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Summary of Contents for Sharp SW-100T
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Page 1: Instruction Manual
SW-100T Instruction Manual Version 1 20171114... - Page 3 Make sure your work area is cleared of uninvited people and obstacles every time before you start operating the machine. Never step or stand on the roller table. Your foot may slip or trip on the rollers and you will fall. ...
- Page 4 Never adjust the wire brush or remove chips while the saw blade is still running. It is extremely dangerous if hands or clothing are caught by the running blade. Stop the saw blade before you clean the machine. It is dangerous if hands or clothing are caught by the running blade.
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Page 5: Table Of Contents
Safety Information Section 1 – Safety Instructions ……………………………………………………………………………………………………... 1-1 Safeguard Devices ………………………………………………………………………………………………………. 1-3 Emergency Stop …………………………………………………………………………………………………………. 1-4 Illustration: Emergency Stop ……………………………………………………………………………………… Safety Labels ………………………………………………………………………………………………………………. 1-6 Illustration: Safety Labels ………………………………………………………………………………………..… Hearing Protection ……………………………………………………………………………………………………… 1-10 CE Compliance ……………………………………………………………………………………………………………. 1-10 Risk Assessment …………………………………………………………………………………………………………. 1-10 General Information Section 2 –... - Page 6 Operating Instructions Section 4 – Safety Precautions …………………..…………………..……………………………………….……………………. 4-2 Before Operating …………………………..……………………………………………………………………………. 4-3 Control Panel ……..……………………………………..………………………………………….……………………. 4-4 Control Panel ………………….………………………………………………………………………..……. 4-4 Control Buttons ……………………………………………………………………………………….…….. 4-4 Cutting Operation ………..………..……………………………………………..……………………………………. 4-5 Selecting Blade Speed ……………………………………………………………………………………. 4-5 Changing Blade Speed – 4 Speed Step Pulley …………………………………………………. 4-5 Selecting Blade ……………………………………………………………………………………………….
- Page 7 Every 2 weeks …………………………………………………………………….………………………. First 600hrs for new machine,then every 1200h…………………….………………………. 8-2 Every Six Months ……………….………………………………………………….………………………. 8-3 Storage Conditions …………………………..………..…………………………………………………………….. 8-3 Terminating the Use of Machine ……..…………..…………………………………………………………….. 8-3 Oil Recommendation for Maintenance ………………………………………………………………………. 8-4 Troubleshooting Section 9 – Introduction ……………………….…….…………………..……………………………………………………………. 9-1 Precautions ………………….…………………..……………………………………………………………………..
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Page 8: Safety Information
Section 1 SAFETY INFORMATION SAFETY INSTRUCTIONS SAFEGUARD DEVICES EMERGENCY STOP SAFETY LABELS HEARING PROTECTION CE COMPLIANCE RISK ASSESSMENT Safety is a combination of a well-designed machine, operator’s knowledge about the machine and alertness at all times. This band machine has incorporated many safety measures during the design process and used protective devices to prevent personal injuries and potential risks. - Page 9 When a workpiece is too long or heavy, Use a sharp saw blade and keep the make sure it is supported with a roller machine in its best and safest table (recommended).
- Page 10 ignite an explosion. SAFEGUARD DEVICES The safeguard devices incorporated in this machine include the following two main parts: 1. Protection covers & guards 2. Safety-related switches Protection Covers & Guards 1. Idle wheel housing cover 2. Drive wheel housing cover 3.
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Page 11: Emergency Stop
Safety Related Switches To protect the operator, the following safety related switches on the machine are actuated when the machine is in operation. Wheel motion detector This is a proximity sensor used to detect the motion of the drive wheel. Once the saw blade is broken as soon as it starts slipping, the sensor will detect and stop the drive wheel and the machine. -
Page 12: Illustration: Emergency Stop
Illustration: Emergency Stop Emergency Stop Button... -
Page 13: Safety Labels
SAFETY LABELS Please read through and understand them before operating the machine. Refer to Illustration: Safety Labels. Label Meaning Label Meaning Impact Hazard Read Operator’s Manual WEAR SAFETY SHOES. Do This manual has important safety not approach dropping area information. Read through it during operation. -
Page 14: Illustration: Safety Labels
Illustration: Safety Labels SW-100T SafetyLabels... -
Page 15: Hearing Protection
HEARING PROTECTION Always use ear protection! When your machine is running, noise generated by the machine may come from the following: Saw blade during cutting or material feed mechanism Wire brush unit Chip conveyor unit Speed reducer ... -
Page 16: General Information
Section 2 GENERAL INFORMATION SPECIFICATION MACHINE PARTS IDENTIFICATION FLOOR PLAN This band saw machine is designed by our R&D engineers to provide you the following features and advantages: Safety This machine is designed to fully protect the operator from its moving parts during cutting operation. - Page 17 SPECIFICATION SW-100T Model Semi-Automatic Horizontal Bandsaw 0° 45° Angle 250 mm (10”) 190 mm (7.5”) Round Capacity 230 mm (9”) 190 mm (7.5”) Square 230 x 400 mm (9” x 15.7”) 190 x 190 mm (7.5” x 7.5”) Rectangular (H x W)
- Page 18 MACHINE PARTS IDENTIFICATION Dovetail slide guide Dovetail gauge plate Idle wheel cover Fixed vise Guide arm handle Movable vise Stopper Control box Blae tension handwheel Motor Blade tension device Variable blade speed control Hydraulic feed cylinder...
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Page 19: Floor Plan
FLOOR PLAN Machine top view Machine front view... - Page 20 Machine front view...
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Page 21: Moving & Installation
Section 3 MOVING & INSTALLATION LOCATION & ENVIRONMENT UNPACKING & INSPECTING LIFTING REMOVING SHIPPING BRACKET CLEANING INSTALLING RELOCATING LOCATION & ENVIRONMENT For your safety, please read all information regarding installation before proceeding. Install your machine in a place satisfying all of the following conditions: Space: ... -
Page 22: Unpacking & Inspecting
UNPACKING & INSPECTING Unpack your machine carefully to avoid damage to machine parts or surfaces. Upon arrival of your new band saw, please confirm that your machine is the correct model and it comes in the same specification you ordered by checking the model plate on the machine base. ... -
Page 23: Lifting
LIFTING When moving the machine, we strongly suggest you choose any one of the methods described below to move your machine. (Only applies to the machine with the design of the hanging point.) Move the machine to its location by using a crane and a wire rope sling that can fully withstand the weight of the machine (refer to machine specification under Section 2 General Information). - Page 24 Keep the machine well balanced during lifting process and make sure the wire rope does not interfere with the saw frame. When you work together with more than two people, it is best to keep constant verbal communication with each other. Use a forklift (Only applies to the machine with the design of the lifting point.) Make sure that the lifting rod can fully withstand the weight of the machine.
- Page 25 You must keep the machine balanced at all times. Make sure the forks are centered before use. (Illustration only. Please follow user guide of your forklift.) 3. Use rolling cylinders You can use rolling cylinders to move your machine in a small machine shop environment. ...
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Page 26: Illustration: Lifting Points
Illustration: Lifting Points Minimum weight capacity for each wire rope: 1 ton Total number of wire ropes required: 4... -
Page 27: Removing Shipping Bracket
REMOVING SHIPPING BRACKET After the machine has been properly positioned, remove the shipping bracket that is used to lock the saw frame and the saw bed. Retain this bracket so that it can be used again in the event that your machine must be relocated. -
Page 28: Supplying Coolant
Supplying coolant Fill the coolant tank to the middle level of the sight gauge by pouring the coolant from above the chip conveyor. Use the sight gauge to check the coolant level remaining in the tank. Always check the coolant supply before starting the machine. -
Page 29: Connecting Electric Power
Connecting electric power Have a qualified electrician make the electrical connections. If the power supply voltage is different from the transformer and motor connection voltage shown on the label attached to the electrical compartment of the machine, contact us or your agent immediately. - Page 30 Make sure the sawing area is clear of any objects. Start the blade and check the blade rotation. If the electrical connections are made correctly, the blade should run in a counterclockwise direction. If not, shut the hydraulics off, turn off the machine as well as the shop circuit breaker.
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Page 31: Installing Roller Table (Optional)
Installing roller table (optional) The roller table is used to support long material at the rear and/or the front of the machine. If you have ordered the optional roller table for cutting long material, position it before or behind the machine. Adjust bolts Level the roller table and the stand with the machine by adjusting the leveling bolts. -
Page 32: Operating Instructions
Section 4 OPERATING INSTRUCTIONS SAFETY PRECAUTIONS BEFORE OPERATING CONTROL PANEL CHECK PRIOR TO OPERATION CUTTING OPERATIONS UNROLLING & INSTALLING THE BLADE ADJUSTING BLADE TENSION ADJUSTING WIRE BRUSH ADJUSTING SAW ARM ADJUSTING HORIZONTAL STOP SPRING CUSHION... - Page 33 SAFETY PRECAUTIONS For your safety, please read and understand the instruction manual before you operate the machine. The operator should always follow these safety guidelines: • The machine should only be used for its designated purpose. • Do not wear gloves, neckties, jewelry or loose clothing/hair while operating the machine. •...
- Page 34 BEFORE OPERATING Choosing an appropriate saw blade and using the right cutting method is essential to your cutting efficiency and safety. Select a suitable saw blade and cutting method based on your work material and job requirements e.g. cutting accuracy, cutting speed, economic concern, and safety control. Wet cutting If you choose dry cutting or low-speed cutting, the chips may accumulate in machine parts and may cause operation failure or insulation malfunction.
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Page 35: Control Panel
CONTROL PANEL The control panel is located on the top of the electrical box. It includes the following function: power system and cooling system. The operator must fully understand the function of each switch and button before operating the machine. Control Buttons 1. -
Page 36: Cutting Operation
CUTTING OPERATIONS Do not connect power cord to power source until the following instructions are clearly understood and followed. Selecting Blade Speed Blade speed selection should be made according to the material being cut. The following chart provides information on blade speed and is used for reference only. Material Speed Pulley Groove Used... -
Page 37: Selecting Blade
Speed Selection Chart Selecting Blade For best results, the correct number of teeth on the workpiece is important. For mild materials, the 3-6-12-24 rule applies. For hard materials, the 6-12-24-48 rule applies. At least two teeth must be in cutting area at all times. -
Page 38: Adjusting Feed Rate (Cutting Pressure)
Adjusting Feed Rate (Cutting Pressure) To obtain desired feed rate (cutting pressure), the “hydraulic cylinder” (Fig 3, #4) and “feed tension spring” (Fig 3, #6) are to be adjusted together. 1. Saw bow 2. By-pass valve (Do not make adjustment here.) 3. -
Page 39: Angle Cutting
Angle Cutting The vise offers the user great flexibility in angle cutting from 0° (Position 1) to 45° (Position 2). - Page 40 Cutting at 45° Step 1 - Move the right guide arm to the end of the dovetail guide. Step 2 - Lift the saw bow up to the highest position. Step 3 - Loosen the two lock bolts (Fig 5, #2 and #3) of the fixed vise jaw (Fig 5, #1). Then adjust the fixed vise jaw until it is 45°...
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Page 41: Adjusting Coolant Flow
When cutting irregularly-shaped material, if possible, avoid positioning the work in the way that the cut would be started on a sharp corner. Arrange your workpiece in the way that as many teeth as possible will be applied to the work at one time. -
Page 42: Installing Material Stop Bracket
Installing Material Stop Bracket Step 1 - Install the depth bar (Fig 9, #2) and tighten the set screw (Fig 9, #1). (The depth bar is taken off from the machine base during transit for safety reason. Step 2 - Lift the saw bow and clamp material securely with vise. -
Page 43: Unrolling & Installing The Blade
UNROLLING & INSTALLING THE BLADE Always wear leather gloves and protection glasses when handling a blade. Unrolling the blade Please follow the procedures illustrated below. Unroll and roll the blade Installing a new blade Make sure the power cord is disconnected from power source. Step 1 - Elevate the saw bow until it is positioned vertically. -
Page 44: Adjusting Blade Tension
Step 6 - Apply tension by turning the blade tension handle lever clockwise. Make sure you have proper blade tension. Proper tension exists when the blade does not slip on the drive wheel when cutting. ADJUSTING BLADE TENSION Turn blade tension handle lever clockwise to increase blade tension; counterclockwise to decrease blade tension. -
Page 45: Adjusting Horizontal Stop Spring Cushion
Step 2 – After adjustment is made, tighten the blade guide locking handle. Locking Handle ADJUSTING HORIZONTAL STOP SPRING CUSHION Always make sure the power cord is disconnected from power source when making adjustments. Complete Cut – Adjusting Horizontal Stop Spring Cushion The workpiece should be able to cut through completely. - Page 46 Automatic Shut-Off – Adjusting Horizontal Stop Spring Cushion The motor should shut off immediately after the blade has cut through the material and right before the head comes to rest on the horizontal stop spring cushion. If it does not, the spring cushion must be adjusted.
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Page 47: Electrical System
Section 5 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS... -
Page 49: Hydraulic System
Section 6 HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM... -
Page 51: Bandsaw Cutting: A Practical Guide
Section 7 BANDSAW CUTTING: A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BladeBreak -In SOLUTIONS TO SAWING PROBLEMS... - Page 52 INTRODUCTION TPI: The number of teeth per inch as measured from gullet to gullet. 2. Tooth Rake Angle: The angle of the tooth face measured with respect to a line perpendicular to the cutting direction of the saw. 3.Tooth Pitch: Tooth pitch refers to the number of teeth per inch (tpi). 1 inch equates to 25.4 mm. A distinction is made between constant tooth pitches with a uniform tooth distance, 2 tpi for example, and variable tooth pitches with different tooth distances within one toothing interval.
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Page 53: Vise Loading
4. Tooth pitch The main factor here is the contact length of the blade in the workpiece. If it is 4P, 25.4 ÷ 4 P = 6.35 mm, that is, one tooth is 6.35 mm. If it is 3P, 25.4 ÷ 3 P = 8.46 mm If the number is small, it means that the tooth is large. What is written as 3/4 is that it is a variable pitch of large (3) / small (4). -
Page 54: Bladebreak -In
The following diagrams suggest some costeffective ways of loading and fixturing. Be sure, regardless of the arrangement selected, that the work can be firmly secured to avoid damage to the machine or injury to the operator. BladeBreak -In Completing a proper break-in on a new band saw blade will dramatically increase its life. 1. -
Page 55: Maintenance & Service
Section 8 MAINTENANCE & SERVICE INTRODUCTION BASIC MAINTENANCE MAINTENANCE SCHEDULE BEFORE BEGINNING A DAY’S WORK AFTER ENDING A DAY’S WORK Every 2 weeks First 600hrs for new machine,then every 1200hrs EVERY SIX MONTHS STORAGE CONDITIONS TERMINATING THE USE OF MACHINE OIL RECOMMENDATION FOR MAINTENANCE INTRODUCTION For the best performance and longer life of the band saw machine, a maintenance schedule is necessary. - Page 56 MAINTENANCE SCHEDULE We suggest you do the maintenance on schedule. Before beginning a day’s work 1. Please check the hydraulic oil level. If oil level volume is below 1/2, please add oil as necessary.(Filling up to 2/3 level is better for system operation.) 2.
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Page 57: Storage Conditions
Mobil gear 630 Recommended hydraulic oil ShellTellus 32 Mobil DTE Oil Light Hydraulic 28 Every six months 1.Clean the filter of the cutting fluid. 2.Replace the transmission oil for every half of a year(or 1200 hours). Check the sight gauge to ascertain the transmission level. Recommended TRANSMISSION OIL ... -
Page 58: Oil Recommendation For Maintenance
OIL RECOMMENDATION FOR MAINTENANCE Item Method Revolution Suggest oil Dovetail guide Keep grease covered. Antirust. Daily Shell R2 Roller bearing Sweep clean and oil with lubricant. Daily SEA #10 Bed roller / surface Sweep clean and oil with lubricant. Daily SEA #10 Nipples of bearing Use grease gun, but not excess. -
Page 59: Troubleshooting
Section 9 TROUBLESHOOTING INTRODUCTION PRECAUTIONS GENERAL TROUBLES & SOLUTIONS MINOR TROUBLES & SOLUTIONS MOTOR TROUBLES & SOLUTIONS BLADE TROUBLES & SOLUTIONS SAWING PROBLEMS & SOLUTIONS RE-ADJUSTING THE ROLLER TABLE INTRODUCTION All the machines manufactured by us pass a 48 hours continuously running test before shipping out and we are responsible for the after sales service problems during the warranty period if the machines are used normally. - Page 60 BEFORE ANY ADJUSTMENT OR MAINTENANCE OF THE MACHINE, PLEASE MAKE SURE TO TURN OFF THE MACHINE AND DISCONNECT THE POWER SUPPLY. GENERAL TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFORE ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Excessive belt tension Adjust belt tension so that belt does not slip on drive pulley while cutting ( 1/2“...
- Page 61 MINOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Saw blade motor does not run Overload relay activated Reset even though blade drive button Saw blade is not at forward Press SAW FRAME is pressed. limit position. FORWARD button MOTOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY...
- Page 62 Motor overloaded Reduce motor load. Frequent opening of Motor overloaded Reduce motor load fuses or circuit Incorrect fuses or circuit Install correct fuses or circuit breakers. breakers. breakers. BLADE TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFORE ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY...
- Page 63 Blade binding in cut Decrease feed pressure Dry cutting Use lubricant on all materials, except cast iron Premature Blade too coarse Use finer tooth blade tooth wear Not enough feed Increase feed so that blade does not ride in cut Excessive speed Decrease speed...
- Page 64 SAWING PROBLEMS AND SOLUTIONS Other than this manual, the manufacturer also provides some related technical documents listed as follows: Sawing Problems and Solutions Vibration during cutting Failure to cut Short life of saw blade Curved cutting Broken blade ✓ ✓ ✓...
- Page 65 ✓ ✓ ✓ Back edge of blade touching wheel Adjust wheel to obtain clearance flange ✓ ✓ ✓ Workpiece of insufficient diameter Use other machine, suited for diameter of workpiece Replace ✓ ✓ ✓ Saw blade teeth worn Replace SOLUTIONS TO SAWING PROBLEMS Table Of Contents #1.
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Page 66: Heavy Even Wear On Tips And Corners Of Teeth
#1. Heavy Even Wear On Tips and Corners Of Teeth Probable Cause : A. Improper break-in procedure. B. Excessive band speed for the type of material being cut. This generates a high tooth tip temperature resulting in accelerated tooth wear. C. -
Page 67: Chipped Or Broken Teeth
#4. Chipped Or Broken Teeth Probable Cause : A. Improper break-in procedure. B. Improper blade selection for application. C. Handling damage due to improper opening of folded band. D. Improper positioning or clamping of material. E. Excessive feeding rate or feed pressure. F. -
Page 68: Chips Welded To Tooth Tips
#7. Chips Welded To Tooth Tips Probable Cause : A. Insufficient sawing fluid due to inadequate supply, improper ratio and/or improper application. B. Worn, missing or improperly positioned chip brush. C. Improper band speed. D. Improper feeding rate. #8. Gullets Loading Up With Material Probable Cause : A. -
Page 69: Heavy Wear On Both Sides Of Band
10. Heavy Wear On Both Sides Of Band Probable Cause : A. Chipped or broken side guides. B. Side guide adjustment may be too tight. C. Insufficient flow of sawing fluid through the side guides. D. Insufficient sawing fluid due to inadequate supply, improper ratio and/or improper application. -
Page 70: Butt Weld Breakage
#13. Butt Weld Breakage Probable Cause : A. Any of the factors that cause body breaks can also cause butt weld breaks. (See Observations #5, #15 and #16) #14. Heavy Wear In Only The Smallest Gullets Probable Cause : A. Excessive feeding rate. B. -
Page 71: Band Is Twisted Into A Figure "8" Configuration
#17. Band is Twisted Into A Figure "8" Configuration Probable Cause : A. Excessive band tension. B. Any of the band conditions which cause the band to be long (#18) or short (#19) on tooth edge. C. Cutting a tight radius. #18. -
Page 72: Re-Adjusting The Roller Table
#20. Broken Band Shows A Twist In Band Length Probable Cause : A. Excessive band tension B. Any of the band conditions which cause the band to be long (#18) or short (#19) on tooth edge. C. Cutting a tight radius. RE-ADJUSTING THE ROLLER TABLE If the feeding table suffers the huge stroke and the alignment is effected, follow the below procedure to adjust. -
Page 73: Parts
Section 10 PARTS SPARE PARTS RECOMMENDATIONS PART LIST SPARE PARTS RECOMMENDATIONS The following table lists the common spare parts we suggest you purchase in advance: Part Name Part Name Saw blade Coolant tank filter Wire brush Steel plates Carbide inserts Rollers Bearings Belt...