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

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
Ph.: 800-274-6848	Revision C2 04/07
www.wmhtoolgroup.com	Copyright © 2007 WMH Tool Group

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

3

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.

4	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	1 HP 1-Ph	1 HP 3-Ph	1 HP 1-Ph	1 HP 3-Ph
	Rating ..................
	Voltage.................	115 vac....................	220/440 vac ..............	115 vac ....................	220/440 vac
	Speed ..................	1725 rpm .................	1725 rpm ..................	1725 rpm..................	1725 rpm
	Cutting Speeds	3300	3300	2600	2600
	Wood (SFPM) ......
	Metal (SFPM) .......	39, 57, 78, 107, ....... 39, 57, 78, 107, ........ 116 – 334 .................			116 – 334
	Dimensions	142, 196, 278 ..........	142, 196, 278 ............	Variable Speed .........	Variable Speed
		20 Inches	20 Inches	20 Inches	20 Inches
	Length .................
	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	3/4-Inch	3/4-Inch	3/4-Inch	3/4-Inch
	Width ...................
	Depth ...................	3/8-Inch ...................	3/8-Inch ....................	3/8-Inch ....................	3/8-Inch
	Miter Gauge .............	Standard ..................	Standard ...................	Standard ..................	Standard
	Blade Dimension	3/8x0.025x92.5 In	3/8x0.025x92.5 In	3/8x0.025x92.5 In	3/8x0.025x92.5 In.
	Standard ..............

- Misuse of this machine can cause serious injury.		- Always follow instructions in Operating Instruc-
- For safety, machine must be set up, used and		tions and Parts Manual when changing acces-
serviced properly.		sory tools or parts.
- Read, understand and follow instructions in the		- Never modify the machine without consulting
Operating Instructions and Parts Manual which		Wilton Corporation.
was shipped with your machine.		You - the Stationary Power Tool User - Hold
When Setting up Machine:		the Key to Safety.
- Always avoid using machine in damp or poorly		Read and follow these simple rules for best results
lighted work areas.		and full benefits from your machine. Used properly,
- Always be sure the machine support is se-		Wilton’s machinery is among the best in design and
curely anchored to the floor or the work bench.		safety. However, any machine used improperly can
When Using Machine:		be rendered inefficient and unsafe. It is absolutely
- Always wear safety glasses with side shields		mandatory that those who use our products be
(See ANSI Z87.1)		properly trained in how to use them correctly. They
- Never wear loose clothing or jewelry.		should read and understand the Operating Instruc-
- Never overreach - you may slip and fall.		tions and Parts Manual as well as all labels affixed to
When Servicing Machine:		the machine. Failure to follow all of these warnings
- Always disconnect the machine from its electri-		can cause serious injuries.
cal supply while servicing.

Machinery General Safety Warnings
1.	Always wear protective eye wear when operat-		Whenever changing accessories or general
	ing machinery. Eye wear shall be impact		maintenance is done on the machine, electri-
	resistant, protective safety glasses with side		cal power to the machine must be discon-
	shields which comply with ANSI Z87.1		nected before work is done.
	specifications. Use of eye wear which does	9.	Maintain all machine tools with care. Follow
	not comply with ANSI Z87.1 specifications		all maintenance instructions for lubricating and
	could result in severe injury from breakage of		the changing of accessories. No attempt shall	5
	eye protection.		be made to modify or have makeshift repairs
2.	Wear proper apparel. No loose clothing or		done to the machine. This not only voids the
	jewelry which can get caught in moving parts.		warranty but also renders the machine unsafe.
	Rubber soled footwear is recommended for	10.	Machinery must be anchored to the floor.
	best footing.	11. Secure work. Use clamps or a vise to hold
3.	Do not overreach. Failure to maintain proper		work, when practical. It is safer than using
	working position can cause you to fall into the		your hands and it frees both hands to operate
	machine or cause your clothing to get caught		the machine.
	pulling you into the machine.	12.	Never brush away chips while the machine is
4.	Keep guards in place and in proper working		in operation.
	order. Do not operate the machine with guards	13.	Keep work area clean. Cluttered areas invite
	removed.		accidents.
5.	Avoid dangerous working environments. Do	14.	Remove adjusting keys and wrenches before
	not use stationary machine tools in wet or		turning machine on.
	damp locations. Keep work areas clean and	15.	Use the right tool. Don’t force a tool or attach-
	well lit.		ment to do a job it was not designed for.
6.	Avoid accidental starts by being sure the start	16.	Use only recommended accessories and follow
	switch is OFF before plugging in machine.		manufacturers instructions pertaining to them.
7.	Never leave the machine running while unat-	17.	Keep hands in sight and clear of all moving
	tended. Machine shall be shut off whenever it		parts and cutting surfaces.
	is not in operation.	18. All visitors should be kept at a safe distance from
8.	Disconnect electrical power before servicing.		the work area. Make the workshop completely

			safe by using padlocks, master switches, or by				19. Know the tool you are using — its application,
			removing starter keys.				limitations, and potential hazards.
		General Electrical Cautions
			This saw should be grounded in accordance				Caution: For circuits which are far away from the
		with the National Electrical Code and local codes
		and ordinances. This work should be done by a					electrical service box, the wire size must be in-
		qualified electrician. The saw should be grounded					creased in order to deliver ample voltage to the
		to protect the user from electrical shock.					motor. To minimize power losses and to prevent
							motor overheating and burnout, the use of wire sizes
		Wire Sizes					for branch circuits or electrical extension cords
							according to the following table is recommended.
			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
		Safety Instructions on Sawing Systems
		1. Always wear leather gloves when handling saw					8. Bring adjustable saw guides and guards as
			blade. The operator shall not wear gloves when				close as possible to the workpiece.
			operating the machine.				9. Always wear protective eye wear when
		2. All doors shall be closed, all panels replaced,					operating,		servicing, or adjusting machinery.
			andother safety guards in place prior to the				Eyewear shall be impact resistant, protective
			machine being started or operated.				safety glasses with side shields complying with
		3. Be sure that the blade is not in contact with the					ANSI Z87.1 specifications. Use of eye wear
			workpiece when the motor is started. The				which does not comply with ANSI Z87.1
			motor	shall be started and you should			specifications could result in severe injury
			allow the saw to		come up to full speed		from breakage of eye protection.
			before bringing the saw			blade into contact	See Figure B
6	4.		with the workpiece.				10. Nonslip footwear and safety shoes are recom-
			Keep hands away from the blade area. See				mended. See Figure C.
			Figure A.				11. Wear ear protectors (plugs or muffs) during
		5. Remove any cut off piece carefully while					extended periods of operation. See Figure D.
			keeping your hands free of the blade area.				12. The workpiece, or part being sawed, must be
		6. Saw must be stopped and electrical supply					securely clamped before the saw blade enters
			must be cut off before any blade replacement				the workpiece.
			or adjustment of blade support mechanism is				13. Remove cut off pieces carefully, keeping
			done, or before any attempt is made to change				hands away from saw blade.
			the drive belts or before any periodic service or				14. Saw must be stopped and electrical supply cut
			maintenance is performed on the saw.				off or machine unplugged before reaching into
		7. Remove loose items and unnecessary					cutting area.
			workpieces from area before starting machine.				15. Avoid contact with coolant, especially guarding
			A			B	your eyes.		D
								C

Introduction

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.

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

Saw Head

Clutch Knob

Gearbox

Oil Level

Gauge Variable Speed

Control

	Drive	Pivoting
		Motor
	Motor
		Mounting
		Plate
		Motor Pulley

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

Setup and Operation

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).

Blade tension adjustment
		knob	Upper drive		7
			wheelUpper
				blade
				guide
				support
				assembly
			Lock Knob
				Upper blade
				guide and
Upper				support
	ON/OFF	Optional rip	Miter	assembly
wheel
guard	switch	fence	slot	Table
Blade guard
Lower wheel guard				Lower drive
Dust chute
				wheel
				Lower blade
				guide and
				support
				assembly
				Base

Figure 3: Band Saw Features (Front View)

(All Models)

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.

Setting-up Saw

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.

There are lugs in the bottom of the saw base for 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.

8 Install the applicalbe fasteners. Install shims as required to level the saw. Tighten the fastners to secure the saw to the floor.

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.

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

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.

Note: local electrical codes or other codes may require direct connection to a covered, protected 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 the saw to power.

CAUTION: KNOW AND OBSERVE ALL LOCAL AND OTHER APPROPRIATE ELECTRICAL CODES WHEN ATTACHING THIS BAND SAW TO YOUR POWER SUPPLY.

	1-ph.	Switch	Motor
	power	Plug
	source

Green or green with white trace

Ground lug

3-ph.	Switch
power		Motor
source	Plug

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 Replacement 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.

9

Operating Instructions

Operating Controls

START/STOP Switch

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.

10

Operating Instructions

Saw blades

The Wilton 14-inch saws accept blades from 1/8- inch 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

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 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 1/4- inch 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	Speed (SF/M) range
Structural steel shapes	165
Low carbon steel	160-165
Medium carbon steel	115
High carbon steel	90-100
Cr-moly steel	105-135
Ni-Cr-moly steel	90-115
Chromium steel	80-140
Cr-vanadium steel	105-115
Tool steel	40-80
Stainless steel	40-70
Free machining steel	80-100
Cast iron	55-90
Copper alloy (CU-Zm)	55
Bronze	90
Al-bronze	40
Monel	40-45
Titanium alloy	25-40
Aluminum (soft)	3000
Aluminum (T-6+)	3000
Carbon	3000
Slate	80-160
PTFE sheet, rod, rounds	3000
Hard rubber	3000
Plywood	3000
Other woods	3000

Figure 6. Blade Speed to Material Chart