Wellsaw 613 User Manual
Parts List
4
613
MODEL
Manual Bandsaw
and
Built better to work stronger and last longer
Operating & Maintenance Manual
REV 140502
2829 N. Burdick St. Kalamazoo, MI 49004
Phone: 269-345-1132 Fax: 269-345-0095
rdick St. Kalamazoo, MI 4900
www.wellsaw.com
Index
A
0
W
Model 613 Specifications
General
utomatic Stop
Blade Brushes
Blade Selection Guide
Dash Pot, Hydraulic Feed
Feed Pressure Adjustment
Fixed Vise Jaw
Gear Box Repair
Lubrication
Maintenance
Motor Switch
Notes on Sawing 4
Placing Blade on Saw 6
Receiving & Installation
Safety Rules 3
Servicing Blade Guides
Service Kits
Sliding Vise Jaw
Trouble Shooting
Warranty
Wheel Pitch Adjustment
22
Drawings
Blade Brush Assembly
Blade Guide Assembly
Bed Assembly 12
Coolant System
Electrical Controls
Frame Assembly
Hydraulic System 18
Leg & Chip Pan 14
Motor & Gear Box 18
Right Tensioning Device
16
16
18
20
-
1
14
Parts Lists & Part Numbers
Blade Brush Assembly 17
Blade Guide Assembly
Bed Assembly
Coolant System
Electrical Controls/Diagram
Frame Assembly 11
Hydraulic System
Leg & Chip Pan
Motor & Gear Box
Right Tensioning Device
17
13
19
21
18
15
19
15
Capacity
6
8
6
6
6
7
8
7
8
3
7
9
6
4
Rectangular 6' high x 13' wide
Round 7” diameter
Flat 13' wide
4 5° Angle 6' high x 6.5' wide
Blade Speed 50-90-160-250 FPM
Motor 3/4 HP, 115-230/60/1 or 206-230-460/60/3
Drive V-Belt
Blade Size 3/4” x .035"x8'3"
Swivel Vise To 45°
Vise control Manual Screw
9
7
Band Wheels 11' dia.
Height to top of bed 29'
Coolant System 8 gallon w/115VAC submersible pump
Recommended Workload Weight 600 lbs.
Floor Space 25" x 60'
Shipping weight (approximate) 650 lbs.
Parts Ordering
For your convenience:
When contacting your Wellsaw supplier
or the Company for parts or service,
it is essential that you have both your saw
Serial Number and Purchase Date available.
Jot them down here for handy reference.
Serial Number _____________________
Purchase Date ____________________
Fill out and return your Warranty Card
so that you can be kept informed of
developments concerning your
ellsaw.
Forward
2. Keep Guards in Place
Keep guards in place and in good working order.
The Model 613 Wellsaw has been designed and
manufactured to conform to WeIlsaw's recognized
high standards of quality and performance. Each saw
must pass a series of final inspection tests, including
actual metal cutting operations, before it is shipped.
For this saw to provide satisfactory service, it is
necessary that it be properly installed, operated and
maintained. This manual has been prepared to assist
you in carrying out these functions. We urge you to
study this manual and follow its suggestions.
Receiving and Installation
Uncrating
Carefully remove the protective crating and skid so
the saw and its parts are not marred or otherwise
damaged. In the event of damage in transit, notify the
carrier and file a Proof of Loss Claim immediately.
Shortages
Inspect the complete shipment carefully against the
itemized packing list. Make sure that all items are
present and in good condition. In the event of any
shortage, notify the distributor from whom you purchased the saw and the carrier who made delivery.
Utility Hook-Up
The use of a qualified electrician is always recommended when connecting the saw to the main power
supply. Electrical codes differ from area to area and it
is the customers responsibility to ensure that his saw
complies with applicable codes. Your Wellsaw is prewired at the factory for a specified voltage. Always
check the motor and electrical panel to ensure that
they are both wired to correspond to your electrical
power supply.
3. Remove Adjusting Keys and Wrenches See
that keys and wrenches are removed from the saw
before operating it.
4. Keep Working Areas
Clean Clutter invites accidents
5. Avoid Dangerous Environment
Do not use power tools in damp or wet locations.
Keep work areas well illuminated.
6. Keep Children Away
Keep all visitors a safe distance from work areas.
7. Use The Right Tools
Do not force a tool or attachment to do a job or
operate at a speed it was not designed for.
8. Wear Proper Apparel
Avoid all loose clothing or jewelry which may get
caught in moving parts.
9. Use Safety Glasses
Also use a face or dust mask if the cutting operation
being performed requires it.
10. Secure Work
Use proper clamps or the vise to hold work before
cutting.
11. Do Not
Keep your footing and balance at all times. Clean up
all liquids spilled in work area.
12. Maintain Tools in Top Condition
Keep tools sharp and clean for best and safest
performance. Follow instructions for lubrication,
maintenance and changing accessories
Over
Reach
Safety Rules
1. Know Your Saw
Read this manual carefully. Learn your saws' application and limitations as well as the specific potential
hazards peculiar to this machine.
13. Disconnect Power
Before servicing and when changing accessories such
as blades, disconnect the power supply.
14. Use Recommended Accessories
Consult this Manual. The use of improper accessories
may be dangerous and can damage the saw.
3
Notes on Sawing
Trouble Shooting
It is widely recognized that a proficient operator is a
key to optimum bandsawing. He makes certain the
machine is properly maintained and adjusted for dependable operation. He carefully sets up each cutting
job to prevent damage to the machine and obtain the
best performance from the equipment.
Blade dealers can be very helpful in selecting the
grade and proper tooth blade for each sawing job. All
blades should be straight, have sharp teeth with uniform set, and be "broken in" at a reduced feed rate to
obtain good cutting performance and blade life.
Every cutting situation has special characteristics
requiring some experimentation to determine which
blade, speed and feed rate will achieve the most satisfactory result. Cutting charts indicate a good starting
point, but must be modified by direct experience if
optimum performance is desired. (See page 24)
Here are some helpful pointers for adjusting speed and
feed for good cutting performance.
1. Make sure the saw is cutting a good chip from the
workpiece.
2. Watch for blue chips or excessive "smoke"
indicating heat in the cut which could damage the blade
or work-harden the material being cut.
3. Watch for excessive vibration or chatter marks on
the cut-off piece indicating possible damage to saw
teeth by "hammering".
4. Check the cut-off piece for flatness. A dull blade or
excessive feed will produce a "belly" in the cut.
5. Inspect the blade for worn, rounded or shiny cutting
edges. Avoid force cutting which will allow chips to
"weld" to saw teeth and eventually cause the teeth to be
stripped off the blade.
6. When experimenting, start with a slow speed and
feed rate. Gradually increase blade speed and then feed
pressure by small amounts until adverse effects are
noted. You can then set the speed and feed at a
reasonable level for continuous cutting. Remember that
blade speed and feed pressure must be balanced to keep
cutting a good chip.
Premature Dulling of Blade Teeth
1. Feed rate too high or low. Check recommendation.
2. Blade speed too slow or too fast.
3. Faulty material; heavy scale, hard spots, etc.
4. Verify material analysis.
5. If coolant flow is not covering saw teeth, increase
coolant flow rate.
6. If saw is vibrating in cut, reduce blade speed or
increase feed rate.
7. Chipped or broken teeth may be lodged in cut.
8. "Chip welding" caused by improper feed and speed.
9. Incorrect coolant mixture.
10. Incorrect blade selection.
11. Improper break-in of ne w blade. New blades
should be run initially with reduced feed pressure for
approximately 50 to 100 square inches of cutting.
12. Saw blade teeth may be hitting blade guides.
Check for proper blade size and guide adjustment.
Saw Blade Vibration
1. Incorrect blade speed fo r materi al being cut.
2. Blad e tension insu fficient.
3. Back-u p be aring may be worn.
4. Incorrect choice of saw tooth pitch.
5. In correct coolan t mixture.
6. Incorrect feed setting. Increase feed pressure.
7. Workpiece not firmly clamped in vice.
8. Worn or improperly adjusted saw guides. Check and
make necessary adjustments or repairs.
Blade Teeth Chipping or Ripping Out
1. Blade pitch too coarse. Use a fine pitch saw blade
on thin work sections.
2. Improper break-in of new blade. Do not start a new
blade in an old cut.
3. Work piece not held firmly enough. Clamp work
securely.
4. Introduce cooling if it is not being used.
5. Faulty material; scale or hard spots.
6. Blade gullets may be loaded. Use higher viscosity
lubricant or coolant.
7. Blade speed and feed may need adjustment.
4
Premature Blade Breakage
1. Poor weld in blade.
2. Feed rate set too high. Reduce it.
3. Excessive blade speed. Adjust it.
4. Blade guides set too tight or misaligned.
5. Blade tension set too high.
6. Blade running against flange on wheels. Adjust
wheel pitch.
Blade Squeal
1. Feed rate too light for blade speed. Increase feed
rate and/or reduce blade speed.
Blade Slips Off Blade Wheels
1. Blade not tensioned correctly.
2. Wheel pitch not set properly.
3. Guides set too tight.
Gullets of Blade Teeth Loading
1. Blade pitch too fine. Review blad e selec tio n.
2. Incorrect blade speed. Consult cutting chart.
3. If not using coolant, apply it.
Chips Welding to B lade T eet h
1. Cutting rate too high.
2. Chip brush may be out of adjustment.
3. Check coolant and application.
Blade Becoming Scored
1. Saw guides may be worn. Check and replace if
necessary.
2. Too much pressure on saw guides. Adjust.
3. Guides may be out of alignment.
Blade Making Belly-Shaped Cut
1. Blade tension too light. Increase it.
2. Saw guides too far from work piece.
3. Blade pitch too fine. Use larger pitch and positive
rake tooth form.
4. Feed force too heavy. Decrease it.
3. Blade guides too far apart. Always set blade
guides as close to work piece as possible.
4. Blade may be dull. Check and replace if necessary.
5. Feed pressure too high. Reduce it.
6. Blade guides loose, worn or out of alignment.
7. Too many teeth-per-inch. Blade not cutting freely.
8.
Chip brush not cleaning teeth properly.
9. Dirty coolant.
10. Check for loose nuts, bolts, etc.
Rough Cut I Poor Finish
1. Excessive feed rate. See recommendations.
2. Blade too coarse. Use finer blade pitch.
3. Inadequate cutting fluid. Change.
Blade Stalls In work.
1. Insufficient blade tension.
2. Excessive feed pressure.
3. Blade tooth spacing too coarse.
4. Motor worn or defective.
5. Guides too tight against blade.
Blade Does Not Track Properly
1. Set wheel pitch so that blade runs to wheel flange
but not against it.
2. Is blade tension proper?
3. Is back of blade riding against back-up bearing? If
not, adjust guides.
Motor Overheating
1. Check for correct voltage supply. Check voltage at
motor. Check magnetic starter heaters.
2. Check for loose electrical connections.
3. Does motor amp reading correspond to rating on
motor specification tag?
4. Is internal motor wiring correct?
5. Is drive belt over-tightened?
Inaccurate Cut-Off
1. Is conveyor or stock stand level with saw bed?
2. Insufficient blade tension.
5
Operating Instructions.
Speed Selection
Cutting Tips
1. For long er bla de life, star t ea c h cut careful ly .
2. For new blade, reduce feed pressure on first two
cuts or about 100 square inches.
3. Keep blade guides as close to the vise jaws as
possible.
4. Make sure all four legs of the saw are in solid
contact with the floor.
Automatic Stop
When the blade has completed a cut through the
material, the saw frame activates a limit switch which
shuts the motor off.
When changing a blade or doing any other maintenance or repair, be sure the automatic stop is engaged or
disconnect the main power supply.
It is necessary to raise the saw frame clear of this limit
switch actuator before the saw can be started.
Dash Pot
Machines are equipped with a dash pot [frame check]
for the purpose of stabilizing downward travel of the
saw frame, thereby protecting the saw blade from
damage. The action of the dash pot is hydraulic and
controlled by fluid being passed through an orifice in
the piston on the downward stroke.
Fill within 1" of the top of the bottom cylinder with
Mobil Velocite Oil #6 or equivalent.
Frame Weight Adjustment
The position of the collar in relation to the spring on
the dash pot acts as the frame weight adjustment.
The proper frame weight is approximately 10 lbs. and
is obtained by positioning the top of the collar 4" down
from the top edge of the upper cylinder. For less frame
weight, loosen the collar and move it down toward the
tension spring. Reverse this action for more frame
weight.
Too much frame weight will cause the blade to make
crooked cuts!
Saws are equipped with step pulleys providing blade
speeds of 50, 90, 160 and 250 feet-per-minute. High
speeds are suggested for cutting thin-wall tubing,
channels, aluminum, brass or any metal that will not
burn blade teeth. Use medium speed for general cutting such as cold rolled, machine steels, heavy channels, etc. Run at low speed for cutting nickel steels or
any metal requiring a slow speed on a lathe. When
cutting brass, use a blade that has not been used on
other metals and apply beeswax to the teeth. See page
22 for suggested Blade Speed combinations.
Belt
Pivoted mounting provides for quick belt change. With
the belt in pulley grooves for the desire speed, swing
motor to put proper tension in the belt. Tighten thumb
screw to hold motor in proper operating position.
Fixed Vise Jaw
The two pins in the fixed vise jaw should be kept in
place the ensure square cuts. For cutting angles, the
pins must be removed to the desired position and
tightened with clamp bolts. The vise pins allow you to
quickly relocate the fixed vise jaw for approximate 90
0
cutting. For final, accurate cutting, the fixed vise jaw
should be squared with the blade. [See Blade Guide
Alignment.]
Sliding Vise Jaw
The sliding vise jaw is fitted with a lift plate and
ratchet dog for quick action. A hand wheel tightens the
vise on the workpiece. Excessive pressure is not needed
to hold the workpiece securely!
Maximum Capacity
To obtain maximum vise capacity, remove vise jaw
pins and move fixed vise toward motor end to the last
two holes in the bed. Make sure the stock in the vise
will not strike the ratchet arm.
Feeding Pressure
Feed pressure is varied by moving the weight on the
top side of the frame. Blade pressure increases as the
weight is moved toward the open end of the saw.
Excessive pressure may cause a run-out of the blade.
[See page 22 for recommendations.]
6
Placing Blade on Saw
1. Raise saw frame.
2. Open Idle and Drive Wheel guards.
3. Loosen Rite Tension take-up screw and remove old
blade. In the event of a broken blade, be sure Rite
Tension is open by turning take-up screw counterclockwise at least six [6] turns.
4. Uncoil new blade. Make certain the blade teeth
point in the direction of blade travel which is toward
the motor. If not, turn blade inside out to have the
proper tooth direction.
5. Place new blade on the guides and the band wheels.
6. Grasp blade on frame side and push it toward guide
bracket beam to hold it in position while turning the
Rite Tension take-up screw.
7. Tighten blade to proper tension. Blade is properly
tensioned when the take-up screw is tightened until the
mechanism bottoms out.
Maintenance Instructions
adjustment. If you then find the saw blade is not
square with the stationary vise jaw, the blade must be
adjusted.
2. This adjustment is. made with the top two Allen
screws on the roller adjusting block of the guide arm.
Looking at the drawing, you will see these adjusting
screws labeled "A" and "B".
3. To make a vertical adjustment of the saw blade, so
that the cut is square from top to bottom, the blade
must be set so that it is perpendicular to the bed. In
making this adjustment, clean the saw bed first.
4. Set the rule of the combination square on the saw
bed with the end of the rule butted against the blade
above the set of the saw teeth. Use a 1-1/2 thousandths
(.0015") shim and slide it along the top and the bottom
edge of the rule where it meets the saw blade. If the
shim slides between the blade and the rule at either the
top or bottom, the roller supports must be adjusted by
using the bottom Allen screws marked "C" and "D" to
obtain the correct 90° angle.
Adjust the side roller guides with the eccentric axle
until both rollers contact blade. When this adjustment
has been made, the roller should be adjusted so that
the PATH OF THE BLADE IS STRAIGHT and the
blade is not forced to curve around the rollers. The top
roller guide should be in contact with the top of the
blade at all times. When running idle, this contact
pressure should be very light
Blade Guide Alignment
To properly align the saw blade for a straight and
accurate cut, do the following.
1. Check the stationary vise jaw. Make sure it is
square. To do this, place a combination square against
the vise jaw slot in the saw bed. Slide the square
toward the stationary vise jaw. Make the necessary
Wheel Pitch Adjustment
If the saw blade runs too low or off the wheels, or runs
too high and rubs the wheel flange, a wheel pitch
adjustment must be made. Loosen the blade before
making the following adjustments.
Idler Wheel
Blade running too low or off the wheel. Adjust the Idler
Wheel Block. Loosen one-half [112] turn the two cap
screws in the block closest to the take-up screw end.
Tighten by one-half turn [112] the two cap screws in the
opposite end of the block. Repeat if more adjustment is
necessary.
Blade running too high and running against the Idler
Wheel Flange. The blade can become distorted, its top
edge rolled over and the wheel flange will wear excessively. To correct this, loosen by one-half [112] turn the
two cap screws opposite the take-up screw on the wheel
block. Tighten the two cap screws closest to the
7
take-Up screw end. Repeat if necessary.
Drive Wheel:
Blade running too low or off the drive wheel.
Loosen the two cap screws closest to the motor
end of the wheel plate by one-half [1/2] turn.
Tighten the two hollow-head screws at the same
end by one-half [1/2] turn. Repeat if more
adjustment is necessary.
Preventive Maintenance
Caution:
emergency STOP button before performing any
maintenance. DO NOT service the Dash Pot unless
the frame is in the Down position or resting on a
mechanical stop, such as a block of wood.
Daily
Disconnect the electrical supply and press
Make certain that all screws are tight after
adjustments have been made.
Gear Box Repair
1. Remove gear box from saw.
2. Remove four machine screws holding gear box
together.
3. Separate gear box by carefully prying castings
apart at a location near pulley shaft. Caution: Do not
use excessive force!
4. Once the gear box is open, the internal parts may
be inspected for wear.
5. Liquid plastic gasket is used to seal the gear case.
Use Loctite No. 51580 or equivalent.
Blade Brushes
Brushes should be cleaned frequently in kerosene
and reversed to take advantage of both rows of
bristles. For efficient cutting, replace worn blade
brushes. In replacing brushes, be sure bristles are
bent in the direction the blade travels.
1. Keep the saw clean and free of chips.
2. Maintain the coolant level and keep the coolant
tank and filter clean of chip accumulation or sludge.
Monthly
1. Check, adjust and replace blade brush as needed.
2. Lubricate drive gears.
3. Inspect guides and bearings.
4. Inspect drive belt.
5. Clean coolant tank and filter as needed.
Annually
1. Check hydraulic oil level.
2. Replace guide rollers.
3. Inspect gear box. Lubricate as needed.
Lubrication
Correct and adequate lubrication is a very important
factor in determining the life and service of your
Wellsaw. It is essential that all dust, dirt, chips, etc. be
thoroughly removed before lubricating the saw. The
following lubrication recommendations cover usual
saw applications. Heavy use and hostile environments
may indicate more frequent lubrication for best saw
performance.
Switch
A "Stop-Start" switch across the line controls the
motor. A heater coil breaks the circuit if an overload
occurs. Allow time for the coil to cool before restarting
the saw. An automatic shut-off operates when the saw
frame contacts a limit switch. Low voltage protection is
provided by the magnetic starter. A separate switch
controls the automatic coolant system.
Vise Screw, Ring Gear, Drive Pinion
1. Inspect monthly.
2. Use anti-seize on vise screw.
3. Use Extreme Pressure Open Gear Lube sparingly
on Ring Gear and Drive Pinion.
Gear Case
1. Inspect after 3 years (6,000 hours).
2. Use Mobilgrease XHP 220 or equivalent.
3. Viscosity: Heavy grease, drop point 550 EF.
4. Military Specification: None.
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