, 6013-3)
Band Filing Assy. (1613-3, 2612-2H,
2613-3, 3612-3. 6013-3)
Band Filing Assy. (2613-2, 3613-2, 6013-2)
Band Filing Assy. (3613-2, 6013-2)
.1/4- File Guide Assy. (Assys # 44780,
1
#404994, #44781)
. 1/4" File Guide Assy. (Assys #111948,
#132773, #45597)
1
1/4" File Guide Assy. (Assy #'48532)
1
. 1/4" File Guide Assy. (Assy '#401438)
1
3/8" File Guide Assy. (Assys #44780,
#404994, #43781 )
1
. 3/8" File Guide Assy. (Assys #111948,
#132773, #45597
1
,
. 3/8" File Guide Assy. (Assy #48532)
1
. 3/8" File Guide Assy. (Assy #401438)
1
1/2" File Guide Assy. (Assy #44780,
1
#404994, #44781
. 1/2” File Guide Assy #111948,
#132773, #45597
1
1/2" File Guide Assy. (Assys #48532).
1
1
. 1/2" File Guide Assy. (Assy #401438)
1
. . Bracket (Assy 27487)
1
. . Bracket (Assy #27490)
1
. . Bracket (Assy #34096)
1
. . Bracket (Assy # 34099)
. . Bracket (Assy # 27488)
1
. . Bracket (Assy # 27491)
1
1
. . Bracket (Assy # 34097)
1
. . Bracket (Assy # 34103)
1
. . Bracket (Assy # 27489)
. . Bracket (Assy # 27492)
1
. . Bracket (Assy #34098)
1
1
. . Bracket (Assy #34104)
. . Washer (Assys #27487, #27490,
2
#34096, #34099)
. . Washer(Assys #247488, #27491,
#34097, #34103, #27489, #27492
#34098, #34104
2
. . Screw, Fil. Hd. Mach. #4-40NC x
5/8 (Assys #27487, #27490, #34096,
2
#34099
. . Screw, Fil. Hd. Mach. #10-24NC x
5/8 (Assys #37488, 27491, #34097,
#34103,#27489, #27492, #34098, #34104) 2
. . Washer, Lock #4 Std. (Assys #27490,
#34099)
2
CODE NO.
C-7-26
CM-7-25
INDEX PART
UNITS PER
NO.
ASS'Y.
DESCRIPTION
NO.
199319 . . Washer, Lock #10 Std. (Assys
#27488, #27491, #34097, #34103
2
#27489, #27492, #34098, #34104)
6-09307
1
11
. . Insert (Assys #27487, #34096
1
6-09303 . . Insert (Assys #27490, #34099)
1
6-09301 . . Insert (Assys #27488, #34097)
1
6-09305 . . Insert (Assys #27491, #34103)
1
6-09309 . . Insert (Assys #27489, #34098)
1
6-09311 . . Insert (Assys #27492, #34104)
1
6-09308 . . File Guide #27487, #34096)
12
1
6-09304 . . File Guide (Assys #27490, #34099).
6-09302 . . File Guide (Assys #27488, #34097) 1
1
6-09306 . . File Guide (Assys #27491, #34103)
1
6-09310 . . File Guide (Assys #27489, #34098)
1
6-09312 . . File Guide (Assys #27492, #3410)
34-09313 . . Guide Plates (Not Shown)(Assys
#27490, #34099
2
34-09402 . . Pin (Not Shown) (Assys #27490,
2
#34099)
1371
. Adapter
13
1
34-09312 . File Guide Back-up (Assys #44780
14
#111948, #132773, #404994, #44781
#45597)
1
110931 . File Guide Back-up (Assys #48532,
1
#401438
34-09001 . Screw Assembly
1
15
3801
1
. . Head
3802
. . Screw
1
10627 . Center Plate (Assys #44780, #111948
16
1
#48532, #401438
120128 . Center Plate (Assys #132773, #404994) 1
106957 Band Polishing Assy (1611-H, 1611-U,
Ref.
1612, 1612-0, 1612-H, 1612-1, 2013,
2013-1,2013-0, 2013-0, 2013-10, 2012-A,
2012-1A, 2012-AT, 2012-1AT, 2612-H,
2612-1, 3612-U, 3612, 3613-0, 3612-H,
3613-1
29023
Ref.
Band Polishing Assy (1612-1, 1613-2,
1612-3, 3613-1, 3613-2, 3612-3)
27485
Ref.
Band Polishing Assy (26-2, 60-2, 2612-2H,
2613-2, 6013-2
27484
Band Polishing Assy (16-2, 16-3, 36-2, 36-3)
Ref.
27486
Ref.
Band Polishing Assy (26-3, 60-3, 2613-3,
6013-3)
106958 Band Polishing Assy (2612-1)
Ref.
16686
17
. Band Polishing Assy (Assys #106957,
1
#29023, #27485, #27484, #106958)
27414
. Band Polishng Sub-Assy (Assy #27486 1
198696 . . Screw, Fil, Hd. Mach #106958
18
3
x 3/8
19
27412 . . Bracket
1
6-10301 . . Backup Plate (Assy #16686)
1
20
1
35-9923 . . Backup Plate (Assy #27414)
34-10505 . . Backup Cloth
1
21
34-10402 . Guide Backup
1
22
34-09001 . Screw Assembly
1
23
3801
1
. . Head
3802
1
. . Screw
1371
. Adapter
1
24
10570
. Center Plate (Not Shown) (Assys.
1
#106957, #106958)
A-10
A-11
CODE NO.
C-2-55
CM-2034
BAND TENSION INDICATOR ASSEMBLY
UNIT PER
ASS’Y
INDEX
NO.
PART NO.
DESCRIPTION
Ref.
Ref.
Ref.
Ref.
Ref.
45510
45511
45716
457l7
40481
1
101966
102015
101805
101804
121920
35-2471
Comm.
3980
Comm .
7144
111597
35-1974
35-1973
35-2473
35-1970
Comm.
111929
3977
4644
3978
17478
Tension Indicator Ass’y. (2612-2H & 2613-2)
Tension Indicator Ass’y. (6013-2)
Tension Indicator Ass’y. (3613-2, 3613-1 & 3612-3) .
Tension Indicator Ass'y. (1612-X1, 1613-2, 1612-3 & 1612-1)
Tension indicator Ass'y. (2612-H, 2612-1, 2612-D, 2614-1,
2613-1H, 2612-1H3)
Dial (2612-2H & 2613-2)
Dial (6013-2)
Dial (3613-2, 3612-3 & 3613-1)
Dial (1612-X1, 1613-2, 1612-3 & 1612-1)
Dial (2612-H, 2612-1 & 2612-D)
Case
Screw, Rd. Hd. Mach. #6-32 NC x 1/4
Glass
Screw, Rd. Hd. Mach. #3-48NC x 1/4
Rack & Wire Sub-Assembly
Shaft
. Cap
. Spacer
. Spur Gear
. Bracket
. Screw, Soc. Hd. Set #8-32NC x 1/4
. Pointer
. Ring
. Bezel
. Rubber Gasket
. Bezel
2
3
4
5
*6
7
8
9
10
11
12
13
14
15
16
17
*NOTE: Refer to Head Assembly for Casing Part Number.
A-12
1
1
1
1
1
1
4
1
4
1
1
1
1
1
1
1
1
1
1
1
1
A - 1 3
CODE NO.
C- 8-64
CM-8-55
MIST COOLANT ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
CATALOG
NO.
504993
093-039568
091-988931
091-993212
091-369181
090-160011
091-317958
090-381245
114-145287
091-980250
090-000035
090-179029
090-389347
DESCRIPTION
Mist Coolant Assembly
Bracket
Scr. Rd. Hd. Mach. 1/4-20NC x 3/8
Washer, Lack 1/4 Med.
Bottle Assembly
Barbed Insert
Sealant
Coolant Manifold Assembly
Close Nipple
Scr. Hex. Hd. Cap 5/16-18NC x 1/2
Hose
Hose Clamp
Air Dome Sub-Assembly
A-14
UNITS PER
ASS'Y.
1
2
2
1
1
A.R.
1
1
2
A.R.
2
1
APPENDIX B
B-1
CODE NO.
C-10-7
Z-IO-4
No. ALL PURPOSE CUT-OFF, RIPPING AND MITERING ATTACHMENT
PART No.
INDEX
No.
Ref.
50493
Ref.
11-28004
Ref.
35-5427
1
2
3
4
5
6
35-5185
1898235
199397
11-28416
11-28415
6-28301
11-28303
35-4725
198236
6-28302
11-28302
35-4726
11-28304
11-28409
11-28110
11-25417
198410
11-28508
11-28418
11-28419
11-29108
34-05103
118116
199019
11-28420
11-28109
11-281O7
11-28111
11-28112
4233
6-28303
11-28308
35-4728
198242
6-28304
11-28307
35-4727
11-28102
198071
11-28405
11-28410
11-28301
11-28306
11-28305
199262
198025
11-28413
198438
11-28106
11-28505
11-28309
198221
4259
116442
115632
118117
7
8
9
10
I1
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
DESCRIPTON
No. 1 All Purpose Cut-Off, Ripping & Mitering Attachment
(24 x 24 Table)
No. 1 All Purpose Cut-Off, Ripping & Mitering Attachment
(30 x 30 Table)
No. 1 All Purpose Cut-Off, Ripping
. - & Mitering Attachment
(36x36Table)
. All Purpose Miter Attachment Sub-Assemble
Screw, Soc. Hd. Cap 1/4 -20NC x 3/8
.. Screw, Rd. Hd. Drive #2 x 1/4 P.K.
.. Feed Screw
Slide Rod
. L.H. Table Guide Spacer (24" Table)
. L.H. Table Guide Spacer (30” Table)
L.H. Table Guide Spacer (36" Table)
. Screw, Soc. Hd. Cap 1/4-20NC x 1/2
L.H. Table Guide (24" Table)
: L.H. Table Guide (30"'Table)
L.H. Table Guide (36"Table)
. . Locking Pad
.. Locking Pad Set Screw
. . Split Nut Adjusting Nut
. . Split Nut Adjusting Pin
Screw, Soc. Set #10-24NC x 1/4
. . Split Nut Spring
Screw Collar
. . Screw Handwheel Collar
Slide Rod & Handle Bracket
. . Handwheel
. . Speed Change Handle
Screw, Truss Hd. Mach. 1/4-20 NC x 3/4
. . Slide Rod Washer
. . Feed Shop Collar
. . Table Slide Casting
. . Split Nut
. . Split Nut Adjusting Handle
Roll Pin
. R.H. Table Guide (24" Table)
. R.H. Table Guide (30" Table)
R.H. Table Guide (36" Table)
. Screw, Soc. Hd. Cap 1/4-20 NC x 1
R.H. Table Guide Spacer (24" Table)
. R.H. Table Guide Spacer (30" Table)
. R.H. Table Guide Spacer (36" Table)
. Miter Head
Screw, Hex. Hd. Cap 1/2-13NC x 2-1/2
Power Feed Chain Washer
Power Feed Chain Collar
. .Miter Bar Support
. . Work Stop
..
Washer, 5/16 Std.
Screw, Hex. Hd. Cap 5/16-18NC x 1/2
Miter Head Support Pin
: : Screw, Soc. Hd. Set 5/16-18NC x 5/8
Miter Head Base
Miter Head Graduated P l a t e
Split Nut Side Plate
Screw, Soc. Hd. Cap #10-24NC x 5/8
Roll Pin
Screw, Soc. Hd. Shoulder
Washer
. . Pin (Not Shown)
B-2
UNITS PER
ASS'Y.
1
7
4
1
2
USE
ONE
2
USE
ONE
I
1
1
1
3
I
1
1
I
1
1
4
4
I
1
1
1
1
USE
ONE
6
USE
ONE
1
1
1
1
1
1
1
1
1
1
1
I
I
1
5
1
1
1
1
B-3
CODE NO.
C-10-28
Z-10-6
NO. 2 STD. CUT-OFF 8 MITERING ATTACHMENT
INDEX
NO.
Ref.
Ref.
Ref.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PART NO.
50419
55290
55305
50511
11-28109
198220
198378
198423
198276
198278
3682
29583
3-20406
4-20401
101935
101931
3681
29584
198423
50711
50710
55304
50712
3676
199008
3672
199399
3-20306
4-20301
102944
11-20301
4-20302
34-17401
4254
34-20407
5131
4229
3677
40598
20941
34-20410
34-20409
198236
DESCRIPTION
No. 2 Std. Cut-Off & Mitering Attachment (20” x 20” Table)
No. 2 Std. Cut-Off & Mitering Attachment (24” x 24” Table)
No. 2 Std. Cut-Off & Mitering Attachment (26” x 26” Table)
No, 2 Std. Cut-Off & Mitering Attachment (30” x 30” Table)
. Stop
. Screw, Soc. Hd. Cap #10-24NC x 1/2 (20” & 24” Tables)
. Screw, Soc. Hd. Cap #10-24NC x 5/16 (26” Table)
. Screw, Soc. Hd. Set 1/4-20NC x 5/16 (30” Table)
. Screw, Soc. Hd. Cap 3/8-16NC x 1/2 (20” & 30” Tables)
. Screw, Soc. Hd. Cap, 3/8-16NC x 3/4 (24” & 26” Tables)
. Rear Slide Rod Bracket (20” Table)
. Rear Slide Rod Bracket (24", 26" & 30” fables)
. Slide Rod (20” Table)
. Slide Rod (24” Table)
. Slide Rod (26” Table)
. Slide Rod (30” Table)
. Front Slide Rod Bracket (20” Table)
. Front Slide Rod Bracket (24”, 26” & 30” Table)
. Screw, Soc. Hd. Set 1/4-20NC x 5/16
. Miter Attachment Sub-Assembly (20” Table)
. Miter Attachment Sub-Assembly (24” Table)
. Miter Attachment Sub-Assembly (26” Table)
. Miter Attachment Sub-Assembly (30” Table)
. . Pointer
. . Screw, Oven Hd. Mach. #8-32NC x 1/4 (Cad. Pltd.)
. . Degree Plate
. . Screw, Rd. Hd. Drive P.K. #4 x 1/4 Type "U"
. . Miter Bar (20” Table)
. . Miter Bar (24” Table)
. . Miter Bar (26” Table)
. . Miter Bar (30” Table)
. . Gage Rod
. . Thumb Screw
. . Roll Pin
. . Miter Head Pivot
. . Handwheel
. . Roll Pin
. . Stud
. . Slide Arm
. . Miter Head
. . Locking Stud Washer
. . Pivot Washer
. . Screw, Soc. Hd. Cap 1/4-20NC x 1/2
B-4
UNITS PER
ASS’Y .
1
1
1
1
4
4
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
4
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
B-5
CODE NO.
C-10-2
CM-9-1
Z-9-4
DISC CUTTER ASSEMBLY
INDEX
NO.
Ref.
Ref.
1
2
3
4
5
6
7
8
8
10
11
12
13
14
15
16
PART NO.
402080
40044
35-3399
5-15413
5-15412
5-15109
35-3400
Comm.
Comm.
4261
35-3402
4276
4275
34019
Comm.
Comm.
5-15415
35-3401
Comm.
Comm.
DESCRIPTION
UNITS PER
ASS'Y
Disc. Cutter Assembly
Disc. Cutter Assembly
. Radius Arm
. Adjustment Screw
. Adjustment Wheel
. Adjustment Housing
. Radius Arm Clamp
. Screw, Hex. Hd. Cap, 3/8-16NC x 1
. Washer, Lock 3/8 Std
. Roll Pin
. Center Pin Clamp
. Roll Pin (Used on Ass’y #402080)
. Roll Pin (Used on Ass’y #40044)
. Bracket (Used on Ass’y #402080)
. Bracket (Used on Ass’y #40044)
. Screw, Hex. Hd. Cap, 5/16-18NC x 1
. Washer, Lock 5/16 Std
. Center Pin
. Center Adjustment Tube
. Screw, Hex. Hd. Cap 5/16-18NC x 2(DZ-36only)
. Screw, Hex. Hd. Cap 5/16-18NC x 1 1/2(AlI other models)
Following items not shown:
. Wrench
34-20308
. Screw, Hex. Hd. Cap 5/16-18NC x 7/8 (Used only on
Comm.
Ass'y #402080)
B-6
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
2
2
1
2
B-7
CODE NO. C-1-56
CM-1-47
DOOR LATCH ASSEMBLY
INDEX
NO.
PART NO.
Ref.
1
2
3
4
5
6
7
8
Ref.
1
2
3
23414
5-01406W
8359
8981
23413
34-01309
34-01306
34-01105
6557
35-2304
5-02101
Comm
5-02003
DESCRIPTION
Upper Door Latch Ass'y
.
Latch Bushing
. Bracket
. Nut
. Door Handle
. Aux. Spring
. Spring
.
Upper Latch
. Latch Hook
Lower Door Latch Ass'y
.
Base Door Latch
Scr, Soc. Hd. Set 1/4-20NC x. 1/4
.
.
Lower Door Handle Sub Ass’y
B-8
UNITS PER
ASS'Y
1
1
1
1
1
1
1
1
1
1
1
B-9
CODE NO.
C-5-66
CM-5-68
THREE SPEED DRIVE LINE ASSEMBLY
INDEX NO. CATALOG NO.
504815
Ref.
504827
Ref.
54079
1
091-995175
2
091-991620
3
4
105-046049
5
093-048361
6
134-135086
7
090-229063
105-051049
8
9
091-994657
10
091-993048
134-054105
11
12
091-984229
13
094-064276
14
091-993329
15
091-980532
16
090-220385
17
091-993279
18
090-028234
19
091-991455
20
091-980722
091-991612
21
091-992627
22
23
106-335151
24
090-541186
090-501867
25
090-042599
26
27
135-008928
28
090-078320
29
090-236431
30
090-052176
091-980441
31
094-067642
32
135-064707
33
34
091-984096
091-402032
35
36
090-161472
091-995126
37
38
090-060500
091-038513
39
40
135-087658
41
091-991273
42
091-992644
43
090-018755
44
134-054147
504825
45
504826
46
091-980466
47
090-379231
48
094-064292
49
091-030494
Items Not Shown:
090-425455
091-982215
090-275199
091-988675
090-174780
091-984526
091-980466
Drive Line Assembly (2613-1H. 2612-1H3)
Drive Line Assembly (2614-1)
. Wheel Ass'y (See Detail)
. Cotter Pin
. Costellated Nut 3/4-16NF
. Woodruff Key
. Lock Sector Sub-Ass'y
. Knob
. Handwheel Sub-Ass'y. (See Detail)
Handwheel Bearing
. Scr. & Self Tap #10-24NC x 3/8
. Washer, Wrought 1/2 S.A.E.
. Collar
. Scr. Soc. Set 1/4-20NC x 1/4
Variable Bracket Ass'y. (See Detail)
. Washer, Lock 3/8 Std
. Scr. Hex. Hd. Cap, 3/8-16NCx2-3/4
Hinge
. Washer, Lock 1/2 Std
. Screw
. Nut, Jam Hex. 7/8-14NF
. Scr. Hex. Hd. Cap 1/2-13NC x2-3/4
5/8-18NF
N u t . Castellated
Washer, Plain 5/8 Std.
Woodruff Key
Sheave (lnput)
MX-2 Transmission Ass'y,(See Detail)
Roll Pin 3/16 x 1
Cable Housing Sub-Ass'y.
. Speed Ind. Cable Key
. Shift Lock Sub-Ass'y.
Spring
Scr. Hex. Hd. Cap 3/8-16NC x 3/4
Gear Shift Sub-Ass'y. (See Detail)
Collar
Scr. Soc. Set #10-24NC x 3/16
Lock Rod
Lock Rod Piston Scr
Cotter Pin 3/32 Dia. x 3/4
Pin
Belt
Stud
Nut, Hex. Jan 3/8-16NC
Washer 3/8 Med.
Spring
Washer
Meter & Base Sub-Ass'y. (See Detail) (2613-1H, 2612-1H3)
Meter & Base Sub-Ass'y. (See Mail) (2614-1)
Scr. Hex. Hd. Cap 3/8-16NC x 1
Variable Sheave Ass'y. 10" (See Detail)
Variable Ass'y. (See Detail)
Belt
Shift Plate
Scr. Soc. Hd. Cap #10-24NC x 5/8
Speed Ind. Head Ass'y
Scr. Rd. Hd. Mach. #10-24NC x 3/8
Speed Ind. Dial
Scr. Soc. Set 3/8-16NC x1
Scr. Hex. Hd. Cap, 3/8-16NC x 1-1/2
B-10
UNITS PER
ASS'Y .
1
2
1
1
1
1
1
1
3
1
1
3
1
12
8
2
4
3
3
3
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
2
1
1
1
2
1
1
1
USE
O N
4
1
1
1
1
3
1
4
1
1
1
B-11
CODE NO.
C-2-75
CM-2-81
HEAD ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
CATALOG
NO.
504989
090-059189
091-988691
091-993196
091-000851
091-984062
135-052967
090-033556
091-988519
091-001891
091-004028
091-995076
135-085827
091-001909
090-046178
091-004044
091-008466
090-285271
091-9986349
091-991323
094-9065927
093-044980
091-988675
091-986984
093-048411
135-086106
090-306010
090-156381
090-134073
. 456451
090-059163
091-980755
091-991455
DESCRIPTION
Head Assembly
. Dowel Pin
Scr. Rd. Hd. Mach. #10-24NC x 1/2
. Washer, Lock #10 Std
Pivot Ass’y.
. Scr. Soc. Set Cup Point #8-32 NC x1/4
. Casing
Casing Clamp
. Scr. Rd. Hd. Mach. #8-32NC x 1/4
. Swivel
Radius Washer
. Cotter Pin 1/16 x 1/2 Lg.
. Ext. Retaining Ring
. Crank Ass’y.
. Ext. Retaining Ring
Pin
. Link
Handle Ass'y.
. Scr. Soc. Set Oval Point 1/2-13 NC x 1-1/2
. Nut, Jam 1/2-13 NC
. Head Sub-Assembly (See Detail)
. Stop
. Scr. Rd. Hd. Mach. #10-24 NC x 3/8
. Scr. Fillister Hd. #10-24 NC x 1/2
. Saw Rand Guard Ass’y.
. Hinge Pin
. Wheel Hinge Ass’y. (See Detail)
. Rearing
. Back-Up Washer
. Wheel Ass’y. (See Detail)
. Lock Bolt
. Scr. Hex. Hd. Cap 1/2-13 NC x 3-3/4
. Nut, Jam 7/8-14NF
UNITS PER
ASS’Y .
2
2
2
1
1
1
1
1
1
1
1
1
1
4
2
2
1
2
2
1
1
6
2
1
1
1
2
A.R.
1
3
3
3
Following Items Not Shown:
090-404815
090-174780
. Tension Indicator Ass’y. (See Detail)
. Bezel
B-12
1
1
B-13
CODE NO.
C-2-76
CM-2-82
HEAD SUB-ASSEMBLY
INDEX
No.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
CATALOG
NO.
406592
095-003745
090-059197
090-410275
091-984336
091-401489
135-086155
091-000836
091-004051
135-094738
091-003970
091-003996
105-014013
091-982819
091-993329
090-051509
091-982876
093-048742
091-983304
135-028108
091-154278
091-209205
091-209254
091-046904
091-209239
091-209221
091-407650
091-984229
090-114356
090-386434
094-017688
040-386442
091-982363
093-048734
091-401505
091-401497
091-235812
090-042250
091-984096
105-013064
091-333104
090-042599
091-240317
090-039710
091-333112
091-333120
091-333138
091-333146
DESCRIPTION
Head Sub-Assembly
Head Casting
Grease Fitting
Slide Block
Screw, Soc. Set 1/4-28NF x 1/2
Screw Assembly
Thrust Bearing
Rod Anchor
Spring
Grease Fitting
Adapter
Dowel Pin
Dowel Pin
Screw, Soc. Hd. Cap 3/8-16NC x 1-1/2
Washer, Lock 3/8" Std.
Washer, Lock Hi-Collar 3/8
Screw, w Soc. Hd. Cap 3/8-16NC x 1-1/2
Post Elevating Mechanism
Screw, Soc. Hd. Mach. #10-24NC x 1
Thrust Bearing
Screw, Soc. Set (Nylok) #10-24NC x 1/4
Block
. . Gear
. . Handle
. . Shaft
. . Bearing
. . Friction Plug
Screw, Soc. Set 1/4-20NC x 1/4
. . Gear
. . Handwheel
. . Housing
Cover
. . Screw, Soc. Hd. Cap 1/4-20 NC x 1/2
Post
. . Screw
. . Tube
Plug Button
. . Roil Pin
. . Screw, Soc. Set #10-24 NC 3/16
. . Spring
. . Shim
. . Roll Pin
. . Bearing
. . Spring
Shim
Shim
. . Shim
. . Shim
Ref.
I
2
3
4
5
6
7
8
9
10
11
30601
105-011084
105-014252
135-075968
091-991273
135-085785
091-984492
090-164O88
090-222688
090-038621
091-991141
105-011092
Wheel Hinge Assembly
. Tilt Knob
. Tilt Screw
. Retaining Ring
. Nut, Jan 3/8-16NC
Insert
. Screw, Soc. Set 3/8-16 NC x 1/2
. Wheel Axis Stud
. Wheel Hinge
. Screw, Soc. Set (Dog Pt.)
. Nut, Jam 1/4-20NC
. Tilt Lock Knob
B-14
UNITS PER
ASS’Y.
1
2
1
2
1
1
1
1
1
1
1
2
2
2
2
2
1
2
1
3
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
1
A.R.
A.R.
1
1
1
A.R.
A.R.
A.R.
A.R.
1
1
1
1
1
1
1
1
1
1
1
APPENDIX C
C-1
CODE NO.
HEAVY
PARALLEL WORK CLAMP ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO.
45009
27950
6-24413
37629
6-24415
199135
6-24307
37628
6-24505
6-24306
198411
35-3797
6-24504
6-24508
5-13313
198689
DESCRIPTION
Parallel Work Clamp Assembly
Center Plate
. Center Support
. Parallel Work Clamp Sub-Assembly
. . Clamp Stud
. . Nut, Hex. 5/8-11 NC
. . Parallel Arm,
. . Clamp Body
. . Steel Ball
. . Ball Cup
. . Screw, Soc. Set #10-24NC x 3/8
. . Ball Retainer Ring
. . Steel Ball
. . Set Screw
. . Work Holding Jaw Sprocket
. . Screw, Rd. Hd. Mach. #10-24NC x 1/2
C-2
C-10-38
CM-10-31
Z-10-17
UNITS PE
ASS’Y
1
1
4
1
1
1
1
195
3
1
3
3
1
1
4
C-3
CODE NO.
CM-10-23
CM-10-33
Z-10-12
HEAVY WORK SLIDES
UNITS PER
ASS’Y
INDEX
NO.
PART NO.
DESCRIPTION
Ref.
45004
Ref.
35-5247
Ref.
1
2
3
4
5
400692
6-23319
27950
6-23452
117814
198320
Heavy Work Support Assembly (1612, 1612-0, 1612-1,
2013, 2013-0, 2013-1, 2013-10, 2612-1, 3612, 3613-0,
3613-1)
Heavy Work Support Assembly (1613-2, 2613-2, 3613-2,
6013-2, ZS-3620, ZV-3620, ZW-3620)
Heavy Work Slide Assembly (2612-2H)
. Work Transport Bar
. Center Plate (Assembly #45004 Only)
. Center Support (Assemblies #45004 & 35-5247)
. Center Support (Assembly #400692 Only )
. Screw, Fl. Hd. Soc. Cap, 1/4-20NC x 3/4 (Assembly
#400692 Only)
C-4
2
1
1
1
2
C-5
CODE NO.
C-8-104
CM-8-53
Z-6-54
JOB SELECTOR
INDEX
NO.
UNITS PER
ASS’Y
PART NO.
DESCRIPTION
Job Selector (1612-U, 3012-U, 1611-H, 2612-1H, 2013,
2013-0, 2012-A, 2012-AT, 1612-0, 3613-0, 1612, 3612,
2013-1,2013-10, 2012-1A, 2012-1AT)
*43560
Job Selector (1612-1, 3613-1, 2612-1, 2613-2, 6013-2,
*Ref.
2618-4, HS-6013, ZW-3620, ZV-3620, ZS-3620)
1
1
Jab Selector Dial
22078
2
4
Outer Edge Felt
6-14304
3
1
Job Selector Plate
400838
4
1
Screw, Hex. Hd. Cop 5/16-18NC x 3/4
198027
1
Acorn Nut 5/16-18NC
4449
5
USE
Bushing
6-14401
6
ONE
Bushing
*2701
4
Screw,
Rd.
Hd.
Mach.
1/4-20NC
x
1/4
198890
*7
4
199374
Washer, Lock Shakeproof 1/4 Internal
*8
4
Nut, Hex. Jam 1/4-20NC
*9
199114
1
Job Selector Frame
42672
*10
NOTE: Job Selectors #46817 & #43560 First Used 9/17/62. Before This Date 400838 Plate and 22078
Dial, Must Be Replaced Together as a Unit.
*NOTE: Starred Items Used Only On Assembly #43560.
Ref.
46817
*NOTE: Last Used On Models:
MODEL
LAST MACH.
1613-2
3613-2
1612-3
2613-3
3612-3
6013-3
1612-H
2612-H
2612-2H
3612-H
150-69593
151-69515
152-691017
198-69361
153-691054
199-70125
288-69204
284-69135
206-69308
272-69152
C-6
C-7
CODE NO.
C-8-8
CM-8-31
PS-8-103
TF-4-100
F9-6.1
Z-7-61
LAMP & MAGNIFIER
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
PART
NO.
406141
15745
15245
104820
133359
14545
14411
14505
15139
198865
199319
102504
138452
13
138436
DESCRIPTION
Lamp Ass'y
. Bushing
. Selector Switch, 2-Postion
. Contact Block
. Legend Plate
. Card Grip Connector
. Washer
. O-Ring
. Cord Grip
. Screw, Rd. Hd. Mach. #10-24UNC x 1/4
. Washer, Lock #10 Std.
. Bracket
. Lamp Sub-Ass'y., 19” Flexible Cable, 11'- 1/2”
Connecting Cord
Magnifier Attachment, Mounts to Lampshade on Lamp Part
#138452
C-8
UNITS PER
ASS’Y
1
1
1
1
1
1
1
1
2
2
1
1
1
C-9
CODE NO.
MAGNIFIER ATTACHMENT ASSEMBLY
INDEX PART
No.
NO.
Ref.
35-555
Ref.
42872
Ref.
47767
Ref.
40532
1
34-17401
198242
2
300189
24393
47763
400073
3
4
35-554
45105
47768
41252
5
6
7
8
35-2104
35-5269
35-552
198690
9
10
35-553
302168
11
12
13
14
15
16
17
18
19
130538
103837
103834
103536
133884
130537
198406
198410
198851
UNITS PER
DESCRIPTION
ASS’Y.
Magnifier Attachment Assembly
(1612, 1612-0, 1612-H, 1612-1,
1613-2, 1612-3, 2012-A, 2012-AT
2013, 2013-0, 2012-1A, 2012-1AT
2013-1, 2013-10, 2612-H, 2612-1
3612, 3613-0, 3612-H, 3613-1,
3613-2, 3612-3)
Magnifier Attachment Assembly
(2613-2, 2613-3, 6013-2, 6013-3)
Magnifier Attachment Assembly
(2618-4)
Magnifier Attachment Assembly
(ZS-3620, ZV-3620, ZW-3620)
. Thumbnut (Ass'y #35-555,
1
#42872, #47767)
. Screw, Soc. Hd. Mach. 1/420NC x 1 (Ass'y #47767, Extra
Work Height)
2
. Post Clamp (Ass'y #35-555)(1-1/2" Post) USE
. Post Clamp (Ass’y #42872)(2-3/4"Post)
Post Clamp (Ass'y #47767)(3-1/4"Post)
: Post Clamp (Ass’y #47767, Extra
Work Height)
ONE
1
. Thumb Nut
. Magnifier Sub-Assembly (Ass'ys
#35-555, #42872
USE
. Magnifier Sub-Assembly (Ass'y
#47767
. Magnifier Sub-Assembly (Ass'y
ONE
#40532
2
. . Lens Spring
. . Magnifier Housing Sub- Assembly 1
1
Frame
Screw, Fil. Hd. Mach. #6
2
32NC x 3/8
1
. . . Housing
. . . Lamp Socket Assembly (Ass'y
1
#45105 Only
1
. . . Electrical Card
2
. . . Wire Terminal
1
. . . Wire Terminal
1
. . . Socket Bushing
1
. . . Socket 75-W, 125-V
1
. . . Strain Relief
. . . Screw, Soc. Set #8-32NC x 1/4 1
. . . Screw, Soc. Set #10-24NC x 1/4 1
x 1/4 (Ass'y #45105 Only)
1
C-10-15
CM-9-3
Z-9-7
INDEX PART
UNITS RR
No.
No.
DESCRIPTION
ASS’Y.
20
133874
Lamp (Ass’ys #45105, #41252
USE
19512-A
Lamp (Ass'y #47768)
ONE
Magnifying Lens
21
34-17501
Pivot Stud
22
35-559
23
199262
Washer 5/16 S.A.E. Std.
1
24
Wing Nut
1
35-562
25
Post Arm Swivel Sub-Assembly
35-560
(Ass'y #45105)
USE
Arm Assembly (Ass'y #47768)
107025
Post Arm Swivel Sub-Assembly
35-876
(Ass'y #47768, 36" Zaphyrs)
Post Arm Swivel Sub-Assembly
18375
(Ass'y #41252)
ONE
Swivel (Ass'y #35-560, #107025) USE
26
35-558
Swivel (Ass’y #35-876, #18375) ONE
35-872
Arm (Ass'y #35-560)
27
33-556
USE
107024
Arm (Ass'y #107025)
35-871
Arm (Ass'y #35-876)
136344
Rod (Ass'y #18375)
ONE
Ref.
40532
Magnifier Attachment Assembly
(ZS-3620, ZV-3620, ZW-3620)
28
. Joint
3108
1
29
Arm
3107
30
35-554 . Thumb Nut
3
31
22903
Post Clamp
1
32
34-17401 . Thumb Nut
1
Ref.
20826
. . Lamp Socket Assembly
33
135394
Midget Cord Connector
34
Stk #792 . . . Rubber Card
A.R.
35
Rushing
135388
2
36
135391
1
Ref.
Lamp Socket Assembly (2618-4
17987
L.A.Machines
1
Lamp Socket Assembly (2618-4
Ref.
107026
37
1
Socket
18347
38
198851
Screw, Rd. Hd. Mach. #8
1
32NC x 1/4
39
Wire
Terminal
103834
40
1
Cord Grip Connector
41
A.R.
18346
Rubber
Cord
42
1
Plug U-Ground
16213
C-10
C-11
CODE NO.
C-5-83
MOTOR AND BASE ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
CATALOG
NO.
504826
090-427089
105-113161
091-984385
135-098499
090-195538
090-195173
091-382523
091-195172
091-980466
091-993253
090-195421
091-991117
191-988666
094-067667
094-067675
091-984377
105-115208
091-980102
091-991158
091-993212
091-992602
DESCRIPTION
Motor and Base Assembly
. Air Pump Assembly (See Detail)
. PulIey
. Screw, Soc. Set 5/16-18NC x 5/8
. Key
Wire #14
. Conduit
. 45° Box Connector
. Electric Motor, 5 H.P. 1200 R.P.M. 60 HZ
. Screw, Hex. Hd. Cap, 3/8-16NC x 1
. Washer, Lock 3/8" Std.
. Wedge-On Contact
. Nut, Hex. #10-24NC
. Screw, Rd. Hd. Mach. #10-24NC x 5/16
. Base Plate Weldment
. Motor Pulley
. Screw, Soc. Set 5/16-18NC x 1/2
. V-Belt
. Screw, Hex. Hd. Cap, 1/4-20NC x 1
. Nut, Hex. 1/4-20NC
. Washer, Lock 1/4” Std.
. Washer 1/4” Std.
C-12
UNITS PER
ASS’Y.
1
1
1
1
A.R.
1
1
1
4
4
3
6
6
1
1
2
1
2
2
2
2
C-13
CODE NO.
C-5-84
MOTOR AND BASE ASSEMBLY
(USED WITH MIST COOLANT)
INDEX
NO.
Ref.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
CATALOG
NO.
504816
505189
094-019577
091-180885
135-008472
090-020041
135-024164
135-023083
094-067667
091-211631
091-980318
091-993014
091-993246
091-991224
091-211615
091-0992628
091-980342
091-211607
094-067675
094-067691
135-098499
091-984377
090-005208
090-007246
090-145079
090-145459
090-005505
090-144114
090-145053
091-195172
091-195180
091-980466
091-993253
090-195421
091-988667
091-991117
091-318170
DESCRIPTION
Motor and Base Assembly (60 HZ)
Motor and Base Assembly (50 HZ)
. Air Compressor (See Detail)
. Safety Valve
. Service Tee
. Barbed Insert
. Belt (Used on Ass’y. #504816)
. Belt (Used on Ass’y. #505189)
. Base Plate Weldment
. Plate Weldment
. Screw, Hex. Hd. Cap, 5/16-18NC x 1-1/2
. Washer 5/16” Std
. Washer, Lock 5/16”
. Nut, Hex, 5/16-18NC
. Spacer
. Washer, 5/16 S.A.E
. Screw, Hex. Hd. Cap 5/16-18NC x 2-1/2
. Spacer
. Motor Pulley (Used on Ass’y. #504816)
. Motor Pulley (Used on Ass'y. #505189)
. Key
. Screw, Soc. Set 5/16-18NC x 1/2
. Conduit 1/2” Sealtite
. Wire #12 AWG 19 Str. Blk
.
Connector
.
Connector
. Wire Markers
. Washer
. O-Ring
. Electric Motor, 5 H.P. (Used on Ass'y. #504816)
. Electric Motor, 5 H.P. (Used on Ass'y. #505189)
. Screw, Hex. Hd. Cap, 3/8-16NC x 1
. Washer, Lock 3/8” Std
. Wedge on Contact
. Screw, Rd. Hd. Mach. #10-24NC x 5/16
. Nut, Hex. #10-24NC
. Tag (Not Shown)
c-14
UNITS PER
ASS’Y .
1
1
1
1
USE
ONE
1
1
2
2
2.
5
1
6
2
2
USE
ONE
1
2
A.R.
A.R.
1
1
A.R.
2
2
USE
ONE
4
4
3
6
6
1
APPENDIX D
D-1
CODE NO.
C-10-20
CM-9-7
Z-10-2
RATCHET TABLE FEED ASSEMBLY
INDEX
NO.
PART NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
42978
42977
198043
40061
40825
20097
1343
1349
1344
35-9613
1345
1332
1346
1331
1350
34-13508
199358
1342
1347
133191
133971
19898
199356
5559
4417
UNITS PER
ASS’Y.
DESCRIPTION
Table Feed Assembly
. Table Feed Bracket
. Screw, Hex. Hd. Cap 3/8-16NC x 5/8
. Table Feed Assembly
. . Base Plate Assembly
. . Rack Weldment
. . Bracket
. . Spring
. . Center Pin
. . Retaining Ring
. . Gear
. . Spacer Pin
. . Thumb Lever
. . Spacer Pin
. . Spring
. . Knob
. . Washer, Lock 3/8 Shakeproof Int.
. . Spacer
. . Arm
. . Shim Option List
. . Knob
. . Screw, Rd. Hd. Mach. 1/4-20NC x 7/8
. . Washer, Lock 1/4 Shakeproof Int.
. . Washer, Flat
. . Screw
D-2
1
2
1
1
1
1
1
1
2
1
1
1
2
1
1
1
2
2
1
1
1
1
1
1
D-3
CODE NO.
C-10-6
Z-9-5
RIP FENCE ASSEMBLY
INDEX
NO.
PART NO.
DESCRIPTION
Ref.
Ref.
1
2
35-542
35-543
5-16302
198278
Comm.
35-5178
35-5251
34-06504
5-16303
5-16403
198278
Comm.
35-546
35-548
198425
5-16004
35-544
35-545
Rip Fence Assembly (30” Table)
Rip Fence Assembly (24” Table)
Clamp Guide
Screw, Sac. Hd. Cap 3/8-16NC x 3/4 (#35-542)
S c r e w , Soc. Hd. Cap 3/8-16NC x 3/4 (#35-543)
Rtp Fence Sub-Assembly (#35-542)
Rip Fence Sub-Assembly (#35-543)
Spring Clip
Clamp Bar
Clamp Bar Screw
Screw, Soc. Hd. Cap 3/8-16NC x 3/4 (#35-5178).
Screw, Soc. Hd. Cap 3/8-16NC x 3/4 (#35-5251)
Work Guide (#35-5178)
Work Guide (#35-5251)
Screw, Soc. Set 1/4-20NC x 1/2
Handwheel Assembly
Clamp (#35-5178)
Clamp (#35-5251)
3
4
5
6
7
8
9
10
11
UNITS PER
ASS’Y.
D-4
1
2
2
1
1
2
1
2
2
2
1
2
1
1
1
D-5
CODE NO.
C-7-18
CM-7-23
#121230
SAW GUIDE SELECTION
UNlTS
INDEX CATALOG
DESCRIPTION
ASS'Y
No.
No.
HEAVY DUTY GUIDES (STEEL BACKUP)
Ref.
091-201434 Upper Saw Guide Ass'y. (1/16" to 1/2")
1
1
. Upper Saw Guide Block
090-380767
2
091-982447 . Screw, Soc. Hd. Cap 1/4-20NC
x 1-1/4
2
. Washer
2
134-085026
3
1
. Bearing Cap
4
090-115403
1
. Retaining Ring
5
090-115411
2
6
090-115296 . Searing
Lower Saw Guide Ass'y. (1/16" to 1/2")
091-201426
Ref.
7
091-982447 . Screw, Soc. Hd. Cap 1/4-20NC 2
x 1-1/4
2
. Washer
8
1
9
090-377383 . Lower Saw Guide Block
1
10
090-115403 . Bearing Cap
1
11
. Retaining Ring
090-115411
2
12
090-115296 . Bearing
Ref.
090-115288 Upper Saw Guide Ass'y (5/8" to 3/4")
Ref.
090-115304 Upper Saw Guide Ass'y (1")
1
091-984450
. Screw Soc. Hd. Set 5/16-24NF
1
x 1/2
1
2
091-203695 . Soc. Hd. Pipe Plug
3
091-982421
. Screw, Soc. Hd. Cap 1/4-20NC
2
x 1 (5/8" to 3/4)
091-982447 . Screw, Soc. Hd. Cap 1/4-20NC
2
x 1-1/4 (1")
1
4
090-115403 . Bearing Cap
5
1
090-115411 . Retaining Ring
2
6
090-115296
. Bearing
7
134-085026 . Washer
2
8
090-252529 . Upper Saw Guide Block (5/8" to
USE
. 3/4")
ONE
090-252537 . Upper Saw Guide Block (1")
Ref.
090-115437 Lower Saw Guide Ass'y. (5/8" to
3/4"
Ref.
090-115429 Lower Saw Guide Ass'y. (1")
9
091-982421 . Screw, Soc. Hd. Cap 1/4-20NC
2
x 1 (5/8" to 3/4")
091-982447 . Screw, Soc. Hd. Cap 1/4-20NC
Text
x 1-1/4" (1")
1
090-115403 . Bearing Cap
10
1
090-115411 . Retaining Ring
II
2
090-115296 . Bearing
I2
134-085026 . Washer
2
13
090-252586 . Lower Saw Guide Block (5/8" to
14
USE
3/4")
ONE
090-252578
HEAVY DUTY GUIDES (CARBIDE BACKUP)
Ref.
091-199182 Upper Saw Guide Ass'y. (1/16" to
1/2"
1
090-380767 . Upper Saw Guide Block
2
091-982389 . Screw Soc. Hd. Cap 1/4-20NC
2
x 5/8
2
. Washer
134-085026
1
. Bearing Cap
8
090-172180
1
9
090-115411 . Retaining Ring
2
. Bearing
10
090-115296
Lower Saw Guide Ass'y. (1/16" to
Ref.
091-190017
1/2)
1
11
090-377383 . Lower Saw Guide Block
Soc. Hd. Cap 1/4-20NC
12
091-982389 . Screw,
x 5/8
2
2
. Washer
13
134-085026
1
. Bearing Cap
14
090-172180
"NOTE If Your Machine Was Equipped With Two
Coolant Lines to the Upper Saw Guide, Order
Additional Parts 091-094524 Swivel Joint, Qty.
1, 090-081166 Barbed Insert Qty . 2 and Delete
091-081166 90° Barbed Insert, Qt. 1.
INDEX
NO.
15
16
Ref.
CATALOG
NO.
090-115411
090-115296
090-178617
1
091-984450
2
3
4
5
091-332023
091-354415
090-252529
091-982421
6
7
8
9
10
Ref.
134-085026
090-183377
090-172180
090-115411
090-115296
00-181686
11
12
090-252586
091-982421
13
14
15
16
Ref.
1
134-085026
090-172180
090-115411
090-115296
093-0301
091-984450
2
3
4
5
6
091-354415
091-332023
090-252537
134-085026
091-982421
7
8
9
10
Ref.
1
2
3
4
090-183377
090-172180
090-115411
090-115296
091-201194
090-335092
090-336314
091-81166
091-982447
5
6
7
8
9
10
Ref.
11
12
134-085026
091-354415
090-183377
090-172180
090-115411
090-118296
090-177320
090-252578
091-982447
13
14
I5
16
Ref.
134-085026
090-172180
080-115411
090-115296
093-048437
1
2
3
091-212100
094-064300
091-982447
4
5
Ref.
131-085026
091-402040
093-048445
6
7
8
091-212100
091-402040
091-982447
9
10
134-085026
094-067683
D-6
UNITS PER
DESCRIPTION
ASS'Y
1
. Retaining Ring
. Bearing
2
Upper saw Guide Ass'y. (5/8" to
3/4")
. Screw, Soc. Hd. Set 5/16-24NF
1
x 1/2
. Pipe Plug
1
1
. Locknut
1
. Upper Saw Guide Block
. Screw, Soc. Hd. Cap 1/4-20NC
2
x1
2
. Washer
. Guide Guard
1
1
. Bearing Cap
1
. Retaining Ring
2
. Bearing
Lower Saw Guide Ass'y. (5/8" to
3/4")
. Lower Saw Guide Block
1
. Screw, Soc. Hd. Cap 1/4-20NC
2
x 1
2
. Washer
1
. Bearing Cap
1
. Retaining Ring
2
. Bearing
Upper Saw Guide Ass'y. (1")
. Screw, Soc. Set 5/16-24NF x
1/2"
1
. Locknut
1
1
. Pipe Plug
. Upper Saw Guide Block
1
. Washer
2
. Screw, Soc. Hd. Cap 1/4-20NC
x1
2
1
. Guide Guard
1
. Bearing Cap
1
. Retaining Ring
2
. Bearing
Upper Saw Guide Ass'y. (1")
1
. Coolant Nozzle
1
. Upper Saw Guide Block
. 90° Barbed Insert
1
. Screw, Soc. Hd. Cap 1/4-20NC
2
x 1-1/4
2
. Washer
1
. Locknut
1
. Guide Guard
1
, Bearing Cap
1
. Retaining Ring
2
. Bearing
Lower Saw Guide Block (1")
1
. Lower Saw Guide Block
. Screw, Soc. Hd. Cap 1/4-20NC
x 1-1/4
2
. Washer
2
1
. Bearing Cap
1
. Retaining Ring
2
. Bearing
. 1 Inch Upper Saw Guide Block
Sub-Assembly
1
. Back-Up Insert
1
. Upper Saw Guide Block
. Scr. Soc. Hd. Cap 1/4-20NC
2
1-1/4
2
. Washer
. Pivot Bolt
1
. 1 Inch Lower Saw Guide Block
Sub Assembly
1
. Back-Up Insert
1
. Pivot Bolt
. Scr. Soc. Hd. Cap 1/4-20NC x
1-1/4
2
2
. Washer
. Lower Saw Guide Block
1
D-7
CODE NO.
C-7-20
CM-7-29
#121230
SAW GUIDE SELECTION
UNITS PER
ASS’Y.
DESCRIPTION
Ref.
090-115197
1
091-984450
2
091-203695
3
091-982389
4
134-085026
5
090-252495
6
134-080092
7
091-985010
Ref.
090-115072
8
091-985010
134-080092
9
091-982389
10
11
134-085026
090-252479
12
Ref.
134-080092
1
134-084185
2
135-090439
3
134-083096
4
134-083120
SPIRAL GUIDES
1
090-268723
2
135-069532
3
NA ALONE
4
NA ALONE
5
090-268715
6
135-069524
7
NA ALONE
8
NA ALONE
HIGH SPEED GUIDES
Ref.
090-280819
1
090-279811
2
091-982389
3
134-085026
4
091-373399
5
090-115411
6
135-022804
7
090-184151
Ref.
090-282827
8
091-982389
9
134-085026
10
090-279837
11
091-373399
12
090-184151
13
135-022804
14
090-115411
90° SAW GUIDE BRACKETS
Ref.
090-448044
1
135-036473
2
090-275975
3
091-982421
4
090-116583
5
091-982397
6
090-275966
090-292616
093-021780
Upper Saw Guide Assembly (1/16" to 1/4")
. Screw, Soc. Set 5/16-24NF x 1/2
. Soc. Hd. Pipe Plug
Screw, Soc. Hd. Caps 1/4-20NC x 5/8
. Washer
. Upper Saw Guide Block
. Bearing Sub-Assembly (See Detail)
. Screw, Soc. Set #8-32Nc x 1/4
Lower Saw Guide Assembly (1/16" to 1/4”)
. Screw, Soc. Set #8-32Nc x 1/4
. Bearing Sub-Assembly (See Detail)
Screw, Soc. Hd. Cap 1/4-20NC x 5/8
. Washer
. Lower, Saw Guide Block
Bearing Sub-Assembly
. Shaft
. Bearing
Roller sod
. Washer
SpiraI Saw Guide Assembly (Upper)
. Eccentric Guide
. Tire Only
. Rim Only
Spiral Saw Guide Assembly (Lower)
. Plain Guide
Tire Only
. Rim Only
Upper Saw Guide Assembly (1/16” to 1/2")
. Upper Saw Guide Stock
Screw, Soc. Hd. Cap 1/4-20NC x 5/8
. Washer
. Plug
Retaining Ring
. Bearing
Bearing Cap
Lower Saw Guide Assembly (1/16" to 1/2')
. Screw, Soc. Hd. Cap 1/4-20NC x 5/8
Washer
. Lower Saw Guide Block
. Pluq
. Bearing Cap
. Ball Bearing
. Retaining Ring
90° Saw Guide Assembly
. 90° Elbow
. Upper Angle Block
. Screw, Soc. Hd. Cap 1/4-20NC x 1
Nipple
. Screw, Soc. Hd. Cap 1/4-20NC x 3/4
. Lower Angle Block
. Center Plate 24 x 24 Table (Not Shown)
STEEL AND CARBIDE INSERT SELECTION
1
Ref.
090-044991
090-044983
090-044975
090-044967
090-044959
O90-039603
090-039595
090-039587
090-039579
090-039561
Steel Insert (4 Req'd)
1/16"
3/32"
1/8"
3/16"
1/4"
3/9"
1/2"
5/8"
3/4"
1"
Ref.
090-161688
090-161704
090-132911
091-058941
090-132929
090-089822
D-8
1
1
2
2
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
2
1
USE
ONE
Carbide Insert (4 Req'd)
1/4”
3/8”
1/2"
5/8"
3/4"
1”
D-9
CODE NO.
C-7-19
CM-7-27
SAW GUIDE SELECTION
INDEX PART
No.
No.
DESCRIPTION
UNITS PER
ASS'Y
INDEX
NO.
TYPE 1
Ref.
Ref.
Ref.
1
2
PART
NO.
DESCRIPTION
UNITS PER
ASS'Y
- ROLLER AND SPINDLE ASSEMBLY
28984 Roller Sub-Assembly 1/4” Side
1779
. Bearing
8
28980
Roller Sub-Assembly 3/8” Side
1568
. Retaining Ring
9
28974 Roller Sub-Assembly 1/2" Side
13530
. Spindle
10
18296
1
. Bearing Shaft
20799 Guide Roller Assembly 1/4” Side
Ref.
28985 . Roller 1/4"
Select
Guide Roller Assembly 3/8” Side
Ref.
20807
. Roller 3/8"
28981
20292 Guide Roller Assembly 1/2” Side
Ref.
One
. Roller 1/2”.
28975
21072
Guide Roller Assembly 5/8" Side
Ref.
11529
. Bearing(N.D.Z99500XRIE)
1
20293
Guide Roller Assembly 3/4” Side
3
Ref.
2
1
100046 . Internal Ring
4
. Spindle
13530
1
1
11541
. Snap Ring
Guide Roller 1/4”
13531
2
5
Select
28982
Flanged Roller Sub-Assembly 1/4" Backup
. Guide Roller 3/8”
13540
Ref.
28978
Flanged Roller Sub-Assembly 3/8” Backup
. Guide Roller 1/2”
13533
Ref.
28976
Flanged Roller Sub-Assembly 1/2” Backup
. Guide Roller 5/9”
13542
Ref.
Select
28983
. Flanged Roller 1/4"
. Guide Roller 3/4”
13535
6
One
28979
. Flanged Roller 3/8”
1
. Bearing
1779
3
One
28977
. Flanged Roller 1/2”.
. Retaining Ring
4
1303
2
1
11541
. Snap Ring
7
1568
Retaining Ring
5
1
2
100046 . lnternal Ring
20798
Backup Roller Guide Assembly 1/4”
8
Ref.
1
11529
. Roaring (N.D. Z99500XRIE).
20808 Backup Roller Guide Assembly 3/8”
9
Ref.
1
18296
. Bearing Shaft
20295 Backup Roller Guide Assembly 1/2”
Ref.
10
21071
Backup Roller Guide Assembly 5/8”
Ref.
TYPE 1A - ROLLER SAW GUIDES WITH ROLLERS
29256 Upper Roller Saw Guide Assembly 1/4”
Ref.
20296
Backup Roller Guide Assembly 3/4”
Ref.
Backup Roller 1/4”
13532
29258
6
Ref.
Upper Roller Saw Guide Assembly 3/8”
Select
13541
. Backup Roller 3/8”
29506
Ref.
Upper Roller Saw Guide Assembly 1/2”
. Backup Roller 1/2”
13534
1
Ref.
Select flanged backup roller sub-assembly from
13543
. Backup Roller 5/8”
type 1 detail and parts list.
13536
. Backup Roller 3/4”
1
One
2
28960
. Upper Saw Guide Mock
1779
. Bearing
7
1
3
Ref.
Select side roller sub-assembly from tvpe 1
. Retaining Ring
1303
8
2
detail and parts list.
. Retaining Ring
1568
1
Comm.
Scr, Soc. Hd. Cap 1/4-20NC x 3/4(Not Shown)2 9
13530
. Spindle
10
1
2
Comm. . Washer, Lock 1/4 Std. (Not Shown)
Roller Guide Black Assembly
29257 Lower Roller Saw Guide Assembly 1/4”
Ref.
109517 Upper Guide Sub-Assembly
Ref.
Ref.
29259 Lower Roller Saw Guide Assembly 3/8"
1
. Upper Guide Block
33517
Ref.
29505
1
Lower Roller Saw Guide Assembly 1/2”
Comm. . Screw, Soc. Hd. Cap 1/4-20NC x 1/2
Ref.
1
4
Select flanged backup roller sub-assembly from 2
Comm. . Washer, Lock 1/4 Std.
3
1
type 1 detail and parts list.
33509 . Coolant Nozzle
1 4
1
28961
. Lower Saw Guide Block
5
5
. Close Nipple
1
Ref.
14-14528
6
Select side roller sub-assembly from type 1
6
7-015104 . Hex. Pipe Nipple
1
detail and parts list.
Comm. . Scr., Soc. Hd. Cap 1/4 - 20NC x 3/4 (Not Shown) 2 7
Comm. . Scr., Soc. Hd. Set 3/8-16NC x 3/8
2
1741
Comm. . Washer, Lock 1/4 Std
2 8
. P l u g
2
Type II - ROLLER AND SPINDLE ASSEMBLY
9
1
33636 . Coolant Guard
1
Ref.
29967 Side Roller Guide Assembly
Cloth Bag (Not Shown)
1
1
Ref.
100758. Guide Roller 1”
17215 Lower Guide Sub-Assembly
I
10
1303
Retaining Ring
2
2
27743 . Lower Guide Block
11
1779
1
.Bearing
2140
. Chip Deflector
3
4
12
1568 . Retaining Ring
I
2
Comm. . Screw, Soc. Hd. Cap 1/4-20NC x 3/8
13
2
l3530
1
5
. Spinale
. Plug
1741
14
2
Ref.
28968
Backup Roller Guide Assembly
Comm. . Screw, Soc. Hd. Set 3/8-16NC x 1/2
1
100758 . Guide Roller 1”
6
7
2
1303 . Retaining Ring
D-10
D-11
CODE NO.
C-10-29
CM-10-17
SCREW FEED ASSEMBLY
UNITS PER
ASS’Y .
INDEX
No.
PART NO.
DESCRIPTION
Ref.
35-6212
Ref.
45467
Screw Peed Assembly (1612,1612-0,1612-1, 2013,
2013-0, 2013-1, 2013-10, 2012-1A, 2012-1AT, 2612-1,
3612, 3613-1)
Screw had Assembly (1613-2, 2613-2, 3613-2,
6013-2)
. Feed Screw Bracket
. Screw, Rd. Hd. Mach. 1/4-20NC x 1/2
. Screw, Soc. Set #10-24NC x 1/4
. Collar
. Screw Feed Handle & Screw Sub-Assembly
. . Screw Feed Screw
. . Roll Pin
. . Screw Feed Handle
. Screw Feed Swivel Sub-Assembly
. . Screw, Rd, Hd. Mach. #6-32NC x 1/4
. . Screw Feed Key
. . Steel
Ball
. . Detent Spring
. . Screw Feed Swivel
1
2
3
4
*5
6
7
8
*9
10
11
12
13
14
35-6211
198895
198410
11-28418
11-03007
11-03401
4255
34-03106
35-5224
198838
5-03402
5-03502
5-03501
5-03401
*NOTE: Starred items are the only parts for assembly #45467.
D-12
1
2
1
1
1
1
1
1
1
1
1
2
1
1
D-13
CODE NO.
C-5-90
CM-5-69
GEAR SHIFT SUB-ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CATALOG
NO.
094-067642
090-052218
135-078152
091-991380
090-410796
09-052200
091-0984229
090-042599
090-052168
090-161449
135-096139
090-040767
090-210287
135-064269
090-052226
090-042557
135-087013
DESCRIPTION
Gear Shift Sub-Assembly
. Shaft
. Adjustment Screw
. Nut, Hex. Jam 5/8-18NF
. Bracket
. Ball Crank
. Scr. Soc. Hd. Set 1/4-20NC x 1/4
. Roll Pin
. Pivot Arm
. Shifter Rod
. Retaining Ring
. Pin
. Swivel Block Sub-Ass'y
. Retaining Ring
. Washer
. Roll Pin
. Socket
Ref.
1
2
3
4
5
6
7
8
9
094-064292
094-064284
090-220369
111-034047
091-991380
091-992701
091-0992677
091-991364
090-058454
091-984369
091-984534
Variable Assembly
. Arm
. Variable Plate Sub-Ass’y.
. Adjustment Ser.
. Nut, Hex. Jam 5/8-18NF
. Washer, 1 SAE Std.
. Plain Washer, 5/8 Light Wt. 1-5/16
. Nut, Hex. Jam 5/8-11NC
. Spring
. Scr. Soc. Hd. 5/16-18NC x 3/8
. Scr. Soc. Hd. Set 3/8-16 NC x 1-1/4
D-14
UNITS PER
ASS’Y.
1
3
3
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
2
2
1
2
2
1
1
1
APPENDIX E
E-1
CODE NO.
C-4-39
CM-4-12
GEAR SHIFT & SHIFTER ASSEMBLIES
INDEX
NO.
Ref.
CATALOG
NO.
090-236449
Ref.
Ref.
Ref.
1
2
3
4
5
6
7
8
9
090-278540
090-410804
090-449075
090-039256
090-052168
091-984229
090-040767
135-096139
090-042557
090-042599
090-410796
090-085267
090-052218
090-172974
090-216516
091-981001
091-991232
091-993014
090-219502
090-052176
135-078152
091-993055
090-052200
135-087013
135-064269
090-052226
090-210287
10
11
12
13
14
15
16
17
18
19
20
21
22
Ref.
1
2
3
4
5
6
7
8
090-402801
090-204280
091-995191
090-203886
090-204272
105-035026
090-023292
090-110008
090-025883
DESCRIPTION
Gear Shift Sub-Assembly (3613-2, 3612-3,1613-2,
3612-1H3)
Gear Shift Sub-Assembly (6013-2)
Gear Shift Sub-Assembly (1612-3)
Gear Shift Sub-Assembly (2613-2, 2612-2H)
. Shifter Rod
. Pivot Arm
. Scr. Soc. Hd. Set 1/4-20NC x 1/4
. Pin
. Retaining Ring
. Roll Pin
. Roll Pin
. Bracket
. Shaft (3613-2, 3612-3, 3612-1H3, 1613-2)
. Shaft (2613-2, 2612-2H, 1613-3)
. Shaft (6013-2)
. Shift Lock Selector Sub-Assembly
. Scr. Hex. Hd. Cap 5/16-18NC x 1
. Nut, Hex. Jam 5/16-18NC
. Washer, Flat 5/16
. Lock Lever
. Spring
. Adjustable Screw
. Nut, Hex. Jam 5/8-18NF
. Ball Crank
. Socket
. Retaining Ring
. Washer
. Swivel Block Sub-Assembly
Shifter Assembly
. Shifter Rod Assembly
. Cotter Pin
. Shifter Rod Cage
. Shifter Rod
. Steel Ball
. Spring
. Spring
. Latch
E-2
UNITS PER
ASS'Y.
1
1
3
1
2
1
2
1
USE
ONE
1
1
2
1
1
1
3
3
1
1
1
1
1
1
2
1
1
2
2
2
2
E-3
E-4
CODE NO.
C-3-78
SLIDING TABLE ASSEMBLY
(Air Feed)
INDEX
NO.
Ref.
Ref.
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
DESCRIPTION
PART NO.
501532
Sliding Table Assembly (1612-0, 1612 3612)(2614-1)
503826
Sliding Table Assembly (2012-A, 2012-1A, 2012-AT, 2012-1AT)
4209
● Roll Pin
10490
● Center Plate
501380
● Table
125361
● Square Weldment
198851
● Screw, Rd. Hd. Mach. #8-32NC x 1/4
129590
● Chain
125393
● Plug
199019
● Screw, Truss Hd. Mach. #1/4-20NC x 3/8
503045
● Pan
198867
● Screw, Rd. Hd. Mach. #10-24NC x 3/8
35-6580
● Pipe Plug
50791
● Trunnion
3647
● Ball Bushing
5180
● Spacer
39464
● Head
41093
● Chip Guard Assembly (#501532)
45080
● Chip Cover Assembly (#501532)
21621
● Trunnion Plate
40903
● Cradle
10501
● Spacer
198123
● Screw, Hex. Hd. Cap 3/4-16NF X 4 3/4
199141
● Nut, Hex. 3/4-16NF
198047
● Screw, Hex. Hd. Cap 3/8-16NC X 1 1/4
199332
● Washer, Lock 3/8 Std
35-328
● Dowel Pin
24241
● Keeper Block
198838
● Screw, Rd. Hd. Mach. #6-32NC X 1/4
34-03315
● Pointer
198893
● Screw, Rd. Hd. Mach. 1/4-20NC x 3/8(#501532)
198822
● Screw, Pan Hd. Mach. 1/4-20NC x 3/8(#503826)
199356
● Washer, Lock 1/4 Shakeproof Int
34212
● Cover
8790
● Lube Fitting 90°
6-33518
● Pipe Plug
4244
● Roll Pin
104632
● Belleville Washer
198252
● Screw, Soc Hd. Cap 1/4-28NF x 1 1/4
115660
● Locknut
131011
● Handle Sub-Assembly
199264
● Washer, Flat 3/8 Std. S.A.E.
Following items not shown:
131948
● Guard Assembly(#503826)
11-05509
● Pipe Plug(#503826)
28527
● Handle Assembly
129447
● Screw Assembly
E-5
UNITS PER
ASSY
1
1
1
1
2
1
1
6
1
16
1
1
4
2
1
1
1
1
1
1
1
1
1
10
2
1
1
1
2
2
8
1
2
1
1
6
1
1
1
2
1
1
1
1
E-6
CODE NO.
C-3-79
SLIDING TABLE ASSEMBLY
(AIR FEED)
INDEX
NO.
Ref.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
PART NO.
501532
503826
125674
198711
198710
125386
9392
14909
9504
9503
198895
23967
198221
125387
199127
125388
125389
4255
125392
118116
4242
131802
21612
5177
404546
119364
199134
403320
198044
198027
198291
34-13407
16351
199319
198865
5176
198069
199327
198046
198264
4599
301371
128231
34-01503
1790
4215
128215
14-06553
301372
16001
128216
198009
122748
198218
199122
6291
DESCRIPTION
Sliding Table Assembly (1612-0, 1612, 3612)(2614-1)
Sliding Table Assembly (2012-A, 2012-1A, 2012-AT, 2012-1AT)
● Regulating Valve
● Screw, Fil. Hd. Mach. #12-24NC x 7/8 (#501532)
● Screw, Fil. Hd. Mach. #12-24NC x 3/4 (#503826)
● Mounting Plate (#503826)
● T-Bolt
● Knob
● Dog
● Stop
● Screw, Rd. Hd. Mach. 1/4-20NC x 1/2
● Slide Bar
● Screw, Soc. Hd. Mach. #10-24NC x 5/8
● Actuator Rod
● Nut, Hex. Jam 3/8-16NC
● Shaft
● Bracket Weldment
● Roll Pin
● Shaft
● Tapered Handle
● Roll Pin
● Shim Option List
● Guide Rod
● Scraper Ring
● Cylinder Bracket
● Grip Ring (#501532)
● Nut, Hex. Jam 1/2-20NF (#503826)
● Table Cylinder Assembly (See Detail)
● Screw, Hex. Hd. Cap 3/8-16NC x 3/4
● Screw, Hex. Hd. Cap 5/16-18NC x 3/4
● Screw, Soc. Hd. Cap 1/2-13NC x 3/4
● Dowel Pin (#501532)
● Dowel Pin (#503826)
● Washer, Lock #10 Std.
● Screw, Rd. Hd. Mach. #10-24NC x 1/4
● Retainer
● Screw, Hex. Hd. Cap 1/2-13NC x 2
● Washer, Lock 1/2 Std.
● Screw, Hex. Hd. Cap 3/8-16NC x 1
● Washer 3/8 Std.
● Clamp
● Release Valve Assembly (2012-A Only)
● ● Seal Disc
● ● Adhesive
● ● Spring
● ● Roll Pin
● ● Plunger
● ● Bearing
● ● Valve Body
● ● Barbed Insert
● ● Actuator Rod
Screw, Hex. Hd. Mach. 1/4-20NC x 7/8
●
● Pipe Plug
● Screw, Soc. Hd. Cap #10-24NC x 1/4
● Bolt, Hex. 5/16-18NC
● Plug Button
E-7
UNITS PER
ASSY
1
2
2
1
2
2
2
1
A.R.
2
10
1
1
1
1
1
1
1
1
A.R.
2
4
1
1
2
1
A.R.
2
4
2
2
16
2
4
4
7
2
A.R.
1
1
A.R.
1
1
1
1
1
1
1
2
1
2
2
1
E-8
CODE NO.
C-3-80
SLIDING TABLE ASSEMBLY
(AIR FEED)
INDEX
NO.
Ref.
Ref.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
*23
*24
*25
*26
*27
*28
*29
*30
*31
*
PART NO.
501532
503826
403320
21594
4261
35-891
5130
25655
12776
35-463
35-466
35-465
198242
3559
125685
127821
302327
115427
300468
5123
127774
17-13521
104478
35-6888
2004
Stk #003
Stk #008
119401
119404
119408
119407
125673
14-03507
3818
14-14528
128148
105996
303417
120369
102918
DESCRIPTION
Sliding Table Assembly (1612-0, 1612, 3612)(2614-1)
Sliding Table Assembly (2012-A, 2012-1A, 2012-AT, 2012-1AT)
● Table Cylinder Assembly
● Swivel
●
● Roll Pin
●
● Shim
●
●
● Swivel Pin
●
● Rear Cylinder Cap
● Locknut
●
● Cylinder Gasket
●
● Snap Ring
●
● Cylinder Collar
●
● Screw, Soc. Hd. Cap 1/4-20NC x 1
●
●
● Washer, Lock 1/4 Hi-Collar
●
● Piston
● Cylinder
●
●
● Piston Rod
● Screw, Soc. Set Self-Locking
●
● End Cap
●
● Bearing
●
● Seal Ring
●
90°
Street Elbow
●
Hose
Clamp (#501532)
●
Hose
Clamp
(#503826)
●
Barbed
Insert
●
● Hose 3/8 O.D. (#501532)
● Hose 5/8 O.D. (#503826)
● Solenoid Valve 120V 60Hz
● Solenoid Valve 240V 60Hz
● Solenoid Valve 380V 60Hz
● Solenoid Valve 480V 60Hz
● Bulkhead Adapter
● Close Nipple
● Reducing Coupling
● Close Nipples
● Manifold
● Reducer Bushing
● Orifice
● Pipe Plug
● Oil Lubricator (Not Shown)
*Note: Starred items used only on assembly #501532
E-9
1
1
1
2
1
1
1
1
2
1
4
4
1
1
1
3
1
1
1
1
6
4
6
A.R.
A.R.
Use
One
1
2
2
3
1
1
1
1
1
E-10
CODE NO.
C-3-52
TABLE & TRUNNION ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
CATALOG
NO.
504939
090-038613
091-994012
134-033158
091-988378
094-065935
090-012352
091-980698
135-004455
091-980474
091-993329
090-242447
135-005163
090-406497
090-406455
134-134071
091-982918
091-980656
091-993774
090-598269
090-104902
091-333104
091-333112
091-333120
091-333138
091-333146
090-394644
091-981407
090-042094
114-004732
091-980466
091-982611
090-045998
091-991414
091-401513
DESCRIPTION
Table & Trunnion Assembly
● Escutcheon
● Scr., Rd. Hd. Mach. PK Type U #6 x 3/8
● Trunnion Tilt Pointer
● Scr. Rd. Hd. Mach. #6-32NC x 3/16
● Spacer
● Spacer
● Scr. Hex. Hd. Cap 1/2-13NC x 2
● Dowel Pin
● Scr. Hex. Hd. Cap 3/8-16NC x 1-1/4
● Washer, Lock 3/8 Std.
● Lower Post Block
● Dowel Pin
● Cradle
● Trunnion
● Dowel Pin
● Scr. Soc. Hd. Cap 1/2-13NC x 3/4
● Scr. Hex. Hd. Cap 1/2-13NC x 1
● Washer, Lock 1/2 Shakeproof
● Table
● Center Plate
● Shim
● Shim
● Shim
● Shim
● Shim
● Head
● Scr. Hex. Hd. Cap 3/4-16NF x 6-1/2
● Roll Pin
● Dowel Pin
● Scr. Hex. Hd. Cap 3/8-16NC x 1
● Washer, Flat 3/8 Std.
● Clamp
● Hex. Nut 3/4-16NF
● Washer
E-11
UNITS PER
ASSY.
1
2
1
1
1
4
4
2
2
3
1
2
1
1
2
4
4
4
1
1
A.R.
A.R.
A.R.
A.R.
A.R.
1
1
1
2
2
1
1
1
1
E-12
CODE NO.
C-9-107
CM-9-4
Z-9-16
TABLE SUPPORT ASSEMBLY
INDEX
NO.
*Ref.
PART NO.
55436
*Ref.
50826
*Ref.
*Ref.
*Ref.
1
51216
52992
17-03003
198046
2
198410
3
*4
5
6
7
8
9
10
11
12
13
14
15
16
17
29592
35-5239
35-877
35-5238
17-03105
4259
17-03406
17-03404
133185
133183
133184
302678
30440
30441
198220
22297
198044
199264
132287
35-7708
198045
198046
199126
199264
199332
17-03104
198423
199332
20
21
22
23
24
25
26
27
NOT SHOWN
199268
DESCRIPTION
Table Support Assembly (1612, 3612, 1612-0, 3613-0, 1612-1, 2612-1,
3613-1, 1613-2, 3613-2, HS6013, 2013-1, 2013-10, 2012-1A, 2012-1AT)
Table Support Assembly (1611-H, 1612-H, 3612-H, 2612-H, 2612-1H,
2612-2H, 1612-3, 3612-3)
Table Support Assembly (2613-2, 6013-2)
Table Support Assembly (2613-3, 6013-3)
Table Support Assembly (
ZS-3620, ZV-3620, ZW-3620)
● Screw, Hex. Hd. Cap 3/8-16NC x 1 (Used on Assy's #55436, #51216,
#50826)
● Screw, Soc. Hd. Set #10-24NC x 1/4 (Used on Assy's #55436, #50826,
#51216)
● Plate (Used on Assy's #55436, #50826, #51216)
● Table Support Rod Assembly
● ● Universal Joint
● ● Table Support Tube Sub-Assembly
● ● Lock Lever
● ● Roll Pin
● ● Lock Shaft
● ● Support Rod
● ● Universal Joint Pin
● ● Universal Joint Swivel
● ● Universal Joint Swivel Pin
● ● Universal Joint Thd. End
● Left Table Support Plate (Used on Assy #55436)
● Right Table Support Plate (Used on Assy #55436)
● Screw, Soc. Hd. Cap #10-24NC x 1/2 (Used on Assy #55436)
● Angle Bracket (Used on Assy #50826)
● Screw, Hex. Hd. Cap 3/8-16NC x 3/4 (Used on Assy #50826)
● Washer 3/8 Std. (Used on Assy #50826)
● Spacer Option List (Used on Assy's #55436, #50826, #52992, 17-03003)
● Spacer (Used on Assy #51216)
● Screw, Hex. Hd. Cap 3/8-16NC x 7/8 (Used on Assy #52992)
● Screw, Hex. Hd. Cap 3/8-16NC x 1 (Used on Assy #17-03003)
● Nut, Hex. 3/8-16NC (Used on Assy's #52992, #17-03003)
● Washer 3/8 Std. (Used on Assy #52992)
● Washer, Lock 3/8 Std. (Used on Assy #52992)
● Bottom Bracket (Used on Assy's #52992, 17-03003)
● Screw, Soc. Set 1/4-20NC x 5/16 (Used on Assy #52992, #17-03003)
● Washer, Lock 3/8 Std. (Used on Assy's #55436, #50826, #51216)
●
UNITS PER
ASSY
Washer 3/4 Std. (Used on Assy #52992)
*NOTE: All Table Support Assemblies use Table Support and Rod Sub-Assembly #35-5239. However,
different upper and lower connecting brackets are used. Locate on the drawing the brackets
used on your machine.
E-13(14 blank)
A.R.
2
1
2
1
1
1
1
1
1
2
2
2
1
1
1
8
1
2
6
1
A.R.
4
4
4
4
4
2
2
A.R.
2
APPENDIX F
F-1
COOE NO.
INDEX
No.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
C-4-38
CM-4-11
MX-2 TRANSMISSION ASSEMBLY
PART NO.
UNITS PER
ASSY
DESCRIPTION
50186
MX-2 Transmission Assembly
2596
● Gasket
35-3419
● Expansion Plug
2266
● Shifter Rod
40280
● Shifter Assembly (See Detail)
5026
● Bearing Retainer
2689
● Oil Seal
Comm.
● Screw, Soc. Hd. Cap #10-24NC x 1/2
2263
● Gasket
2264
● Bearing Cap
2276
● Ball Bearing
24698
● Counter Shaft
3872
● Gasket
5027
● Ball Bearing
42974
● Cluster Gear Sub-Assembly
21290
● Output Shaft Sub-Assembly
20947
● ● Output Shaft
13-01304
● Spacer
4575
● ● Bushing
4581
● Ball Bearing
3908
● Screw, Soc. Set Dog. Pt
Comm.
● Screw, Soc. Set 1/4-20NC x 1/4Lg. Cut Pt
3688
● Stationary Clutch Jaw
Comm.
● Screw, Soc. Hd. Cap 1/4-20NC x 3/8
Comm.
● Washer, Lock 1/4 Std. Shakeproof Int.
3465
● Sliding Clutch Jaw
2690
● Oil Seal
25998
● Input Shaft
13611
● Retaining Ring
2265
● Bearing Retainer
Comm.
● Screw, Soc. Hd. Cap #10-24NC x 1/2
35-3436
● Spacer
2277
● Retainer Ring
35-7192
● Woodruff Key
42976
● Counter Shaft Gear
11273
● Tachometer Drive Assembly
4229
● ● Roll Pin
10540
● ● Helical Gear
2271
● ● Spacer
14-06553
● ● Oilite Bushing
2278
● ● O Ring
2279
● ● Body
2280
● ● Spindle
2989
● Pipe Nipple
14-348
● 90° Elbow
1276
● Pipe Plug
50193
● Housing Assembly
20399
● ● Gasket
1993
● ● Washer, Lock
4122
● O Ring
35-6068
● Breather
Comm.
● Screw, Rd. Hd. Mach. #10-24NC x 1/2
Comm.
● Washer, Lock #10 Reg
2595
● Cover
6-04405
● Pin
20425
● Shifter Arm
5-04412
● ● Dowel Pin
25123
● Intermediate Gear
Following items not shown:
● Pipe Plug
5-04612
Comm.
● Screw, Soc. Set 1/4-20NC x 5/16 Lg. Cup Pt
F-2
1
1
1
1
1
1
5
3
2
3
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
5
A.R.
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
1
1
14
14
1
1
1
2
1
1
1
F-3
CODE NO.
C-5-91
CM-5-71
VARIABLE BRACKET & HANDWHEEL SUB-ASSY.
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CATALOG
NO.
094-064276
111-034047
091-991364
090-418468
135-028108
134-054105
090-042599
091-984229
090-418450
090-073511
090-089616
093-048635
091-991406
091-984104
090-099714
135-017804
090-042334
DESCRIPTION
Variable Bracket
● Adjustment Scr
● Nut, Hex. Jam 5/8-11 NC
● Swivel Base
● Thrust Bearing
● Collar
● Roll Pin
● Scr. Soc. Set 1/4-20NC x 1/4
● Swivel
● Oilite Bearing
● Spacer
● Screw
● Nut, Hex. Jam 3/4-10NC
● Scr. Soc. Set #10-24NC x 1/4
● Miter Gear
● Collar
● Roll Pin
Ref.
1
2
3
4
5
090-229063
090-425356
090-042599
091-181164
091-181172
090-073529
Handwheel Sub-Assembly
Handwheel
● Roll Pin
● Handle
● Pin
● Shaft
●
F-4
UNITS PER
ASSY
3
3
1
2
1
2
2
1
2
2
1
4
2
2
1
1
1
1
1
1
1
F-5
CODE NO.
C-5-92
C-5-72
10” VARIABLE ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
CATALOG
NO.
090-379231
111-055125
091-195198
091-984237
090-304569
090-379223
DESCRIPTION
10” Variable Assembly
● Variable
Oiler
● Stop Collar
● Scr, sac. set 1/4-20NC x 5/8
● Variable Sub-Assembly (Replace as a unit)
● Shaft
F-6
UNITS PER
ASSY
1
1
1
1
1
F-7
CODE NO.
CM-4-124
VARIABLE OILER ATTACHMENT
INDEX
NO.
Ref.
Ref.
Ref.
Ref.
1
2
3
4
5
6
7
PART NO.
47802
47771
56402
56187
108204
8437
14545
8438
14505
Stk #520
Stk #746
108205
198008
8
9
10
11
12
13
14
199321
108297
199396
Stk #210
16968
198691
198012
198011
15
16
17
18
199115
1400
107027
107967
108206
1843
6969
3849
35-2456
17110
15780
19
20
21
22
UNITS PER
DESCRIPTION
ASSY
Variable Oiler Attachment (2612-2H) (2613-1H, 2612-1H3, 2614-1)
Variable Oiler Attachment (2624-5)
Variable Oiler Attachment (2613-3)
Variable Oiler Attachment (6013-3) (6013-H3)
1
● Reservoir
● St. Connector (Assy's #47802, #47771)
1
● Sealtite Connector (Assy's #56187, #56402)
1
● 90° Connector (Assy's #47802, #47771)
1
● O-Ring (Assy's #56187, #56402)
1
● 1/2” Conduit Sealtite
A.R.
● Wire, Stranded #14 Red
A.R.
● Reservoir Bracket
1
● Screw, Hex. Hd. Cap 1/4-20NC x 3/4 (Assy's #47771,
56402, #56187)
A.R.
A.R.
● Washer, Lock 1/4 Std
● Auto. Oil Reservoir Plate
1
4
● Screw, Drive #2 x 3/16 Type “U”
● Nylon Tubing 1/4 O.D.
A.R.
A.R.
● Tubing Clamp
● Screw, Fil. Hd. Mach. #8-32NC x 1/4
A.R.
4
● Screw, Hex. Hd. Cap 1/4-20NC x 1-1/2 (Assy #47771)
● Screw, Hex. Hd. Cap, 1/4-20NC x 1-1/4 (Assy's #47802,
3
● #56402, #56187)
● Nut, Hex. 1/4-20NC
A.R.
● Male Connector
A.R.
● Manifold Bracket (Assy #47771 Only)
1
● Manifold (Assy's #47802, #47771)
1
● Manifold (Assy's #56402, #56187)
1
1
● Hose 3/8 O.D. x 12 (Assy's #47771, #56402, #56187)
● Hose 3/8 O.D. x 18 (Assy #47802)
1
A.R.
● Swivel Adapter
1
● Reducer Bushing
1
● 90° Elbow (Not Shown) (Assy's #47802, 56402, 56187)
1
● Grommet (#47802, #56402, #56187)
Following Items Not Shown:
14411
● Flange Washer
● Sealtite Connector
14504
● Capper Tubing 1/4 O.D.
Stk #102
F-8
2
1
A.R.
F-9
CODE NO.
C-9-14
WEIGHT FEED ASSEMBLY
INDEX
No.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
*30
CATALOG
NO.
095-04826
135-053221
135-063956
091-980052
134-133016
091-993758
134-135045
105-133094
134-054147
134-134188
135-063980
134-054147
105-133094
091-991273
091-993329
091-992669
135-063972
135-074979
134-135045
090-032756
134-133115
090-032749
090-032764
135-050110
105-134175
105-134183
106-135015
091-402131
091-993048
091-306555
090-540998
*31
090-042599
*32
*33
*34
35
36
37
38
*39
*40
*41
42
43
44
45
46
090-099714
091-984104
091-984229
105-131122
091-991786
091-993279
091-980748
091-980458
091-993329
090-168717
091-990325
091-991265
091-306571
093-023299
091-992644
091-306563
091-995183
105-133169
090-275272
090-042599
090-425489
091-181164
091-181172
090-167958
134-054105
090-168725
47
48
*50
*51
*52
*53
*54
*55
*56
*57
49
DESCRIPTION
Weight Feed Assembly
● Bracket and Cable Assembly
● ● Horizontal Pulley Assembly
● ● ● Scr. Hex. Hd. Mach. 1/4-20NC x 3/8
● ● ● Cap
● ● ● Washer, Shakeproof #1214
● ● ● Pulley
● ● ● Spacer
● ● ● Washer
● ● ● Thumb Nut
● ● ● Pulley Screw
● ● Washer
● ● Spacer
● ● Nut, Hex. Jam 3/8-16NC
● ● Washer, Lock 3/8 Std.
● ● Washer, 1/2" Plain
● ● Cable Carrier
● ● Equalizer Pulley Assembly
● ● ● Pulley
● ● ● Pulley Axis
● ● ● Cap
● ● ● Clevis
● ● ● Retaining Ring
● ● Power Feed Chain Sub-Assembly
● ● Housing
● ● Hook
● ● Feed Chain
● Pivot Bracket Weld't. Assembly
● Wrought Washer 1/2 Std.
● Chain Roller
● ● Power Feed Hinge
● ● Roll Pin
● ● Miter Gear
● ● Scr. Soc. Set #10-24NC x 1/4
● ● Scr. Soc. Set 1/4-20NC x 1/4
● Stop Nut
● Nut, Square Hd. 1/2-13NC
● Washer, Lock 1/2" Std.
● Bolt, Hex. Hd. Mach. 1/2-13NC
● ● Scr. Hex. Hd. Cap 3/8-16NC x 7/8
● ● Washer, Lock 3/8 Std.
● ● Weight Beam
● Scr. Oven Hd. Mach. 3/8-16NC x 1-1/4
● Nut, Jam 3/8-16NC Std.
● Release Arm
● Bracket
● Washer, Flat 3/8 Std.
● Shaft
● Cotter Pin
● Chain Anchor
● ● Handwheel Assembly
● ● ● Roll Pin
● ● ● Handwheel
● ● ● Handle
● ● ● Pin
● ● ● Shaft
● ● Collar
● ● Hinge Bushing
* NOTE: Starred Items are part of Hinge Assembly #090-447962.
F-10
UNITS PER
ASSY
1
2
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
2
1
1
4
1
2
1
1
1
2
1
1
2
2
2
2
2
1
1
1
6
6
1
1
2
1
2
4
1
2
1
1
1
1
1
1
1
2
1
F-11
CODE NO.
C-9-15
WEIGHT FEED ASSEMBLY
INDEX
NO.
Ref.
1
2
3
*4
*5
*6
*7
*8
*9
*10
*11
**12
* *13
**14
**15
**16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
**38
CATALOG
NO.
504828
090-447962
091-980441
091-993329
134-131069
105-135099
135-063964
134-133016
134-135045
135-063998
091-993741
091-980052
090-213448
105-131056
105-134019
105-134100
090-167966
105-134118
105-131122
091-980466
091-991265
105-133086
091-980425
094-010352
093-013423
091-980276
091-991224
091-993238
091-980128
091-991158
091-993212
105-131130
093-028520
090-139965
135-050128
091-995472
105-133144
105-135107
090-275256
DESCRIPTION
Weight Feed Assembly
● Hinge Assembly
● Scr. Hex. Hd. Cap 3/8-16NC x 3/4
● Washer, Lock 3/8 Std.
● Handwheel
● Cord
● Vertical Pulley Sub-Assembly
● ● Cap
Pulley
●
● ● Stud
● ● Washer, Shakeproof #1214
● ● Scr. Hex. Hd. Mach. 1/4-20NC x 3/8
● ● Weight Bracket Screw Assembly
● ● ● Weight Bracket
● ● ● Weight Adjustment Screw
● ● Stop Nut
● ● Cable Beam
● Pin
● Weight
● Scr. Hex. Hd. Mach. 3/8-16NC x 1
● Nut, Hex 3/8-16NC
● Weight Bracket
● Scr. Hex. Hd. Cap, 3/8-16NC x 1/2
● Bracket
● Catch Bracket
● Scr. Hex. Hd. Cap 5/16-18NC x 3/4
● Nut, Hex. 5/16-18NC
● Washer, Cock 5/16 Std.
● Scr. Hex. Hd. Cap 1/4-20NC x 1-1/2
● Nut, Hex. 1/4-20NC
● Washer, Lock 1/4 Std.
● Foot Pedal
● Release Lever Weld’t. Assembly
● Dowel Pin
● Chain Assembly
● ● Rd. Hd. Rivet 3/16 Dia. x 5/8
● ● Chain Anchor
● ● Chain
● ● Hinge Bracket
UNITS PER
ASSY
*NOTE: Single Starred items are part of Bracket and Cable Assembly ,#135-053221.
**NOTE: Double Starred items are part of Hinge Assembly #090-447962.
F-12
1
8
10
2
1
2
1
1
1
1
1
1
1
1
2
1
1
1
5
2
1
2
1
1
4
2
4
1
1
1
1
1
2
1
1
1
1
1
F-13
UPPER & LOWER WHEEL ASSEMBLIES
INDEX NO.
Ref.
1
2
3
4
DESCRIPTION
CATALOG NO.
Upper
Wheel Assembly
46451
13-001502
● Tires
46444
● Wheel
●
Bearing
16538
●
Plastic Plug
106748
Ref.
1
2
3
4
5
6
54079
304742
7430
54035
35-4212
22513
199015
Lower Wheel Assembly
●
Tire Assembly
Retainer
●
●
Wheel
●
Retainer Ring Segment
Retainer Ring Segment
●
● Screw, Truss Hd. Mach. #10-24NC x 3/8
F-14
UNITS PER
ASSY
1
1
2
2
1
2
1
2
4
18
APPENDIX G
G-1
CODE NO.
WORKHOLDING JAW
INDEX
NO.
Ref.
PART NO.
Ref.
40262
1
2
3
4
5
6
7
Ref.
1
2
3
4
*5
6
7
34-03107
5-13313
198698
20386
198235
2162
198410
20385
5-13007
5-13512
5-13318
40678
5-13110
5-13313
198892
199015
C-10-16
CM-9-5
Z-9-9
DESCRIPTION
Work Jaw (1612, 1612-0, 2013, 2013-0, 2013-1, 2013-10,
3612, 3613-0)
Work Holder Assembly (1612, 1612-0, 1612-H, 1612-1,
1613-2, 1612-3, 2013, 2013-0, 2012-A, 2012-AT,
2013-1, 2013-10, 2012-1A, 2012-1AT, 2612-H, 2612-1,
2612-2H, 2613-2, 3612, 3613-0, 3612-H, 3613-1,
3613-2, 3612-3, 6013-2)
● Sprocket
● Screw, Fil. Hd. Mach. #10-24NC x 1/2
● Left Arm
● Screw, Soc. Hd. Cap 1/4-20NC x 3/8
● Knurled Screw
● Screw, Soc. Hd. Set #10-24NC x 1/4
● Right Arm
UNITS PER
ASSY.
Workholding Jaw Assembly (1612, 1612-0, 1612-1, 1613-2,
1612-3, 2013, 2013-0, 2013-1, 2013-10, 2012-1A, 2012-1AT,
2612-1, 2613-2, 3612, 3613-0, 3613-1, 3613-2, 3612-3,
6013-2, ZW-3620)
● Handle
● Handle Bracket
● Workholding Jaw Sub-Assembly
● ● Work Holding Jaw
● ● Sprocket
● ● Screw, Rd. Hd. Mach. 1/4-20NC x 5/16
● ● Screw, Truss Hd. Much. #10-24NC x 3/8
*NOTE: Before 2-12-44 on Hydraulic Machines use #6-23337 Sprocket with
3/16" Pitch, Specify Pitch of Chain when Ordering.
G-2
2
4
1
1
1
2
1
2
2
1
1
2
6
4
G-3
INSTRUCTION
AND
PARTS MANUAL
Model DBW-15
H-0
APPENDIX H
CHAPTER 1
INSTALLATION
LOCATION
Locate the welder so that the operator will have sufficient room for
handling and welding saw bands. Space should be allowed so that the
coiled band will not injure persons passing nearby. The welder should
also be located so that the welding sparks will not ignite flammable
material.
ELECTRICAL CONNECTIONS (PORTABLE ONLY)
The welder must be connected to an electrical power line of sufficient
capacity to provide for the instantaneous load specified on the data plate.
The welder should be fused according to the amperage on the data plate.
Refer to the wiring diagram supplied with the welder. The welder will
not operate on direct current.
The welder may be installed on band sawing machines. The location is convenient
for welding bands to fit over two or three band wheels of saw. Correct band length
for the machine is stamped on a data plate attached to the rear of the machine column.
H-1
CHAPTER 2
OPERATING FEATURES
GENERAL DESCRIPTION
The Model DBW-15 is a resistance-type butt welder. The
two clamping jaws of the welder hold the butted band ends together.
When the welding switch lever is pressed, an electric current is induced through the butted band ends, creating enough heat to soften and
join them.
Pressing the welding lever also releases a spring which causes the
jaws to force the band ends together. The electrical current is shut
off before the movable jaw completes its movement. Final upset or
“forging” occurs when the band is still hot, but is no longer being
heated by its electrical energy source.
JAW GAP AND UPSET FORCE CONTROLS
The initial gap between the welder jaws and the spring upset force
must both be adjusted in proportion to the cross-sectional area of
the band being welded. A greater jaw gap will allow a wider or thicker
band to reach its proper welding temperature. A greater upset force
produces the same unit pressure in welding a wider or thicker band.
A jaw upset force selector is used to provide a variable control of
upsetting force. Initial jaw gap is set by adjusting the position of the
weld lever before making the weld.
A N N E A L I N G
When the band is heated in the butt welding process, the steel at the
point of weld air-hardens and becomes brittle. The annealing push
button is used to anneal the weld by reheating it. This returns the
band to an approximation of its original condition. A selector switch
is provided for choosing the correct annealing heat, depending upon
the width of the saw blade.
WELD GRINDER
The grinding wheel is used to prepare the blade for welding and to remove
fIash from the weld. Flash on both sides of the weld must be ground off
to blade’s thickness. The gage at the top of the wheel guard is used to
check for complete removal of the flash. After grinding, the weld should
pass freely through this gage.
Since it may be difficult to see if the grinding wheel is rotating, a pilot
light is provided as a safety feature. This light is on when the grinding motor is running.
H-2
Model DBW-15 welder controls and features, front view.
H-3
H-4
CHAPTER 3
OPERATION
PREPARING THE BLADE
(1) Cutting the Blade: Cut the saw blade to length. Use the blade shear
if it is available. Using the blade shear will insure that the blade
ends are flat, square and smooth.
(2) Tooth Spacing: In fine pitched bands, one or more teeth on each
side of the cut must be removed by grinding, so that the cross
section of the weld area of the band is uniform. This will also
insure proper tooth spacing at the weld area and that the set
pattern of the teeth will be retained.
If snips are used to cut blade,
grind ends square as shown.
Using the Blade Shear.
NOTE
If the Blade Shear has not been used to cut the blade, square the ends of the blade
before welding. Grind both ends of the saw blade in one operation as shown in the
sketch. Hold the ends so that the teeth point in opposite directions. Regardless
of the angle of grinding, the two ends will match perfectly when turned over.
(3) Clean the band: Use No. 120 grit emery cloth or equivalent for
this operation. Care must be taken so that the teeth are not
touched with the emery cloth, because the set or sharpness of the
teeth could be damaged. The part of each end of the band that comes
into contact with the inserts must be sanded. Any dirt, oil, oxide or
scale that is not removed will prevent good electrical contact. The
oxide on Dart Blade -must be removed.
H-5
SAW BLADE ALIGNMENT BEFORE WELDING
For internal sawing, the blade is inserted through the starting
hole in the work. The ends of the saw blade are then brought
together to be clamped into the jaws.
When rewelding a used band cut out the old weld - it is
recommended that the saw
band contain only one weld.
NOTE: When welding band which
passes through hole in workpiecebe sure to insulate bond from
contact with workpiece or table,
this will insure a better weld.
(2)
Place the band ends between the jaws with the teeth against the
line-up guides which are attached to the front edge of the jaws,
see sketch.
NOTE
Blades which are 1/8 inch or less in width are too
narrow to be clamped correctly when they are placed
against the line-up plates. Move these narrow blades
back slightly from the line-up plates and align them
by eye, then clamp them in place.
(3)
The jaws are clamped by moving the handles upward.
(4)
Check to be sure that the band ends meet in the center of the jaw
gap without any offset either in thickness or across the width. If
the contact across the width is not complete, remove one end and
recut it. A misaligned joint will cause an incomplete weld.
H-6
MAKING THE WELD
WARNING
STEP TO ONE SIDE TO AVOID WELDING SPARKS.
(1) Press (using a smooth and steady motion - not too fast or slow)
and hold down the weld lever to make the weld. The lever should
held down until the weld has cooled.
(2) Release the stationary jaw clamping handle before releasing the
weld lever. This will prevent scoring the welder jaw surface.
(3) Release the weld lever. When the lever is released, the welder
mechanism and electrical switches are automatically recocked.
CAUTION
Special note only for IMPERIAL BI-METAL Saw Band or very narrow carbon bond:
in order to protect the weld from accidental breakage it is recommended that the
weld be annealed before it is removed for grinding as well as after grinding.
Follow the annealing instructions given on
page 11.
(4) Remove the welded saw band. Inspect the weld as described on
the next page. If weld is poor, see the Troubleshooting Chapter
for possible causes.
CLEAN-UP WELDER JAWS AFTER WELDING
It is important that the welder jaws be kept clean at all times. The
jaws and inserts must be wiped or scraped clean after every weld.
Doing this will insure better welds by:
(1) Holding proper alignment.
(2) Preventing flash from becoming embedded in the band.
(3) Preventing shorts or poor electrical contact.
CAUTION
This welder is designed for intermittent use. Repeated welding within a short
period of time may cause the welder to overheat.
H-7
INSPECTION OF THE WELD
When the band is removed from the welder it should be inspected
carefully. The spacing of the teeth should be uniform and the weld
should be located in the center of the gullet. Major jaw misalignment
is easily noted at this time from the weld appearance. See the Trouble
shooting Chapter if the weld is imperfect.
Some of the
characteristics
of good and bad
welds.
Hold a straight edge
to the back edge of
the band to check for
misalignment.
H-8
GRINDING THE WELDED BAND
WARNING
Keep hands away from rotating grinding wheel. Because it may be difficult
to see if the wheel is rotating, a pilot light is provided. This light is on
when the grinder motor is running.
After welding, the band must be dressed to remove excess metal or
flash from the weld. Grind the welded area down to the same thickness
as the rest of the band. With the teeth facing out, grind the weld as
shown in the drawing. Handle the band carefully - the weId will be
brittle because it has not been annealed.
Grind Carefully: do not hit the teeth; or grind deeper than the thickness of the band; or burn or overheat the weld area. Be sure to remove
flash from the back edge of the band. Any flash or "stub" teeth which
project beyond the normal set or height of the other teeth must be ground
off. Check the weld thickness by passing it through the correct gage for
the thickness of the band.
Grinding the weld.
SPEClAL NOTE FOR EARLY MODELS Of THE DBW-15
EarIy models of this welder had a different wiring arrangement for the
grinder motor. Thes welders can be recognized easily because they
were equipped with a grinder motor pushbutton and did not have a pilot
light. On these early models only: the grinder motor will not operate
if the weld lever is in its lowest position. Move the lever up before
running the grinder.
H-9
ANNEALING THE WELDED BAND
(1) Swing the weld lever up all the way to the anneal’ position which
is marked by the letter "A". The lever will be held in place by the
bend in the drag spring.
(2) Clamp the band just as in welding.
(3) Set the anneal heat selector switch for the width of the band.
(4) Anneal the band as explained below.
CAUTION
Follow these instructions carefully.
(a) For Carbon Blade: Press and jog the annealing switch button
until the weld is a dull cherry to cherry red color. Allow
the blade to cool slowly by decreasing the jogging frequency.
(b) For Dart Blade: Heat the blade slowly until the weld becomes
a deep blue color. Continue to heat by jogging the anneal
button until the width of the blue color is one-half the
length of the band exposed between the jaws. Do not overheat
or the temper of the band will be damaged.
CAUTION
Do not heat beyond the blue state - if the band
begins to show any red color, it is too hot.
Coot quickly by releasing the anneal button.
Correct annealing of Dart Blade.
(c) For IMPERIAL BI-METAL Blade: Heat the band slowly by jogging
the annealing
h button until the weld just begins to emit light
(this would be the dullest red color). The desired color may not be
visible in normal room light. Always shade the weld area with your
hand.’ Cool the weld quickly by releasing the annealing button.
NOTE: This procedure should be followed both before and after
grinding IMPERIAL BI-METAL Blades.
H-10
CHAPTER 4
MAINTENANCE
LUBRICATION
The slide rod, upset force selector cam, and all miscellaneous pivot
points should be lubricated every six months. The interval between lubrication may be shortened or lengthened, depending upon how much dust
and dirt are in the area. If the slide rod sticks, then the rod should be
cleaned and greased more often. The grinder motor will not normally
require lubrication for several years. Use ASTM Grade 215
or equivalent oil on all lubrication points except the slide
SLIDE ROD MAINTENANCE
The slide rod should be kept clean and greased. Rust or dirt may cause
rod to stick and "burn out” the weld.
Check movable jaw for freedom of movement. If it binds, apply a drop
of oil to slide rod and work it in by repeatedly pressing the lever. If
this does not free the jaw movement, remove slide rod and clean and
grease it. Before removing slide rod, clamp a piece of saw band securely
between welder jaws to maintain correct spacing. Use ASTM
Grade 465 grease, or equivalent on slide rod.
The slide rod stop screw should not bind slide rod. Turn screw in, then
back off 3/4 turn.
WELDER JAWS MAINTENANCE
TO secure consistent results, the welder jaws must be kept clean.
During the welding cycle, excess metal in the form of incandescent
particles is blown out of the weld, causing a scale or flash to build
up on the welder jaws. The welder will not weld properly unless the
jaws are wiped clean after every weld.
Misalignment of the weld is usually caused by worn or dirty jaws.
However, if the welder jaws are clean and not worn and the welds
are out of line, then the jaws are not aligned properly. This misalignment can be determined by inspection of the weld after the
flash has been removed. After determining which jaw is not in
alignment, the jaws can be adjusted as desired. Jaw alignment
instructions are given in a separate Engineering Adjustment
Summary. Replace lower jaw inserts that are worn excessively.
CUT-OFF SWITCH AND WELD SWITCH CONTACT POINTS
If the cut-off and weld switch contact points are welded together,
pitted, corroded, or covered by oxide, they must be replaced. If
the points are only dirty, clean them with a commercial point
cleaner and clean, Iintless cloth (such as linen tape).
H-11
Maintenance and adjustment locations.
H-12
JAW ALIGNMENT
The importance of accurate jaw alignment cannot be overemphasized.
The jaws have been carefully aligned during assembly at the factory;
however, it may be necessary to align the jaws if they are bumped or
damaged. The easiest and most effective way to see if misalignment
exists is to actually inspect the weld joint. A misaligned weld is
usually caused by worn or dirty welder jaws.
(1)
Check with a straight edge to see if the jaws are in alignment
with each other with respect to elevation, inclination, and twist.
(2)
The stationary jaw can be moved slightly on its mounting screws
by loosening the screws and tapping the jaw.
(3)
The movable jaw tilt is adjusted with two set screws as shown
in drawing.
Detailed alignment instructions are given in a separate Engineering
Adjustment Summary .
ADJUSTMENTS (Jaw Gap, Electrical Cut-off, Upset Force)
Incomplete and burned out welds are a result of incorrect adjustments. If the weld cycle is cut off too soon, the weld will be incomplete
(low heat produces a weak weld which may be only partly joined). Too
long a weld cycle will produce excessive heat which will result in a
burned out weld (excess molten metal around a discontinuous joint).
For adjusting the cut-off point, a hole in the outside leaf of the cut-off
switch permits insertion of a socket wrench into the end-knob of the
slide rod (see drawing).
For all adjustments, follow the procedures given in the
Adjustment Summary .
WARNING
DISCONNECT ELECTRIC POWER TO THE WELDER BEFORE
MAKING ADJUSTMENTS.
H-13
Engineering
CHAPTER 5
TROUBLESHOOTING
MISALIGNED WELD
(1) Dirt or scale on jaws or blade.
(2) Blade ends not cut off square.
(3) Blade ends not correctly aligned when clamped in jaws.
(4) Worn jaws or inserts.
(5) Jaws are not aligned correctly.
Overlapped weld.
Misaligned weld.
MISALIGNED WELD-BLADE ENDS ARE OVERLAPPED
(1) Jaw upset force control set for wider blade than used, adjust
correctly.
(2) Blade ends or jaws not aligned correctly.
WELD BREAKS WHEN USED
(1) Weld not annealed correctly.
(2) Weld has been ground too thin.
(3) Weak incomplete weld.
H-14
INCOMPLETE WELD (joint is not complete, blow holes in joint)
(1) Incorrect Initial Set-Up:
(a) Initial jaw gap (weld lever position) not set correctly.
(b) Upset force control not set correctly.
(2) Improper clamping procedures.
(3) Defective cut-off switch may not break the circuit at end of
welding operation.
(4) Cut-off switch not adjusted correctly.
(5) Points of cut-off switch welded together.
(6) Slide rod sticking because of rust or dirt. Clean and oil rod see Maintenance. (chapter 4)
(7) Slide rod movement obstructed because stop screw too tight
on rod.
(8) Jaw movement obstructed by kinked jaw cable or tangled wires.
Bend cable and untangle wires.
(9) Movable jaw binding on jaw bearings because of tilt adjustment
screw turned in too far.
BRITTLE WELDS
(1) Weld has not been annealed correctly, see Annealing in Operation
Chapter. Poor annealing can be caused by:
a.
Incorrect annealing heat. Bring weld up to correct color as
described under Annealing in Operation Chapter.
b.
Scale or oil on weld can cause poor annealing.
H-15
CHAPTER 6
ACCESSORIES
ETCHING PENCIL
The Etching Pencil is used with the butt welder to mark
tools, jigs, fixtures, templates, etc.
TO use the etching pencil:
(1)
Clamp cable end of etching pencil in welder stationary
jaw. Move weld lever up to anneal position.
(2)
Press the anneal and etching pushbutton and clamp the
button down with the etching pencil clamp. This closes
the circuit through the welder and also grounds the
etching current through the machine.
(3)
Place the work to be marked on the table of the machine.
Since the machine is grounded there is no second lead
required to the work.
(4)
Etch with sufficient pressure to prevent the point from
arcing, but not great enough to destroy the copper point.
The copper point should be kept sharp to secure best
results.
Using the Etching Pencil.
H-16
BLADE SHEAR
The cutter blades can be easily replaced. Disassemble by
removing the snap rings from the pivot pin and eccentric disk.
Then remove the retaining screws on the bottom blades.
The Blade Shear Assembly.
H-17
H-18
CODE NO.
H1-19.0
BLADE SHEAR ASSEMBLY
INDEX
NO.
PART NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
35-8440
35-8438
34-13508
35-8447
35-8448
35-7558
35-8441
35-8437
35-8582
35-8451
100015
198865
198011
35-8445
198012
100016
35-8585
199115
199321
35-8446
UNITS PER
ASSY.
DESCRIPTION
Blade Shear Assembly
● Handle
● Ball
● Side Plate L. H.
● Side Plate R.H.
● Retaining Ring
● Eccentric
● Knife
● Retaining Ring
● Pin
● Blade
● Screw, Rd. Hd. Mach. #10-24NC x 1/4
● Screw, Hex. Hd. Cap 1/4-20NC x 1-1/4
● Square L.H.
● Screw, Hex. Hd. Cap 1/4-20NC x 1-1/2
● Spacer
● Spacer
● Nut, Hex. 1/4-20NC
● Washer, Lock 1/4 S.A.E. Std.
● Square R.H.
H-19
1
1
1
1
2
1
1
2
1
2
4
2
1
1
3
1
3
3
1
H-20
CODE NO.
H1-20.0
ETCHING PENCIL ASSEMBLY
INDEX
NO.
*Ref
1
2
3
4
3
6
7
8
9
10
11
**12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
UNITS PER
ASS’Y.
PART NO.
DESCRIPTION
1347003
35-5109
6-07420
2154
19546
19545
198852
199109
199292
13-07302
13-47303
34-18407
13-07004
2154
19545
198852
199109
199292
13-07304
6-07424
6-07310
607309
135994
6-07423
6-07307
647311
35-5077
6-07425
6-07421
6-07201
6-07503
6-07308
Etching PenciI Assembly
. Short End Assembly
. . Plug
. . Ferrule
. . Cable
. . Solder Lug
. . Screw, Rd. Hd. Mach. #8-32NC x 5/16
. . Nut, Hex #8-32NC
. . Washer, Brass #8 Std
. . Terminal Strip
. . Insulator
. . File Rivet
. Etching Pencil Assembly
. . Ferrule
. . Terminal Lug
. . Screw, Rd. Hd. Mach. #8-32NC x 5/16
. . Nut, Hex. #8-32NC
. . Washer, Brass #8-Std
. . Terminal Strip
. . Paint
. . Fin
. . Fin
. . Cable
. . Connector
. . Fin
. . Washer
. . Stem Assembly
. . . Pin
. . . Tube
. . . Stem
. . Tube
. . Fin
*NOTE: For welders shipped before 6-23-44 with ground bushing in panel.
**NOTE: For welders shipped after 6-23-44.
H-21
1
1
2
A.R.
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
A.R.
1
12
2
1
1
1
1
1
1
STANDARD 240 VOLT DIAGRAM
STANDARD 380-480-575-VOLT DIAGRAM
No. 119995-6
No. 119994-7
STANDARD 240-VOLT DIAGRAM
PORTABLE
No. 132816-3
STANDARD DIAGRAM FOR OPERATION
ABOVE 240 VAC PORTABLE
No. 132817-3
ELECTRICAL SCHEMATICS
FOR ALL
DBW-15 BUTT WELDERS
H1-13.5.1
H-22
FIRST USED FEB 1977
PRINTED IN U.S.A.
STANDARD 240 VOLT DIAGRAM
#119994-6
STANDARD 380-480-575-VOLT DIAGRAM
#119995-5
STANDARD 240-VOLT DIAGRAM
PORTABLE
#132816-2
STANDARD DIAGRAM FOR OPERATION
ABOVE 240 VAC PORTABLE
#132817-2
ELECTRICAL SCHEMATICS
FOR ALL
DBW-15 BUTT WELDERS
H-23
FIRST USED APRIL 1974
LAST USED FEB 1977
PRINTED IN U.S.A.
DBW-15
BUTT WELDER ASSEMBLY
H1-13.0
H-24
PRINTED IN U.S.A.
CODE NO.
H1-13.0
DBW-15 BUTT WELDER ASSEMBLY
INDEX
NO.
PART NO.
Ref.
1
2
3
4
5
6
7
401436
199019
199356
131807
59788
116552
199396
132814
132815
6-06342
50528
1927
132821
16180
408838
198895
199321
199115
7506
198897
199321
133848
133861
104770
133160
199396
8
9
10
11
12
13
14
15
16
17
18
19
20
21
UNITS PER
ASS’Y.
DESCRIPTION
DBW-15 Portable Assembly
. Screw, Truss Hd. Mach. 1/4-20NC x 3/8
. Washer, Lock 1/4 Shakeproof Int
. Blade Shear Assembly (See Detail)
Butt Welder Assembly (See Detail)
. Data Plate
. Screw, Rd. Hd. Drive #2 x 3/16 Type “U”
Butt Welder Box Assembly (Std. 240 Vac.)
Butt Welder Box Assembly (Above 240 Vac.)
.Butt Welder Box
.Butt WELDER Box
. . Spacer (Sq. D Switch Only) (#132815 Only)
. . Safety Switch 39010
. . Safety Switch 39010
. . Transformer (#132815 Only)
. . Screw, Rd. Hd. Mach. 1/4-20NC x 1/2 (#132815 Only)
. . Washer, Lock 1/4 Std. (#132815 Only)
. . Nut, Hex 1/4-20NC (#132815 Only)
. . Grommet
. . Screw, Rd. Hd. Mach. 1/4-20NC x 3/4
. . Washer, Lock 1/4 Std.
. . Fuse 10A-250 V
. . Fuse 5A-600 V
. . Ground Tag
. . Escutcheon (“Warning ---”)
. . Screw, Rd. Hd. Drive #2 x 3/16 Type “U”
4
4
1
1
1
4
USE
ONE
USE
ONE
4
USE
ONE
1
4
4
4
1
4
4
2
2
1
1
4
Following Items Not Shown:
STK#714
STK#724
. . Wire, #10 AWG Green
. . Wire, #12 AWG Black
H-25
A.R.
A.R.
H1-13.1
H-26
PRINTED IN U.S.A.
CODE NO.
H1-13.1
DBW #15 BUTT WELDER ASSEMBLY
INDEX
No.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
*35
*36
*37
*38
*39
40
41
42
PART NO.
59788
136185
136186
198840
114591
119906
121067
121066
198346
199023
34-06518
107171
108450
114568
119861
199397
199015
119880
198866
120268
119883
119564
119879
4231
119862
38660
34-06503
35-2010
199538
303886
59767
2761
3172
2748
35-9614
119863
401871
121477
UNITS PER
ASS’Y.
DESCRIPTION
DBW-15 Butt Welder Assembly
.Escutcheon (English)
.Escutcheon (International)
.Screw, Rd. Hd. Mach. #6-32-NC x 3/8
.Glo-Lite 240-V
.Pin
.Insert Bearing
.Line Up Guide
.Screw, Soc. Hd. Cap #8-32NC x 3/8 (Button)
.Screw, Truss, Hd. Mach. 1/4-20NC x 3/4
.Knob
.Washer, Lock
.Switch S.P.D.T.
.Nut, Hex. 15/32-32 NC
.Escutcheon
.Screw, Rd. Hd. Drive Pk #2 x 1/4 Type “U”
.Screw, Truss Hd. Mach. #10-24NC x 3/8
.Drag Spring
.Screw, Rd. Hd. Mach. #10-24NC x 5/16
.Shim
.Handle Assembly
. . Handle
. . Shaft
. . Roll Pin
.Escutcheon
.Jaw Insert
.Escutcheon
.Anneal Switch
.Pushbutton Clamp
.Rivet, Rd. Hd. 1/8 Dia. x 1/2
.Grinder Wheel Guard Assembly (See Detail)
.Panel
.Insulator
.Screw Hex. Hd. Cap
.Connector
.Insulator Bushing
.Insulator
.Stationary Welder Jaw
.L.H. Can Sub-Assembly
USE
ONE
2
1
2
1
2
8
2
1
1
1
1
1
5
3
1
2
3
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
2
1
1
1
Following Items Not Shown
.Wire Connector
133826
103848
.Wire Terminal
133827
.Wire Connector
Stk #731
.Wire, Stranded #14 Black
111123
.Wire Terminal
3
10
1
A.R.
4
NOTE: The Following Items Are For Machines After Serial #290-68182 and Before Serial
#290-745446.
10776
.On-Off Plate (English)
131202
.On-Off Plate (International)
111123
.Wire Terminal
110953
.Toggle Switch
107171
.Washer, Lock
114591
.Glo-Lite 250-V
113262
.Circuit Breaker 1.5A E-T-A
121410
.Wire Terminal
121411
.Escutcheon (English)
131203
.Escutcheon (International)
USE
ONE
A.R.
1
2
1
1
2
USE
ONE
*NOTE: For Canadian Welders Omit Items 35, 36, 37, 38 and 39 and replace with:
100888
.Plug Button
H-27
2
DBW-15
BUTT WELDER ASSEMBLY
H1-13.2
H-28
PRINTED IN U.S.A.
CODE NO.
H1-13.2
DBW-15 BUTT WELDER ASSEMBLY
INDEX
NO.
PART NO.
Ref*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
59788
35-9545
198039
12736
6-06502
199563
405422
198025
199323
35-9617
7677
12442
135510
303815
198422
199115
1006
6-06417
119859
12038
199023
133971
199356
199115
119858
4229
119857
103947
198423
121478
401872
105116
19
20
21
22
23
24
25
26
27
28
29
30
UNITS PER
ASS'Y.
DESCRIPTION
DBW-15 Butt Welder Assembly
Switch Bracket
. Screw, Hex. Hd. Cap, 5/16-18NC x 3/4
. Washer
. Butt Welder Tag
. Key, Hex. 3/32 Across Flats
. Transformer Assembly 240-V
. Screw, Hex. Hd. Cap 5/16-18NC x 1/2
. Washer, Lock 5/16 Std.
. Conduit Anchor
. Grommet
. Stop
. Motor 1/6 H.P. 1 PH
. Rear Adapter
. Screw, Soc. Set 1/4-20NC x 1/4
. Nut, Hex. 1/4-20NC
. Bearing Stud
. Jaw Bearing
. L. H. Cam Lever & Pin Assembly
. R.H. Cam Lever & Pin Assembly
. . Screw, Truss Hd. Mach. 1/4-20NC x 3/4
. . Knob
. . Washer, Lock 1/4 Shakeproof Int.
. . Nut, Hex. 1/4-20NC
. . Pin
. . Roll Pin
. . Cam Lever Sub-Assembly
. Bearing
. Screw, Soc. Set 1/4-20NC x 5/16
. R.H. Can Sub-Assembly
. Movable Welder Jaw
. Hardened Washer
*NOTE: Before Serial #290-745446, Item 13 #303815 was 35-614.
H-29
1
1
2
1
1
1
8
12
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
DBW-15
BUTT WELDER ASSEMBLY
H1-13.3
H-30
PRINTED IN U.S.A.
CODE NO.
H1-13.3
DBW-15 BUTT WELDER ASSEMBLY
INDEX
NO.
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PART NO.
DESCRIPTION
59788
28091
199033
198446
103147
198591
199114
35-9549
198447
199125
35-9557
119884
4227
35-5078
198861
199318
104030
35-9592
35-9548
6-06324
198410
1005
35-9550
198887
20017
6-06313
6-06339
1998026
199122
135944
28090
DBW-15 Butt Welder Assembly
. L.H. Bracket Assembly
. Screw, Truss Hd. Mach. 5/16-18NC x 5/8
. Screw, Soc. Set, 5/16-24NF x 3/4
. Slide Rod Assembly (See Detail)
. Screw, Soc. Set 1/4-20NC x 5/8 Dog Pt)
. Nut, Hex, Jam 1/4-20 NC
. Spring Stud
. Screw, Soc. Set 5/16-24NF x 1-1/4
. Nut, Hex. Jam 5/1624NF
. Butt Welder Frame
. Lever Weldment
. Roll Pin
. Welder Switch Sub-Assembly
. Screw, Rd. Hd. Mach. #8-32NC x 1-1/2
. Washer, Lock #8 Std.
. Spring
. Spring Stud
. Shaft
. Cam
. Screw, Soc. Set #10-24NC x 1/4
. Pivot
. Lever
. Screw, Rd. Hd. Mach. #10-32NF x 1
. Cutoff Switch Assembly
. Insulator
. Spring
. Screw, Hex. Hd. Mach. 5/16-18NC x 5/8
. Nut, Hex. 5/16-18NC
. Circuit Breaker
. R.H. Bracket Assembly
H-31
UNITS PER
ASS’Y.
1
4
1
1
1
1
1
1
2
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
H1-13.4
H-32
CODE NO.
H1-13.4
DBW-15 BUTT WELDER DETAIL
REF. 59788 ASS’Y
INDEX
NO.
UNITS PER
ASS’Y.
PART NO.
DESCRIPTION
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
*13
14
303886
198888
133798
133799
13-06304
13-06307
405735
6-06306
13-06306
199113
199319
113447
13-06501
303816
198890
Guard Sub-Assembly FIG - 1
. . Screw, Rd. Hd. Mach. #10-32 NF x 1
..Spacer (.015)
.. Spacer (.012)
.. Spacer (.0359)
.. Spacer (.040)
.. Grinder Wheel Guard
.. Block
. . Block
.. Nut, Hex. #10-32NF (Plated)
.. Washer, Lock #10 Std.
.. Escutcheon
. Abrasive Wheel
. Front Adaptor
. Screw, Rd. Hd. Mach. 1/4-2ONC x 1/4
1
2
1
1
1
1
1
2
3
2
1
1
1
1
2
Ref.
Ref.
1
2
3
4
5
6
7
59788
103147
6-06418
199113
6-06336
6-06337
6-06338
198420
16541
Butt Welder Assembly
. Slide Rod Assembly. FIG-2
.. Knob
.. Nut, 10-32NF Std.
.. Collar
.. Key
.. Spring
Screw, Soc. Set 10-32NF x 1-1/4
. . Slide Rod
1
1
1
1
1
1
1
1
Ref.
1
2
3
402520
39653
198424
503117
Butt Welder Pedestal FIG-3
. Pedestal Top, Weldment
. Screw, Soc. Set 1/4-2ONC x 3/8
. Pedestal Base
1
2
1
*NOTE: Before Ser. #290-745446, Front Adapter #303816 was replaced with
#34-12402 washer and #6-06429 screw.
H-33
ENGINEERING ADJUSTMENT SUMMARY
MODEL DBW-15
NUMBER
SHEET
1
OF
11
120739-2
This welder is a resistance type butt welder capable of welding
1/16 x 0.025" up to 1" x 0.035" Carbon, Dart and Imeprial band.
WARNING
All adjustments must be made with the power-off,
except where specifically instructed otherwise.
WELDER JAW ALIGNMENT:
There are three basic adjustments for the alignment of
the welder jaws. They are Elevation, Inclination and Twist.
They are all dependent on one another. Any adjustment of one may
require a readjustment of one or both of the others. The welder
jaws shall be aligned to result in a finish weld which is within 4%
of the band gage. The blade alignment guides shall insure that
the tooth edge of the band be straight within 0.004” per 4”, measured 2" on either side of the weld.
The initial line up of the welder jaws is accomplished
with a straight edge. The final adjustment is made so that the
weld produced in a 1" x 0.035" Imperial band will meet the above
specifications.
In order to make the initial adjustment with the straight
edge, it is necessary to remove the lower jaw inserts, the insert
bearings, and the blade alignment guides. It is advisable to remove
the transformer straps from the jaws, the jaw upset spring, the
weld lever return spring, and space the jaws approximately 1/8”
apart.
Prepared by: Roger Harris
Approved:
Date: 7-31-69
H-34
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
MODEL DBW-15
120789-2
FIG. 1
1.
Fig. 1 is an example of jaw elevation misalignment.
It is checked with a straight edge. The fixed jaw
must be moved to correct this problem. Loosen
the mounting screws and move the jaw as required.
The mounting screws are located inside the welder
case and behind the fixed jaw.
Prepared by: Roger Harris
Approved:
H-35
Date: 7-31-69
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
DBW-15
MODEL
120789-2
FIG. 2
2.
Fig. 2 is an example of inclination misalignment as
checked with a straight edge. The fixed jaw must be
moved to correct this problem. Loosen the mounting
screws and move the jaw required. The mounting
screws are located inside the welder case - behind the
fixed jaw.
Prepared by: Roger Harris
Approved:
H-36
Date: 7-31-69
ENGINEERING ADJUSTMENT SUMMARY
MODEL
DBW-15
NUMBER
120789-2
Welder Jaw Alignment -- continued
FIG. 3
3.
Fig. 3 is an example of twist misalignment. The movable jaw must be
adjusted to correct this problem. Two adjustment screws are provided.
Both of them must be used when making a correction. Care must be taken
to prevent any binding on the slide rod.
4.
Verify the proper setting of the slide rod stop screw (item 2, fig. 4). It is
adjusted to maintain 1/4 turn clearance between the end of the stop screw
and the milled flat on the slide rod. The movable jaw must move freely
with both tilt adjustments barring on the jaw.
Prepared by: Roger Harris
Approved:
H-37
Date: 7-31-69
ENGINEERING ADJUSTMENT SUMMARY
MODEL D B W - 1 5
NUMBER
120789-2
FIG. 4
Prepared by: Roger Harris
1.
2.
Movable jaw lock screw
Slide rod stop screw
3.
Jaw gap adjustment screw
4.
Cut-off adjustment screw
5.
Weld lever return spring
6.
7.
Upset force adjustment screw
8.
Cut-off switch
Jaw upset spring
Approved:
H-38
Date: 7-31-69
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
MODEL - DBW-15
120789-2
Welder Jaw Alignment -- con't.
5.
The final jaw alignment cannot be finished until all of the steps in this
Adjustment Summary have been completed. Only then can a weld be
made that is suitable for alignment purposes.
FINAL JAW GAP
The final jaw gap shall be 0.075” with the weld lever fully
depressed. It is set in the following manner:
1.
Loosen the lockscrew (item 1, fig. 4) that holds the movable jaw
to the slide rod.
2.
Place a 0.075” gage beween the jaws. The jaws must hold the
gage is place.
3.
Push the slide rod toward the fixed jaw until the shoulder of its
milled flat contacts the slide rod stop screw (item 2, fig. 4).
4.
Tighten the lockscrew (item 1, fig. 4) and lock the jam nut on it.
5.
Recheck the final jaw gap dimension.
JAW GAP AT ELECTRICAL CUT--OFF
The jAW GAP AT the electrical cut-off shall be 0.140". Adjust the
electrical cut-off in the following manner, with the power OFF :
1.
Connect a continuity meter to the wires on the cut-off switch.
2.
Place a 0.140” gage between the jaws. The jaws must hold the
gage in place.
3.
Turn the adjustment screw (item 4, fig. 4) as required to just
break the circuit with 0.140” gap. (Cw reduces the gap; CCW
increases the gap.)
Prepared by: Roger Harris
Approved:
H-39
Date:
7-31-69
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
MODEL DBW - 15
120789-2
WELD UPSET FORCE:
The upset force shall be from 10 to 12 lbs. when measured
at the movable jaw with the upset force selector set for the
narrowest width band. The approximate locations of the
upset force adjustment screw (item 6, fig. 4) is with the
back end of the screw flush with the cost jaw surface. The
final adjustment is made in the following manner:
1.
Disconnect the weld lever return spring (item 6, fig. 4).
2.
Disconnect the jaw upset spring.
3.
Bend the transformer lead that attaches to the movable jaw so that
when it is connected it will just urge the jaw to its fina1 jaw gap
position.
4.
Reconnect the jaw upset spring.
5.
Attach a spring scale to the movable jaw and with it, manually pull
the jaw to its maximum open position, (approximately 15/32”).
6.
Gradually release the pull on the scale. Note the reading when the
jaw just starts to move.
7.
If the spring scale reading at this point does not fall in the required
range (10 to 12 lbs.) the upset force adjustment screw must be reset,
(item 6, fig. 4).
8.
To re-set the screw, disconnect the jaw upset spring (item 7, fig. 4)
and turn the screw, as required.
9.
Replace the jaw upset spring and re-check as in steps 5 and 6.
10.
Replace the weld lever return spring.
Prepared by: Roger Harris
Approved:
H-40
Date: 7-31-69
ENGINEERING ADJUSTMENT SUMMARY
MODEL
DBW-15
NUMBER
120789-2
WELD LEVER DRAG SPRING
The weld lever drag spring (item 1, fig 5) serves two
functions: First, the upper corner acts as a detent to locate
the movable jaw for annealing band; and second, the force
exerted by the spring against the weld lever provides the
frictional drag to held 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 jaw gap setting.
The spring is mounted on the band width escutcheon,
(item 2, fig. 5). (Both are secured by two screws.) It is
adjusted by shimming between the escutcheon and the spring.
Shim as required to obtain both objectives. Shims under either
top or bottom screws will effect function, however, the top shim
(item 3, fig. 5) usually is used to establish detent, and the
bottom shim (item 4, fig. 5) to establish frictional drag.
MAXIMUM JAW GAP
With the weld lever in the anneal position, (as located by
the detent of the drag spring) and the upset force doctor in its
widest position, turn the jaw gap adjustment screw (item 3, fig. 4)
to obtain 15/32" jaw gap. Lock the adjustment in place.
Prepared by: Roger Harris
Approved:
H-41
Date: 7-31-69
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
MODEL DBW - 15
120789-2
FIG. 5
1. Drag spring
2. Escutcheon
3. Top shim
4. Bottom shim
5. Weld lever
Prepared by: Roger Harris
Approved:
H-42
Date: 7-31-69
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
DBW-15
MODEL
120789-2
WELD LEVER must be calibrated in the following manner:
1.
The weld lever drag spring must be properly shimmed as described above.
2.
Loosen but do not remove the two screws that secure the spring, shims
and escutcheon.
3.
Place a 0.150" gage between the jaws and bring the weld lever down, so
the jaws just touch the gage.
4.
Move the escutcheon (note elongated holes fig. 5) so the weld lever pointer
indicates the narrowest position (the bottom line on the escutcheon that also
corresponds with 1/16” band - note fig. 5) and then tighten the two screws.
BLADE ALIGNMENT GUIDES
The blade alignment guides are used to maintain tooth edge alignment of the
wide of the band being welded. Before installing the band guides, check their
mounting surfaces on the welder jaws. These surfaces must be in line within
0.004”, when checked with a straight edge. A file may be used to bring the surfaces in line. The guides are aligned to protrude below the band clamping surface
of the welder jaws by 0.025" (fig. 6). Adjust in the following manner:
1.
Loosen the screws holding the Band Guides to the jaws.
2.
Insert a section of 1” x0.035 ga. band into the welder jaws. The band
must be out of the jaws (teeth extend in front of alignment guides by at
least 3/16”) as shown in fig. 6.
3.
Place a 0.025” shim on top of the band, but within the jaw clamping area.
4.
Clamp the jaws.
5.
Adjust the Band Guides so they touch the ride of the 1” x 0.035 band and
lock in place.
Prepared by: Roger Harris
Approved:
H-43
Date: 7-31-69
NUMBER
ENGINEERING ADJUSTMENT SUMMARY
MODEL DBW - 15
120789-2
FIG. 6
FINAL JAW ALIGNMENT
A weld must be made in 1” x0.035 ga. Imperial band in order to check the
final alignment. The finished weld must be within 4% of the band gage.
The both edge of the hand must be straight within (0.004” in 4” measured 2”
on either ride of the weld. To make this weld:
1.
Set the jaw upset force knob to its maximum wide position.
2.
Set the initial jaw gap by adjusting the position of the weld lever.
It must be set to the line indicating the widest width.
3.
Make the final jaw alignment adjustment as required to result
in the tolerances listed.
Prepared by: Roger Harris
Approved:
H-44
Date: 7-31-69
By Order of the Secretary of the Army:
E. C. MEYER
General, United States Army
Chief of Staff
Official:
ROBERT M. JOYCE
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with Special List.
*U.S. GOVERNMENT PRINTING : 1990 O - 262-912 (30618)
PIN : 049461-000
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