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5" x 6" SWIVEL MAST BANDSAW MODEL SB1018 OWNER'S MANUAL Hundreds of Thousands of Lathes Sold With a Tradition of Q uality Since 1906! Copyright © May, 2010 Revised March, 2011 (JB) For Machines Mfg. Since 8/09 Scope of Manual This manual helps the reader understand the machine, how to prepare it for operation, how to control it during operation, and how to keep it in good working condition. We assume the reader has a basic understanding of how to operate this type of machine, but that the reader is not familiar with the controls and adjustments of this specific model. As with all machinery of this nature, learning the nuances of operation is a process that happens through training and experience. If you are not an experienced operator of this type of machinery, read through this entire manual, then learn more from an experienced operator, schooling, or research before attempting operations. Following this advice will help you avoid serious personal injury and get the best results from your work. Manual Feedback We've made every effort to be accurate when documenting this machine. However, errors sometimes happen or the machine design changes after the documentation process—so the manual may not exactly match your machine. If a difference between the manual and machine leaves you in doubt, contact our customer service for clarification. We highly value customer feedback on our manuals. If you have a moment, please share your experience using this manual. What did you like about it? Is there anything you would change to make it better? Did it meet your expectations for clarity, professionalism, and ease-of-use? South Bend Lathe, Inc. C /O Technical Documentation Manager P.O. Box 2027 Bellingham, WA 98227 Email: [email protected] Updates For your convenience, any updates to this manual will be available to download free of charge through our website at: www.southbendlathe.com Customer Service We stand behind our machines. If you have any service questions, parts requests or general questions about the machine, feel free to contact us. South Bend Lathe Co. P.O. Box 2027 Bellingham, WA 98227 Phone: (360) 734-1540 Parts Department: (417) 886-2954 Fax: (360) 676-1075 (International) Fax: (360) 734-1639 (USA Only) Email: [email protected] Table of Contents INTRODUCTION................................................................2 About This Machine.............................................. 2 Capabilities.......................................................... 2 Features. ............................................................. 2 Identification......................................................... 3 Machine Specifications......................................... 4 SAFETY.................................................................................6 Understanding Risks of Machinery..................... 6 Basic Machine Safety........................................... 6 Additional Metal Bandsaw Safety....................... 8 PREPARATION..................................................................9 Preparation Overview........................................... 9 Things You'll Need................................................ 9 Power Supply Requirements................................ 9 Availability.......................................................... 9 Full-Load Current Rating..................................... 9 Circuit Information............................................ 10 Circuit Requirements for 110V. .......................... 10 Circuit Requirements for 220V. .......................... 10 Grounding Requirements. .................................. 10 Extension Cords................................................. 11 Unpacking........................................................... 11 Inventory............................................................. 11 Cleaning & Protecting........................................ 13 Location............................................................... 14 Physical Environment........................................ 14 Electrical Installation......................................... 14 Lighting............................................................. 14 Weight Load....................................................... 14 Space Allocation................................................. 14 Assembly............................................................. 15 Power Connection............................................... 18 Test Run.............................................................. 19 Inspections & Adjustments................................ 19 OPERATION..................................................................... 20 Operation Overview............................................ 20 Description of Controls & Components............. 21 Blade Selection.................................................... 22 Blade Terminology. ............................................ 22 Blade Length. .................................................... 22 Blade Width....................................................... 22 Tooth Set. .......................................................... 23 Tooth Type......................................................... 23 Blade Pitch (TPI)................................................ 24 Blade Changes.................................................... 25 Blade Tension...................................................... 26 Blade Breakage................................................... 26 Blade Care & Break-In....................................... 27 Blade Care......................................................... 27 Blade Break-In................................................... 27 Blade Speed......................................................... 27 Blade Speed Chart.............................................. 28 Chip Inspection Chart........................................ 28 Downfeed Rate.................................................... 29 Angle Cuts........................................................... 29 Cuts to the Right................................................ 29 Cuts to the Left.................................................. 30 Vise...................................................................... 30 Work Stop............................................................ 31 Blade Guide......................................................... 31 Operation Tips.................................................... 31 MAINTENANCE.............................................................. 32 Maintenance Schedule........................................ 32 Cleaning.............................................................. 32 Lubrication.......................................................... 32 Gearbox. ............................................................ 33 Machine Storage................................................. 33 Service........................................................................... 34 Blade Tracking.................................................... 34 Blade Guide Bearings......................................... 35 Squaring Blade................................................... 35 V-Belt................................................................... 36 Downfeed Stop.................................................... 37 TROUBLESHOOTING.................................................. 38 ELECTRICAL.................................................................... 41 Electrical Safety Instructions............................ 41 220V Conversion................................................. 42 Wiring Diagram.................................................. 43 Wiring Component Locations............................. 44 PARTS................................................................................ 45 Base & Cabinet Stand........................................ 45 Head & Vise........................................................ 47 Motor & Blade Guides........................................ 49 Switch.................................................................. 51 Machine Labels................................................... 52 WARRANTY & RETURNS........................................... 53 Model SB1018 INTRODUCTION For Machines Mfg. Since 8/09 INTRODUCTION About This Machine Capabilities Features This metal cutting bandsaw uses a gravity-fed blade to make straight cuts through workpieces that are clamped in a vise. Since the workpiece is secured and remains stationary while the blade lowers automatically, accuracy and operator safety are maximized. In addition to its capabilities, the Model SB1018 has several features to increase versatility and efficiency. The vise on the Model SB1018 is capable of holding rectangular stock up to 5" x 6" and round stock up to 5". After a cut is complete, the OFF switch is triggered and the motor automatically turns off. The headstock can be rotated to make angled cuts from -45°–60° while three blade speeds ensure that the proper cutting rate is available for a variety of workpiece sizes and materials. Both the downfeed rate and pressure are adjustable for fine-tuning each cutting operation and an adjustable auto-OFF power switch maximizes safety and minimizes energy use by turning the machine off at the end of every cut. A storage compartment in the cabinet base provides a convenient location for keeping spare blades or other accessories and the transport handle makes moving the machine easy. Finally, the cast-aluminum knobs and belt cover proudly bear the legendary South Bend name. -2- INTRODUCTION For Machines Mfg. Since 8/09 Model SB1018 Identification Blade Tension Knob Guide Post Knob Belt Cover Motor Blade Downfeed Rate Adjust Knob Downfeed Stop Bolt Downfeed Ram Headstock ON/OFF Switch w/Auto-Off Lever Vise Jaw Vise Jaw Handwheel Transport Handle Front View Cabinet Access Door Leveling Foot Rear View Figure 1. Identification. Serious personal injury could occur if you connect the machine to power before completing the setup process. DO NOT connect power until instructed to do so later in this manual. Untrained users have an increased risk of seriously injuring themselves with this machine. Do not operate this machine until you have understood this entire manual and received proper training. -3- INTRODUCTION Model SB1018 For Machines Mfg. Since 8/09 Machine Specifications Machine Specifications P.O. Box 2027, Bellingham, WA 98227 U.S.A. PHONE: (360) 734-1540 • © South Bend Lathe Co. www.southbendlathe.com Model SB1018 5" x 6" Swivel Mast Bandsaw Product Dimensions: Weight ..........................................................................................................................................................................209 lbs. Length/Width/Height ................................................................................................................................ 383⁄4" x 17" x 421⁄4" Foot Print (Length/Width) ......................................................................................................................................383⁄4" x 17" Space Required for Full Range of Movement (Length/Width/Height) .......................................................... 80" x 70" x 78" Shipping Dimensions: Type ................................................................................................................................................................................ Carton Weight ...........................................................................................................................................................................214 lbs. Length/Width/Height ....................................................................................................................................... 41" x 19" x 24" Electrical: Required Power Source .................................................................................................. 110V or 220V, Single-Phase, 60 Hz Switch ........................................................................................................................................Push Button ON/OFF Switch Switch Voltage .................................................................................................................................................................. 110V Cord Length ........................................................................................................................................................................ 7 ft. Cord Gauge .................................................................................................................................................................18 gauge Minimum Circuit Size ..................................................................................................................................................15 Amp Plug Included .......................................................................................................................................................................Yes Included Plug Type.................................................................................................................................NEMA 5-15 for 110V Recommended Plug Type for 220V....................................................................................................................... NEMA 6-15 Motors: Main Type ............................................................................................................................TEFC Capacitor Start Induction Horsepower............................................................................................................................................................. 1⁄2 HP Voltage ............................................................................................................................................................110V/220V Phase .......................................................................................................................................................... Single-Phase Amps ................................................................................................................................................................... 8.6/4.3A Speed............................................................................................................................................................... 1725 RPM Cycle ....................................................................................................................................................................... 60 Hz Number Of Speeds .........................................................................................................................................................1 Pre-Wired ................................................................................................................................................................ 110V Power Transfer.........................................................................................................................................V-Belt & Gear Bearings................................................................................................................... Shielded and Permanently Sealed Main Specifications: Operation Information Head Swivel..........................................................................................................................................................60 deg. Blade Speeds ...................................................................................................................................... 80, 120, 200 FPM Std. Blade Length ....................................................................................................................................................641⁄2" Blade Size Range .........................................................................................................................................................1⁄2" Model SB1018 -4- Page 1 of 2 For Machines Mfg. Since 8/09 INTRODUCTION Model SB1018 Cutting Capacities Angle Cuts ............................................................................................................................................................60 deg. Vise Jaw Depth ......................................................................................................................................................... 77⁄8" Vise Jaw Height ........................................................................................................................................................ 21⁄2" Max. Capacity Rect. Height At 90D ........................................................................................................................... 5" Max. Capacity Rect. Width At 90D ............................................................................................................................ 6" Max. Capacity Rnd. At 90D ........................................................................................................................................ 5" Max. Capacity Rect. Height At 45D ....................................................................................................................... 25⁄16" Max. Capacity Rect. Width At 45D ......................................................................................................................... 33⁄4" Max. Capacity Rnd. At 45D ..................................................................................................................................... 33⁄4" Max. Capacity Rect. Height At 60D ........................................................................................................................ 11⁄2" Max. Capacity Rect. Width At 60D ........................................................................................................................ 23⁄16" Max. Capacity Rnd. At 60D ..................................................................................................................................... 11⁄2" Construction Wheel Construction Upper .............................................................................................................................. Cast Iron Wheel Construction Lower .............................................................................................................................. Cast Iron Body Construction ........................................................................................................................................... Cast Iron Base Construction ............................................................................................................................................ Cast Iron Stand Construction ................................................................................................................................................. Steel Tire Material ........................................................................................................................................................Rubber Other Wheel Size .................................................................................................................................................................... 5" Blade Guides Upper ...................................................................................................................................................Yes Blade Guides Lower ...................................................................................................................................................Yes Table Info Floor to Cutting Area Height ................................................................................................................................. 281⁄8" Other Specifications: ISO Factory ................................................................................................................................................................ ISO 9001 Country Of Origin ........................................................................................................................................................ Taiwan Warranty .........................................................................................................................................................................1 Year Serial Number Location .................................................................................................................. ID Label on Body Frame Customer Setup and Cleaning Time .................................................................................................. Approximately 1 Hour Features: Heavy-Duty Steel Stand Adjustable Hydraulic Down Feed Cast Iron Handwheel with Chromed Handle Die Cast South Bend Star Knobs Die Cast South Bend Belt Guard Built-In Storage Cabinet Leveling Feet and Wheels to Ease Mobility Swiveling Head Precision Ground Vise Deck and Table Model SB1018 Page 2 of 2 -5- Model SB1018 SAFETY For Machines Mfg. Since 8/09 SAFETY Understanding Risks of Machinery Operating all machinery and machining equipment can be dangerous or relatively safe depending on how it is installed and maintained, and the operator's experience, common sense, risk awareness, working conditions, and use of personal protective equipment (safety glasses, respirators, etc.). The owner of this machinery or equipment is ultimately responsible for its safe use. This responsibility includes proper installation in a safe environment, personnel training and usage authorization, regular inspection and maintenance, manual availability and comprehension, application of safety devices, integrity of cutting tools or accessories, and the usage of approved personal protective equipment by all operators and bystanders. The manufacturer of this machinery or equipment will not be held liable for injury or property damage from negligence, improper training, machine modifications, or misuse. Failure to read, understand, and follow the manual and safety labels may result in serious personal injury, including amputation, broken bones, electrocution, or death. The signals used in this manual to identify hazard levels are defined as follows: Death or catastrophic harm WILL occur. Moderate injury or fire MAY occur. Death or catastrophic harm COULD occur. Machine or property damage may occur. Basic Machine Safety 1. Owner’s Manual: All machinery and machining equipment presents serious injury hazards to untrained users. To reduce the risk of injury, anyone who uses THIS item MUST read and understand this entire manual before starting. 2. Personal Protective Equipment: Operating or servicing this item may expose the user to flying debris, dust, smoke, dangerous chemicals, or loud noises. These hazards can result in eye injury, blindness, longterm respiratory damage, poisoning, cancer, reproductive harm or hearing loss. Reduce your risks from these hazards by wearing approved eye protection, respirator, gloves, or hearing protection. -6- 3. Trained/Supervised Operators Only: Untrained users can seriously injure themselves or bystanders. Only allow trained and properly supervised personnel to operate this item. Make sure safe operation instructions are clearly understood. If electrically powered, use padlocks and master switches, and remove start switch keys to prevent unauthorized use or accidental starting. 4. Guards/Covers: Accidental contact with moving parts during operation may cause severe entanglement, impact, cutting, or crushing injuries. Reduce this risk by keeping any included guards/covers/doors installed, fully functional, and positioned for maximum protection. For Machines Mfg. Since 8/09 SAFETY Model SB1018 5. Entanglement: Loose clothing, gloves, neckties, jewelry or long hair may get caught in moving parts, causing entanglement, amputation, crushing, or strangulation. Reduce this risk by removing/securing these items so they cannot contact moving parts. 11. Chuck Keys or Adjusting Tools: Tools used to adjust spindles, chucks, or any moving/ rotating parts will become dangerous projectiles if left in place when the machine is started. Reduce this risk by developing the habit of always removing these tools immediately after using them. 6. Mental Alertness: Operating this item with reduced mental alertness increases the risk of accidental injury. Do not let a temporary influence or distraction lead to a permanent disability! Never operate when under the influence of drugs/alcohol, when tired, or otherwise distracted. 12. Work Area: Clutter and dark shadows increase the risks of accidental injury. Only operate this item in a clean, nonglaring, and well-lighted work area. 7. Safe Environment: Operating electrically powered equipment in a wet environment may result in electrocution; operating near highly flammable materials may result in a fire or explosion. Only operate this item in a dry location that is free from flammable materials. 8. Electrical Connection: With electically powered equipment, improper connections to the power source may result in electrocution or fire. Always adhere to all electrical requirements and applicable codes when connecting to the power source. Have all work inspected by a qualified electrician to minimize risk. 9. Disconnect Power: Adjusting or servicing electrically powered equipment while it is connected to the power source greatly increases the risk of injury from accidental startup. Always disconnect power BEFORE any service or adjustments, including changing blades or other tooling. 10. Secure Workpiece/Tooling: Loose workpieces, cutting tools, or rotating spindles can become dangerous projectiles if not secured or if they hit another object during operation. Reduce the risk of this hazard by verifying that all fastening devices are properly secured and items attached to spindles have enough clearance to safely rotate. 13. Properly Functioning Equipment: Poorly maintained, damaged, or malfunctioning equipment has higher risks of causing serious personal injury compared to those that are properly maintained. To reduce this risk, always maintain this item to the highest standards and promptly repair/service a damaged or malfunctioning component. Always follow the maintenance instructions included in this documentation. 14. Unattended Operation: Electrically powered equipment that is left unattended while running cannot be controlled and is dangerous to bystanders. Always turn the power OFF before walking away. 15. Health Hazards: Certain cutting fluids and lubricants, or dust/smoke created when cutting, may contain chemicals known to the State of California to cause cancer, respiratory problems, birth defects, or other reproductive harm. Minimize exposure to these chemicals by wearing approved personal protective equipment and operating in a well ventilated area. 16. Difficult Operations: Attempting difficult operations with which you are unfamiliar increases the risk of injury. If you experience difficulties performing the intended operation, STOP! Seek an alternative method to accomplish the same task, ask a qualified expert how the operation should be performed, or contact our Technical Support for assistance. -7- Model SB1018 SAFETY For Machines Mfg. Since 8/09 Additional Metal Bandsaw Safety 1. Blade Condition. A dull or damaged blade can break apart during operation, increasing the risk of operator injury. Do not operate with a dull, cracked or badly worn blade. Inspect the blade for cracks or missing teeth before each use. 2. Hand Placement. Hands could be cut by the blade or crushed when lowering the headstock. Never position fingers or thumbs in line with the cut or under the headstock while it is moving. 3. Blade Guard. Hands and fingers can easily be cut by the bandsaw blade. To reduce the risk of laceration injuries, do not operate this bandsaw without the blade guard in place. 4. Starting Position. To reduce the likelihood of blade breakage and possible entanglement, never turn the saw ON with the blade resting on the workpiece. 5. Blade Replacement. The blade can only make a safe and efficient cut if the teeth are facing the workpiece. When replacing blades, make sure the teeth face toward the workpiece. Wear gloves to protect hands and safety glasses to protect eyes. -8- 6. Workpiece Handling. A shifting workpiece can result in impact or laceration injuries. To reduce the risk of injury, always securely clamp the workpiece in the vise and use additional support fixtures if needed. Never hold the workpiece with your hands during a cut. Flag long pieces to reduce the risk of tripping over them. 7. Power Interruption. Unplug the machine and turn the power switch OFF after a power interruption. If left plugged in and turned ON, this machine will start up when power is restored, resulting in possible entanglement, laceration, or amputation hazards. 8. Hot Surfaces/Sharp Edges. Due to the cutting process, a freshly cut workpiece, chips, and some machine components can be hot enough to burn you and sharp enough to cut you. Allow components to cool and use safe handling methods to reduce the risk of these injuries. 9. Moving Blade. A moving bandsaw blade presents a serious risk for laceration or amputation injuries. Always allow the blade to come to a complete stop before mounting or repositioning a workpiece in the vise. Never touch a moving blade. For Machines Mfg. Since 8/09 P R E PA R AT I O N Model SB1018 PREPARATION Preparation Overview Power Supply The purpose of the preparation section is to help Requirements you prepare your machine for operation. The list below outlines the basic process to follow to prepare your machine for operation. Specific steps for each of these points will be covered in detail later in this section. The typical preparation process is as follows: 1. Unpack the machine and inventory the contents of the carton. 2. Clean the machine and its components. 3. Make any necessary adjustments or inspections to ensure the machine is ready for operation. 4. Connect the machine to the power source. 5. Test run the machine to make sure it functions properly and is ready for operation. Things You'll Need The items listed below are required to successfully set up and prepare this machine for operation. For Machine Setup • • Wrench 12mm Wrench 14mm For Power Connection • • A power source that meets the minimum circuit requirements for this machine. (Refer to the Power Supply Requirements section for details.) A qualified electrician to ensure a safe and code-compliant connection to the power source. Availability Before installing the machine, consider the availability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by a qualified electrician in accordance with all applicable codes and standards. Electrocution or fire may occur if machine is not correctly grounded and attached to the power supply. Use a qualified electrician to ensure a safe power connection. Full-Load Current Rating The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations. Full-Load Rating at 110V................... 8.6 Amps Full-Load Rating at 220V................... 4.3 Amps The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating. If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result—especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid overloading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section. -9- Model SB1018 P R E PA R AT I O N For Machines Mfg. Since 8/09 Circuit Information Grounding Requirements A power supply circuit includes all electrical equipment between the main breaker box or fuse panel in your building and the incoming power connections inside the machine. This circuit must be safely sized to handle the full-load current that may be drawn from the machine for an extended period of time. In the event of certain types of malfunctions or breakdowns, grounding provides a path of least resistance for electric current—in order to reduce the risk of electric shock. For your own safety and protection of property, consult a qualified electrician if you are unsure about wiring practices or electrical codes in your area. Note: The circuit requirements listed in this manual apply to a dedicated circuit—where only one machine will be running at a time. If this machine will be connected to a shared circuit where multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation. For 110V Connection (Prewired) This machine is equipped with a power cord that has an equipment-grounding wire and a grounding plug (similar to the figure below). The plug must only be inserted into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances. GROUNDED 5-15 RECEPTACLE Grounding Prong 5-15 PLUG Current Carrying Prongs Circuit Requirements for 110V This machine is prewired to operate on a 110V power supply circuit that has a verified ground and meets the following requirements: Nominal Voltage................................ 110V/120V Cycle..............................................................60 Hz Phase...............................................Single-Phase Circuit Rating....................................... 15 Amps Plug/Receptacle (included)............NEMA 5-15 Circuit Requirements for 220V This machine can be converted to operate on a 220V power supply. To do this, follow the Voltage Conversion instructions included in this manual. The intended 220V circuit must have a verified ground and meet the following requirements: Nominal Voltage................................ 220V/240V Cycle..............................................................60 Hz Phase...............................................Single-Phase Circuit Rating....................................... 15 Amps Plug/Receptacle................................NEMA 6-15 -10- Figure 2. NEMA 5-15 plug and receptacle. For 220V Connection Use the plug type listed in the Circuit Requirements for this voltage. The listed plug (similar to the figure below) has an equipmentgrounding wire to safely ground the machine. The plug must only be inserted into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances. GROUNDED 6-15 RECEPTACLE Current Carrying Prongs 6-15 PLUG Grounding Prong Figure 3. NEMA 6-15 plug and receptacle. For Machines Mfg. Since 8/09 P R E PA R AT I O N Model SB1018 Unpacking Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual. Improper connection of the equipment-grounding wire can result in a risk of electric shock. The wire with green insulation (with or without yellow stripes) is the equipment-grounding wire. If repair or replacement of the power cord or plug is necessary, do not connect the equipmentgrounding wire to a live (current carrying) terminal. Check with a qualified electrician or service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with a new one. This item was carefully packaged to prevent damage during transport. If you discover any damage, please immediately call Customer Service at (360) 734-1540 for advice. You may need to file a freight claim, so save the containers and all packing materials for possible inspection by the carrier or its agent. Inventory Description (Figure 4) Qty A. Handle............................................................. 1 B. Axle.................................................................. 1 C. Wheels............................................................. 2 D. Leveling Feet................................................... 2 E. Handwheel...................................................... 1 F Handwheel Handle......................................... 1 G. Pulley Cover.................................................... 1 H. V-Belt............................................................... 1 F Extension Cords A We do not recommend using an extension cord with this machine. If you must use one, only use it if absolutely necessary and only on a temporary basis. Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller (higher gauge numbers indicate smaller sizes). Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle listed in the Circuit Requirements for the applicable voltage, and meet the following requirements: E D C G H B Figure 4. Small components. Minimum Gauge Size.............................16 AWG Maximum Length (Shorter is Better).....50 ft. -11- P R E PA R AT I O N Model SB1018 Description (Figure 5) Qty I. Chip Tray......................................................... 1 J. Rear Panel....................................................... 1 K. Front Panel...................................................... 1 I J For Machines Mfg. Since 8/09 Not Shown Qty • Hex Wrench 4mm........................................... 1 • Hex Bolt M8-1.25 x 15.................................. 12 • Hex Nut M8-1.25........................................... 18 • Flat Washer 8mm......................................... 30 • Flat Head Screws M8-1.25 x 15..................... 2 • Hex Bolt M12-1.75 x 25 ................................. 4 • Flat Washer 12mm......................................... 4 • Hex Bolt M8-1.25 x 40.................................... 4 • Knob M6-1 x 15............................................... 1 • Cotter Pins...................................................... 2 The items listed below are optional components and are not required for bandsaw operations. Their installation and use is covered in Operation, beginning on Page 20. K Description Qty P. Work Stop Assembly....................................... 1 Q. Chip Deflector................................................. 1 Figure 5. Stand components. Description (Figure 6) Qty L. Left Panel........................................................ 1 M. Right Panel...................................................... 1 N. Bottom Shelf.................................................... 1 O. Shelf................................................................. 1 P Q L M N O D Figure 6. Additional stand components. -12- Figure 7. Optional components. For Machines Mfg. Since 8/09 P R E PA R AT I O N Model SB1018 Cleaning & Protecting The unpainted surfaces are coated at the factory with a heavy-duty rust preventative that prevents corrosion during shipment and storage. The benefit of this rust preventative is that it works very well. The downside is that it can be time-consuming to thoroughly remove. Be patient and do a careful job when cleaning and removing the rust preventative. The time you spend doing this will reward you with smooth-sliding parts and a better appreciation for the proper care of the unpainted surfaces. Although there are many ways to successfully remove the rust preventative, we have cleaned thousands of machines and found the following process to be the best balance between efficiency and minimized exposure to toxic fumes or chemicals. Before cleaning, gather the following: • • • Disposablerags Cleaner/degreaser (certain citrus-based degreasers work extremely well and they have non-toxic fumes) Safetyglasses&disposablegloves Note: Automotive degreasers, mineral spirits, or WD•40canbeusedtoremoverustpreventative. Before using these products, though, test them on an inconspicuous area of a painted area to make sure they will not damage it. Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area. Avoid chlorine-based solvents, such as acetone or brake parts cleaner that may damage painted surfaces. Always follow the manufacturer’s instructions when using any type of cleaning product. Basic steps for removing rust preventative: 1. 2. Coatallsurfacesthathaverustpreventative with a liberal amount of your cleaner or degreaser and let them soak for a few minutes. 3. GA S Wipe off the surfaces. If your cleaner or degreaser is effective, the rust preventative will wipe off easily. Note: To clean off thick coats of rust preventative on flat surfaces, such as beds or tables, use aPLASTICpaintscrapertoscrapeoffthe majority of the coating before wiping it off withyourrag.(Donotuseametalscraperor it may scratch the surface.) 4. Gasoline and petroleum products have low flash points and can explode or cause fire if used for cleaning. Avoid using these products to remove rust preventative. Put on safety glasses and disposable gloves. Repeat Steps 2–3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant or light oil to prevent rust. -13- P R E PA R AT I O N Model SB1018 Location For Machines Mfg. Since 8/09 Weight Load Physical Environment Physical Environment The physical environment where your machine is operated is important for safe operation and longevity of parts. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous or flammable chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature is outside the range of 41°– 104°F; the relative humidity is outside the range of 20–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps. Electrical Installation Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave access to a means of disconnecting the power source or engaging a lockout/tagout device. Refer to the Machine Specifications for the weight of your machine. Make sure that the surface upon which the machine is placed will Installation bear the weight Electrical of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Lighting Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine. Weight Load Space Allocation Consider the largest size of workpiece that will be processed through this machine and provide Space Allocation enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual. Children or untrained people may be seriously injured by this machine. Only install in an access restricted location. Lighting Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated. Wall 19½" Power Connection 31" 11" Minimum 6" 38" (Drawing Not to Scale) Figure 8. Clearances. -14- For Machines Mfg. Since 8/09 P R E PA R AT I O N Assembly To assemble the bandsaw: 1. Attach the left and rear panels and the bottom shelf together as shown in Figure 9 with three M8-1.25 x 15 hex bolts, three M81.25 hex nuts, and six 8mm flat washers. Left Panel Model SB1018 4. Install the shelf in the stand assembly as shown in Figure 11 with (2) M8-1.25 x 15 hex bolts, (2) M8-1.25 x 15 flat head screws, (4) M8-1.25 hex nuts, and (6) 8mm flat washers. Rear Panel x2 x2 Top View x3 Bottom Shelf Figure 9. Left and rear panel assembly. Figure 11. Shelf installation. 5. Install the handle with four M8-1.25 x 40 hex bolts, eight 8mm flat washers and four M8-1.25 hex nuts as shown in Figure 10. 2. Attach the front panel in the same manner as Step 1. 3. Attach the right panel to the stand assembly as shown in Figure 10 with four M8-1.25 x 15 hex bolts, four M8-1.25 hex nuts, and eight 8mm flat washers. Right Side Panel x4 Stand Assembly Figure 12. Handle installation. x4 6. Carefully place the stand assembly upside down. Figure 10. Right panel assembly. -15- P R E PA R AT I O N Model SB1018 7. Insert the axle through the holes in the base assembly, then slide the wheels over the axle and secure each with a cotter pin, as shown in Figure 13. Axle Base For Machines Mfg. Since 8/09 10. With the help of another person, lift the bandsaw assembly and place it onto the stand assembly, lining up the mounting holes. 11. Secure the bandsaw to the stand with four M12-1.75 x 25 hex bolts and 12mm flat washers, as shown in Figure 15. Wheel Hex Bolts (2 of 4 Shown) Cotter Pin Figure 13. Wheel assembly. 8. Thread the leveling feet into the stand assembly, as shown in Figure 14. You can adjust these later as needed to level the bandsaw. (Handwheel Not Yet Installed) Figure 15. Mounting bandsaw to stand. 12. Loosen the belt tension bolt shown in Figure 16. (Pulley Cover Not Yet Installed) Belt Tension Bolt Leveling Feet Figure 14. Leveling feet. 9. With the help of another person, flip the stand assembly right-side up, then place the chip tray onto the stand, lining up the mounting holes. -16- Figure 16. Belt tension bolt location. For Machines Mfg. Since 8/09 P R E PA R AT I O N Model SB1018 13. Pivot the motor assembly upward, then place the belt over the gearbox and motor pulleys, as shown in Figure 17. Motor Pulley Gearbox Pulley Knob Location Motor Assembly Figure 19. Pulley cover knob. Figure 17. Installing belt. 14. Install the pulley cover (Figure 18) with two M6-1 x 12 hex bolts, three 6mm flat washers, and the South Bend cast aluminum knob (see Figure 19). Hex Bolts 15. Slide the vise handwheel onto the leadscrew and tighten the set screw shown in Figure 20. Thread the handle into the handwheel and tighten it. Belt Cover Handle Set Screw Handwheel Figure 20. Vise handwheel. Figure 18. Pulley cover. -17- P R E PA R AT I O N Model SB1018 16. Remove the shipping strap hex bolt and strap with a 12mm wrench, as shown in Figure 21. Re-install the fasteners. Save this strap in case you need to transport or ship the bandsaw in the future. For Machines Mfg. Since 8/09 Power Connection Electrocution or fire may occur if machine is ungrounded, incorrectly connected to power, or connected to an undersized circuit. Use a qualified electrician to ensure a safe power connection. Once your machine is set up and assembled as previously described in this manual, it is ready to be connected to the power source. • If you plan to use the machine at 110V, simply plug it into a receptacle on a 110V circuit that meets the requirements listed on Page 10. • If you plan to use the machine at 220V, you will have to convert the machine for 220V. Refer to Electrical, beginning on Page 41. Figure 21. Removing shipping strap. 17. If you choose to use the deflector, position it as shown in Figure 22 (the deflector directs swarf from the cut and small workpieces into the chip tray when the cut is complete). Deflector Figure 22. Chip tray installed. -18- For Machines Mfg. Since 8/09 P R E PA R AT I O N Test Run Model SB1018 4. Connect the machine to the power source. After all preparation steps have been completed, the machine and its safety features must be tested to ensure correct operation. If you discover a problem with the operation of the machine or its safety components, do not operate it further until you have resolved the problem. 5. Put on safety glasses and secure loose clothing or long hair. Note: Refer to Troubleshooting on Page 38 for solutions to common problems that may occur with metal-cutting bandsaws. If you need additional help, contact our Tech Support at (360) 734-1540. 7. Start the bandsaw while keeping your finger near the ON/OFF switch at all times during the test run. The bandsaw should run smoothly with little or no vibration. To test run your machine: 1. Read and follow the safety instructions at the beginning of the manual, take the required safety precautions, and make sure the machine is set up properly. 2. Clear away all tools and objects used during assembly and preparation. 3. Open the downfeed valve (Figure 23) and allow the headstock to travel all the way down. If the blade contacts the machine base, adjust the downfeed stop bolt as described in Downfeed Stop Bolt, on Page 37. 6. Lift the headstock by the handle to the raised position, then close the downfeed valve to prevent it from lowering. —If you suspect any problems, immediately turn the bandsaw OFF, disconnect it from power, and correct the problem before continuing. —If you need any help with your bandsaw call our Tech Support at (360) 734-1540. 8. Open the downfeed valve to lower the saw through its full range of motion. When it reaches the bottom of its travel, it should turn OFF. If it does not, manually turn it OFF, disconnect it from power, then readjust the auto-OFF lever, by performing Steps 3–6 on Page 37. Inspections & Adjustments The following list of adjustments were performed at the factory before your machine was shipped. If you find that the adjustments are not set according to the procedures in this manual or your personal preferences, re-adjust them. Downfeed Valve • Blade Tracking . .................................Page 34 • Squaring the Blade ............................Page 35 • Blade Guide Bearings ........................Page 35 Figure 23. Downfeed valve location. -19- Model SB1018 O P E R AT I O N For Machines Mfg. Since 8/09 OPERATION Operation Overview To complete a typical cutting operation, the operator does the following: The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so they can more easily understand the controls discussed later in this manual. 1. Examines the workpiece to make sure it is suitable for cutting. Note: Due to the generic nature of this overview, it is not intended to be an instructional guide for performing actual machine operations. To learn more about specific operations and machining techniques, seek training from people experienced with this type of machine, and do additional research outside of this manual by reading "how-to" books, trade magazines, or websites. To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations. 2. Checks/adjusts the V-belt position on the pulleys to ensure the correct cutting speed for the workpiece. 3. Raises the headstock, then closes the downfeed valve. 4. Adjusts the headstock angle for the type of cut, then securely clamps the workpiece in the vise. 5. Adjusts the guide post so the opening between the two blade guides is approximately 1 ⁄4" larger than the width of the workpiece. 6. Adjusts the downfeed rate adjust knob for the correct feed rate. 7. Makes sure the workpiece and bandsaw are stable and that there are no obstructions in the way of the cut. 8. Puts on safety glasses. Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk. During operation, small metal chips may become airborne, leading to serious eye injury. Wear safety glasses to reduce this risk. -20- 9. Starts the bandsaw and waits for the blade to reach full speed. 10. Opens the downfeed valve to lower the head and blade into the workpiece, then allows the bandsaw to complete the cut. 11. Once the bandsaw has stopped, raises the head, and removes the workpieces. For Machines Mfg. Since 8/09 O P E R AT I O N Model SB1018 Description of Controls & Components Refer to Figure 24 and the following descriptions to become familiar with the basic controls and components used to operate this machine. A G D H A. Blade Tension Knob: Adjusts the position of the upper blade wheel to increase/decrease blade tension. B. Guide Post Knob: Locks the guide post in the position set by the operator. C B E F I C. Downfeed Rate Adjust Knob: Controls the speed at which the blade lowers into the workpiece. D. Downfeed Valve: Controls the starting and stopping of the headstock downfeed. E. ON/OFF Switch & Auto-Off Lever: Turns the saw motor ON and OFF. F. Swivel Lock Handle: Locks the headstock at the position set by the operator. Figure 24. Front Identification. G. Vise Jaw Handwheel: Controls the vise jaw movement. H. Downfeed Stop Bolt: Adjusts to determine the absolute bottom limit of blade travel. I. Fence Scale: Indicates the angle of the vise fence. -21- O P E R AT I O N Model SB1018 Blade Selection Selecting the right blade for the cut requires a knowledge of various blade characteristics. This section breaks down blade characteristics to help the reader make an informed decision about what blade to use for a given operation. Blade Terminology B F. Gullet Depth: The distance from the tooth tip to the bottom of the curved area (gullet). G. Tooth Pitch: The distance between tooth tips. I. C F Blade Pitch or TPI: The number of teeth per inch measured from gullet to gullet. Blade Length H D G I Figure 25. Bandsaw blade terminology. A. Kerf: The width of the cut made during operation. B. Tooth Set: The distance each tooth is bent left or right from the blade. C. Gauge: The thickness of the blade. D. Blade Width: The widest point of the blade measured from the tip of the tooth to the back edge of the blade. -22- E. Tooth Rake: The angle of the tooth face from a line perpendicular to the length of the blade. H. Blade Back: The distance between the bottom of the gullet and the back edge of the blade. A E For Machines Mfg. Since 8/09 Measured by the blade circumference, blade lengths are usually unique to the brand of your bandsaw and the distance between the wheels. Model Blade Length SB1018..............................................................641⁄2" Blade Width Measured from the back of the blade to the tip of the blade tooth (the widest point), blade width is often the first consideration given to blade selection. Blade width dictates the largest and smallest curve that can be cut, as well as how accurately it can cut a straight line—generally the wider the blade, the straighter it will cut. Model Blade Width SB1018..................................................................1⁄2" O P E R AT I O N For Machines Mfg. Since 8/09 Model SB1018 Tooth Set Three common tooth sets are alternate, wavy, and raker (see Figure 26). Each removes material in a different manner to make the kerf in the workpiece. Standard (or Raker) Raker Wavy Alternate Variable Pitch (VP) Variable Pitch Positive Rake Hook (or Claw) Figure 26. Bandsaw blade tooth sets. Alternate: An all-purpose arrangement with teeth bent evenly left and right of the blade. Generally used for milder metals. Wavy: Generally three or more teeth in a group that are bent one way, followed by a non-set tooth, and then a group bent the other way. Recommended for straight cuts in thin metals or thin-wall tubing. Raker: Three teeth in a recurring group—one bent left, next one bent right, and then a nonset tooth. The raker set is ideal for most contour cuts. Tooth Type The most common tooth types are described below and illustrated in Figure 27. Each removes, gathers, and expels material differently. Skip (or Skip Tooth) Figure 27. Bandsaw blade tooth types. Variable Pitch (VP): Varying gullet depth and tooth spacing, a "0" rake angle, excellent chip removing capacity, and smooth cutting. Variable Pitch with Positive Rake: Varying gullet depth and tooth spacing, a positive rake angle, better chip formation, and aggressive cutting. Hook or Claw: Wide gullets (round or flat), equally spaced teeth, positive rake angle, and fast cut with good surface finish. Skip or Skip Tooth: Wide, flat gullets, a "0" rake angle, equally spaced teeth, and recommended for non-ferrous materials. Standard or Raker: Equally spaced teeth set at a "0" rake angle. Recommended for all purpose use. -23- O P E R AT I O N Model SB1018 Blade Pitch (TPI) 2. Refer to the "Material Width/Diameter" row of the blade selection chart in Figure 28, and read across to find the workpiece thickness you need to cut. The chart below is a basic starting point for choosing teeth per inch (TPI) for variable pitch blades and standard raker set bi-metal blades/ HSS blades. However, for exact specifications of bandsaw blades that are correct for your operation, contact the blade manufacturer. 3. Refer to the "Material Shapes" row and find the shape of the material to be cut. 4. In the applicable row, read across to the right and find the box where the row and column intersect. Listed in the box is the minimum TPI recommended for the variable tooth pitch blades. To select the correct blade pitch: 1. Measure the material thickness. This measurement is the distance from where each tooth enters the workpiece to where it exits the workpiece. Material Width/Diameter For Machines Mfg. Since 8/09 Teeth Per Inch (TPI) for Bandsaw Blades Material Shapes TOOTH SELECTION mm 50 75 100 150 5/8 4/6 4/6 3/4 2/3 3/4 inch 2 2½ 3 3½ 4 5 6 200 3/4 250 300 2/3 350 400 2/3 1.5/.8 1.4/2.5 1.5/.8 1.4/2.5 7 8 9 10 11 12 13 14 15 Figure 28. General guidelines for blade selection and speed chart. -24- 450 16 17 18 19 O P E R AT I O N For Machines Mfg. Since 8/09 Model SB1018 Blade Changes Change blades when they become dull, damaged, or if the operation requires a different type of blade. Bla de Tra vel To change the blade on the bandsaw: 1. DISCONNECT BANDSAW FROM POWER! 2. Raise the head of the bandsaw, then remove the wheel access cover. 3. Loosen the tension knob and slip the blade off of the wheels. 4. Install the new blade through both blade guide bearings, as shown in Figure 29, and around the bottom wheel. ! Figure 30. Blade cutting direction. 6. When the blade is around both wheels, adjust the position so the back of the blade is against the wheel shoulder, as shown in Figure 31. ! Wheel Shoulder Blade Guide Bearings Figure 29. Installing blade. 5. Hold the blade around the bottom wheel with one hand and slip it around the top wheel with the other hand, keeping the blade between the blade guide bearings. Note: It is sometimes possible to flip the blade inside out, in which case the blade will be installed in the wrong direction. Check to make sure the blade teeth are facing toward the workpiece, as shown in Figure 30, after installing it on the bandsaw. Some blades will have a directional arrow as a guide. Figure 31. Installing blade around wheel. 7. Tighten the tension knob so the blade will not slip on the wheels upon startup. 8. Connect the bandsaw to the power source. 9. Briefly turn the bandsaw ON then OFF to position the blade and resume the previous tracking. —If the tracking needs to be adjusted, see Blade Tracking on Page 34. —If the tracking is fine, proceed to Blade Tension on Page 26. -25- Model SB1018 O P E R AT I O N For Machines Mfg. Since 8/09 blade selection Blade Tension Blade Breakage Proper tension is essential to avoid vibration, twist, or`slippage on the wheels. A correctly tensioned blade provides long life, straight cuts, and efficient cutting. Many conditions may cause a bandsaw blade to break. Some of these conditions are unavoidable and are the natural result of the stresses placed on the bandsaw; other causes of blade breakage are avoidable. The three major signs of incorrect tension are: 1) The blade stalls in the cut and slips on the wheels, 2) the blade frequently breaks, and 3) the cuts are not straight. The most common causes of avoidable blade breakage are: • Faulty alignment or adjustment of the blade guides. • Forcing or twisting a wide blade around a tight radius. • Feeding the workpiece too fast. • Dull or damaged teeth. • Over-tensioned blade. • Top blade guide assembly set too high above the workpiece. Adjust the top blade guide assembly so that there is less than 1⁄2" between the bottom of the assembly and the workpiece. Understand that with smaller workpieces, this may not be possible. In these cases, simply adjust the blade guide as far down as possible. • Using a blade with a lumpy or improperly finished braze or weld. • Continuously running the bandsaw when not in use. • Leaving the blade tensioned when not in use. • Using the wrong blade pitch (TPI) for the workpiece thickness. The general rule of thumb is to have no fewer than three teeth in contact with the workpiece during cutting operations. To tension the blade on the bandsaw: 1. Make sure the blade is tracking properly. 2. DISCONNECT BANDSAW FROM POWER! 3. Loosen and slide the blade guide as far out as it will go, then tighten it down again. 4. Turn the tension knob in Figure 32 clockwise to tighten the blade or clockwise to loosen it. ! Tension Knob Figure 32. Adjusting blade tension. 5. Using moderate finger pressure, push against the side of the blade. If it flexes more than 1⁄8", tighten the tension knob further, then repeat this step. -26- For Machines Mfg. Since 8/09 O P E R AT I O N Model SB1018 Blade Care & Break-In Blade Speed Blade Care To prolong blade life, always use a blade with the proper width, set, type, and pitch for each application. Maintain the appropriate feed rate, feed pressure, and blade speed. Keep your blades clean, since dirty or gummed up blades pass through the cutting material with much more resistance than clean blades, causing unnecessary heat. Blade Break-In The tips and edges of a new blade are extremely sharp. Cutting at too fast of a feed rate or too slow of a blade speed can fracture these tips and edges, causing the blade to quickly become dull. Properly breaking-in a blade allows these sharp edges to wear without fracturing, thus keeping the blade sharp longer. Use the Chip Inspection Chart on Page 28 to ensure that the optimal blade speed and feed rate are being used. To properly break-in a new blade: 1. Choose the correct speed for the blade and material of the operation. The bandsaw is capable of operating at 80, 120, or 200 FPM (Feet Per Minute). The speed can easily be adjusted by changing the V-belt placement. Figure 33 shows the pulley positions required for each speed. The charts on the following page provide guidelines for determining which speed to use for a cutting operation Gearbox Pulley Motor Pulley 80 FPM 120 FPM 200 FPM Figure 33. Pulley and V-belt configuration. To change the 1. DISCONNECT BANDSAW FROM POWER! 2. Open the belt cover, then loosen the belt tension bolt shown in Figure 34 to allow the motor to pivot. Belt Tension Bolt 2. Reduce the feed pressure by half for the first 50–100 in2 of material cut. 3. To avoid twisting the blade when cutting, wait until the total width of the blade is in the cut before adjusting the feed pressure. Figure 34. Motor tension bolt. 3. Lift the motor to relieve the belt tension and position the belt in the desired pulley alignment. 4. Release the motor and let its weight tension the belt. 5. Re-tighten the belt tension bolt and close the belt cover. -27- O P E R AT I O N Model SB1018 For Machines Mfg. Since 8/09 Blade Speed Chart The chart in Figure 35 offers blade speed guidelines for various metals, given in feet per minute (FPM) and meters per minute (M/Min). Choose the closest available speed on the machine, then adjust the feed rate as necessary, using the appearance of the chips produces as a guide. Refer to the Chip Inspection Chart that follows for recommendations on adjusting your operation based on the appearance of the chips produced