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Summary of Contents for Sharp SW-165HT
- Page 1 SW-165HT Instruction Manual Version 1 20211019...
- Page 3 Safety rules ƒ It’s essential to power on your bandsaw machine for at least one hour every two years, if you seldomly use the machine. (This period of power-on must be without proceeding with other operation) Otherwise the machine program may disappear due to not strictly follow this safety rule.
- Page 4 Safety rules ƒ Never cut carbon or any other material that may produce and disperse explosive dust. It is possible that sparks from motors and other machine parts will ignite and explode the air-borne dust. ƒ Never adjust the wire brush or remove chips while the saw blade is still running.
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Page 5: Table Of Contents
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 ……………………………………………………………………………………………………… 1-8 CE Compliance ……………………………………………………………………………………………………………. 1-8 Risk Assessment …………………………………………………………………………………………………………. - Page 6 Table of Contents Control Buttons ……………………………………………………………………………………….…….. 4-5 Blade Descend Pressure & Speed ………..…………………………………………………….…… 4-7 Standard Accessories ………….………………………..……………………………………………….…………… 4-7 Optional Accessories …….…….………………………..…………………………………………….……………… 4-9 Blade Deviation Detector & Calibration Procedure (Optional)…………………………………….. 4-11 Unrolling & Installing the Blade …………………………………………………………………….……………. 4-12 Adjusting Wire Brush ………..……………………………………………………………………….………………. 4-14 Adjusting Saw Arm……………………………………………………………………………………………………….
- Page 7 Table of Contents Troubleshooting Section 9 – Introduction ……………………….…….…………………..……………………………………………………………. 9-1 Precautions ………………….…………………..……………………………………………………………………..9-2 General Troubles & Solutions ………………………..……………………………………………………………. 9-2 Minor Troubles & Solutions ………………………..………………………………………………..……………. 9-3 Motor Troubles & Solutions ………………………..…………………………………………………..…………. 9-3 Blade Troubles & Solutions ………………………..……………………………………………………………….. 9-4 Sawing Problems & Solutions ………………………..…………………………………………………………… 9-5 Re-Adjusting the Roller Table ………………………..…………………………………………………………….
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Page 9: 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 10 Keep the work environment safe. Do not Use a sharp saw blade and keep the use band saw in a damp or wet location. machine in its best and safest...
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Page 11: Safeguard Devices
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. Gear reducer cover 4. -
Page 12: 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 or as soon as it starts slipping, the sensor will detect and stop the drive wheel and the machine. -
Page 13: Illustration: Emergency Stop
Illustration: Emergency Stop Emergency Stop... -
Page 14: Safety Labels
SAFETY LABELS Please read through and understand these safety labels 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. -
Page 15: Illustration: Safety Labels
Illustration: Safety Labels... -
Page 16: 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 17: 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 18 SPECIFICATION SW-165HT Semi-Automatic Swivel Head Model Double Mitering Band Saw 0° +45° +60° Angle 420 mm (16.5”) 400 mm (15.8”) 250 mm (10”) Round 380 mm (15”) 400 mm (15.8”) 250 mm (10”) Square Capacity 380 x 650 mm 400 x 400 mm...
- Page 19 MACHINE PARTS IDENTIFICATION Blade Motor Quick Approach Device Left Guide Arm Saw Bow Pulley Cover Vise Drive Wheel Idle Wheel Cover Electrical Compartment Base Work Bed...
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Page 20: Floor Plan
FLOOR PLAN Machine top view Machine front view... - Page 21 Machine side view...
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Page 23: 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 24 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. ...
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Page 25: 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 26 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. (Refer to Section 2 – General Information for Specifications.) Machine lifting with a forklift should be done strictly according to the lifting points designated by the original manufacturer.
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Page 27: Illustration: Lifting Points
3. Use rolling cylinders You can use rolling cylinders to move your machine in a small machine shop environment. You must use rolling cylinders made in material of proper compressive strength. 4. Other ways to move If the machine does not have stickers, please contact your local agent immediately. -
Page 28: 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 29: 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 30: Leveling
Turn off the shop circuit breaker. Make sure the machine circuit breaker switch on the electrical compartment door is turned to OFF. Remove the screw securing the electrical compartment and then open the door. Pull the power supply cable and grounding conductor through the power supply inlet into the electrical compartment. -
Page 31: Anchoring The Machine
Anchoring the machine Normally there is no need to anchor the machine. If the machine is likely to vibrate, fix the machine to the floor with anchor bolts. Shock absorption steel plates are provided and can be placed under each leveling bolt to prevent their sinking into the concrete floor. -
Page 33: Operating Instruction
Section 4 OPERATING INSTRUCTION SAFETY PRECAUTIONS BEFORE OPERATING CONTROL PANEL STANDARD ACCESSORIES OPTIONAL ACCESSORIES UNROLLING & INSTALLING THE BLADE ADJUSTING WIRE BRUSH ADJUSTING SAW ARM ADJUSTING COOLANT FLOW ADJUSTING BLADE SPEED BREAKING-IN THE BLADE TEST-RUNNING THE MACHINE CUTTING OPERATION USING TOP CLAMP FOR BUNDLE CUTTING TERMINATING A CUTTING OPERATION... -
Page 34: Safety Precautions
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 35: Before Operating
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. -
Page 36: Control Panel
CONTROL PANEL The control panel is located on the top of the electrical box. It includes the following function: power system, hydraulic system, cooling system and the light system. The operator must fully understand the function of each switch and button before operating the machine. Name Power indicator lamp Hydraulic start/stop buttons with built-in... -
Page 37: Control Buttons
Control Buttons 1. Power indicator lamp When the lamp is on, it indicates the power to the machine is turned on. 2. Hydraulic start/stop buttons with built-in lamp (CE model) Hydraulic start button with built-in lamp (non-CE model) CE model When the green button is pressed, the built-in-lamp will come on and the hydraulic motor starts to operate. - Page 38 The vise open/clamp switch must be turned to the right to “clamp” position before the blade can start running. 6. *Saw bow up button When this button is pressed, the saw bow rises until the operator release the button. *If the optional angle display is installed: DO NOT rise the saw bow over 420mm...
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Page 39: Blade Descend Pressure & Speed
12. Work light button (Not available) 13. Lift rollers up/down switch (Not available) 14. Coolant on/off button Flip the switch to the right to turn on the coolant pump; to the left to turn it off. A started blade will also start the coolant automatically. Blade Descend Pressure and Speed The part of control panel is where cutting pressure and saw blade descend speed can be adjusted. -
Page 40: Standard Accessories
STANDARD ACCESSORIES Blade tension device This blade tension device equipped with hydraulic cylinder provides appropriate tension to the saw blade. To tighten the saw blade, turn the selector to Upon saw blade breakage, the safety device will activate and automatically stop all machine operation. - Page 41 Gear reducer The specially designed gear reducer can work toward your preset blade speed and torque. Please refer to section 8 for information on maintenance. Coolant pump The coolant pump supplies coolant to cool off cutting temperatures during cutting. Also, it can be used to wash off chips. Powered wire brush The wire brush is hydraulically driven to rotate at the same speed as the blade motor.
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Page 42: Optional Accessories
OPTIONAL ACCESSORIES Vise pressure regulator This adjustment valve is used to control vise pressure. Adjust vise pressure based on the material of your workpiece. Pressure When cutting pipes or soft materials, reduce vise pressure to gauge prevent exerted pressure from damaging the workpiece shape or exterior. - Page 43 Angle Display Device The angle display shows the current saw bow angle, it’s easier to process miter cutting when you have angle display. *To prevent the angle display sensor from pressed damage by saw bow: *DO NOT rise the saw bow over 420mm height, otherwise the angle display sensor beside the angle scale will get pressed by saw bow and caused damage.
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Page 44: Blade Deviation Detector & Calibration Procedure (Optional)
Blade Deviation Detector & Calibration Procedure (Optional) This device detects blade deviation. If the blade deviates out of the tolerance range, the machine will stop automatically. ※ [Remark] When this device is installed, the cutting width will be reduced. The blade deviation detected value and present values are displayed on the HMI screen. - Page 45 Picture B : Deviation calibration Value Display Make the proximity sensor connect Deviation with power & adjust the proximity Value sensor until the blade deviation displayed on the control panel is 0 mm 。 Tolerance: ±0.03 mm (0.0012”) 。 ...
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Page 46: 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 Step 1 - Select the most suitable saw blade for your workpiece considering the size, shape and material. - Page 47 Step 4 - Turn the tension controller handle from “ ” to “ ” position to release tension. The idle wheel will then move slightly toward the direction of the drive wheel. Step 5 - Open the idle and drive wheel cover. Step 6 - Press the Blade Clip device to hold onto the blade.
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Page 48: Adjusting Wire Brush
Step 15 - Make sure the sides of the blade are in close contact with the carbide inserts and then tighten the left and right carbide inserts by tightening the “lock nut.” Step 16 – Gently close the idle and drive wheel covers. Step 17 - Press the saw blade start button to start the blade. -
Page 49: Adjusting Coolant Flow
Step 3 – Use the flow control valve (shown below) to adjust the amount of fluid flowing to the cutting area. Adjust the flow amount if you observe the following changes to the chips generated from cutting. If the chips are sharp and curved, increase the coolant flow amount. If the chips are granulated, decrease the coolant flow amount. -
Page 50: Test-Running The Machine
TEST-RUNNING THE MACHINE Test-running this machine can ensure good machine performance in the future. We suggest you run the following tests on the machine before first use: Testing machine performance: Turn on the power and run a basic performance test after you finish installing the machine. Follow these steps to test machine performance: Step 1 –... -
Page 51: Using Top Clamp For Bundle Cutting
Before you start cutting, check again that there is no other object in the cutting area. Step 8 – While the blade descends, adjust the blade speed if necessary. You can do so by turning the blade speed control knob, clockwise to speed up and counterclockwise to slow down. The blade speed is displayed in the blade speed indicator. - Page 52 Proper and improper stacking of workpieces Proper Improper Step 2 – Align the top clamp cylinders with the center of the workpiece and tighten the lock nuts. Step 3 – Open the adjustment valve (pointed by the arrow), which is used to adjust the top clamp speed during clamping/unclamping.
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Page 53: Electrical System
Section 5 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS Non CE model: p. 5 2~5 5 CE model: p.5 6~5 9... -
Page 63: Hydraulic System
Section 6 HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS... -
Page 65: Bandsaw Cutting: A Practical Guide
Section 7 BANDSAW CUTTING: A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BLADE BREAK-IN... - Page 66 INTRODUCTION Constant Variable Min. SAW BLADE SELECTION 1. Band length The dimensions of the band will depend on the band saw machine that has been installed. Please refer to Section 2 – General Information 2. Band width Band width: the wider the band saw blade, the more stability it will have. 3.
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Page 67: 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 68: Blade Brake-In
BLADE BREAK-IN... -
Page 69: 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 for routine change 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... - Page 70 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.
- Page 71 Grease Injection Hole: Grease Injection Nozzles at the middle of drive wheel Grease Injection Nozzle and idle wheel; (You need to rotate the wheel until you ssee the Grease injection nozzle.) : The position of injection indicating. Please inject the grease into the Nozzle. 1.
- Page 72 (if applicable) Manual Lubrication Injection Device: Lubrication volume indicator. Recommend keeping the volume over 50% inside the vessel. Please take down this vessel cap to replenish the lubrication. For the prevention of working environment pollution, DO NOT replenish too much volume of lubrication while supplying the lubrication into the vessel.
- Page 73 Gear Oil & Grease Injection Hole : 1. A grease injection hole and a gear oil injection Grease Injection Nozzle hole on the top of gear reducer. : The position of injection indicating. Gear Oil Injection Hole Recommend keeping the volume under 50% inside 。...
- Page 74 TERMINATING THE USE OF THE MACHINE Waste disposal: When your machine can not work anymore, you should drain the oil from machine body. Please store the oil in safe place with bottom tray. Ask a environment specialist to handle the oil. It can avoid soil pollution.
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Page 75: Precautions
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 Clausing pass a 72 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 76 PRECAUTIONS When an abnormality occurs in the machine during operation, you can do it yourself safely. If you have to stop machine motion immediately for parts exchanging, you should do so according to the following procedures: Press HYDRAULIC MOTOR OFF button or EMERGENCY STOP button. ...
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Page 77: Motor Troubles & Solutions
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 78 BLADE TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFOER ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Too few teeth per inch Use finer tooth blade Loading of gullets Use coarse tooth blade or cutting lubricant. Teeth strippage Excessive feed Decrease feed...
- Page 79 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 80 SOLUTIONS TO SAWING PROBLEMS Table Of Contents #1. Heavy Even Wear On Tips and Corners Of Teeth #11. Uneven Wear Or Scoring On The Sides Of Band #2. Wear On Both Sides Of Teeth #12. Heavy Wear And/Or Swagging On Back Edge #3.
- Page 81 #2. Wear On Both Sides Of Teeth Probable Cause : A. Broken, worn or missing back-up guides allowing teeth to contact side guides. B. Improper side guides for band width. C. Backing the band out of an incomplete cut. #3. Wear On One Side Of Teeth Probable Cause : A.
- Page 82 #5. Body Breakage Or Cracks From Back Edge Probable Cause : A. Excessive back-up guide "preload" will cause back edge to work harden which results in cracking. B. Excessive feed rate. C. Improper band tracking – back edge rubbing heavy on wheel flange.
- Page 83 #8. Gullets Loading Up With Material Probable Cause : A. Too fine of a tooth pitch – insufficient gullet capacity. B. Excessive feeding rate producing too large of a chip. C. Worn, missing or improperly positioned chip brush. D. Insufficient sawing fluid due to inadequate supply, improper ratio and/or improper application.
- Page 84 #12. Heavy Wear And/Or Swagging On Back Edge Probable Cause : A. Excessive feed rate. B. Excessive back-up guide "preload". C. Improper band tracking – back edge rubbing heavy on wheel flange. D. Worn or defective back-up guides. #13. Butt Weld Breakage Probable Cause : A.
- Page 85 #16. Body Breakage Or Cracks From Gullets Probable Cause : A. Excessive back-up guide "preload". B. Improper band tension. C. Guide arms spread to maximum capacity. D. Improper beam bar alignment. E. Side guide adjustment is too tight. F. Excessively worn teeth. #17.
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Page 86: 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 87: 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 Coolant pump...