TM 9-3405-216-14&P

TECHNICAL MANUAL

OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORTAND GENERAL SUPPORT MAINTENANCE

MANUAL INCLUDING REPAIR PARTS LIST

FOR

SAW, BANDMODEL L-9

(NSN 3405-00-473-6430)W.F. Wells & Sons, Inc.

HEADQUARTERS, DEPARTMENT OF THE ARMY

AUGUST 1982

TM 9-3405-216-14&P

Technical Manual

No. 9-3405-216-14&P

HEADQUARTERSDEPARTMENT OF THE ARMY

Washington, DC, 4 August 1982

OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORTAND GENERAL SUPPORT MAINTENANCE MANUAL

INCLUDING REPAIR PARTS LISTFOR

S A W , B A N D

MODEL L-9

( N S N 3 4 0 5 - 0 0 - 4 7 3 - 6 4 3 0 )

W.F. Wel ls & Sons, Inc .

REPORTING OF ERRORSYou can help improve this manual. If you find any mistakes or if you know of a wayto 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 ArmamentMateriel 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 useof the personnel to whom this equipment is issued.

Manufactured by: W.F. Wells & Sons, Inc.16645 Heimbach RoadThree Rivers, Michigan 49093

Procured under Contract No. DAAA09-79-C-4819

This technical manual is an authentication of the manufacturers’ commercialliterature and does not conform with the format and content specified in AR 310-3,Military Publications. This technical manual does, however, contain availableinformation that is essential to the operation and maintenance of the equipment.

i/(ii blank)

INSTRUCTIONS FOR REQUISITIONING PARTS

NOT IDENTIFIED BP NSN

W h e n r e q u i s i t i o n i n g p a r t s n o t i d e n t i f i e d b y N a t i o n a l S t o c k N u m b e r , i ti s m a n d a t o r y t h a t t h e f o l l o w i n g i n f o r m a t i o n b e f u r n i s h e d t h e s u p p l yo f f i c e r .

1 - Manufacturer ' s Federa l Supply Code Number . 82331

2 - M a n u f a c t u r e r ' s P a r t N u m b e r e x a c t l y a s l i s t e d h e r e i n .

3 - Nomenc la tu r e exac t l y a s l i s t ed he re in , i nc lud ing d imen-s i o n s , i f n e c e s s a r y .

4 - Manufacturer ' s Model Number . L-9

5 - Manufacturer ' s Ser ia l Number (End I tem).

6 - Any other information such as Type, Frame Number, andE l e c t r i c a l C h a r a c t e r i s t i c s , i f a p p l i c a b l e .

7 - I f D D F o r m 1 3 4 8 i s u s e d , f i l l i n a l l b l o c k s e x c e p t 4 , 5 , 6 ,and Remarks field in accordance with AR 725-50.

Complete Form as Follows:

( a ) I n b l o c k s 4 , 5 , 6 , l i s t m a n u f a c t u r e r ' s F e d e r a lSupply Code Number - 82331 followed by a colon andm a n u f a c t u r e r ' s P a r t N u m b e r f o r t h e r e p a i r p a r t .

( b ) C o m p l e t e R e m a r k s f i e l d a s f o l l o w s :Noun: ( n o m e n c l a t u r e o r r e p a i r p a r t )F o r : NSN: 3405-00-473-6430Manufacturer : W. F. Wells & Sons Inc.

16645 Heimbach RoadModel: L-9 Three Rivers , Michigan 49093S e r i a l : (of end i tem)

Any other per t inent informat ion such as Frame Number ,Type, Dimensions , e tc .

iii

SAFETY MANUAL

For Use and Care of

Band Sawing Machinery

CONTENTSA. OSHA and the metal cutting band saw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

B. Safety during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C. Safety during manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D. Safety during operation with barfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E. Safety during maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1

A. OSHA AND THE METAL CUTTING BANDSAW MACHINE

A1. As of this writing OSHA regulations do notcarry a single set of standards for metal bandsawing machinery such as those applying topresses. Instead, metal band sawing machineryfalls under the general safety regulations. Thismeans that each inspector makes his own decisionsas to whether or not a machine is safe and properlyguarded.

A2. In this manual we will present the safety pointswe have found to be of importance to many in-spectors.

A3. The general regulations provide many rules foryour guidance. Listed below are the most commonsafety problems in the field. However, let us stressthat this is our interpretation, and that your areainspector is the proper person to contact for an-swers to your questions. He may require safetydevices other than those suggested here, based onmore recent rulings or regulations.

A4. Many states also have codes similar to OSHA,but with different interpretations. Therefore, wewill limit this discussion to the nationalrequirements. You should check with your own areainspector for further regulations.

A5.

A. The machine should be installed in accordancewith the national electrical code and any area codesthat are more restrictive.

B. Be sure to ground the machine with thegrounding wire. This wire should be green.

C. Sawing machines should have all guards in placeand maintained in good condition.

D. A guard should be used to cover the saw bladefrom the cutting head to the blade guides.

E. Most metal sawing is below the 90 decibel noiselevel. However, when using high blade speeds,check for excessive noise and consult your regionalOSHA Office for proper employee protection whenover 90 decibels.

F. Be sure to train employees who operate andmaintain the machine in accordance with thismanual and the other manuals supplied with themachine.

G. We recommend you discuss the possibility ofcolor coding the various parts of your machine withyour area inspector.

B. SAFETY DURING INSTALLATION

B1. Many metal cutting band sawing machines aretop heavy and should always be handled as such.Use tag chains when moving a machine with forklift trucks or cranes.

B2. Do not lift the machine by the cutting headwhen moving with fork lift trucks or cranes. Liftthe machine only by connecting to the base or bed.

B3. When moving the machine, be careful to placeslings and chains where they will not damagehydraulic hose, tubing, fittings or electricalequipment.

B4. After installation, make sure the machine hasbeen grounded with the grounding wire, and thatthe energized conductors are properly attached tothe switch terminals (and not accidentally crossedwith the grounding wire). Check the voltage beforeusing the machine to be sure of the proper con-nection.

B5. Install the machine to comply with any areacode as well as the national electrical code.

C. SAFETY DURING OPERATION

C1. The operator should always keep his hands andfeet clear when operating a metal band sawingmachine to prevent injury from moving parts orwhile loading or removing metal pieces.

C2. Reports show that many accidents whileworking around metal sawing machines are causedby dropping work pieces on the toes, and in somecases over half of the reported accidents were fromthis cause.

C3. Never place round barstock or cut pieces on astock support table without some type of retainingdevice to keep them from rolling off the table.

C4. Use some type of supporting or catching devicefor the cut off work pieces, whether long or short.They can drop off unexpectedly and injure feet andlegs.

C5. Never use pedestal type single roller stocksupport devices (stock stands) with heavy loads.They are very unstable with large bars and tip overeasily. These devices are designed for light loadsthat can be lifted manually and placed on the rollerby one operator.

C6. When cutting thin pieces from large blocks(such as die blocks) always remember these thinwork pieces are likely to tip over when cut off. Takesteps to support them or they can cause injury.

2

C7. Be sure to keep clear of the clamping area whenoperating machines equipped with hydraulic vises.When these vises clamp, a very high force is appliedthat can cause severe injury.

C8. When loading large material requiring morethan one person, be sure the operator and hishelpers are all clear before starting any machinemovement.

C9. Never reach or position any part of your bodyunder a saw blade. Someone could start themachine, or some type of malfunction could causethe cutting head to drop.

C10. Never reach through or under a pinch pointthat could create a hazard if a machine part shouldmove.

C11. Never wipe or clean off parts which are beingsawed. The wipe rag could catch on the saw blade,and pull the operator’s hand into the moving blade.

C12. It is good sawing practice to support the sawblade as close as possible to the work piece formaximum cutting accuracy as well as safety.Always keep the saw guides as close as possible tothe work piece. Attaching blade guards to theguides will also keep the guards closed as far aspossible.

C13. Always stop the machine when it becomesnecessary to adjust it.

C14. If the operator leaves his control station toobserve or inspect the operation of the machine, heshould always have another qualified operator atthe control station in case he is inadvertentlycaught in the machine. Failure to do this could bevery serious.

C15. Do not get into the habit of climbing orleaning on the machine while it is in operation.Greasy, coolant-covered surfaces can be veryslippery.

C16. It is very important that your mind be entirelyon your job at all times when working on a machine.Outside activities and problems which occupy yourmind during working hours greatly endanger yourpersonal safety.

C17. Always keep the floor and working areaaround the machine free from debris, oil and coolantslicks. These can be extremely hazardous.

C18. Avoid unnecessary contact with machinecoolants or other cutting compounds.

C19. Always wear safety glasses when operating aband sawing machine.

C20. If it is necessary for two or more operators towork with a machine, be sure only one lead operator

“calls the signals”, and make sure the otherworkers are clear before starting any machinemovement.

C21. Read, study and know this manual and theother machine manuals before any attempt is madeto operate the band sawing machine.

D. SAFETY DURING OPERATION WITHBARFEED

D1. Always remember that movements occurwithout warning when automatic machinery isoperating. In manual operation, a push button isdepressed to start a movement so one can an-ticipate what will happen. When in the automaticmode, the movement occurs without operatoraction. If someone has reached into the machine, aserious accident can happen.

D2. This suggests two good rules to remember: (1.)Whenever someone is around a machine running inautomatic operation, the operator should always beat his station to stop the machine in case the persongets caught by it. This may be a person walking bywho stops for a moment, but carelessly places hisfoot on the machine, or lays his hand near a movingpart.

(2.) If the operator decides to leave his controlstation to perform a quick adjustment, first shutdown the machine. If the operator does not shut itdown, and should accidentally slip and becomecaught, the machine will keep running. With no oneat the stop button to shut it down, he could sustainserious injuries before help arrived.

D3. Many automatic sawing machines have bar-feeds with a moving carriage. Never allow anyone,or yourself, to get between the carriage and the sawbase.

E. SAFETY DURING MAINTENANCE

E1. Always lock off the electrical supply disconnectwhen working on moving parts of the machine, itselectrical or hydraulic systems.

E2. Never remove hydraulic lines or parts from themachine unless the cutting head is resting on thesaw bed or other solid support. In normal operationthe cut t ing head is supported by hydrauliccylinders. Removal of hoses or machine parts willpermit a discharge of pressurized oil, allowing thecutting head to fall to its lower position. This couldcause injury to personnel as well as damage to themachine.

E3. Never adjust the hydraulic system pressuresbeyond those given on the hydraulic diagrams. Todo so can cause hydraulic lines or other parts torupture and create a hazard.

3

E4. Always replace guards before putting themachine back into operation.

E5. A saw blade which has been removed fromservice and coiled should always be tied with wireor other suitable device to keep it from uncoiling. Acoiled blade suddenly springing open can causeserious cuts to persons nearby.

E6. Never change a broken blade on a machinemanufactured for high blade speeds until you are

sure the blade wheels have stopped coasting.Opening the covers too soon may allow the blade tocatch on a wheel and be thrown out, strikingsomeone.

E7. When changing saw blades, always close theblade wheel guards before applying the final bladetension.

E8. If a machine should for any reason stop orrefuse to start, lock out the electrical disconnectswitch before starting any service procedures.

4

BAND SAW BLADE SELECTION AND APPLICATION

INDEX

SUBJECT SECTION PAGE

GeneralBlade TypesCarbon Stee l BladesHard Edge, Flexible

Back BladesHard Back BladesAl loy S t ee l B ladesHigh Speed Steel BladesSuper High Speed BladesCarbide Tipped BladesCarbide Edge Coated BladesWhat Blade Should I Use?Blade P i t ch Se l ec t i onBlade Se t Se l ec t i onBlade Tooth Form or StyleCoolantCut t ing ForceBlade SpeedAccuracy of CutProduct ion Cut t ingCost Per CutBlade Speed ChartC u t t i n g R a t e C a l c u l a t i o nSawing ProblemsBlade Tension

122 .1

666

2 . 22 . 32 . 42 . 52 . 62.72 . 83456789

10111213141516

6667777779999

11111 11214151718

5

1. GENERAL

Bandsawing machines are unique compared toother machine tools in that they use a flexiblecutting tool. Tensioning the tool (saw blade) andsupporting it near the cutting zone (with sawguides) results in its becoming sufficiently rigidto perform useful work.

Most machine tools feed the cutting tool on thebasis of inches per revolution. Band saws generallyfeed the cutting tool based on pounds of cuttingforce. This allows the tool to cut at its own ratein relation to inches per revolution.

When the proper cutting feed force is applied to theblade, it will cut at maximum efficiency and stillmaintain good accuracy. This type of feed isnecessary because most cutoff sawing involvesever-changing cross section areas. With thismethod the blade will not be over-fed as it entersa larger cross section area. The cutting force willbe maintained but the forward progress of the bladeinto the cut will slow, until it enters a smallersection. At this point it will progress faster throughthe cut. This explains why THE BLADE CUTSAT ITS OWN RATE.

2. BLADE TYPES

Band saw blades are generally referred to by thetype of material from which they are made. “CAR-BON” blades are manufactured from high carbonsteel and “HIGH SPEED” blades are manufac-tured from high speed steel. The “WELDEDEDGE” blade has a high speed steel strip weldedto an alloy blade back. “CARBIDE” blades havecarbide steel fused to the tooth tips.

2.1 CARBON STEEL BLADES

Carbon steel blades can be called the work horseof the industry, as they are very widely used. Theyperform well on steel sections, aluminum, plastics,carbon and similar materials. The limiting factoris the cutting rate. As the cutting rate is increasedthe heat generated in the blade increases. Carbonblades will easily reach a temperature that removesthe heat treatment of the steel, allowing the teethto dull. They do, however, work very well on appli-cations where high cutting rates are not required.On steel they are seldom run over 120 lineal feet perminute with coolant, and will cut materials up to250 Brinell hardness with good results.

The two basic types of carbon steel blades are asfollows:

2.2 CARBON STEEL BLADES WITH A HARDEDGE AND A SOFT OR FLEXIBLE BACK

This blade is available with several types of backs,

6

from soft to spring tempered, with a hard edge onlythe depth of the teeth. It is the most common of thecarbon steel blades.

The softer back on this type of blade has the lowesttensile strength of all blades. This makes for thelowest “beam strength”, limiting the amount ofcutting force which can be applied. (Beam strengthis the deflection of the blade body between the sawguides as it contacts the work piece and a cuttingforce develops. ) Blade tensioning is also the lowestof all blades as a result of the low tensile strengthof the blade back.

2.3 HARD BACK BLADES

Hard back blades are the second type of carbonsteel blade. This blade is completely heat treated,edge and back, with the back as hard as possiblewhile still allowing it to flex around the drivewheels. The hard back improves the two limitingfactors discussed in section 2.2, beam strength andtensile strength.

Because this blade is an improvement over the“soft back”, it can be more highly tensioned witha resulting improved beam strength. It can be fedinto the work piece with. more cutting force. Thisprovides an increased cutting rate. However, theblade cannot travel any faster in lineal feet per min-ute without losing the heat treatment.

2.4 ALLOY STEEL BLADES

Alloy steel blades offer an improvement over car-bon steel blades. They can be operated at higherlineal feet per minute speeds, and have greaterbeam strength and tensioning strength. Thisresults in increased cutting rates as we can operatethe blade at higher speeds and with greater cuttingforce.

Some alloys that work-harden with cutting can becut with alloy steel blades that cannot be cut withcarbon steel blades. A very heavy cutting forcemust be used, and the alloy steel teeth have suffic-ient strength to cut without stripping.

Alloy steel blades are also referred to as “interme-diate” or “semi-high speed”. Their performancelevels fall somewhere between carbon steel and highspeed steel blades. There is no standardization be-tween manufacturers of these blades, and they varywidely. Some approach the performance of highspeed steel blades while others are only slightlyimproved over carbon steel blades.

When using alloy steel blades we suggest workingclosely with the blade manufacturer.

2.5 HIGH SPEED STEEL BLADES

High speed steel blades are available in two types,solid high speed and welded edge. The latter is ahigh speed steel edge welded to an alloy back.

Solid high speed blades are the most popular “pre-mium” blades in use today. However, the weldededge blades are predicted to surpass the solid highspeed blades within a few years.

Both blade types have high beam and tensilestrength. This, combined with the high tempera-ture capabilities of high speed steel, provides ablade with the fastest cutting rates available. Tiphardness is greater than other blades, thus harderalloys (up to 400 Brinell) can be cut successfully.Blade speeds up to 350 lineal feet per minute withcoolant can be used on mild steel without genera-ting excessive heat.

Solid high speed blades require a special weldingunit, while the welded edge blade can be welded onequipment used for other blades.

Some welded edge blades are prone to losing teethif they are subjected to a sudden impact such asstarting a cut too hard or cutting tubing withexcessive vibration. We would recommend tryingboth types on your applications and using the onethat works best for you.

2.6 SUPER HIGH SPEED BLADES

Super high speed blades are high speed steel bladeswith alloys added to provide higher tip wear andheat resistance. These blades can be best evalu-ated by using them on a production cutting appli-cation where you have past performance recordsof other blades.

2.7 CARBIDE TIPPED BLADES

Carbide tipped blades have an alloy back and teethwith carbide tooth tips welded on by variousmeans. These blades provide the hardest toothavailable. They will cut much harder materialsthan any other type of blade, even to the point ofcutting case hardened materials.

The blade speed can be increased to greater linealfeet per minute when using these blades. However,the feed rate and cutting force should not be higherthan other blades, as most blade damage resultsfrom chipping the carbide teeth. The most success-ful sawing applications are those without severevibration.

Generally the successful use of carbide tippedblades is based on experience with the blade. We

would recommend trying it on a particularly diffi-cult job.

2.8 CARBIDE EDGE-COATED BLADES

Carbide edge-coated blades are alloy blades withno teeth, but with carbide granules bonded to oneedge, forming the cutting surface. These blades areusually operated at higher lineal feet per minutespeeds and with less cutting force, as the chipstorage area is small and may load if forced toohard. However, this blade will cut hard materialsthat cannot be cut by any other method.

3. WHAT BLADE SHOULD I USE?

These general guidelines will help you choose theproper blade type:

3.1 If cutting mild steel is the primary operation,either carbon steel or high speed steel blades willdo a good job. Use carbon steel blades if machinetime is not a factor and cost per cut does not in-clude overhead rates. If overhead cost is included,high speed blades may be the least expensive over-all. See cutting cost section.

3.2 When many operators use a machine each dayfor cutting a variety of materials, consider usingcarbon steel blades. A high speed steel blade canbe ruined just as easily and will cost much more toreplace. High speed steel blades work best whenone operator only has control of a machine on eachshift.

3.3 When cutting alloy steels that work-harden,use a high speed steel or alloy steel blade so thatgreater cutting forces can be used.

3.4 Brass and bronze should always be cut with aNEW BLADE. The sharpest teeth possible arerequired. Then use the blade on steel to finish outthe life.

3.5 Aluminum can usually be cut very successfullywith carbon steel blades run at high lineal feetper minute speeds, if the machine has a sufficientlylarge drive motor. Speeds from 300 to 1200 linealfeet per minute are not uncommon.

3.6 Tough alloy steels, such as many die steels,require slow blade speeds and medium to low cut-ting forces. On large blocks use a new blade for eachcut. Save the used blades to cut smaller pieces.

3.7 Use high speed steel blades for cutting stain-less steel.

4. BLADE PITCH

Three teeth minimum should be in contact with

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the work at all times if possible. Gullet capacity(space between each tooth) must be large enoughto store all chips cut during travel of the toothacross the work.

Any blade meeting the above conditions can beused for the job. In general it follows that: a coarsetooth blade will cut faster-a fine tooth blade will

give the smoothest finish and usually the leastburr.

Fig. 4-1 chart gives the usual choice of pitch.Special conditions may cause use of pitches listedhere to be wrong; however, it is a good startingplace until one has the experience of cutting aparticular material.

FIG. 4.1TABLE OF BLADE TOOTH SIZE AND STYLE

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5. BLADE SET

Blade set is normally one of two types:

5.1 Raker (or regular type). One tooth left, onetooth right, one tooth straight and then the patternis repeated. This is the most common set and isalmost universal in use and application. We recom-mend using this type of set.

5.2 Wavy set. All teeth slowly oscillate from centerto left across to right then back to center, repeatingthis oscillating pattern. This set is common onblade pitches that are too fine for regular setting,usually 18 and finer. We recommend using this setonly when fine teeth are used, and regular set is notavailable.

5.3 A raker tooth form is best for all normal appli-cations.

6. TOOTH FORM OR STYLE

6.1 Regular or normal tooth style works well onmost applications, as the cutting angle does notencourage the blade to dig into the work piece butstill generates a good chip. The tooth will normallyhave enough chip storage.

6.2 Skip tooth blades are used for cutting wide sur-faces where maximum tooth gullet storage is re-quired, and for non-ferrous materials making largerchips.

6.3 High positive cutting angles or hook toothforms are fast cutting in non-ferrous materials andare made with large gullet capacity. They are equal-ly good in cutting larger steel bars.

7. COOLANT

7.1 Coolant and cutting oil perform nearly thesame task. They lubricate the blade against wearand absorb most of the cutting heat.

7.2 At slow cutting speeds one can use a plain lightoil with very good results; however, most oils arecombustible and use of them increases insurancecosts.

7.3 Soluble oil and water work together and do agood job with most of the advantages of otherfluids. The oil is in an emulsion, but still gives goodlubricating properties. Water carries away cuttingheat better than pure oil. It can be used for all cut-ting speeds below 200 surface feet per minute. Over200 surface feet per minute the heat will breakdown the oil. At these higher blade speeds otherfluids will carry the heat away faster than a solubleoil and water solution.

7.4 Synthetic cutting fluids are recommended forblade speeds above 200 surface feet per minutebecause of the more intense heat generated. Syn-thetic cutting fluids are equally good below 200surface feet per minute and make a good all-pur-pose coolant. We recommend using this type ofcoolant for all general work.

7.5 In general, all metals can be cut faster withcoolant; however, some alloys and cast iron arebest cut dry. Refer to the cutting speed chart forinformation.

8. CUTTING FORCE

8.1 Cutting force is the force required for a sawblade tooth’s cutting edge to penetrate the workpiece and form or shear a chip from the material.

8.2 When the cutting force is too light, small dustychips will be formed. The blade will slide over thework, doing little cutting, and abrasive wear willquickly dull the blade.

8.3 When the cutting force is correct, most chipswill be curled or rolled up with a few small chipsmixed in. At this point the blade is cutting full con-tact length of the work, giving the longest bladelife and most accurate cutting.

8.4 Increasing the cutting force beyond this pointwill produce coarse curled chips. This will put thecutting edge at its maximum point of stress. Al-though the blade will be cutting at the maximumpossible speed, the high force will be undesirable.High shearing force, high heat generation, and thehigh chip storage load at these forces will cause theblade to fail or cut inaccurately.

8.5 The ideal cutting force is outlined in section8.3. Any additional cutting force will shorten bladelife, but increase production per hour, also bladecost per cut.

8.6 Any less cutting force than outlined in section8.3 will increase blade cost per cut and decreasecuts per hour. See Fig. 8.1.

8.7 The proper cutting force can easily be reachedby operator’s experience. Various blades will differslightly and the amount of blade wear causes vari-ations. Different materials will vary also. There isno substitute for an observant, experienced oper-ator.

8.8 Cutting force recommendations are given inChart 8.2. They are very general due to the varyingconditions in the field; however, they will serveas a starting place and will usually provide good

9

blade life. After gaining some experience, most op-erators will watch the chip and adjust the forceaccordingly.

8.9 Some materials will not produce curled chips(cast iron is one). In this case judge the cuttingforce by the volume of chips being removed fromthe work. If it looks similar to the volume fromcuttings of mild steels, cutting force should be inthe proper range.

8.10 When cutting large solid work, decrease thecutting force. This gives the blade its best oppor-tunity to cut straight. Also, the length of toothcontact is great and a fine chip may roll up andbecome very large during the travel time across thework. It is in an area of maximum heat generation;therefore, running the blade 15% slower than onaverage work will add to the blade life. This is re-flected in the cutting charts in this section.

FIG. 8-1

APPROXIMATE BLADE LIFE CURVE

CHART 8.2 AVERAGE CUTTING FORCE CHART

NOTE: Start all new blades at 20% lower cutting force for the first 150 square inches of cutting. This allowshigh points of any long teeth or extra-sharp teeth to wear down until all teeth are cutting uniform-ly. Failure to do this could cause tooth tips to fracture and ruin a new blade.

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*Increasing the cutting force any higher on blades of less than 1” width may cause crooked cuts,

†Reduce the cutting force on blades of less than 1-1/4” or crooked cuts may result.

9. BLADE SPEED

9.1 Blade speed is measured in feet per minute ofblade travel. Slower than normal speeds will notharm the blade. Faster than normal speeds willgenerate excess heat and will quickly destroy thecutting edge of the blade. Blade speed selection isa compromise between good blade life, number ofcuts per hour, and keeping the heat generated to anacceptable level. Fig. 9-1 shows this graphically.

9.2 Small work can be cut at higher speeds due tothe short time during which the cutting edge is incontact with the work. As the work size becomeslarger, the blade speed becomes slower to compen-sate for the longer contact time and more heat gen-erated per tooth contact. When cutting large solidblocks 20 inches and over, the cutting speed shouldbe reduced 15% to 30% from the average speedsshown on the cutting charts. This will compensatefor the extra long blade contact.

9.3 If a good blade life is obtained at the givenspeeds, it may be possible to increase the cuttingspeed for better production. On production cutting,increase the blade speed 5% to 10% each time a newblade is installed. When the new blade fails to equalthe number of cuts made by the last blade, reducethe speed to that of the last blade. This can soonreveal the best speed for your particular job.

FIG. 9-1

TEMPERATURE DUE TO BLADE SPEED

9.4 See recommended blade speeds later in thisbooklet (Section 13, table of blade speeds andcutting rates).

10. ACCURACY OF CUT

10.1 Accuracy of cut is shown in Fig. 8-1. Theblade should be run on the conservative side inorder to keep maximum tooth sharpness. Proceedas follows for maximum cutting accuracy:

A. Use less cutting forceB. Use less blade speedC. Use maximum blade tension for highest

beam strength

This technique is suggested for tool room cuttingwhere time is not important, but where the highestpercentage of straight cuts is necessary. However,straight cuts can also be made in productioncutting. The possibility of slight run-off is higher,and the chance of a blade breakdown during acritical job is much more likely.

11. PRODUCTION CUTTING

Maximum production speed should be based on al-lowable blade life.

11.1 If more production per hour is necessary, usethe highest reasonable speeds and feeds. This willresult in less blade life but more production. Totalcost per cut with all overhead expenses includedmay be the least overall cost.

This is a figure each must compute for himselfas much depends upon work load. Many shopswant minimum blade cost per cut and use carbonsteel blades with slower production rates. Othersuse automatic equipment with high speed steelblades with maximum cutting conditions. This willoften give the lowest cost per cut when total over-head is used to compute cost.

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12. HOW TO DETERMINE THECOST PER CUT

To determine this you must have the followinginformation1. Overhead cost per hour.2. Blade cost.3. Hours of run time4. Number of pieces cut, or square inches

cut

The following is a typical example with a simplified overhead figure:1. Overhead cost per hour.

Cost of machine $5000.00Cost per year for 10 year life $ 500.00Cost per year for operator 7000.00

Total $7500.00Total hours worked 1 shift per yr. 2000.00Simplified overhead cost per hr. $ 3.75

2. Blade cost (approximate for this example)High speed steel blade $40.00 Example ‘A’Carbon steel blade $8.00 Example ‘B’

Cost of cutting 200 pieces of 4” 4140

Example ‘A’High speed steel bladeCutting rate 4 in.2 minute*Running time 10.5 hoursBlade cost 3 blades$40.00 each $120.00 total

Example ‘B’Carbon steel bladeCutting rate .84 in.2 minute*Running time 50 hoursBlade cost 6 blades$8.00 each $48.00 total

Referring to the nomograph 1 select cost perhour overhead on column 1 (3.75). Selecthours per run on column 3. Find total runoverhead on column 2.

Example ‘A’ (continued)Total overhead $ 39.37Add blade cost 120.00Total cost $159.37

Example ‘B’ (continued)Total overhead $ 187.50Add blade cost 48.00Total cost $235.50

NOW select total cost on column 4 and num-ber of pieces cut on column 6. Now read costper cut from column 5

Example ‘A’ (continued)Cost per cutExample ‘B’ (continued)Cost per cut

*Square inches per minute

12

$0.79

$1.18

LOWEST

If cost per square inch is desired, figure totalrun 200 x 12.56 area equals 2,512 squareinches cut.Example ‘A’ (continued)Find 2,512 on column 7 and move horizontallyleft to column 6.Select 159.37 on column 4, read 6.5 oncolumn 5, move decimal two places to the leftfor cost of $0.065 per square inch.Example ‘B’ (continued)Select column 7 as above use total cost235.50 for column 4.Read 9.3 on column 5. move deceimal twoplaces to left for cost per square inch of$0.093.Graph 1Graph 1 has been constructed by computingmore examples as above with the high speedsteel blade, except the overhead rate has been

changed to:Curve A $3.75 per hour

B $6.00 per hourC $10.00 per hourD $Blade cost only

Also the number of blades used to cut thesame number of pieces increased as thecutting rate Increased, as the blades were fedharder and therefore broke down sooner andthis also changed the total cost used.By connecting the minimum cost points oneach curve (Line E) a general cost trendappears. That is, as overhead rates increase,more economical sawing is acheived byIncreasing the cutting rate even though bladelife IS shortened.The only way to find the minimum costs foryour applications is to compute a chart asshown, or use this one as an average until yourown shop history accumulates.

13

13. TABLE OF BLADE SPEEDS AND CUTTING RATESFOR USE WITH COOLANT

CARBON STEEL

1010-10351038-10951100 SERIES1200 SERIES1300 SERIES2000 SERIES3000 SERIES4000 SERIES5000 SERIES521006000 SERIES8000 SERIES9000 SERIES

STAINLESS STEEL

BLADE SPEEDHIGH SPEED

STEEL BLADE

WORKPIECEWIDTH

0"-3" 3”-6” 6”-UP

300 250 200175 140 100350 300 250325 250 200250 200 150175 130 100200 150 125225 175 150225 175 150150 100 75200 150 125200 150 125150 125 75

SQUAREINCHES

PER MINUTECUTTING

RATE

10-166 - 98-208-206-103 - 73 - 73 - 84 - 83-73-74-72-5

BLADE SPEEDCARBON SQUARE

STEEL BLADE INCHESPER MINUTE

WORKPIECE CUTTINGWIDTH RATE

0”-3” 3”-6" 6”-UP

130 120 90 1-2100 80 60 1-2140 130 120 1-3120 100 80 1-3100 80 60 .5-185 75 50 .5-1

110 80 50 .5-185 70 50 .5-165 50 50 .5-170 50 50 .5-165 50 50 .5-165 50 50 .5-1

100 60 50 .5-1

300 SERIES 125 80 60 1-3 50 50 50 .2-.7400 SERIES 125 80 50 2-4 50 50 50 .2-.7

HIGH SPEED TOOL STEEL

S,H SERIES 120 100 50 3-5 50 50 50 .5-1T,M SERIES 100 75 50 1-2 50 50 50 .2-.7

DIE STEEL

A,H SERIES 175 125 100 3-4 50 50 50 .5-1D* SERIES 100 75 50 1-2 50 50 50 .2-.7L,O SERIES 175 100 75 4 - 6 50 50 50 .5-1

NICKEL BASE ALLOY STEEL

MONEL 75 50 50 .5 -2 50 50 50INCONEL X 75 50 50 .5-2 50 50 50

TITANIUM 50 50 50 50 50 50

ALUMINUM

BAR STOCK 500 500 500 10-40 500 500 500 10-30CAST 200 200 200 10-20 200 200 200 10-15

CAST IRON* 100 75 50 2-4 100 75 50 .5-1

KIRKSITE 500 400 300 5-20 200 120 80 5-10

BRONZE

MANGANESE 300 200 150 4-10 200 100 80 .5-1ALUMINUM 100 75 50 3-10 50 50 50 .5-1PHOSPHOR 275 225 200 3 - 8 125 100 80 .5-1SILICON 175 150 100 3-12 75 50 50 .5-1

*Do not use coolant.Above blade speeds are for cutting with coolant. When dry cutting reduce high speed steel bladespeeds 50% and carbon steel blade speeds 25%.

14

14. HOW TO DETERMINE CUTTING RATEOR TIME

After selecting the desired cutting rate from theforegoing charts, locate the same point on Column3 of Nomograph 2. Now compute the cross sectionalarea of the work piece and locate it on Column 1 ofNomograph 2. Now place a straight line from theColumn 1 point to the Column 3 point and read thecutting time required per cut from the intersectingpoint on Column 2.

When sawing conditions are set for the listed bladespeed, blade tooth pitch, and cutting force, the timeper cut should be similar to the time per cut. onNomograph 2. If not the cutting force can be ad-justed to increase or decrease the cutting time.

When the cutting time is known it can be set onColumn 2 and a line from Column 1 through Col-umn 2 will intersect Column 3 to give the presentcutting rate.

TABLE OF STEEL SECTION WEIGHT ANDCORRESPONDING AREA IN SQ. INCHES

Steel SectionWeight PerFoot - Pounds

Area ofSection inSquare inches

500 147.05450 132.35400 117.64350 102.94300 88.23250 73.52200 58.82150 44.11100 29.4190 26.4780 23.5270 20.5860 17.6450 14.7040 11.7630 8.8220 5.8810 2.94

9 2.688 2.357 2.056 1.765 1.474 1.173 0.882 0.581 0.29

TABLE OF DIAMETERS IN INCHES ANDCORRESPONDING AREAS IN

SQUARE INCHES

DiameterInches

Area

3-8 .111-2 .209-16 .255-8 .313-4 .447-8 .60

Diameter Area6 28.276 1-8 29.476 1-4 30.706 3-8 31.926 1-2 33.186 5-8 34.476 3-4 35.806 7-8 37.12

1 .79 7 38.481 1-8 .99 7 1-8 39.871 1-4 1.22 7 1-4 41.3013-8 1.49 7 3-8 42.721 1-2 1.76 7 1-2 44.171 5-8 2.07 7 5-8 45.661 3-4 2.40 7 3-4 47.201 7-8 2.76 7 7-8 48.71

2 3.14 8 50.262 1-8 3.55 8 1-8 51.852 1-4 3.97 8 1-4 53.502 3-8 4.43 8 3-8 55.092 1-2 4.90 8 1-2 56.742 5-8 5.41 8 5-8 58.432 3-4 5.93 8 3-4 60.002 7-8 6.49 8 7-8 61.86

3 7.06 9 63.613 1-8 7.67 9 1-8 65.403 1-4 8.25 9 1-4 67.203 3-8 8.95 9 3-8 69.033 1-2 9.62 9 1-2 71.003 5-8 10.32 9 5-8 72.763 3-4 11.04 9 3-4 74.503 7-8 11.79 9 7-8 76.59

4 12.56 10 78.534 1-8 13.36 10 1-8 80.524 1-4 14.18 10 1-4 82.504 3-8 15.03 10 3-8 84.544 1-2 15.90 10 1-2 86.604 5-8 16.80 10 5-8 88.664 3-4 17.72 10 3-4 91.004 7-8 18.67 10 7-8 92.89

5 19.63 11 95.005 1-8 20.63 11 1-8 97.215 1-4 21.64 11 1-4 99.505 3-8 22.69 113-8 101.625 1-2 23.75 11 1-2 104.005 5-8 24.85 11 5-8 106.145 3-4 25.96 11 3-4 108.405 7-8 27.11 11 7-8 110.75

15

16

15. SAWING PROBLEMS

SLOW CUTTINGUse coarser pitch tooth if possible.Use faster blade speed when possible.Increase cutting force if possible.

POOR BLADE LIFEBlade is running too fast.Cutting force is too heavy.Blade pitch is too fine.Use ample coolant.

TOOTH STRIPPINGCutting force is too heavy.Blade pitch is wrong. Use a coarser pitch bladeon wide sections, a finer pitch on thin sections,plus ample coolant.Check blade brush to make sure it is cleaningthe blade.

BLADE STARTS CUT INTO WORK PIECE,THEN STOPS CUTTING

This condition is typical of work hardeningmaterial. Apply ample cutting force so teethare continually cutting, not sliding throughthe work piece.Blade running too fast, causing the teeth todull from overheating.Use coarser pitch blade.

CROOKED CUTSReplace old blade.Place blade guides as close to work as prac-tical.Check alignment of blade guides.Check for leakage in hydraulic system allowingthe cutting head to leak down.Check alignment of the cutting head guidepost.

BLADE BREAKAGEBlade tensioned too tight. See manual for yourmachine.Roller guides adjusted too tight, causing highflexing of band.Check blade wheels for wear and alignment(see maintenance instructions).If saw blade is breaking at welds, use a longerannealing period with gradual decreasing ofheat. If blades were purchased, return for re-welding.Cutting force may be too high.

CONCAVE CUTSIncrease the blade tension.Use a coarser pitch blade if possible.

Use less feed force.Place guides as close as possible to the workpiece.Replace old blade.Check for leakage in hydraulic system allowingcutting head to leak down.

JUMPING OF CUTTING HEADCheck blade weld carefully for improper align-ment or grinding.Check blade for stripped teeth.

CUTTING HEAD BINDING ON HINGE ORCOLUMNS

Machine is not properly leveled causing thehinge or columns to misalign.Clean columns of rust, dirt, etc. and applylight film of oil.

BLADE VIBRATIONChange blade speed to break the resonantpattern of the blade.Increase blade tension.Use different pitch blade.Change the cutting force.Check work clamping.Move blade guides closer to work.Blade speed is too fast.

LOADING OF TOOTH GULLETSUse a coarser pitch blade.Apply coolant liberally or try a different typeof coolant.Use less feed force with increased blade speed.

BLADE STALLS IN WORKDecrease cutting force.Decrease cutting head approach speed.Check blade tension.Check drive motor belts.Blade not tracking properly on wheels.

CHIPS WELDED TO TEETHUse coolant.Check blade brush.Decrease cutting force rate.

LOSS OF TOOTH SETBlade is running with teeth between guiderollers or on blade wheels.

BLADE SIDES ARE HEAVILY SCOREDCheck carbide blocks in guide.Check coolant supply

BLADE NOT TRACKING PROPERLYConsult manual and align blade wheels.

(Continued Next Page)

17

15. Continued

SCALE ON WORKPIECEAll hot rolled materials will have a degree of millscale. On low carbon mild steels this scale isnegligible as far as cutting rates are concerned, butit shortens the blade life. When structurals, angles,etc. are being cut, the ratio of exterior area to thecross section area is very high, resulting in extremeabrasion to the blade and consequent shorter bladelife.

On alloy steels this mill scale can be verydetrimental to the band saw blade and we definitelyrecommend it be removed prior to the cut. Somescales are so hard and abrasive that they must beremoved in order to successfully cut the materials.

HARD SURFACESHard surfaces can be created on a work piece by awide variety of operations. The following are a fewof the more common problems encountered:

CUTTING WITH A TORCH can create a“case hardened” area if an excess of acetyleneis used to make the cut. While this shell is onlya few thousandths of an inch thick, cuttingthrough it with a band saw blade will dull theteeth, creating extreme problems.

GROUND SURFACES -- on some high carbonand die steels, improper grinding practices canresult in the hardening of the surface.

HARD SPOTS IN THE WORK PIECESome welded seam tubing will have a hard zone bythe welded area if it is not properly annealed. Thishard section can at times be too hard to cut.

Some die steels may have inclusions of slag or scalewithin the block. These inclusions are as hard as theteeth on the blade, and will dull the teeth as theblade cuts through them. This in turn will cause theblade to start cutting crooked.

16. BLADE TENSION

As a general guide line, the higher the blade ten-sion, the sooner the blade will fail and break due torunning stress and tension. However, as the bladetension is increased, the accuracy of cut also in-creases. This means that a tension must be usedthat is high enough for accurate cutting, but nothigh enough to shorten blade life.

as comfortably possible. This will put the blade inthe proper operating range.

Machines with hydraulic blade tension control canin most cases be adjusted to over-tension a blade.As a starting point, we recommend checking thehydraulic diagram for the recommended pressureadjustment. On average sized work pieces this willbe adequate tension for good cutting and goodblade life.

When cutting large material with wide blade spans,the blade tension may have to be increased toobtain maximum blade stability. Because themaximum allowable tension varies from bladetypes and manufacturers, the best procedure is tocheck with the blade manufacturer for themaximum allowable tension of the blade beingused. This tension can then be applied and used as agood starting point.

Another method may also be used in the absence ofany available information. Keep a record of therunning time on the saw blade until it breaks. Thenincrease the blade tension 10% each time a newblade is installed until the blade breaks before itwears out. This will then be the maximum tensionpoint. Reduce the tension 15% below this point andoperate the blades long enough to see if the averageblade life is used before the blade breaks.

When this point is reached, the blade will beoperating at its maximum practical beam strength.Let us again call to your attention that this isnormally only necessary when large machines aresawing near capacity work.

For most applications and blades, the tension rangegiven on the hydraulic diagram or manual willresult in adequate tension and good cutting. Somemachines show the proper hydraulic pressuresetting on the blade tension gauge by setting thegauge needle to a green dot on the dial.

Machines that are equipped with manual handknobs for blade tensioning have knobs sized so onecan generally tighten them with one hand as tight

18

M O D E L L - 9

I N D E X1. INTRODUCTION 20

202. INSTALLATION 2420A. Location

B. Electrical hookupC. Check-out 25D. Stock stop installationE. Blade installation.

3. OPERATIONA. Cutting ForceB. Blade speed.C. Vise operationD. Stock stop barE. Guide arm setting

22F. Cutting head descent rate 26G. CoolantH. Angle cutting

4. MAINTENANCEA. Lubrication

202020202121 5.21222222

2223 6.2324 7.

B. Blade wheel alignmentC. Ring gear&pinion adjustmentD. Timing Belt adjustmentE. Motor switch adjustmentF. Drive belt adjustmentG. Blade guide adjustmentH. Blade brush adjustmentI. Blade tension indicator accessoryTROUBLE SHOOTINGA. Crooked cutsB. Blade stallsC. Broken bladesD. Stripped teethE. Poor blade lifeF. Erratic feedSPARE PARTS FOR

24

2525

2525252626262626

26

MINIMUM DOWNTIME 26REPLACEMENT PARTS LIST. 26

19

1. INTRODUCTION

The purpose of this manual is to provide in-structions for the installation, operation andmaintenance of your Model L-9 metal cutting bandsaw machine, a comparatively simple but ruggedmachine tool.

Any power driven machine tool constitutes apotential hazard to the operator’s safety. TheModel L-9 saw has been designed with safety inmind, but it is still necessary to observe all thesafety rules employed in the operation of anymachine. We recommend you read the safetymanual included with this manual before you startup the machine. CAUTION: Some guards havebeen removed to show the underlying parts in thefollowing photos. In actual use, make sure allguards are in place before operating the machine.

2. INSTALLATION

A. LOCATION. When installing the L-9 saw, it isimportant that proper consideration be given to thesurroundings and location. It should be in an arealarge enough for operator safety. The machine andthe work area should be properly lighted, withoutsevere reflections or other visibility hazards.

The L-9 saw does not normally require any specialfoundations or footings. However, the floor under itshould be adequate to support the machine with itsmaximum intended load. The machine should belevel and shimmed so that each foot is restingfirmly on the floor, carrying its proportion of theload without twisting or straining the machine bed.

B. ELECTRICAL HOOKUP. All electrical wiringto the machine must meet all local and nationalelectrical codes, and should be installed so that itwill not be subject to damage from normaloperation of the machine or related materialhandling equipment.

C. CHECK-OUT. Before the initial start-up,visually inspect the machine to see that all drivebelts are in proper position and that the machineappears free from damage. The cutting head shouldlift freely, and when the cutting head descent valve(Fig. 8) is opened, the cutting head should lowerfreely. If it does not, consult Section 4A concerninglubrication. If this does not adequately free up thecutting head, the machine should be thoroughlyinspected for concealed damage such as bent framemembers or broken cutting head hinge bolts.

Using the switch next to the cutting head descentvalve (Fig. 8), turn on the blade motor. Themachine should start and run quietly and freely. Ifit does not, check for damaged pulleys or belts,bent shafts, etc.

D. STOCK STOP INSTALLATION. Insert thebar slot end first into the hole in the machine bed.Align the slot in the bar end with the pin on theopposite side of the machine base. As the barengages the pin, place the push arm into the notchon the cutting head pivot arm (Fig. 1). Attach thespring to the bracket as shown.

F i g u r e 1

20

Figure 2

The purpose of the arm and pin is to swing thelength stop up and away from the work piece, sothat when cut off it will not twist and jam betweenthe blade and length stop.

E. BLADE INSTALLATION. Raise the cuttinghead 6” or 7” and hold it in this position by closingthe cutting head descent valve. Open both bladewheel guards on the cutting head. Swing up theblade guard cover (mounted on the saw guide).Hold the looped blade in front of you with thesmooth back edge toward you. Lower the blade intothe cutting head and place it around the wheels(Fig. 2). The teeth on the lower strand of the bladeshould be in position to cut as the blade travelstoward the driving wheel. If the teeth are notpointing in this direction, remove the blade, turn itinside out, and replace it. At each blade guide, twistthe blade to a vertical position (teeth down) andinsert it up between the guide rollers (Fig. 3). Turnthe blade tensioning knob just enough to take theslack out of the blade, but leave the blade looseenough so that it can be slid up against the wheelflanges (Fig. 4). After lifting the blade against theflanges, close the wheel guards and tension theblade by turning the handknob as tight as iscomfortably possible with one hand (Fig. 5). If theblade is too loose, it may slip on the driving wheelor it may not cut straight. If the blade is too tight,metal fatigue will cause premature failure. With the

blade properly installed and tensioned, start theblade motor for a final check.3. OPERATION

A. CUTTING FORCE. When a new blade is in-stalled on the machine, the cutting force shouldalways be reduced for the first five or six cuts. Anew blade, being sharp, will penetrate the workmuch faster and may be damaged by tooth tipschipping off or teeth stripping if the cutting force isnot reduced. After the “break-in” period thecutting force may be increased to normal and, asthe blade dulls, the cutting force may be increasedmore to maintain cutting speed. Eventually a pointwill be reached where either the blade will cut tooslowly, or the force required to make it cut will beso high that crooked cuts will result, dictating anew blade.

The cutting force is adjusted by the step cam (Fig.6) that controls the tension on the counterbalancespring. Lift the cutting head completely up. Thenpull the spring rod out and rotate the cam up to thehighest point for minimum cutting force, or thelowest point for maximum cutting force. In normaluse, position the spring rod in the second step downfrom the top. If you find the blades are producingfine dust when cutting, increase the cutting forceby iowering the rod one step. If the blade is being

raise the spring rod one step on the cam to reducethe cutting force. Ideally, the average cuttingshould produce a mixture of chips and curled chips.

Normally, a narrow work piece requires a lightcutting force, and a wide work piece requires amedium to heavy cutting force. Tooth pitch mustalso be considered in determining cutting force. Acoarse pitch blade on a narrow work piece willrequire much less cutting force that a fine pitchblade on the same work piece. To familiarizeyourself with the saw blades, tooth pitch, cuttingforce and other related factors, read the ac-companying Saw Blade Selection and ApplicationManual.

B. BLADE SPEED. One of the critical factorswhen cutting any type of material is the bladespeed. If a blade is run too fast for the materialbeing cut, it will burn out long before it would haveworn out had it been run at the proper speed. Whenthe surface speed of any cutting tool is increased,the cutting edge will run hotter. At some point thecritical temperature of the cutting tool will beexceeded and the tool will “soften” and sub-sequently fail.

To change the blade speed on 4-speed machines,open the belt guard and loosen the cap screw in the

overfed and is producing large heavy curled chips, motor mount bracket (Fig. 7) so the motor will

2 1

F i g u r eFigure 3

Figure 4 Figure 6

swing, and loosen the primary drive belt. Move thebelt toward the large end of the motor pulley toincrease the blade speed, or toward the small end todecrease the blade speed. Be sure to also move thebelt on the counter-shaft pulley, in the samedirection and the same number of steps, so that thebelt will run straight from the motor pulley to thecountershaft pulley. If the belt runs angled frompulley to pulley it will wear unduly and may jumpoff the pulley. When the belt is adjusted to theproper step for the desired blade speed, swing themotor to tension the belt and tighten the cap screwto securely clamp the motor mount bracket.

On variable speed machines, start the drive motor,then turn the crank arm (Fig. 7b) until the indicatorshows the desired blade speed. The crank arm willbe self locking as long as the small friction screw iskept snug.

C. VISE OPERATION. To adjust the saw vise tothe work piece size, place the work piece on the sawbed against the stationary vise jaw. Then simplylift the half nut carrier handle (Fig. 8) connected tothe movable vise jaw and slide it up against thework piece. Lowering the handle engages the halfnut and vise screw so that final tightening can bedone with the handwheel at the end of the visescrew.

D. STOCK STOP BAR. If a number of pieces areto be cut the same length, the stock stop bar maybe used to preclude measuring each piece. Place thework in the machine vise and lower the cuttinghead until the blade is just above the work piece.Position the work piece under the blade for thedesired length of cut, and tighten the vise securely.Loosen the clamp screw in the stop arm casting(Fig. 9) so that the casting will slide along the stockstop bar. Slide it up against the end of the workpiece and tighten the clamp screw, positioning thestop on the upper edge of the work piece.

This will allow the arm to swing up and away fromthe work piece, eliminating jamming of the workpiece between the blade and the stop arm at thecompletion of the cut. When setting the stop forshort work pieces, be careful not to adjust the stoparm so that it will swing up into the saw guide.

E. GUIDE ARMS SETTING. Before starting acut, adjust the two saw guide arms as close aspossible to the work piece, but be sure to leaveenough room so that the guides will not hit the visejaws or stock stop bar as the cutting head swingsthrough the cut. Keeping the guides as close to thework as possible will insure the best cutting resultsand will maintain the blade guard as close aspossible to the work piece.

F. CUTTING HEAD DESCENT RATE. To starta cut, start the blade motor and “crack open” the

Figure 7

Figure 8

Figure 7-B Figure 9

22

cutting head descent valve to lower the blade veryslowly onto the work piece. This will protect theblade at the start of the cut when only a few teethare engaged. As soon as the cut has progressed farenough that several teeth are engaged, the valvemay be opened about l/4 turn. This will allow thecutting head to descend at its sawing rate, andopening the valve further will not speed the cuttingaction.

If the work piece to be cut is thin wall tubing or anyother thin section (so that only a few teeth will be incontact with the work piece at any time), a lightcutting force should be used, and the cutting headdescent valve should be opened only enough toallow a slow, even feed through the cut. A thinsection does not present enough area to the sawblade for normal cutting forces to be used.Therefore, the cutting head would fall through thework too rapidly, causing overfeeding and bladefailure. This situation is prevented by slowing themaximum rate of descent.

G. COOLANT. If your machine is equipped with acoolant system, it is wired so that the coolant pumpwill run whenever the blade motor is turned on.CAUTION: Do not run the coolant pump anylength of time unless it is submerged in coolant. Ifyou wish to run the machine without coolant in thetank, unplug the coolant pump.

For most sawing applications, a weak soluble oiland water mixture is used for coolant. If the coolantbecomes too thick or oily, it will result in too muchlubrication and poor blade life. Most materials canbe cut satisfactorily without coolant, but blade lifewill be somewhat less and the time per cut will besomewhat longer because the blade speed must bereduced to prevent overheating. It may be desirableto cut some items dry due to their size, shape orother physical characteristics, or to eliminate otherpossible problems which may arise when usingcoolant. The only materials on which we do notrecommend using coolant are the “D” series of airand oil hardening tool steels, cast iron, and brass orbronze alloys.

H. ANGLE CUTTING. To make cuts of variousangles from 90 to 45 degrees, loosen the two boltsholding the stationary vise jaw to the saw bed. Usea protractor to position the vise jaw on the bed tothe desired angle. As the angle becomes moreacute, it may be necessary to remove the bolt fromthe slot in the vise jaw (Fig. 10). This bolt may thenbe placed in either of the other holes in order toobtain the desired angle. Tighten the bolts securelywhen the angle is set. Next, loosen the two bolts onthe movable vise jaw (Fig. 11), slide it snugly upagainst the adjusted stationary jaw, and retightenthe bolts. Be sure to check the guide arms beforemaking a cut to be sure they are as close aspractical, but with the necessary clearance.

Figure 10

Figure 11

Machine set up for 45° cuts.

4. MAINTENANCE

Any machine tool will require periodic maintenanceincluding lubrication, minor adjustments, andeventual replacement of some parts. A goodmaintenance program will insure a smooth runningmachine. For normal maintenance we recommendthe following:

23

2 4

Before making any blade wheel pitch adjustments,we strongly recommend that a new blade be in-

A. LUBRICATION.

SAW BLADE GUIDE ROLLERSVISE SLIDE WAYSVISE SCREW

Clean and lubricate with a light to medium weight oil,daily for heavy use and weekly for occasional use.

RING GEAR We do not recommend any lubrication. If it is greasedor oiled it will pick up dirt and shavings which wouldnormally fall away.

GUIDE BEAM This should be kept clean, with a light film of oilmaintained on it.

CUTTING HEAD PIVOT POINTSCYLINDER PIVOT POINTSBLADE TENSION SCREW

A few drops of light to medium oil should be appliedweekly.

VARIABLE SPEED DRIVE PULLEY Grease monthly (Fig. 13).

The oil level of the hydraulic cylinder should bemaintained within l/2” from the top, with thepiston rod all the way down. This will requireoccasional filling with a medium grade of hydraulicoil. If the oil level falls below the top hose fittings inthe cylinder, the cutting head action will becomespongy and a considerable drop in the head will benoticed after the head is raised and released ontothe hydraulic cylinder. If this happens, remove thecylinder cap and fill the cylinder. Replace the cap,leaving it loose, and work the head up and down 8or 9 times, closing the cutting head descent valveeach time before the head is lifted. Remove the capand refill the cylinder. Repeat this cycle until all airhas been worked out of the system and the oil leveldoes not fall between cycling periods.

B. BLADE WHEEL ALIGNMENT. When theblade wheels are properly adjusted, the blade willrun with the smooth edge making light contactwith the wheel flanges. If this contact becomes tooheavy, it will wear the wheel flange unduly andcreate a noisy scrubbing sound. It also causes anedgewise strain on the blade at the point of wheelcontact which can cause blade fatigue andbreakage.

stalled on the machine. If a blade that is worn orstretched out of shape is used to make this ad-justment, the end result may not be satisfactory.To make a wheel pitch adjustment, release theblade tension and loosen the cap screw in the outeredge of the wheel axle plate (Fig. 12). Turn thesocket set screws next to them in or out to get thedesired change of axle inclination. If the blade isrunning hard against the wheel flange, turn the setscrews out (counterclockwise) and retighten the capscrews. This will lower the outer edge of the wheel,reducing the tendency of the blade to run againstthe flange. If the blade runs down away from theflange, turn the set screws in (clockwise) andtighten the cap screws. This will raise the outeredge of the wheel, causing the blade to run closer tothe flange.

C. RING GEAR AND PINION ADJUSTMENT.The ring gear and pinion should be adjusted to.010” to .015” clearance between the two gears.To make this adjustment, loosen the cap screw inthe lower edge of the pinion bearing flange (Fig.13). Lightly tap the flange in the direction desiredto get the proper clearance, then tighten the capscrew and check the clearance. Be sure to have ablade on the machine, under normal tension, whenmaking this adjustment.

Figure 12 Figure 13

D. TIMING BELT ADJUSTMENT (Fig. 13). Thetiming belt should be adjusted tight or snug, butnot tensioned as one may do with V-belts. If thebelt “sings” it indicates too much tension. If thebelt is run too loose it may jump cogs. Therefore,when performing this adjustment, the mid-spanpoint of the belt, when moved with the fingers,should have a small but definite up and downmovement. Loosen the timing belt adjustment boltand rotate the cam sleeve until the desired positionis reached. Then hold the cam in position whileretightening the bolt.

E. MOTOR SWITCH ADJUSTMENT. Switchadjustment can be made by means of the set screwin the end of the pin which the switch rod passesthrough (Fig. 14). Loosen the set screw and adjustthe switch rod longer or shorter as required so thatthe cutting head, when lowered, will turn the switchoff just before it comes to rest on the stop. Theswitch should not be turned off so soon that thecutting head rests on the switch rather than on thestop.

Figure 14

F. DRIVE BELT ADJUSTMENT. 4-speedmachines: There are two different V-belt drives onthe 4-speed machine. The primary drive belt goesfrom the motor to a countershaft pulley, and thefinal drive belts go from the countershaft pulley tothe ring gear pinion shaft pulley. To adjust the finaldrive belts, turn the screw shown in Fig. 15. Thesebelts should be reasonably tight, so that there isonly l/4” of movement when the belt is pushedwith the fingers midway between the pulleys.

To adjust the primary drive belt, loosen the capscrew in the motor mount bracket (Fig. 15) andswing the motor up until the belt is tensioned. Thisbelt will not require much tension to drive themachine satisfactorily. With the belt tensionedproperly, retighten the cap screw to clamp themotor mount bracket securely to the support bar.

G . B L A D E G U I D E A D J U S T M E N T . F o rsatisfactory cutting results, it is necessary tomaintain the blade guides in good repair and properadjustment. This is probably the most importantadjustment on the machine, and must be donecarefully and thoroughly. It is very important thata new blade be installed on the machine beforemaking any blade guide adjustments. Because thisadjustment is so important, a separate manual hasbeen prepared and is included with the originalmachine manuals.

H. BLADE BRUSH ADJUSTMENT. The bladebrush should engage the blade lightly, usually justenough to turn it. The blade brush should notengage the blade beyond the depth of the teeth. Tomake this adjustment, slightly loosen the wingnutand turn the thumb screw to engage the brushagainst the blade (Fig. 16). Retighten the wingnut.Do not make this adjustment with the machinerunning for safety reasons.

I . B L A D E T E N S I O N I N D I C A T O R A C -CESSORY. When the blade has been installed inaccordance with this manual, tighten the bladeuntil the marks on the indicator line up (Fig. 17).

Figure 15 Figure 16

25

Figure 17

5. TROUBLE SHOOTING

Problems will eventually be encountered with anymachine tool, and it is our intent here to help solvethem. The Model L-9 saw is a basically simplemachine, and it is usually not difficult to find theunderlying cause of the problem.

A. CROOKED CUTS. This problem can be causedby many faults which may occur singly or in anycombination. A machine that is perfectly alignedand properly operated can make unsatisfactorycuts if the blade being used is defective. For thisreason, if a machine suddenly begins to cut out oftolerance, we recommend that a new blade be in-stalled as a first attempt to obtain satisfactorycuts. Always keep the blade guide arms adjusted asclose to the work as practical, as a long blade spanprovides less rigidity.

If a new blade is installed and the machine con-tinues to make crooked cuts, consult Section 3-Aand the saw blade manual concerning the propercutting force for the material being cut and thelength of blade in contact with the cut.

Crooked cuts are sometimes caused by the bladebeing too loose. Consult Section 2-E concerningblade tension. If the preceding suggestions havebeen followed and the machine still does not cutstraight, consult the separate manual on saw guideadjustment and carefully check the adjustment andalignment of the saw blade guides.

B. BLADE STALLS. If the blade stalls during acut, first check to determine whether the blade isslipping on the drive wheel or if the V-belts areslipping on the pulleys. If the saw blade is slippingon the drive wheel, the blade is not properly ten-sioned. Consult Section 2-E and properly tensionthe saw blade. If the V-belts are slipping on thepulleys, consult Section 4-F and properly tensionthe belts. If nothing is slipping but the motor isstalled and will not start, allow it to cool, then pushthe stop or reset button to reset.

C. BROKEN BLADES. Consult the separateguide booklet and check to see if the blade guiderollers are too tight. Sometimes poor blade wheel

26

alignment causes broken blades. Consult Section 4-B and check for this condition. Another cause ofblade breakage is too much cutting force. ConsultSection 3-A and the Saw Blade Selection andApplication Manual to determine the correctcutting force for the material being cut.

D. STRIPPED TEETH. The most frequent causeof stripped blade teeth is incorrect tooth pitch forthe job being performed. Consult the saw blademanual to determine the proper blade tooth pitchfor the material and size being cut. Sometimesexcessive cutting force will cause teeth to strip.Consult Section 3-A and the saw blade manualconcerning proper cut t ing force . Anotherpossibility is improper blade brush adjustment.Consult Section 4-H to correct this condition.

E. POOR BLADE LIFE. This problem is usuallycaused by a blade speed too fast for the type ofmaterial being cut. Consult Section 3-B and the sawblade manual to determine the proper blade speed.Cutting scaly material or cutting through or neartorch-cut areas can also reduce blade life.

F. ERRATIC FEED. If the cutting head does notfeed smoothly into the cut but surges and hesitates,we suggest you consult Section 4-A concerninglubrication. This problem may also be caused byimproper blade tooth pitch for the job being per-formed. In this case, consult the Saw BladeSelection and Application Manual to determine thecorrect blade pitch. Another possibility is poorblade brush adjustment. Consult Section 4-H ofthis manual.

6. SPARE PARTS FOR MINIMUM DOWN-TIME DESCRIPTION ANDQUANTITY PART NO. COMMERCIAL PART NO.

4 901500 Guide Bearing Fafnir 5200 PP2 901200 Guide Bearing Fafnir 200 PP1 900083 Blade Brush

4-SPEED MACHINES ONLY:1 908503 Drive Motor Belt 4L2802 908504 Final Drive Belt 4L390

VARIABLE SPEED MACHINES ONLY:1 909041 Variable Speed Belt 260K81 908550 Timing Belt 270L100

7. REPLACEMENT PARTS LIST

A. Required for any part order:1. Saw model2. Serial number

B. This parts list does not show all the parts thatmake up the machine. We have tried to show all thecommon parts that may require replacement. Also,some parts may not be shown due to machinedesign changes. When this occurs, order parts asdescribed above.

C. Parts that can normally be obtained from localmill supply stores, etc. are not listed.

D. Parts not listed: Give a complete detaileddescription of what it is, where it is used, and whatit does in operation. This will often give us enoughinformation to supply the part.

27

28

415190 DRIVE WHEEL. BEARINGS. AND GEAR ASSEMBLY(415191 WITHOUT GEAR)

DRIVE WHEEL ASSEMBLY

BEARING SPACERRING GEARDRIVE WHEEL ONLY415191 WHEEL, BEARINGS,AND SPACER415190 WHEEL, BEARINGS,SPACER, AND GEARECCENTRIC BUSHINGWHEEL AXLE PLATEGUARD HINGEWHEEL BEARINGS

29

GUIDE ARM ASSEMBLYGUIDE ARM ASSEMBLY

410350 GUIDE ARM ONLY(WILL FIT LEFT OR RIGHT)

410390 CLAMP WASHER410400 ARM STUD411030 ECCENTRIC BOLT916013 ARM KNOB

VISE ASSEMBLY

410090410100410110410120410130410140410150410170410175410180410190410200410210410220410230907001

STATIONARY VISE JAWVISE JAW BACK-UP BARSTATIONARY JAW STUDVISE ANGLE BARANGLE BAR STUDMOVABLE VISE JAWSLIDE BLOCKSLIDE BLOCK STUD BARMOVABLE JAW CLAMP BARSLIDE BLOCK HINGE PINSLIDE BLOCK HANDLEHANDLE LOCKBRASS HALF NUTVISE SCREWVISE HANGLELOCK SPRING

30

STOCK STOP ASSEMBLY

410250 STOCK STOP PIN410270 STOCK STOP ARM410280 S T O C K S T O P P U S H R O D410310 STOCK STOP BOLT410260 S T O C K S T O P BAR907003 STOCK STOP SPRING

COOLANT PARTS

911500 COOLANTVALVE912000 COOLANT HOSE (SPECIFY LENGTH)912111 HOSE FITTING912902 COOLANT NOZZLE

931900 115 VOLT COOLANT PUMP931901 230 VOLT COOLANT PUMP

31

HYDRAULIC CYLINDER AND VALVE ASSEMBLY

010307010333010334010335010343900086900088907013907037907038911505912301NOTE A

CYLINDER CAPPISTON RODPISTONCYLINDER TUBEROD SEAL RETAINERPISTON LEATHERROD SEALRETAINING CLIPSPRINGPISTON LEATHER RETAINERVALVEPIPE THREAD TO HOSE FITTINGTO ORDER HOSE ASSEMBLIES, SPECIFYLENGTH OF 912000 HOSE WITH 912154 FITTINGSAND 912155 COLLARS INSTALLED.

32

VARIABLE SPEED DRIVE ASSEMBLY

380230385110410490410500410510410520410530410540410550410560410570410580410590410600410610410620410630410640

VARIABLE SPEED DRIVE ASSEMBLY

MOTOR MOUNTCOMPLETE MOTOR PULLEY ASSEMBLYRING GEAR PINIONPINION GEAR BEARING AND SHAFTBEARING HOUSINGECCENTRIC BUSHINGLARGE TIMING BELT PULLEYPULLEY HALF (COMES WITH 410550)PULLEY HALF (COMES WITH 410540)PULLEY KEYSMALL TIMING BELT PULLEYCOUNTERSHAFTBEARING SPACERSPEED INDICATORSPEED CHANGE CRANKMOTOR PULLEY HALF (COMES WITH 410640)PULLEY KEYMOTOR PULLEY HALF (COMES WITH 410620)

410650410660410690410700415110

900020901103901204901503904111906057906400907002907004908550909041

SPRING RETAINERGREASE SLEEVEBELT GUARDINDICATOR COVERCOMPLETE COUNTERSHAFT ANDPULLEY ASSEMBLYGREASE FITTINGBEARING TYPE 103BEARING TYPE 204BEARING TYPE 5203O-RING TYPE 2-111INTERNAL RETAINING RINGEXTERNAL RETAINING RINGINDICATOR SPRINGMOTOR PULLEY SPRINGTIMING BELT 27OL100VARIABLE SPEED BELT 24V10

33

4 SPEED DRIVE ASSEMBLY

4 SPEED DRIVE ASSEMBLY

330220 MOTOR MOUNT LOCK BOLT380240 PINION BEARING AND SHAFT380250 COUNTERSHAFT MOUNT380260 COUNTERSHAFT AND BEARING380320 BELT GUARD HINGE380340 MOTOR MOUNT410490 PINION GEAR410510 BEARING HOUSING410520 ECCENTRIC BUSHING908503 MOTOR BELT 4L280908504 FINAL DRIVE BELTS 4L390908600 LARGE FINAL DRIVE PULLEY908601 LARGE PULLEY HUB908602 LARGE 4 STEP PULLEY

908603 SMALL FINAL DRIVE PULLEY908604 SMALL 4 STEP MOTOR PULLEY

34

SAW BLADE GUIDE AND METERING VALVE MANUAL

Adjustment, Maintenance, and Replacement Parts

INDEX

A. G u i d e A d j u s t m e n t .

B. M e t e r i n g V a l v e A d j u s t m e n t

C. Preventive Maintenance

D. P r o b l e m s a n d S u g g e s t i o n s

E. Spare Parts for Minimum Downtime

F. R e p l a c e m e n t P a r t s

PAGE

. . . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

................................................... 38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

35

A. BLADE GUIDE ADJUSTMENT-TYPE 415200, L-9 AND W-9 MACHINES

Adjustment of the saw blade guides is one of themost critical on your machine as it plays an im-portant part in the overall machine performance. Itis VERY IMPORTANT that a NEW BLADE beINSTALLED and PROPERLY TENSIONEDbefore adjusting the blade guides.

TO ADJUST THE BLADE GUIDE ROLLERCLEARANCE, refer to Fig. 1. One guide roller ismounted on shoulder bolt 411140 and threadeddirectly into the housing 411080. This roller isrigidly mounted and non-adjustable. The opposingroller (Fig. 2) is mounted on a cam shoulder bolt411100 and an adjustment of the roller centers canbe made by loosening the hex nut on the top (Fig. 3)and rotating the bolt. These rollers should beadjusted just tight enough so that grasping theblade in the area between the guide and its adjacentband wheel and oscillating it across the verticalcenter will not permit movement of the blade in thecutting area between the two guides. Anymovement of the blade transmitted through the

Fig. 1

Fig. 2

rollers into the cutting area should be removed byadjusting the cam bolt. It is also very importantthat after this adjustment has been completed youcan manually push the blade down partially out ofthe guide and when released it will partially returnof its own accord. CAUTION: If these two guiderollers are adjusted too tightly it will cause theblade to “snake” through the rollers, resulting inmetal fatigue and blade breakage. Guide rollersadjusted too tightly will also cause the meteringvalves controlling the cutting head feed to becomeinoperative or very erratic, resulting in extremefeed problems.

PARALLEL AND VERTICAL ALIGNMENT OFTHE BLADE GUIDES. In order to make anaccurate adjustment of the blade guides it is firstnecessary to check the stationary vise jaw forsquareness on the saw bed (Fig. 4). Place a com-bination square on the machine bed using the frontedge of the wide bed top plate in the vise slideway,and adjust the rear stationary vise jaw to obtain atrue 90o setting. The guide settings will be trued tothe vise face, so it is very important that the viseface be at right angles to the saw bed.

Fig. 3

Fig. 4

36

Fig. 5

Fig. 6

Fig. 7

With a properly tensioned new blade on themachine, place the combination square against thefront face of the blade very lightly so the blade willnot be deflected and slide the square against therear vise jaw (Fig. 5). If the blade and vise jaw arenot at right angles, refer to Fig. 6. The cam bolt410520 on the lower end of each guide arm can beadjusted to bring the blade into parallel alignmentwith the saw bed and at right angles to the workvise. Loosen the hex head cap screw (Fig. 6 ) and thehex nut on the 410520 cam bolt. By turning the cambolt the lower end of the blade guide casting 411040or 411060 can be moved in or out to bring the bladeinto parallel alignment with the saw bed. Thequestion at this point is which guide should bemoved in which direction to keep the blade in asstraight a line as possible between the lower edge ofthe two blade carrier wheels. To find out, in-dividually loosen the hand knob clamps which holdthe guide arms to the guide beam, so that guidearm movement caused by the tensioned blade maybe observed (Fig. 6, Ref. A & B). Then adjust theguide castings to minimize this deflection with thesaw bed and at right angles to the work vise. Afterretightening the hex nut on the cam bolt and thehex head cap screw, recheck the blade against thestationary vise jaw to assure proper alignment isstill intact.

At this point, place the blade gauge furnished withthe machine on the saw blade (Fig. 7) adjacent tothe stationary vise jaw and lower the cutting headuntil the cutting edge of the blade is near the workbed top. Place the combination square blade acrossthe bed top and move the base of the square againstthe face of the blade gauge. If the gauge is not invertical alignment with the square an adjustmentcan be made with blade screw 411070 (Fig. 7).

Turn the adjusting screw clockwise to cause the topend of the blade gauge to move away from the visejaw or turn the screw counterclockwise to cause thetop end of the blade gauge to move towards the visejaw. After this has bean done on the guide armadjacent to the stationary vise jaw, repeat theoperation on the guide arm adjacent to themoveable vise jaw. If a large correction must bemade on the second guide arm, recheck the settingof the first guide arm. If large corrections are madealternately, check and adjust each guide arm asnecessary until the blade at either guide arm is in atrue vertical position.

B. METERING VALVE ADJUSTMENT,TYPE 010660, MODEL W-9 MACHINESONLY.

This is an extremely simple adjustment to make,yet is the one that creates the most problems.

37

Lower the cutting head slowly (with a low cuttingforce of 20 to 40 pounds) and as the head lowers,pry up the bearing arm as shown in Fig. 8 with ascrew driver or similar tool. Note the clearancebetween the bearing arm and guide casting (Fig. 8)just at the point where the valve has been closed bylifting up the bearing arm and the cutting headstops its descent. This clearance should be ,060” to.090”. If it is more than .090”, lengthen the linkageby loosening the locknut (Fig. 9) and turning thethreaded stud counterclockwise. Retighten thelocknut and check the clearance by repeating theprocedure. Repeat if necessary. If the clearance isless than .060”, loosen the locknut (Fig. 9) and turnthe threaded stud clockwise to shorten the linkage.Retighten the locknut and recheck the clearance.Repeat if necessary.

After adjustment has been completed, check to besure the back edge of the saw blade closes themetering valve before it contacts the guide casting.If the upper edge of the blade contacts the guidebody before it closes the metering valve, all cuttingforce control is lost and the machine will overfeed,stripping the teeth from the blade.

The metering valve may require adjustment of theminimum cutting force. With reference to Fig. 10,turn the cutting force thimble “D” completely upinto the valve body as shown. Next, adjust the selflocking nut “A” up or down on the threaded stem“B” until the spring “C” is just touching at eachend. Then turn nut “A” l/2 turn to tighten thespring. This adjustment establishes the minimumcutting force. If nut “A” is misadjusted toovertighten the spring, the minimum cutting forceis increased and can become high enough to stripteeth from the blade.

C. PREVENTIVE MAINTENANCE

A MONTHLY CHECK should be performed on themetering valve and guide rollers as follows:

( 1.) Open the cutting head control valve so the headcan descend slowly. Now pry up the blade back-uproller as illustrated in Fig. 8. The arm should raise.060” to .090” to close the metering valve and stopthe cutting head descent. If this test stops andholds the cutting head from descending, themetering valve is functioning properly.

(2,) A monthly check on the guide rollers can easilybe performed by twisting the blade near the sawguides. The guide rollers, when adjusted properly,will not allow any movement of the blade in thecutting area when twisted, but still must be looseenough to allow the blade to slide through asoutlined in Section A.

(3.) Check the blade to be sure it is vertical asshown in Fig. 7.

38

Fig. 8

Fig. 9

Fig. 10

(4.) These checks cover the most common main-tenance adjustments on a band saw machine. Ifthey are not performed regularly, good blade lifeand straight cuts cannot be achieved. They takeonly a few minutes and will assure that yourmachine will perform well.

D. PROBLEMS AND SUGGESTIONS

(1.) SAW NOT CUTTING STRAIGHT FROMTOP TO BOTTOM

A. The most common cause is loose blade guiderollers (Fig. 2) which allow the blade to “lean”from a vertical position, causing crooked cuts.See Section A for adjustments.

B. The saw blade guide casting is rotated so theblade is not held in a vertical position. SeeSection A for adjustment.

C. Long work piece is not being supportedhorizontally and level through the machine.

D. Check metering valve as outlined in Section C.

(2.) SAW NOT CUTTING STRAIGHT FROMSIDE TO SIDE

A. The saw vises are not at 90“ with the blade asillustrated in Fig. 5. See Section A for ad-justment.

B. Long work piece is not being positionedsquarely to the saw blade and flat against thesaw vise.

(3.) POOR BLADE LIFE

A. Metering valve is not closing completely,allowing the cutting head to slowly bleed down,overfeeding the blade. See Section B for ad-justment.

B. Blade guide rollers or carbides are too tightagainst the blade, preventing the blade frommoving up and down freely enough to operatethe metering valves.

C. Metering valve is dirty inside so that it cannotclose. Test as outlined in Section C.

(4.) CUTTING HEAD WILL NOT LOWER

A. The metering valve is held closed because theguide rollers are too tight and will not permitthe blade to move downward, opening thevalve.

B. Metering valve control rod is adjusted too long,stopping the valve from opening. See Section Bfor adjustment.

C. Metering valve is held closed by dirt or otherforeign material so that it cannot open. The dirtwill normally be lodged between the valve boreand valve spool, causing i t to becomeinoperative.

E. SPARE PARTS FOR MINIMUM DOWN-TIME.

F.

A.1.2.

B.

C.

D.

REPLACEMENT PARTS

Required for any part order:Saw model.Serial number.

Parts that can normally be obtained from localmill supply stores, etc., are not listed.

Parts not listed: Give a complete detaileddescription of what it is, where it is used, andwhat it does in operation. This will often give usenough information to supply the part.

This parts list does not show all the parts thatmake up the machine. We have tried to show allt h e c o m m o n p a r t s t h a t m a y r e q u i r ereplacement.

Also some parts may not be shown due tomachine design changes. When this occurs,order parts as described above.

39

SAW GUIDE PARTS

METERING VALVE PARTS

010329010331015030205090411030

411050411070411090411100411110411120411130411140411150415220

415220

415240

415300901200901500907006907011

CONNECTING RODSADDLE LINKMETERING VALVE ASSEMBLYTWO IDLER END CASTINGS ASSEMBLEDECCENTRIC BOLT FOR CONNECTING EITHERGUIDE TO GUIDE ARMBEARING ARM, IDLER ENDWORM SCREWSTRAIGHT BEARING BOLTCAM BEARING BOLTCAM BEARING BOLT NUTBEARING ARM, DRIVE ENDBEARING ARM PINBACK-UP BEARING BOLTBACK-UP BEARING WASHERCOMPLETE IDLER END GUIDE ASSEMBLYWITH BEARINGS AND BOLTSCOMPLETE IDLER END GUIDEASSEMBLY WITH BEARINGS AND BOLTS(205090 ASSEMBLY IS LESS BEARINGS AND BOLTS)COMPLETE DRIVE END GUIDE ASSEMBLYWITH BEARINGS AND BOLTS, NO SADDLE LINK PARTS.(415300 ASSEMBLY IS LESS BEARINGS AND BOLTS)TWO DRIVE END CASTINGS ASSEMBLEDBACK-UP BEARING ROLLERSIDE BEARING ROLLERIDLER END BACK-UP ARM SPRINGDRIVE END METERING VALVECUTTING FORCE SPRING

010323 VALVE BODY010324 NYLON VALVE PLUNGER010325 OVERRIDE SPRING CUP010326 CUTTING FORCE SPRING TUBE010327 TUBE NUT010328 CUTTING FORCE THIMBLE010332 DIAPHRAGM015030 COMPLETE METERING VALVE

ASSEMBLED907007 OVERRIDE SPRING907011 CUTTING FORCE SPRING

(NOT ILLUSTRATED)

40

41

BLADE BRUSH ASSEMBLY

411020 BRUSH BOLT411010 BRUSH HOUSING900083 WIRE BRUSH901200 BEARING

42

CUTTING FORCE CHECK BULLETIN NO. 900414

The hydraulic control system or spring balancemechanism of a band saw machine applies uniformlycontrolled pressure to the saw blade. After beingcleaned and adjusted, the machine must maintainan applied pressure at the saw blade of 50 lbs. or less.

If the band saw applies 50 lbs. of cutting pressure atthe minimum setting of the cutting pressure con-trol, the pressure can readily be increased as re-quired for heavier cutting. Excessive pressurecauses the blade to deflect or strip teeth.

For the cost of a bathroom scale (which is less thanthe cost of one saw blade), the actual applied cuttingpressure may be determined. To check the machine,stop the blade and lay the scale on the saw bed.

Place a block of wood on the scale and lower the sawblade onto the block. Repeatedly tap the saw bladelightly with a screw driver while lowering it. If thehydraulic system or spring balance mechanism isworking properly, a minimum setting on the cuttingpressure control will register 50 lbs. or less on thescale.

If the pressure on the scale continues to increase,this indicates either a leak in the hydraulic systemor improper adjustment. This must be correctedbefore the machine is operated. Unless the aboveprocedure is followed, applied pressure is unknownand the machine may destroy several blades beforethe problem is recognized.

43

BLADE ALIGNMENT CHECK BULLETIN NO. 900413

To check the vertical alignment of the band sawblade, raise the cutting head several inches abovethe bed. Place the contact point of a dial indicatoragainst the side of the blade, directly above thetooth gullet near the right guide assembly. Open thecontrol valve to allow the cutting head to descend,moving the blade slowly past the indicator point.Adjust the guide as required to align the blade towithin .005 T.I.R.

Raise the cutting head and move the indicator nearthe left guide assembly. Repeat the above pro-

cedure. If the left guide assembly requires morethan .010 T.I.R. adjustment to be within the .005T.I.R. allowance, recheck the right guide assembly.

This procedure should be used to check blade align-ment on all hinged, horizontal, or vertical cut-offmachines. It will eliminate problems normally causedby cutting head misalignment, bed twist, or operatorerror.

44

By Order of the Secretary of the Army:

Official:

ROBERT M. JOYCEBrigadier General United States Army

The Adjutant General

Distribution:

To be distributed in accordance with Special Distribution.

E. C. MEYERGeneral, United States Army

Chief of Staff

U.S. GOVERNMENT PRINTING OFFICE : 1992 0 - 311-831 (61610)

.

PIN : 051253 - 000

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