Wilton 7020, 7040 User Manual
Operating Instructions & Parts Manual
10-Inch x 16-Inch Horizontal
Cut-Off Band Saw
Models 7020/7040
Part No. 9078341
Revision C4 07/03
WMH TOOL GROUP
2420 Vantage Drive
Elgin, IL 601237
TEL: 1-888-594-5866
FAX: 1-800-626-9676
www.wmhtoolgroup.com
Table of Contents
General Specifications ....................................................................................................................................... 5
Specifications .................................................................................................................................................... 5
General Specifications ....................................................................................................................................... 5
Machinery General Safety Warnings ................................................................................................................. 6
Operating Precautions ....................................................................................................................................... 6
General Electrical Cautions ................................................................................................................................ 7
Safety Instructions on Sawing Systems ............................................................................................................. 7
Introduction ...................................................................................................................................................... 8
Operating Instructions .................................................................................................................................... 8
Controls ............................................................................................................................................................. 8
Setting Blade Speed........................................................................................................................................... 8
Operating Instructions ........................................................................................................................................ 8
Raising/Lowering the Saw Head ......................................................................................................................... 9
Controlling the Cut: Hydraulic Feed Control ...................................................................................................... 9
Evaluating Cutting Efficiency ............................................................................................................................. 9
Blade Selection .................................................................................................................................................. 9
Blade Break-in Procedures .............................................................................................................................. 10
Work Setup .................................................................................................................................................... 10
Securing the Workpiece for Square Cuts ........................................................................................................ 10
Adjusting the Vise for Angle Cuts ..................................................................................................................... 10
Work Set-up .................................................................................................................................................... 10
Installation and Adjustment of Work Stop.......................................................................................................... 11
Starting the Saw ............................................................................................................................................... 11
Adjustments ................................................................................................................................................... 12
Blade Tracking Adjustment ............................................................................................................................... 12
Coolant Flow .................................................................................................................................................... 12
Coolant Mixture and Quantity ........................................................................................................................... 12
Factory or Field Procedure .............................................................................................................................. 12
Adjustments ..................................................................................................................................................... 12
Blade Guide Bearing Adjustment ...................................................................................................................... 13
Test Cutting to Verify Adjustment Accuracy ...................................................................................................... 14
Adjustment of the Limit Switch .......................................................................................................................... 14
Maintenance ................................................................................................................................................... 14
Cleaning .......................................................................................................................................................... 14
Lubrication ....................................................................................................................................................... 14
Maintenance .................................................................................................................................................... 14
Changing Blades .............................................................................................................................................. 15
Changing the Drive Belt ................................................................................................................................... 15
Replacing the Drive Motor ................................................................................................................................ 15
Adjusting the Counterbalance Spring ............................................................................................................... 15
Replacing the Drive Wheel ............................................................................................................................... 16
Adjusting the Blade Guides .............................................................................................................................. 16
Replacement of Carbide Blade Guide .............................................................................................................. 16
Replacement of Guide Bearings ....................................................................................................................... 17
Replacement of Blade Edge Bearings .............................................................................................................. 17
Replacement of the Wire Brush ....................................................................................................................... 17
Machine Setup ............................................................................................................................................... 17
Uncrating and Spotting ..................................................................................................................................... 17
Electrical .......................................................................................................................................................... 18
Wiring Diagrams .............................................................................................................................................. 18
Troubleshooting............................................................................................................................................. 20
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Table of Contents
Replacement Parts ........................................................................................................................................ 21
Parts List - Base .............................................................................................................................................. 23
Parts List - Head .............................................................................................................................................. 27
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General Specifications
The Wilton Models 7020/7040 Horizontal Cut-Off
Bandsaws are ruggedly built, precision machines designed for either wet or dry applications. The 2 HP
motor along with the worm gear reduction drive train in
an oil bath, transmits smooth and positivepower to the
blade. This drive system coupled with the recirculating
coolant system keeps the blade running cool and true,
which results in longer blade life.
Specifications
Capacity 10" Round
10" x 10" Square
9" x 16" Rectangle
Speeds 100 to 350 feet per minute - variable speed
Motor Model 7020 - 1.5 H.P., 1 phase, 110/220V
Model 7040 - 2 H.P., 3 phase, 220/440V
Blade Size 1" x .035" x 135"
Blade Guides Adjustable 6 point contact combination bearing and carbide
Blade Wheels 14" diameter, cast iron
Dimensions Length: 79" / Width: 31" / Height: 41"
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Shipping Weight Approximately 725 pounds
Vise Rapid acting, 3 jaw design
Coolant System Recirculating system standard with each machine complete with 1 GPM pump, 8
gallon reservoir, and coolant applied through the blade guides.
- Misuse of this machine can cause serious injury.
- For safety, machine must be set up, used and
serviced properly.
- Read, understand and follow instructions in the
Operating Instructions and Parts Manual which
was shipped with your machine.
When Setting up Machine:
- Always avoid using machine in damp or poorly
lighted work areas.
- Always be sure the machine support is se-
curely anchored to the floor or the work bench.
When Using Machine:
- Always wear safety glasses with side shields
(See ANSI Z87.1)
- Never wear loose clothing or jewelry.
- Never overreach - you may slip and fall.
When Servicing Machine:
- Always disconnect the machine from its electri-
cal supply while servicing.
- Always follow instructions in Operating Instruc tions and Parts Manual when changing acces sory tools or parts.
- Never modify the machine without consulting
Wilton Corporation.
You - the Stationary Power Tool User - Hold
the Key to Safety.
Read and follow these simple rules for best results
and full benefits from your machine. Used properly,
Wilton’s machinery is among the best in design and
safety. However, any machine used improperly can
be rendered inefficient and unsafe. It is absolutely
mandatory that those who use our products be
properly trained in how to use them correctly. They
should read and understand the Operating Instructions and Parts Manual as well as all labels affixed to
the machine. Failure in following all of these warnings can cause serious injuries.
Machinery General Safety Warnings
1. Always wear protective eye wear when
operating machinery. Eye wear shall be impact
resistant, protective safety glasses with side shields
which comply with ANSI Z87.1 specifications. Use
of eye wear which does not comply with ANSI
Z87.1specifications could result in severe injury
from breakage of eye protection.
2. Wear proper apparel. No loose clothing or jewelry
which can get caught in moving parts. Rubber soled
footwear is recommended for best footing.
3. Do not overreach. Failure to maintain proper working position can cause you to fall into the machine
6
or cause your clothing to get caught pullingyou
into the machine.
4. Keep guards in place and in proper working order.
Do not operate the machine with guards removed.
5. Avoid dangerous working environments. Do not use
stationary machine tools in wet or damp locations.
Keep work areas clean and well lit.
6. Avoid accidental starts by being sure the start
switch is OFF before plugging in the machine.
7. Never leave the machine running while unattended.
Machine shall be shut off whenever it is not in operation.
8. Disconnect electrical power before servicing.
Whenever changing accessories or general maintenance is done on the machine, electrical power
to the machine must be disconnected before work
is done.
9. Maintain all machine tools with care. Follow all
maintenance instructions for lubricating and the
changing of accessories. No attempt shall be made
to modify or have makeshift repairs done to the
machine. This not only voids the warranty but also
renders the machine unsafe.
10. Machinery must be anchored to the floor.
11. Secure work. Use clamps or a vise to hold work,
when practical. It is safer than using your hands
and it frees both hands to operate the machine.
12. Never brush away chips while the machine is in
operation.
13. Keep work area clean. Cluttered areas invite accidents.
14. Remove adjusting keys and wrenches before turning machine on.
15. Use the right tool. Don’t force a tool or attachment to do a job it was not designed for.
16. Use only recommended accessories and follow
manufacturers instructions pertaining to them.
17. Keep hands in sight and clear of all moving parts
and cutting surfaces.
18. All visitors should be kept at a safe distance from
the work area. Make workshop completely safe by
using padlocks, master switches, or by removing
starter keys.
19. Know the tool you are using — its application,
limitations, and potential hazards.
General Electrical Cautions
Wire Sizes
This saw should be grounded in accordance with
the National Electrical Code and local codes and
ordinances. This work should be done by a qualified
electrician. The saw should be grounded to protect
the user from electrical shock.
Conductor Length AWG (American Wire Gauge) Number
240 Volt Lines 120 Volt Lines
0 - 50 Feet No. 14 No. 14
50 - 100 Feet No. 14 No. 12
Over 100 Feet No. 12 No. 8
Caution: For circuits which are far away from the
electrical service box, the wire size must be increased
in order to deliver ample voltage to the motor. To minimize power losses and to prevent motor overheating
and burnout, the use of wire sizes for branch circuits
or electrical extension cords according to the following
table is recommended.
Safety Instructions on Sawing Systems
1. Always wear leather gloves when handling saw
blade. The operator shall not wear gloves when
operating the machine.
2. All doors shall be closed, all panels replaced, and
other safety guards in place prior to the machine
being started or operated.
3. Be sure that the blade is not in contact with the
workpiece when the motor is started. The motor
shall be started and you should allow the saw to
come up to full speed before bringing the saw blade
into contact with the workpiece.
4. Keep hands away from the blade area. See Fig-
ure A.
5. Remove any cut off piece carefully while keeping
your hands free of the blade area.
6. Saw must be stopped and electrical supply must
be cut off before any blade replacement or adjustment of blade support mechanism is done, or before any attempt is made to change the drive belts
or before any periodic service or maintenance is
performed on the saw.
7. Remove all loose items and unnecessary workpieces
from the area before starting machine.
8. Bring adjustable saw guides and guards as close
as possible to the workpiece.
A
B
9. Always wear protective eye wear when operating,
servicing, or adjusting machinery. Eyewear shall
be impact resistant, protective safety glasses with
side shields complying with ANSI Z87.1 specifications. Use of eye wear which does not comply
with ANSI Z87.1 specifications could result in severe injury from breakage of eye protection. See
Figure B.
10. Nonslip footwear and safety shoes are recommended. See Figure C.
11. Wear ear protectors (plugs or muffs) during e x tended periods of operation. See Figure D.
12. The workpiece, or part being sawed, must be
securely clamped before the saw blade enters
the workpiece.
13. Remove cut off pieces carefully, keeping hands
away from saw blade.
14. Saw must be stopped and electrical supply disconnected before reaching into cutting area.
15. Avoid contact with coolant, especially guarding
your eyes.
C
7
D
Introduction
This manual includes the operating and maintenance
instructions for the Wilton 10-inch by 16-inch Cut Off
Band Saw, Models 7020/7040. This manual also includes parts listings and illustrations of replaceable parts.
Operating Instructions
Controls
The operating controls for the saw are provided in a
control panel on the left side of the machine. The control panel is mounted on a pivoting tube. The pivoting
tube allows the operator to position the control panel in
a convenient location.
Power-on
Light
Motor
Pushbutton
Emergency
Reset
Button
Saw Head
Pushbutton
Figure 1: Control panel
Setting Blade Speed
1. The blade speed is controlled by an adjustment
mechanism on the right end of the saw. Speed
increases when the adjustment knob is turned
counterclockwise. Speed decreases when the
knob is turned clockwise.
2. A placard on the drive belt guard provides recom
mended speeds for various materials.
3. A speed indicator is provided on the barrel of the
adjustment mechanism. The indicator provides
speed indications in feet per minute and meters
per minute. (The meters per minute values are
shown in parenthesis on the indicator.)
4. The feed rates on the placard are expressed in
meters per minute. The feed rate graduations
available on the indicator may not match the
recommended feed rate. An approximate speed
may therefore be required. For example, to set a
speed rate of 25 meters per minute, the indicator
would be set about midway between 21 metersper-minute and the 30 meters-per-minute graduations.
WARNING: TO CHANGE SPEED, THE SAW
MOTOR MUST BE OPERATING.
5. Turn the speed adjustment knob to the desired
rate setting as determined by the material being
cut.
1. A power-on light is provided on the left side of the
control panel. The power-on light indicates when
power is connected to the machine.
2. A n emergency stop button is provided on the
control panel. The emergency stop button provides a means to rapidly cut off electrical
power.
3. The saw motor pushbutton switch starts the saw
motor and the E-stop button stops the saw motor.
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4. A green pushbutton switch is provided to the right
of the emergency stop pushbutton. The pushbutton
opens an electro-magnetic valve in the hydraulic
cylinder circuit. Opening the valves allows the saw
head to move downward and put the saw blade in
contact with the workpiece.
5. A red release button on the electro-magnetic
valve provides a means to lower the saw head
when power to the machine has been disconnected (see figure 4).
6. The rate at which the saw head moves downward
is controlled by a hydraulic feed rate control
located on the top, rear of the saw head (see
figure 3).
7. A coolant pump switch is provided on the electrical equipment box on the back of the machine
Coolant
Pump
Switch
Figure 2: Coolant pump switch
Raising/Lowering the Saw
Head
1. Lift the saw head using the handle on the far left
side of the saw head.
2. To lower the saw head, press the green pushbutton
on the right side of the control panel.
3. To adjust the feed rate, adjust the feed rate control
valve knob on the top of the saw head (see figure
3).
4. To lower the saw head with power off, pull and turn
the red knob (manual override) on the electro-magnetic valve (see figure 4).
Controlling the Cut:
Hydraulic Feed Control
The weight of the saw arm provides all the force
needed to move the saw blade through the workpiece.
In fact, if the full weight of the arm is allowed to make
the cut, rapid blade wear and poor cutting accuracy
will result. A hydraulic feed control is provided that
gives the operator a means to control the speed and
efficiency of cutting.
The hydraulic cylinder is attached between the saw
base and the saw head. The hydraulic cylinder resists
movement of the saw head in the downward direction.
However, the hydraulic cylinder offers no resistance
when the saw head is raised upward.
The amount of downward force can be controlled by
using the feed rate control valve. When the valve is
opened slightly, the saw head will move downward. The
further the valve is opened, the faster the saw head will
move downward.
The feed control is adjusted by the operator until the
saw is operating efficiently. This is usually determined
by observing the chip formation. (See Evaluating Blade
Efficiency for more information on cutting efficiency.)
Control Box
Saw Head
Lift Handle
Figure 3: Controls
Blade Tensioning
Hand Wheel
Vise Clamping
Hand Wheel
Blade
Blade Guide
Supports
Drive Motor
Saw Head
Feed Rate
Control
Speed
Control
Belt
Cover
Saw
Head
Red
Release
Button
ElectroMagnetic
Valve
Figure 4: Lowering head with power off
Evaluating Cutting Efficiency
Is the blade cutting efficiently? The best way to
determine this is to observe the chips formed by the
cutting blade.
If the chip formation is powdery, then the feed rate
is much too light, or the blade is dull.
If the chips formed are curled, but colored — that
is, either blue or straw-colored from heat generated
during the cut — then the feed rate is too high.
If the chips are slightly curled and are not colored
by heat — the blade is sufficiently sharp and is cutting
at its most efficient rate.
Blade Selection
The cut-off saw is provided with a saw blade that is
adequate for a variety of cut-off jobs on a variety of
common materials. A 4/6 vari tooth bi-metal blade
(5674011) and a 6/10 vari tooth bi-metal blade
(5674021) are available from Wilton.
See Setting Blade Speed for the speeds recommended for various materials. These selections, while
appropriate for many shop cutting needs, do not encompass the wide variety of blades of special configuration (tooth pitch and set) and special alloys for cutting unusual or exotic materials.
A coarse blade could be used for a solid steel bar
but a finer tooth blade would be used on a thin-wall
tube. In general, the blade choice is determined by
the thickness of the material; the thinner the material,
the finer the tooth pitch.
9
10
A minimum of three teeth should be on the work
piece at all times for proper cutting. The blade and
workpiece can be damaged if the teeth are so far apart
that they straddle the workpiece.
For very high production on cutting of special materials, or to cut hard-to-cut materials such as stainless
steel, tool steel, or titanium, you can ask your industrial
distributor for more specific blade recommendations.
Also, the supplier who provides the workpiece material
should be prepared to provide you with very specific
instructions regarding the best blade (and coolant or
cutting fluid, if needed) for the material and shape supplied.
Blade Break-in Procedures
New blades are very sharp and, therefore, have a
tooth geometry which is easily damaged if a careful
break-in procedure is not followed. Consult the blade
manufacturer’s literature for break-in of specific blades
on specific materials. However, the following procedure will be adequate for break-in of Wilton-supplied
blades on lower alloy ferrous materials.
1. Clamp a round section workpiece in the vise. The
workpiece should be 2 inches or larger in diameter.
2. Set the saw on low speed. Start the cut with a very
light feed rate.
3. When the saw has completed 1/3 of the cut, in-
crease the feed rate slightly and allow the saw to
complete the cut.
4. Keep the same hydraulic cylinder setting and begin
a second cut on the same or similar workpiece.
5. When the blade has completed about 1/3 of the cut,
increase the feed rate. Watch the chip formation
until cutting is at its most efficient rate and allow the
saw to complete the cut (see Evaluating Blade Efficiency). The blade is now considered ready for
regular service.
Work Setup
Securing the Workpiece for
Square Cuts
1. Raise the saw head (refer to Figure 5).
2. Slide the left vise jaw far enough to the left to allow
the workpiece to be placed in the vise.
3. Place the workpiece on the work table. If the
workpiece is long, provide support at the other end.
It may also be necessary to provide additional downward clamping to hold the workpiece securely on
the work table.
4. Turn clamping hand wheel clockwise to clamp the
workpiece in position against the fixed (right) vise
jaw.
5. After completing the cut, turn the clamping hand
wheel counterclockwise and slide the left jaw away
from the workpiece.
Clamping
Hand
Wheel
Left Vise Jaw
Work Table
Figure 5: Securing workpiece
Adjusting the Vise for Angle
Cuts
1. Referring to Figure 5, loosen the angle locking screw
and the pivot screw on the left vise jaw.
2. Turn the locking handle on the round, angle-setting
block counterclockwise to unlock the block. Slide
the block until the pointer on the block is aligned
with desired angle (see figure 7). Tighten the locking handle to set the angle.
3. Set the workpiece in the vise. Put the front end of
the workpiece against the corner of the right vise
jaw. Put the rear end of the workpiece against the
angle-setting block.
4. Turn clamping hand wheel clockwise until the left
vise jaw is parallel with the workpiece. Tighten the
pivot screw and angle locking screw on the left vise
jaw. Clamp the workpiece in position.
5. After completing the cut, turn the clamping hand
wheel counterclockwise and slide the left jaw away
from the workpiece.
Saw Head
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