Wilton 8203VS, 8203, 8201VS, 8201 User Manual

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Operating Instructions — Parts Manual

14-Inch Vertical Band Saws

Models: 8201, 8203, 8201VS and 8203VS

WHM TOOL GROUP

2420 Vantage Drive Elgin, Illinois 60123 Part No. 9078171

Table of Contents

Cover Page.................................................................................................. 1

General Specifications ................................................................................. 4

Operating Precautions ................................................................................. 5

Set-up and Operation ................................................................................... 7

Wiring Diagrams .......................................................................................... 8

Operating Instructions ................................................................................ 10

Maintenance .............................................................................................. 14

Troubleshooting.......................................................................................... 18

Replacement Parts..................................................................................... 19

General Specifications

Wilton’s 14-inch Tradesman Vertical Band Saws are specially designed to effectively cut a variety of materials including wood, plastic, bakelite, composites, ferrous and non-ferrous metals. Models 8201 and 8203 are wood and metal cutting band saws.

Wilton’s Model 8201VS and 8203VS 14-inch Tradesman Variable Speed Band Saws are ideally suited for metal cutting only with an infinitely variable speed range from 116 to 334 SFPM. The variable speed drive system allows the operator to fine-tune the blade speed to the material being cut to maximize the life of today’s bi-metal blades. These versatile and dependable saws are capable of contour cutting, straight cutting and re-sawing, and these band saws can cut delicate curves in thick or thin stock.

Specifications

Capacity 8201 8203 8201VS 8203VS

Standard ..............6-in. under guide ..... 6-in. under guide ....... 6-in. under guide ...... 6-in. under guide

With 12-in. Riser ..12-in. under guide ... 12-in. under guide ..... 12-in. under guide .... 12-in. under guide

Blade to frame ..... 13.5-in. .................... 13.5-in. ..................... 13.5-in. ..................... 13.5-in.

Motor

Rating .................. 1 HP 1-Ph ............... 1 HP 3-Ph ................. 1 HP 1-Ph ................ 1 HP 3-Ph

Voltage ................. 115 vac .................... 220/440 vac .............. 115 vac .................... 220/440 vac

Speed .................. 1725 rpm ................. 1725 rpm .................. 1725 rpm.................. 1725 rpm

Cutting Speeds

Wood (SFPM) ...... 3300 ........................ 3300 ......................... 2600 ......................... 2600

Metal (SFPM) ....... 39, 57, 78, 107, ....... 39, 57, 78, 107, ........ 116 – 334 ................. 116 – 334

142, 196, 278 .......... 142, 196, 278 ............Variable Speed ......... Variable Speed

Dimensions

Length ................. 20 Inches ................ 20 Inches ..................20 Inches ................. 20 Inches

Width ................... 16 Inches ................ 16 Inches .................. 16 Inches ................. 16 Inches

Height .................. 66 Inches ................ 66 Inches ..................66 Inches ................. 66 Inches

Height from Floor .....66 Inches ................ 66 Inches .................. 66 Inches ................. 66 Inches

Table Tilt to Right ..... 45 Degrees ............. 45 Degrees ............... 45 Degrees .............. 45 Degrees

Table Tilt to Left ....... 10 Degrees ............. 10 Degrees ............... 10 Degrees .............. 10 Degrees

Miter Gauge Groove

Width ...................3/4-Inch ................... 3/4-Inch .................... 3/4-Inch .................... 3/4-Inch

Depth ...................3/8-Inch ................... 3/8-Inch .................... 3/8-Inch .................... 3/8-Inch

Miter Gauge .............Standard.................. Standard ................... Standard .................. Standard

Blade Dimension

Standard ..............3/8x0.025x92.5 In.... 3/8x0.025x92.5 In. .... 3/8x0.025x92.5 In. ... 3/8x0.025x92.5 In.

- 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 to follow 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 Z87.1 specifications 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 or cause your clothing to get caught pulling you 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 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 the workshop completely

safe by using padlocks, master switches, or by removing starter keys.

General Electrical Cautions

19. Know the tool you are using — its application, limitations, and potential hazards.

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.

Wire Sizes

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, andother 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

Figure 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 loose items and unnecessary workpieces from area before starting machine.

8. Bring adjustable saw guides and guards as close as possible to the workpiece.

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 extended 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 cut off or machine unplugged before reaching into cutting area.

15. Avoid contact with coolant, especially guarding your eyes.

Introduction

Setup and Operation

This manual includes operating and maintenance instructions for the Wilton 14-Inch Tradesman Vertical Band Saws, Models 8201, 8203, 8201VS, and 8203VS. This manual also includes parts listings and illustrations of replaceable parts.

Band Saw Features

Refer to Figures 1 through 3 for key features of the band saw machine. Refer to the Specifications section for additional information on the features and capabilities of the saw.

Set-up

The band saw is shipped with the saw frame separated from the saw base. Set-up of the band saw involves installing the frame and setting-up the saw on the shop floor.

Assembly of Band Saw

The saw is shipped as two separate units — saw frame and base. The saw frame must, therefore, be assembled to the base.

1. Remove loose parts from the saw base and sawframe.

2. Place the base in the location in the shop and bolt the base to the floor. (See following section on spotting saw.) Put shims under the hold-down bolts as required to make sure the saw is level.

3. Place the saw frame on the base. Be sure the pulleys on the saw frame and pulleys in the base are aligned with each other.

4. Install the four bolts, upper washers, lower washers, lock washers and nuts that secure the frame to the base finger tight. Using a straight edge, align the pulleys. Then tighten the four attachment bolt and nuts.

5. Loosen the motor mounting bolts and install the drive belt(s).

Figure 1: Band Saw Features (Rear View) (Models 8201/8203)

Saw Head

Clutch Knob

Gearbox

Oil Level Gauge

Drive Motor

Variable Speed Control

Pivoting Motor Mounting Plate

Motor Pulley

Figure 2: Band Saw Features (Rear View) (Models 8201VS/8203VS)

Blade tension adjustment

Upper wheel

switch

guard

Blade guard

Lower wheel guard

Dust chute

knob

Optional rip fence

Figure 3: Band Saw Features (Front View) (All Models)

Upper drive wheel

Upper blade guide support assembly

Lock Knob

Upper blade guide and support assemblyON/OFF

Miter

Table

slot

Lower drive wheel

Lower blade guide and support assembly

Base

6. Tension the belts (refer to Changing Drive Belt Position).

7. Check gearbox fluid level in sight gauge. If required, add lubricant to bring level halfway up the sight gauge. (Two containers of Shell Spirax 90 HD gear oil are packed with the saw. The containers have sufficient amount of lubricant to fill the gearbox.)

8. Check blade tension and support mechanism adjustment (refer to Changing Saw Blades).

9. Plug the motor cable into the switch box on the saw frame. For 3-phase motors, follow the instructions in the Electrical section to complete the electrical hookup.

NOTE: Observe all electrical codes. Local codes

or difficult environmental conditions may demand special electrical hook-ups. Always use a licensed electrician for any special electrical hook-up.

the saw before attempting electrical connections.

2. Connect the green or green-with-white-trace wire to the branch circuit ground wire.

3. Connect the remaining three wires to the power wires in the 3-phase branch circuit.

4. Reestablish power in the electrical branch.

5. Turn on power to the saw motor using the switch.

6. Observe the direction of the blade. It should be going DOWNWARD, into the slot on the table. If it is not going downward, the power wires are hooked-up incorrectly.

7. To correct hook-up, disconnect and lock out power to the branch, again. Reverse any two of the power wires on the hook-up to the saw cable.

8. Reestablish power in the branch and turn the saw on again. The blade should now be going downward into the table slot.

Setting-up Saw

Note: local electrical codes or other codes may

require direct connection to a covered, protected The saw should be bolted securely to the shop floor to make sure the saw is stable when sawing long, heavy or unwieldy work pieces. Always use extra support for long or heavy stock.

junction box, or other electrical hook-up method.

Especially under difficult industrial conditions,

specialized electrical connections may be

necessary. For special electrical hook-ups, a

licensed electrician should be used to connect There are lugs in the bottom of the saw base for

the saw to power. use in bolting down of the saw. After positioning the saw, open the door in the base and mark the positions of the four lug holes. Move the saw to expose the marks. Prepare for attachment as

required by the attachment method being used. Install the applicalbe fasteners. Install shims as required to level the saw. Tighten the fastners to secure the saw to the floor.

CAUTION: KNOW AND OBSERVE ALL LOCAL

AND OTHER APPROPRIATE ELECTRICAL

CODES WHEN ATTACHING THIS BAND SAW

TO YOUR POWER SUPPLY.

1-ph. power source

Switch

Plug

Motor

Electrical

Models 8201 and 8201VS are delivered with a 115 volt single phase motor. Models 8203 and 8203VS are delivered with a 220/440 volt, 3-phase motor.

When the saw is a 115 volt model, it is supplied with a standard 115 volt plug and power cord which can be plugged into any suitable branch circuit.

3-ph. power source

Ground lug

Switch

Green or green with white trace

Plug

Motor

When the saw is equipped with a 3-phase motor there will be no plug on the 4-wire cable to the saw switch box. Instead, follow these instructions to connect the 3-phase motor to the power source:

Connecting to 3-phase power

1. Disconnect and lock out the branch circuit to

Green or green with white trace

Ground lug

Figure 4: Wiring Diagrams

Installing Optional Frame Riser

NOTE: Refer to the illustrations in the Replacement

Parts section for location of the parts used on the frame riser.

1. Remove the saw blade (refer to Changing Saw

Blades).

2. Remove the two screws at the top and bottom

of the blade guide that holds the blade guide on the frame.

WARNING: The saw must be turned off and

power disconnected any time the rubber protectors are being changed.

3. Unplug the electrical cord or open the circuit

breaker in the branch circuit.

4. Support the upper frame and wheel assembly

with a strap attached to an overhead crane. Use additional straps to be sure the frame assembly will be held in a stable position when it is lifted off the lower frame assembly.

5. Remove the nut on the bolt that clamps the

upper frame to the lower frame and remove the bolt, two washers and nut.

6. Lift the upper frame high enough off of the

lower frame to clear the riser casting.

7. Be certain the mating surfaces of the lower

frame, riser, and upper frame are all clean and free from dirt and debris.

8. Position the riser casting over the lower frame.

Make sure the locating dowels are inserted in the mating holes in the riser casting.

9. Lower the upper frame onto the riser casting.

Make sure the locating dowels fit into their mating holes.

10. Put the new (longer) attaching bolt and top

washer through the upper frame and riser, into the lower frame.

11. Put a washer and nut on the bolt and tighten

securely.

12. Attach the bracket hooks to the top and bottom

of the blade guard using self-tapping screws.

13. Attach the blade guide using the screws that

held the original (shorter) guard.

14. Remove the old (shorter) blade guide post

assembly from the upper frame.

15. The guide support assembly with the carbide

guides and blade support bearings should be transferred to the new, longer support rod. Several other new parts are included for this component. (Refer to the parts illustrations for more detail.)

16. Install a new 105-inch blade (refer to Changing

a Blade). Make sure blade tension and tracking

are checked and adjusted as required.

18. Install the extension plug cable between the motor plug and switch plug.

19. Plug the electrical cord into the power source or close the circuit breaker on the branch circuit. Operate the band saw to verify blade tracking.

Installing Optional Rip Fence

The rip fence slides on two rails attached at the front and rear of the work table. Install the fence mechanism as follows:

NOTE: Refer to the illustrations in the Replace-

ment Parts section for location of the parts used on the rip fence.

1. Slide the rails into the fence.

2. Ease the fence and rails into position on the table.

3. Using the four spacers and four attachment bolts, attach the rails securely to the saw table.

4. The fence can now be adjusted and used according the instructions in Adjustment and Use of Optional Rip Fence.

Operating Instructions

Operating Controls

START/STOP Switch

Figure 6 provides suggested blade speeds for various types of materials. The recommended speeds should be decreased 30 to 50% when using carbon steel blades. (The chart provides speeds that are based on cutting a 4-inch thick work piece using a bi-metal blade without cutting fluid.)

The START/STOP switch (refer to Figure 5) is used to turn on the band saw drive motor. The START switch has a molded guard which prevent inadvertent pressing of the START pushbutton.

START/STOP Switch

Guarded START Switch

E-Stop

Figure 5. START/STOP Controls

The STOP pushbutton is not guarded to allow use as an E-stop in an emergency.

Variable Speed Control

The variable speed control (refer to Figure 9) is used to change the speed of the saw blade. Refer to Adjusting Blade Speed for additional information on the use of the variable speed control.

Operating Instructions

Saw blades

The Wilton 14-inch saws accept blades from 1/8inch wide to 3/4-inch wide. The narrower widths are used for cutting shapes or circles; the wider widths are used for straight cuts.

For straight cuts, use the widest available saw blade. A wide blade provides cutting stability, and allows for more accurate and straighter cuts. Blade speed effects the efficiency of the cut and the service life of the blade. Good shop practice requires that work-hardening materials, such as stainless steel, require the cut be completed in a single pass. Otherwise, the effect of stopping the cut can result in hardening of the cut interface.

Other materials such as wood require higher blade speeds to prevent fiber tearing. The chart in

The following conditions should also be considered:

1. Increase speed 15% for materials 1/4-inch thick, 12% for 3/4-inch thick, 10% for 1 1/4inch thick, and 5% for 2 1/2-inch thick.

2. Decrease speed 12% when cutting 8-inch thick material.

To avoid tooth breakage, select a blade-tooth pitch that will have two or more teeth in contact with the workpiece at all times.

Different blade materials and tooth geometry (pitch and set) permit sawing a wide range of common and exotic materials. Contact your industrial distributor for recommendations on specialized blades. Using the corrrect blade can save you time, trouble, and the possibility of dulling and pemature discarding of the blade you normally might use. NOTE: Always use a sharp blade. SHARP BLADES ARE CHEAP INSURANCE AGAINST POOR CUTTING EFFICIENCY AND ACCELERATED MACHINE WEAR.

Material being cut

Structural steel shapes Low carbon steel Medium carbon steel High carbon steel Cr-moly steel Ni-Cr-moly steel Chromium steel Cr-vanadium steel Tool steel Stainless steel Free machining steel Cast iron Copper alloy (CU-Zm) Bronze Al-bronze Monel Titanium alloy Aluminum (soft) Aluminum (T-6+) Carbon Slate PTFE sheet, rod, rounds Hard rubber Plywood Other woods

Figure 6. Blade Speed to Material Chart

Speed (SF/M) range

165 160-165 115 90-100 105-135 90-115 80-140 105-115 40-80 40-70 80-100 55-90 55 90 40 40-45 25-40 3000 3000 3000 80-160 3000 3000 3000 3000

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