STALEX BS-115 User Manual

Horizontal and Vertical
Metal Cutting Band Saw
MODEL: BS-115
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1. Know your band saw. Read the operators Manual carefully. Learn the operations, applications and limitation.
2. Use recommended accessories. Improper accessories may be hazardous.
3. Wear proper apparel.
4. Keep unnecessary people away.
5. Dont overreach or stand on tool.
6. Avoid dangerous environment. Dont use band saw in damp or wet locations. Keep work area well lighted.
7. Keep work area clean. Cluttered and slippery floors invite accidents.
8. Remove adjusting keys and wrenches from band saw before turning on power.
9. Avoid accidental starting. Mark sure switch is off before plugging in power cord.
10. Dont force band saw. It is safe to operate at the cutting rate for which it was designed.
11. Be specially careful when using band saws in vertical position to keep fingers and hands out of the path of blade, both above and beneath the table.
12. Never hand hold the material with saw in horizontal position. Always use the vise, clamp securely.
13. Keep belt guard and wheel covers in place and in working order.
14. Support long, heavy work from the floor.
15. Always remember to switch off the machine when the work is completed.
16. Disconnect power cord before adjusting. Servicing and changing blade.
17. Check damaged parts. Damaged parts must be replaced or repaired.
18. Moving parts should keep in alignment. All adjustments are to be made with power disconnected.
19. Use a sharp blade and keep tool clean for best and safest performance.
20. Safety is a combination of operators common sense and alertness at all times when the saw is functioning.
21. Keeping the band saw in top condition is essential for safety.
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FEATURES
1. Special designed horizontal and vertical band saw.
2. Offers three speeds for cutting metal plastic or wood.
3. Shuts off automatically when material is cut.
4. With scale for the mitering vise.
5. No noise while operating.
6. Casters (optional) quick and easy moving.
SPECIFICATION
1. Capacity: 41/2’’ (115mm) round
4’’x6’’ (100mmx150mm) rectangular
2. Speeds: 80-120-200 FPM 60HZ (65-95-165 FPM 50HZ)
3. Motor: 1/3HP or 1/2HP 1700 RPM 60HZ (1400RPM 50 HZ)
4. Blades: 1/2’’x1/40’’x641/2’’ (12.5mmx0.64mmx1638mm)
5. Blades wheels: 73/8’’ (187mm) High strength flanged cast iron.
ASSEMBLY
1. Assemble stand legs on Band Saw Base. See assembly diagram
2. Assemble handle vice wheel, tighten set screw.
BLADE GUIDE BEARING ADJUSTMENT
This is the most important adjustment on your saw. It is impossible to get satisfactory work from your saw if the blade guides are not properly adjusted. The blade guide bearings for your Metal cutting Band saw are adjusted and power tested with several test cuts before leaving the factory to insure proper setting. The need for adjustment should rarely occur when the saw is used properly. If the guides to get out of adjustment, it is extremely important to readjust immediately. If proper adjustment is not maintained, the blade will not cut straight and if the situation is not corrected, it will cause blade damage. Because guide adjustment is a critical factor in the performance of your saw, it is always best to try a new blade to see if this will correct poor cutting before beginning to adjust the bearings. If a blade becomes dull on one side sooner than the other, for example, it will begin cutting crooked. A simple blade change should correct this problem-the more difficult guide adjustment will not. If a new blade does not correct the problem, check the blade guides for proper spacing.
There should be 0.001’’ clearance between the 0.025’’ thickness blade
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and guide bearing. To obtain this clearance adjust as follows:
1. The inner guide bearing is fixed and cannot be adjusted.
2. The outer guide bearing is mounted to an eccentric bolt and can be adjusted.
3. Loosen the nut while holding the bolt with a wrench.
4. Position the eccentric by turning the bolt to the desired position of clearance.
5. Tighten the nut
6. Adjust the second blade guide bearing in the same manner.
7. The back edge of the blade should just touch the lip of the Blade Guide Bearing.
BLADE GUIDE ASSEMBLY ADJUSTMENT
The Metal Cutting Band Saw is equipped with two adjustable blade guide assemblies. This feature will permit you to adjust the position of the blade guide for various widths work pieces. To effect the most accurate cut and prolong the life of the blade. The blade guide assemblies should be adjusted to just clear the piece to be cut. This is done as follows:
1. Place the work piece in the vise of band saw and clamp tightly.
2. Adjust catch blade guide assembly to the desired position by loosening the hand knobs and positioning the guides required.
3. Tighten the hand knobs.
ADJUSTING BLADE TENSION
1. Make sure the motor is shut off.
2. Press the blade lightly with left hand, make the rear blade against the flange of blade wheel and test the blade tension.
3. Adjust the blade tension adjustable knob with the Figure (1) Adjusting Blade Tension right hand until the blade obtain the proper tension.
CHANGING SPEED
1. When using your Band Saw, always change the blade speed to best
suit the material being cut. Cutting chart is shown in figure (2).
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2. Cut off power. Open the pulley guard cover. Loosen the lead screw
Material, Stainless or Alloy Steel, Bearing Bronzes/Mild Steel, Hard Brass or Bronze Soft Brass/Aluminum Other light materials
Speed (SFM) Belt Groove Used
60Hz
Motor Pulley
Saw Pulley
80FPM 120FPM 200FPM
Small Medium Large
Large Medium Small
(#98), you are now able to change the position of the belt to gain the desired speed. Check the belt tension as instructed before. When the tension the belt is well adjusted, lock the motor firmly. Close the pulley guard cover.
MATERIAL CUTTING CHART
Figure (2) Material Cutting Chart
BLADE SELECTION
1. Special note: 1(1/2’’ x 0.025’’x 641/2min, 651/2max) tooth per inch general use blade is furnished with the metal cutting Band Saw. Additional blades in 10 and 14 tooth sizes are available.
2. The choice of blade pitch is governed by the thickness of the work to be cut; the thinner the work piece, the more teeth advised. A minimum of 3 teeth should be in the work piece at all times for proper cutting.
3. If the teeth of the blade are so far apart that they straddle the work, server damage to the work piece and to the blade can result.
CHANGING BLADE
Raise saw head to vertical position. Loosen blade tension adjustable knob sufficiently to allow the saw blade to slip off the wheels. Install the new blade as follows:
1. Place the blade in between each of guide bearing.
2. Slip the blade around the motor pulley (bottom) with left hand and hold in position.
3. Hold the blade taut against the motor pulley by pulling the blade upward with the right hand which is placed at the top of the blade.
4. Remove left hand from bottom pulley and it s the top side of the blade to continue the application on the upward pull on the blade.
5. Remove right hand from blade and adjust the position of top pulley to
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permit left hand to slip the blade around the pulley using the thumb,
Step 1: Turn simultaneously with adjusting set screw to make the blade track against the shoulder of the pulley. To increase blade tension
Step 2: Loosen this hex. Head screw-before turning the adjusting set screw.
Step 4: Tighten after adjusting
Step 3: Turn simultaneously with
blade tension knob to make blade track against shoulder of pulley
Step 5: Adjust the blade adjustable seat according to the material size.
To relieve blade tension
The arrow indicates the moving direction
Step 6: Adjust guide assembly to where the blade just touches the back-up bearing.
index and little finger as guides.
6. Adjust the blade tension knob clockwise until it is just right enough so no blade slippage occurs. Do not tighten excessively.
7. Place 2-3 drops of oil on the blade.
8. Replace the blade guard.
ADJUSTING THE BLADE TRACKING
This adjusting has been completed and power-tested at the factory. The need for adjusting should rarely occur when the saw is used properly. If the tracking goes out of adjusting is listed below:
Figure (3)
HORIZONTAL CUTTING OPERATION
Before operating, please read instruction manual and examine every part including speed, Blade selection, guide assemble position, etc. Operation is as follows:
WORK SET UP
1. Raise the saw head to the vertical position.
2. Open the vise to accept the piece to be cut by rotating the wheel at the end of base (counter clockwise).
3. Place the work piece on the saw bed. If the price is long, support the end.
4. Clamp the work piece securely in the vise by rotating the hand wheel clockwise.
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CUTTING
Close switch, letting the head down slowly onto the work, Do not drop or force. Let the weight of the saw head provide the cutting force. The saw automatically shuts off at end of the cut. Method of adjusting blade: A. Loosen the screw #11. B. Adjust the blade adjustable seat #64 to make the blade vertical to bed. C. Place the square on the bed to check if the blade is vertical, if not, repeat the process A to C. D. Tighten the screw #11.
Figure (4)
Adjusting the blade
LUBRICATION
Lubricate the following components using lubricant, L-HV32
1. Ball bearing –none.
2. Blade guide bearing-none
3. Driven wheel bearing-none.
4. Vise lead screw- as needed.
5. The driven gears run in the bath and will not require a lubricant change more than then once a year. When needing a change, first put down the bead to a Horizontal position, then loosen 4 screw (#75) of the gear box open the cover (#93). Placing a pan under the tight lower corner of the gear box, slowly raise the head until the oil flows out, Lower corner of the gear box, slowly raise the head until the oil flows out, Lower head. Then wipe up excess oil and foreign matter with soft rags. Then add lubricant into the box until it is full and not flow over. Close the cover, tighten 4 screws.
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THE VERTIACAL CUTTING PLATE ASSEMBLY DRAWING.
Plate
Vertical cutting plate stand
Steps for assembling:
1. Loosen the A.B.C. three screws from the blade guide. And take away the part “D”
2. To lock the vertical cutting plate stand on the valve.
3. To put the plate on the guide and vertical cutting plate stand, then lock the A.B.C. three screws.
4. Please operate the vertical cutting.
5. Use the miter gauge in the work table grooves to obtain any angle up to 45 degree either left or right.
CAUTION-The use of any other accessories may be hazardous. CAUTION-Always use push sticks particularly when cutting small pieces.
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1. Hexagon head screw
8PCS
2. Washer
16PCS
3. V. shape fixed plate
4PCS
4. Hexagon nut
8PCS
The manual of V shape fixed plate
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TROUBLE SHOOTING CHART
Symptom
Possible Cause (s)
Corrective Action
Excessive Blade Breakage
1. Material loose in vise
2. Incorrect speed or feed
3. Blade teeth spacing too large
4. Material too coarse
5. Incorrect blade tension
6. Teeth in contact with
material before saw is started
7. Blade rubs on wheel flange
8. Misaligned guide bearings
9. Cracking at weld
1. Clamp work securely
2. Adjust speed or feed
3. Replace with a small teeth
spacing blade
4. Use a blade of slow speed
and small teeth spacing
5. Adjust where blade just
does not slip on wheel
6. Place blade in correct with
work after motor is started
7. Adjust wheel alignment
8. Adjust guide bearings
9. Weld again, note the weld
skill
Premature Blade Dulling
1. Teeth too coarse
2. Too much speed
3. Inadequate feed pressure
4. Hard spots or scale on
material
5. Work hardening of
material
6. Blade twist
7. Insufficient blade
1. Use finer teeth
2. Decrease speed
3. Decrease spring tension
on side of saw
4. Reduce speed, in crease
feed pressure
5. Increase feed pressure by
reducing spring tension
6. Replace with a new blade,
and adjust blade tension
7. Tighten blade tension
adjustable knob
Unusual Wear on Side/Back of Blade
1. Blade guides worn
2. Blade guide bearings not
adjusted properly
3. Blade guide bearing
bracket is loose
1. Replace
2. Adjust as per operators
manual
3. Tighten
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Symptom
Possible Cause (s)
Corrective Action
Teeth Ripping from Blade
1. Tooth too coarse for work
2. Too heavy pressure, too
slow speed
3. Vibrating work piece
4. Gullets loading
1. Use finer tooth blade
2. Decrease pressure,
increase speed
3. Clamp work piece
securely
4. Use coarse tooth blade or
brush to remove chips
Motor running too hot
1. Blade tension too high
2. Drive belt tension too high
3. Gears need lubrication
4. Cut is binding blade
5. Gears aligned improperly
1. Reduce tension on blade
2. Reduce tension on drive
belt
3. Check oil bath
4. Decrease feed and speed
5. Adjust gears so that worm
is in center of gear
Bad Cuts
1. Feed pressure too great
2. Guide bearing not
adjusted properly
3. Inadequate blade tension
4. Dull blade
5. Speed incorrect
6. Blade guide spaced out
too much
7. Blade guide assembly
loose
8. Blade truck too far away
from wheel flanges
1. Reduce pressure by
increasing spring tension on side of saw
2. Adjust guide bearing, the
clearance can not be greater than 0.001mm
3. Increase blade tension by
adjust blade tension
4. Replace blade
5. Adjust speed
6. Adjust guides space
7. Tighten
8. Re-track blade according
to operating instructions
Bad Cuts (Rough)
1. Too much speed or feed
2. Blade is too coarse
3. Blade tension loose
1. Decrease speed or feed
2. Replace with finer blade
3. Adjust blade tension
Blade is twisting
1. Cut is binding blade
2. Too much blade tension
1. Decrease feed pressure
2. Decrease blade tension
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Parts No.
Description
Quantity required
1 2 3 4 5
6 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 30 32 33 34 35 36 37 39 40 43 44 45 46 47 48 49 50
Hexagon head screw Hexagon nut Washer Floor stand (right) Wheel assay (optional) Cotter pin Hexagon head screw Hexagon nut Floor stand (left) Floor stand handle (optional) Adjusting rod Electric cord Pivoting rod Support plate Stock stop Hexagon socket headless screw Stock stop rod Wire relief retainer Switch Hexagon nut Switch panel Adjusting rod support Hand wheel Thrust washer Lead screw Vise nut Movable vise plate Washer Hexagon head screw Bed Scale Electric cord cover Rubber ring Electric cord Nut plate Spring adjusting screw Spring Screw Mitering vise plate Hexagon head screw
2 2 4 1 1
2 13 10
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
4
1
1
PARTS LIST
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Parts No.
Description
Quantity required
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 75 76 77 79 80 81 83 84 85 86 87 88 89 90 91 92 93 94 96 98
99 100 101 103
Washer Hexagon head screw Hexagon head screw Pivot Vertical cutting plate Vertical cutting plate stand Adjustable bracket (left) Plum screw Blade back safety cover Thrust washer Bearing Guide pivot Bearing shaft pin Blade adjustable seat Adjustable bracket (right) Blade roller bearing guide adjustable lock Spring washer Screw Blade guard Hexagon nut Blade wheel (front) Blade wheel bearing cover Key Hexagon head screw Switch cut off tip Blade wheel (rear) Blade tension adjustable knob Spring Body frame Hexagon head screw Motor mount plate Motor Motor pulley Ball bearing Bearing bushing Oil seal Transmission wheel shaft Transmission gear Gear box gasket Gear box cover Worm gear Bearing bushing Plum screw Washer Screw Worm gear pulley Blade tension sliding plate
5 4 1 1 1 1 1 1 1 4 6 4 2 2 1 2 2 5 1 4 1 1 5 1 1 1 1 1 1 2 1 1 1 4 1 2 1 1 1 1 2 1 1 1 6 1 1
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Parts No.
Description
Quantity required
104 105 106 107 108 109 110 112 113 114 117 118 120 121 122 126 131 132 134 140 156 157 169 170 171 172 173 174 175 176
Hexagon socket headless screw Spring pin Sliding plate draw block Blade wheel shaft Shaft block Blade tension sliding guides Motor pulley cover Belt Blade Washer Washer Thrust washer Bearing Round head cross socket screw Hexagon nut Bushing Switch protection bracket Blade safe guard Screw Hexagon nut Round head cross socket screw Star washer Cross socket screw Tool plate Hexagon head screw Hexagon nut Washer Wheel stand Cotter pin Axle
2 1 1 1 1 2 1 1 2 2 1 1 1 1 3 1 1 2 4 4 3 1 2 1 4 4 4 1 4 1
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Part Assembly Drawing
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