STARTRITE 403, 603, 503 Original Instruction Manual

403 16" Trade Bandsaw 503 20" Trade Bandsaw 603 24" Trade Bandsaw

Original Instruction Manual

Important

For your safety read instructions carefully before assembling or using this product.

Save this manual for future reference.

Always wear safety glasses when using woodworking equipment.

Always read the instructions provided before using woodworking equipment.

Version 3.4

December 2017

Contents

1 Explanation of Symbols

2 General Health and Safety Guidance

3 Additional Health and Safety Guidance for Bandsaws

4 Features of the 403, 503 and 603 Bandsaws

5 Speciﬁcations

6 Dust Extraction

7 Installation and Operation

8 Operation and Bandsawing Practice

9 Maintenance

10 Troubleshooting

11 Parts Lists and Diagrams - 403/UK1 and 403/UK3

12 Parts Lists and Diagrams - 503/UK3

13 Parts Lists and Diagrams - 603/UK3

14 Electrical Connection and Wiring Diagrams

EU Declaration of Conformity

THE SYMBOLS AND THEIR MEANINGS SHOWN BELOW MAY BE USED THROUGHOUT THIS MANUAL. PLEASE ENSURE THAT YOU TAKE THE APPROPRIATE ACTION WHEREVER THE WARNINGS ARE USED.

1. Explanation of Symbols

Mandatory

Instructions

Warning

Read and fully understand the instruction manual before attempting to use the machine.

Indicates an instruction that requires particular attention

Wear protective eyewear

Use respiratory protective equipment

Use suitable protective footwear

Use hearing protection

Use protective work gloves

Indicates a risk of severe personal injury or damage to the machine

Indicates a risk of severe personal injury from electrical shock

Risk of personal injury from lifting of heavy items

Indicates a risk of severe personal injury from airborne objects

Risk of ﬁre

2. General Health and Safety Guidance

Ensure that you carefully read and fully understand the instructions in this manual before assembly, installation and use of this product. Keep these instructions in a safe place for future reference.

WARNING: for your own safety, do not attempt to operate this machine

until it is completely assembled and installed according to these instructions.

WARNING: When using any machine, basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury.

Safe Operation

1. Use Personal Protective Equipment (PPE)

• The operation of any machine can result in foreign objects being thrown into your eyes, which can result in severe eye damage. Protective eyewear or other suitable eye protection or face shield should be used at all times. Everyday spectacles only have impact resistant lenses. They are not protective eyewear and do not give additional lateral protection.

• Use respiratory protective equipment (dust mask etc.) if the machining operation creates dust. Exposure to high levels of dust created by machining hardwoods, softwoods and man made composite boards can result in serious health problems. Some imported hardwoods give off highly irritating dust, which can cause a burning sensation. The use of respiratory protective equipment should not be seen as an alternative to controlling the risk of exposure at source by using adequate dust extraction equipment.

• The use of ear plugs or ear defenders is recommended when the machine is in use, particularly if the noise level exceeds 85 dB.

• Wear suitable protective gloves when handling cutting tools or blades. Gloves should NOT be worn when using the machine as they can be caught in moving parts of the machine.

• Non-slip safety footwear is recommended when using the machine and handling large work pieces.

2. Dress appropriately

• Do not wear loose clothing, neckties or jewellery; they can be caught in moving parts of the machine.

• Roll up long sleeves above the elbow.

• Wear protective hair covering to contain long hair.

3. Safety warnings

• Find and read any warning labels on the machine

• It is important that any labels bearing health and safety warnings are not removed, defaced or covered. Replacement labels can be obtained by contacting our Customer Service Department.

4. Familiarise yourself with the machine

• If you are not thoroughly familiar with the operation of this machine, obtain advice from your supervisor, instructor, or other qualified person or contact your retailer for information on training courses. Do not use this machine until adequate training has been undertaken.

5. Take care when moving or positioning the machine

• Some machines can be very heavy. Ensure the floor of the area in which the machine is to be used is capable of supporting the machine.

• The machine and its various components can be heavy. Always adopt a safe lifting technique and seek assistance when lifting heavy components. In some cases it may be necessary to use mechanical handling equipment to position the machine within the work area.

• Some machines have optional wheel kits available to allow them to be manoeuvred around the workshop as required. Care should be taken to install these according to the instructions provided.

• Due to the nature of the design of some machines the centre of gravity will be high making them unstable when moved. Extreme care should be taken when moving any machine.

• If transportation of the machine is required then all precautions relating

to the installation and handling of the machine apply. In addition, ensure that any vehicles or manual handling equipment used for transportation

are of adequate specification.

6. The machine should be level and stable at all times

• When using a leg stand or cabinet base that is designed to be fitted to the machine, always ensure that it is securely fastened to the machine using the fixings provided.

• If the machine is suitable to be used on a workbench, ensure that the workbench is well constructed and capable of withstanding the weight of the machine. The machine should always be securely fastened to the workbench with appropriate fixings.

• Where possible, floor standing machines should always be secured to the floor with fixings appropriate to the structure of the floor.

• The floor surface should be sound and level. All of the feet of the machine should make contact with the floor surface. If they do not, either re-locate the machine to a more suitable position or use packing shims between the feet and the floor surface to ensure the machine is stable.

7. Remove adjusting keys and wrenches

• Ensure that all adjusting wrenches and keys are removed before switching the machine ‘ON’. There is a risk of severe personal injury or damage to the machine from airborne objects.

8. Before switching the machine ‘ON’

• Clear the machine table of all objects (tools, scrap pieces etc.)

• Make sure there is no debris between the work piece and the table / work support.

• Ensure that the work piece is not pressed against, or touching the saw blade or cutting tool.

• Check all clamps, work holding devices and fences to ensure that they are secure and cannot move during machining operations.

• Plan the way that you will hold and feed the work piece for the entire machining operation.

9. Whilst machining

• Before starting work, watch the machine while it runs. If it makes an unfamiliar noise or vibrates excessively, switch the machine ‘OFF’ immediately and disconnect it from the power supply. Do not restart until finding and correcting the source of the problem.

10. Keep the work area clear

• Working clearances can be thought of as the distances between machines and obstacles that allow safe operation of every machine without limitation. Consider existing and anticipated machine needs, size of material to be processed through each machine and space for auxiliary stands and/or work tables. Also consider the relative position of each machine to one another for efficient material handling. Be sure to allow yourself sufficient room to safely operate your machines in any foreseeable operation.

• Cluttered work areas and benches create the risk of accidents. Keep benches clear and tidy away tools that are not in use.

• Ensure that the floor area is kept clean and clear of any dust and debris that may create trip or slip hazards.

11. Consider the work area environment

• Do not expose the machine to rain or damp conditions.

• Keep the work area well lit and ensure that there is artificial lighting available when there is insufficient natural light to effectively light the work area. Lighting should be bright enough to eliminate shadow and prevent eye strain.

• Do not use the machine in explosive environments eg. in the presence of flammable liquids, gases or dust.

• The presence of high levels of dust created by machining wood can present a risk of fire or explosion. Always use dust extraction equipment to minimise the risk.

12. Keep other persons away (and pets)

• The machine is designed to be used by one person only.

• Do not let persons, especially children, touch the machine or extension cable (if used) and keep visitors away from the work area.

• Never leave the machine running unattended. Turn the power supply off and do not leave the machine unattended until it comes to a

2. General Health and Safety Guidance

complete stop.

• If the work area is to be left unattended, all machinery should be switched ‘OFF’ and isolated from the mains power supply.

13. Store machines safely when not in use

• When not in use, machines should be stored in a dry place, out of reach of children. Do not allow persons unfamiliar with these instructions or with the machine to operate it.

14. Do not overreach

• Choose a working position that allows your body to remain balanced and feed the work piece in to the machine without overreaching.

• Keep proper footing and balance at all times.

15. Electrical supply

• Electrical circuits should be dedicated to each machine or large enough to handle combined motor amp loads. Power outlets should be located near each machine so that power or extension cables are not obstructing hightraffic areas. Observe local electrical guidelines for proper installation of new lighting, power outlets, or circuits.

• The machine must be connected to an earthed power supply.

• The power supply must be equipped with a circuit breaker that provides short circuit, overload and earth leakage protection.

• The voltage of the machine must correspond to the voltage of the mains power supply.

• The mains plug fitted to the machine should always match the power outlet. Do not modify the plug in any way. If a replacement plug is required it should be fitted by a competent person and of the correct type and rating for the machine.

• If you are unsure about any electrical connections always consult a qualified electrician.

16. Avoid unintentional starting of the machine

• Most machines are fitted with a no-volt release (NVR) switch to prevent unintentional starting. If in doubt always ensure the machine switch is in the ‘OFF’ position before connecting it to the power supply. This means the machine will not automatically start up after a power cut or switching on of the power supply, unless you first reset the start switch.

17. Outdoor use

• Your machine should not be used outdoors.

18. Extension cables

• Whenever possible, the use of extension cables is not recommended. If the use of an extension cable is unavoidable, then it should have a minimum core cross section of 2.5 mm² and limited to a maximum length of 3 metres.

• Extension cables should be routed away from the direct working area to prevent a trip hazard.

19. Guard against electric shock

• Avoid body contact with earthed or grounded surfaces such as pipes and radiators. There is an increased risk of electric shock if your body is earthed or grounded.

20. Always work within the machine’s intended capacities

• Operator safety and machine performance are seriously adversely affected if attempts to make the machine perform beyond its limits are made.

21. Do not abuse the power cable

• Never pull the power cable to disconnect it from the power socket. Always use the plug.

• Keep the power cable away from heat, oil and sharp edges.

• Do not use the power cable for carrying or moving the machine.

22. Secure the work piece

• Ensure that the work piece is securely held before starting to machine it.

• When working within 300 mm of the machining area, always use a push stick to feed the work piece in to the blade or cutting tool. The push stick should have a minimum length of 400 mm. If the push stick becomes damaged, replace it immediately.

• Use extra supports (roller support stands etc.) for any work pieces large enough to tip when not held down to the table top.

• Do not use another person as a substitute for a table extension, or as additional support for a work piece that is longer or wider than the basic table, or to help feed, support, or pull the work piece.

• Do not attempt to machine more than one work piece at a time.

• When feeding the work piece towards the blade or cutting tool never position your hands in direct line of the cutting path. Avoid awkward operations and hand positions where a sudden slip could cause your hand or fingers to move into the machining area.

23. Stay alert

• Safety is a combination of operator common sense and alertness at all times when the machine is being used.

• Use all machines with extreme care and do not use the machine when you are tired or under the influence of drugs, alcohol or medication.

24. Use the correct tool for the job

• Do not use the machine for any purpose other than which it was designed.

• When selecting replacement cutting tools and blades, always ensure that they are designed to cut the material that you intend to use them for. If in any doubt seek further advice from the manufacturer.

25. Connect dust extraction equipment

• Always use dust extraction equipment. The dust extractor should be of suitable size and capacity for the machine that it is connected to and have a filtration level appropriate to the type of waste being collected. Refer to the relevant section of the manual for details of the specific dust extraction requirements for this machine.

• The dust extractor should be switched ‘ON’ before starting the machine that it is connected to. The dust extractor should be left running for 30 seconds after the last machining operation is complete in order to clear any residual waste from the machine.

26. Ensure that the machine is correctly guarded

• Never use the machine if any of the standard safety guards and equipment are removed or damaged.

• Some machines incorporate safety interlocks to prevent the machine from being used without the guards in place. Never attempt to bypass or modify the interlocks to allow the machine to be used without the guards in place.

27. Maintain your machine with care

• This manual gives clear instructions on installation, set up and operation of the machine and also details any routine and preventative maintenance that should be performed periodically by the user.

• Remember always to switch off and unplug the machine from the power supply before carrying out any setting up or maintenance operations.

• Follow any instructions for the maintenance of accessories and consumables.

• Do not use compressed air to clean the machine. Always use a brush to dislodge dust in places that are awkward to reach and a dust extractor to collect the waste.

• Inspect electric cables periodically and, if damaged, have them replaced by an authorised service facility or qualified electrician.

• Inspect extension cables (if used) periodically and replace if damaged.

28. Keep cutting tools sharp and clean

• Correctly maintained cutting tools are easier to control and less likely to bind.

• Cutting tools and blades can become hot during use. Take extreme care when handling them and always allow them to cool before changing, adjusting or sharpening them.

29. Disconnect the machine from the power supply

• When not in use, before servicing, changing blades etc. always disconnect the machine from the power supply.

30. Check for damaged parts

• Before each use of the machine, it should be carefully checked to determine that it will operate properly and perform its intended function.

• Check for alignment of moving parts, binding of moving parts, breakage

2. General Health and Safety Guidance

of parts and any other conditions that may affect the operation of the machine.

• A guard or other part that is damaged should be properly repaired or replaced by a qualified person unless otherwise indicated in this instruction manual.

• Do not use the machine if the switch does not turn the machine ‘ON’ and ‘OFF’.

• Have defective switches replaced by a qualified person.

31. Warning!

• The use of any accessory or attachment, other than those recommended in this instruction manual, or recommended by our Company may present a risk of personal injury or damage to the machine and invalidation of

the warranty.

32. Have your machine repaired by a qualified person

• This machine complies with the relevant safety rules and standards appropriate to its type when used in accordance with these instructions and with all of the standard safety guards and equipment in place. Only qualified persons using original spare parts should carry out repairs. Failure to do this may result in considerable danger to the user and invalidation of warranty.

33. Caution! Motor may become hot during use

• It is normal for motors on some machines to become hot to the touch

during use. Avoid touching the motor directly when in use.

Safe Operation

1. Familiarise yourself with the machine

• Machining operations using bandsaws have a history of serious accidents. Most result from contact with the moving blade while presenting material to the blade or moving it from the table. Other minor accidents can occur whilst setting, cleaning, adjusting or maintaining the machine.

• The machine is designed for cutting wood and composite board (plywood, MDF etc.). Certain plastics can also be cut using a suitable blade.

2. Before switching the machine ‘ON’

• Ensure that the blade is correctly tensioned and aligned on the bandwheels and the blade guides are correctly adjusted.

• Ensure that the teeth of the blade are pointing downwards.

• Check the condition of the blade to ensure that no teeth are missing, damaged or deformed and the blade is not cracked or split. If any of these conditions apply, replace the blade immediately.

• Ensure that the saw blade type and width are suitable for the material to be cut.

• Check that the blade width is within the minimum and maximum permitted on the machine and that the thickness of the blade is suitable for the diameter of the wheel.

• Some machines have more than one cutting speed. For most wood cutting applications the faster of the speeds should be used.

• Check the condition of the table insert. Replace it immediately if it is damaged or showing signs of wear.

• Adjust the guard as close as possible to the work piece being cut.

• Check that access doors are fully closed and that the latches are secure.

3. Whilst machining

• Never apply sideways pressure to the blade as this may cause the blade to break.

• Care must be taken when cutting wood with knots, nails or cracks in it and / or dirt on it, as these can cause the blade to get stuck. If this happens, switch the machine ‘OFF’ immediately and follow the procedure detailed in the manual to remove the blade from the work piece.

• If cutting cylindrical timber use a suitable jig to prevent twisting of the

work piece.

4. This machine falls under the scope of the ‘Health and Safety at Work

etc. Act 1974’, and the ‘Provision and Use of Work Equipment Regulations 1998’. In addition the elimination or control of risks from wood dust is included in the above regulations and the ‘Control of Substances Hazardous to Health (COSHH) Regulations 2002’. We recommend that you study and follow these regulations.

Further guidance can be found in the ‘Safety in the use of narrow bandsaws – Woodworking sheet No.31’ and the ‘Safe use of woodworking machinery’ code of practice booklet (L114) published by Health and Safety Executive and available from their website www.hse.gov.uk.

3. Additional Health and Safety Guidance for Bandsaws

4. Features of the 403, 503 and 603 Bandsaws

1 Upper wheel 2 Upper guide lifting handwheel 3 Upper guide 4 Rip fence assembly 5 Table 6 Dust port 7 Lower wheel 8 Lower door 9 Switch with electric brake 10 Upper door

Model 403/UK1 403/UK3 503/UK3 603/UK3 Motor voltage 230 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz Current 9 A 4.8 A 7 A 8.2 A Motor power output 1.5 kW 2.2 kW 3 kW 4 kW Blade length 3531 mm 3531 mm 3962mm 4470 mm Blade width 6 - 30 mm 6 - 30 mm 6 - 30 mm 10 - 35 mm Max. cut depth 280 mm 280 mm 335 mm 370 mm Throat width 390 mm 390 mm 480 mm 580 mm Blade speed 1100 m/min 1100 m/min 1500 m/min 1500 m/min Table size 578 x 420 mm 578 x 420 mm 633 x 485 mm 700 x 608 mm Table tilt 0 - 45° 0 - 45° 0 - 45° 0 - 22.5º Dust port diameter 100 mm 100 mm 100 mm 100 mm Weight 166 kg 166 kg 227 kg 342 kg

5. Specifications

No Load Load Sound Pressure Level < 80 dB(A) < 90 dB(A) Sound Power Level < 90 dB(A) < 100 dB(A)

6. Dust Extraction

The Importance of Dust Extraction Suitable dust extraction is essential to avoid the possibility of serious health problems related to wood dust. It is also necessary in order to ensure the waste producing machine performs safely and effectively. Some woods are extremely toxic and in addition to suitable dust extraction machines it is recommended that PPE such as respirators are also used.

Record Power Dust Extraction Machines Below is a summary of the Record Power range. Please visit your local stockist or go online for full details.

DX1000 Fine Filter 45 Litre Extractor 45 litre capacity, 1 kW motor, 0.5 micron filtration. Includes hose.

RSDE1 Fine Filter 45 Litre Extractor 45 litre capacity, 1 kW motor, 0.5 micron filtration. Includes hose.

RSDE/2 Fine Filter 50 Litre Extractor with Accessories 50 litre capacity, 1 kW motor, 0.5 micron filtration, includes wheel kit, hose cuff power tool adaptor hose and spare filter bags. Includes hose.

RSDE/2A Fine Filter Auto-Switching 50 Litre Extractor with Accessories

50 litre capacity, 1 kW motor, 0.5 micron filtration, includes wheel kit, hose cuff power tool adaptor hose and spare filter bags. Includes hose.

DX4000 Fine Filter Twin Motor 80 Litre Extractor 80 litre capacity, 2 x 1 kW motors, 0.5 micron filtration. Includes hose.

DX5000 Fine Filter Twin Motor 200 Litre Extractor 200 litre capacity, 2 x 1 kW motors, 0.5 micron filtration. Includes hose.

CGV286 CamVac Series Compact Extractor 36 litre capacity, 1 kW motor single or twin, 0.5 micron filtration.

CGV286-WALL CamVac Series Wall Mounted Extractor 150 litre capacity, 1 kW motor single or twin, 0.5 micron filtration.

CGV336 CamVac Series Medium Extractor 55 litre capacity, 1 kW motor single or twin, 0.5 micron filtration.

CGV386 CamVac Series Large Extractor 90 litre capacity, 1 kW motor twin or triple, 0.5 micron filtration.

CGV486 CamVac Series Heavy Duty Extractor 200 litre capacity, 1 kW triple motor, 0.5 micron filtration.

CX2000 Compact Chip Collector 54 litre capacity, 0.56 kW motor. Includes hose.

CX2500 80 Litre Chip Collector 80 litre capacity, 0.55 kW motor. Includes hose.

CX3000 Heavy Duty Chip Collector 128 litre capacity, 0.56 kW motor. Includes hose.

AC400 2 Stage Air filter with Remote, 3 speeds and Time Delay Collects airborne dust, 1 micron filtration.

Bandsaws Table Saws

Planer Thicknessers

Dust Extraction SystemsLathes

Sanding Machines

Airborne Dust Collection

DX1000

RSDE1

RSDE/2

RSDE/2A

DX4000

DX5000

CGV286

CGV286-WALL

CGV336

CGV386

CGV486

CX2000

CX2500

CX3000

AC400

Recommended for heavy use

Recommended for light / intermittent use

Can be used

6. Dust Extraction

All bandsaws should be used only with suitable dust extraction equipment connected.

The minimum advisable air speed is 20 m/s for wood with a humidity of less than 12%. For wood with greater humidity it is advisable to increase the air speed to 25-28 m/s.

Capacity: Approximately 600 m3/h.

Pressure drop at each dust extraction connection outlet at the conveying air velocity: 530 Pa.

7. Installation and Operation

Installation Zone Characteristics

It is prohibited to install the machine in explosive environments.

The installation zone must be selected evaluating the work space required depending on the dimension of the pieces to be machined,and taking into account that a free space of at least 800 mm must be left around the machine.It is also necessary to check The floor capacity and its surface, so that the machine base is evenly resting on its four supports.A power outlet and a chip-suction system connection shall be closeto the selected machine setting and it must be conveniently lighted.

Lifting The machine can be lifted using a fork-lift truck, placing the forks under the feet or by using a “SLING”, as shown in Fig 7.1, with a lifting capability of 2000 Kg.

Positioning The Machine

For correct and rational organisation of the work area:

• Install the machine in an area that will not amplify vibration or noise

• Verify that the work area is adequately illuminated.

• When placed between other machinery there should be a space of at least 80 cm. It is necessary to anticipate sufficient space for cutting long work pieces traversly and for the fitting of rollers or other types of support,in front and at the rear of the table.

There are four holes for fixing the machine to the floor. When fixing to the floor it is recommended not to over tighten the fixtures to avoid increasing vibration.It is also advisable to place anti-vibration materials between the floor and the feet of the machine.

Sling 2000 kg

Timber

Fig 7.1

WARNING

Fig 7.2

Blade Mounting and Adjustment

Before fitting the blade ensure that the machine is unplugged from the power supply. Turn the brake off to allow manual movement of the band wheels.

To mount the blade first remove the table insert (Fig 7.2, A) Place the blade onto the bandwheel checking the teeth are in a correct position, and then tighten the tension using the handwheel (Fig 7.3, A). The correct tension value is indicated on the tension scale inside the upper door, the indicated value corresponds to the width of the blade.

Turn the bandwheels manually, checking that the blade does not interfere with any fixed parts and that the blade is placed correctly on the bandwheels. The points of the teeth should slightly protrude over the edge of the bandwheels. To adjust the blade position on the bandwheels slacken the locking lever (Fig 7.3, B), and then turn the knob (Fig 7.3, C): the blade will move inwards when turn the knob clockwise and the blade will move further out when turn the knob anticlockwise; A quarter of one circle is sufficient to make a noticeable displacement. Tighten the locking lever after the blade is positioned correctly.

Reinstall the table insert, close the band wheels accessing doors.

After use we recommend slackening the blade tension, and to display a visible sign on the machine advising of this procedure. Remeber to check and re-tension before use. This operation prevents damage to the bandwheel tyres.

Setting the Blade Guard and Guides

Adjusting the Saw Blade Guard

The adjustable saw band guard should be positioned as close as possible to the work piece. To adjust the height, release the locking knob (Fig 7.3, D) and turn the hand wheel (Fig 7.3, E) to move the guard up or down. Lock the knob once the correct guard position is obtained. This operation must always be carried out when the machine has stopped.

Roller Bearings Blade Guide

7.4. Once they have been adjusted, tighten screw A. They should be 2 mm

behind the teeth of the blade. The rear bearing prevents excessive backward movement of the blade during operation and should be 1 - 2 mm from the back of the blade. This can be adjusted using screw B of Fig 7.4.

Lower Saw Blade Guide

The roller bearings should be positioned as close to the blade as possible but without touching it, to help maintain the correct cutting direction during use. The positioning of these rollers is controlled by screw A of Fig 7.5. Once adjusted, tighten screw A. They should be 2 mm behind the teeth of the blade. The thrust shaft prevents excessive backwards movement of the blade during operation and should be 1 - 2 mm from the back of the blade. This can be adjusted using screw B of Fig 7.5.

CAUTION

Fig 7.3

Fig 7.5

Fig.4.4.1

Fig.4.4.2

Fig.4.5.1

Fig 7.4

Fig.4.4.1

Fig.4.4.2

7. Installation and Operation

Fig 7.6

Tilting The Work Table of the 403 and 503

The table may be set at 90º to the blade by adjusting the table stop screw beneath the table. The table stop screw rests on the top of the lower wheel bandwheel housing. By first slackening the locking nut A of Fig 7.6 and then adjusting the screw B of Fig 7.6, the table can be set correctly. Retighten the locking nut A making sure that the setting is maintained.

To make adjustments of table tilting, slackening the locking handle D of Fig

7.6 and rotate the shaft C of Fig 7.6 with the special handle found in the loose parts bag supplied with the machine. When adjustment is complete, tighten the handle D of Fig 7.6 to lock it.

Tilting the Work Table of the 603

The table may be set at 90º to the blade by adjusting the table stop screw beneath the table. The table stop screw rests on the top of the lower wheel bandwheel housing. By first slackening the locking nut A of Fig 7.7 and then adjusting the screw B of Fig 7.7, the table can be set correctly. Retighten the locking nut A making sure that the setting is maintained.

To make adjustments of table tilting, slackening bolt C of Fig 7.7. When adjustment is correctly finished, tighten the handle D of Fig 7.7 to lock it.

Operating the Bandsaw

Before attempting to start the bandsaw ensure the emergency stop switch is not in the depressed position. If necessary, unlock the switch with the key.

Ensure the brake switch is in the ON position as shown in Fig 7.8 then press the on button.

To stop the bandsaw press either the off button or the emergency stop button.

If the bandsaw is stopped using the emergency stop button the key must be used to unlock it from the depressed position.

Prevention of Unauthorised Use

To prevent the bandsaw being used without authorisation, depress the emergency stop button and remove the key.

On button

Off button

Emergency stop button

Brake switch

Fig 7.7

Fig 7.8

7. Installation and Operation

8. Operation and Bandsawing Practice

Basic Bandsawing Principles

• The blade cuts on a continuous down stroke.

• Slowly feed the workpiece towards the blade, using only light pressure whilst letting the blade do the cutting. Always use a push stick and take care.

• Firmly hold the workpiece and feed it towards the blade slowly, using the push stick and keeping your hands well away from the blade.

• For best results the blade must be sharp. Damaged or worn blades should always be replaced.

• Select the correct blade for the job, depending on the thickness of the wood and the cut to be made (see blade selection).

• For straight cutting use the rip fence supplied.

• When cutting shapes, follow the design marked out by pushing and turning the workpiece evenly. Do not attempt to turn the workpiece without pushing it, as this may cause the workpiece to get stuck, or the blade to bend.

CAUTION! Particular care should be taken towards the end of the cut as there will be a sudden decrease in resistance and care must be taken to stop hands from being thrown towards the blade. Always use a push stick.

Always ensure that your machine is properly maintained and clean. Before commencing work on an important project, it is advisable to familiarise yourself with the operation of the equipment by practising on low value or scrap materials.

Complicated Cutting

Very complicated cuts and small radius curves are the best accomplished with the aid of pre-drilled holes combined with a few tangential or radial cuts. This technique will achieve excellent results without putting undue tension on the blade and blade guide assembly.

WARNING! In circumstances such as cutting deep or wet timber, the work piece may close up behind the blade causing it to stall. In the event that the blade stalls whilst cutting, ease the work piece backwards slightly, to release feed pressure from the blade. Allow the blade to reach full speed before continuing to feed the work piece in to the blade. If the blade fails to move when feed pressure is released, immediately switch off the machine and disconnect the power supply before attempting to free the blade from the work piece.

WARNING! If any component of the machine fails whilst in use or if the blade should break whilst the machine is running, immediately switch off the machine and disconnect from the power supply. Remove the faulty component and replace only with genuine Record Power replacement parts. Any electrical components should only be replaced by a suitably qualiﬁed person. To replace a broken blade, please refer to the section of this manual entitled “Band saw Blade Set Up”. Always remember to fully release the blade tension mechanism before attempting to ﬁt a new blade. If you are in any doubt about using the machine following a failure or if you need to order replacement spare parts or blades, please contact customer services in your country.

Restarting In the Event of a Blockage or if the Machine Stalls

If the bandsaw stalls due to the blade becoming trapped in the work piece, switch it off immediately by pressing the emergency stop button and wait for the machine to come to a complete stop before proceeding further. If the blade is trapped within the work piece, it may be necessary to prize the work piece apart slightly using a suitable lever in order to free the blade. If it is not possible to free the blade using this method, then it may be necessary to cut the blade using suitable side cutters or tin snips. Replace the blade if necessary and ensure that it is correctly tracked and tensioned and that both doors of the bandsaw are fully closed and secured before attempting to re-start the machine. To re-start the machine, press the green button marked ‘I’ on the switch.

In the Event of a Power Failure

The bandsaw is fitted with a no volt release (NVR) switch to protect the user against automatic starting of the machine when power is restored after a power failure. In the event of a power failure, first locate and rectify the source of the failure. If the fault is within the power circuit of the workshop, there may be an underlying cause (circuit overload etc.) that should be investigated by a qualified electrician, before attempting to restore the power source. If a cutting operation was taking place when the power supply was interrupted, then it may be necessary to free the blade from the work piece before attempting to re-start the machine. Once the power is restored, the machine can be re-started by pressing the green button marked ‘I’ on the switch.

Blade Selection (TPI)

The selection of the best blade configuration (see the table below) is necessary for optimum cutting performance.

• Correct blade choice is primarily dependant on two factors: material thickness and material type.

• Greater TPI should be selected as material thickness decreases.

• However, if the TPI is too great, the tooth loading will be insufficient to enable penetration; and cutting. The teeth will also rapidly lose their sharpness.

• For thicker material a lower TPI should be used otherwise the gullet will not be sufficient to clear the waste and the blade will stall or burn the wood.

• In general a minimum of 3 teeth should be in contact with the wood at all times during cutting.

The accompanying blade selection chart (see the table below) gives guidance on the TPI that should give the best results when cutting a variety of material types and thickness. The table below provides recommendations on selecting the correct blade for a variety of commonly used materials. If in doubt about any aspects of blade selection contact Customer Services in your country.

The table provides a guide to selection only. Exact tooth configurations are not always available, nor are all blade configurations covered, but the principles remain the same.

For special applications, custom blades can be supplied please call Customer Services in your country and we can advise you accordingly on your specific needs.

+ 28 hidden pages

STARTRITE 403, 603, 503 Original Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual