Sharp SW-100H Instruction Manual Download Page 69

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10. Heavy Wear On Both Sides Of Band

Probable Cause :

Chipped or broken side guides.

Side guide adjustment may be too tight.

Insufficient flow of sawing fluid through the

side guides.

Insufficient sawing fluid due to inadequate supply,

improper ratio and/or improper application.

#11. Uneven Wear Or Scoring On The Sides Of Band

Probable Cause :

Loose side guides.

Chipped, worn or defective side guides.

Band is rubbing on part of the machine.

Guide arms spread to maximum capacity.

Accumulation of chips in side guides.

#12. Heavy Wear And/Or Swagging On Back

Edge

Probable Cause :

Excessive feed rate.

Excessive back-up guide "preload".

Improper band tracking – back edge rubbing

heavy on wheel flange.

Worn or defective back-up guides.

Summary of Contents for SW-100H

Page 1: ...SW 100T Instruction Manual Version 1 20171114 ...

Page 2: ......

Page 3: ...nds clothing or gloves are caught by the running blade Make sure any use of fire is prohibited in the shop and install a fire extinguisher or other fire control device near the machine when cutting titanium magnesium or any other material that produces flammable chips Never leave the machine unattended when cutting flammable materials Use a water soluble cutting fluid on this machine Oil based cut...

Page 4: ... been clamped firmly If the workpiece is not securely clamped it will be forced out of the vise during cutting Take preventive measures when cutting thin or short pieces from the work to keep them from falling It is dangerous if the cut pieces fall Use roller tables at the front and rear sides of the machine when cutting long work It is dangerous if the work piece falls off the machine Turn off th...

Page 5: ...al Information 2 1 Specification 2 2 Machine Parts Identification 2 3 Floor Plan 2 4 Section 3 Moving Installation 3 1 Location Environment 3 1 Unpacking Inspecting 3 2 Lifting 3 3 Illustration Lifting Points 3 5 Removing Shipping Bracket 3 6 Cleaning 3 6 Installing 3 6 Supplying Hydraulic Oil 3 6 Supplying Coolant 3 7 Connecting Electric Power 3 7 Leveling Anchoring 3 8 Installing Roller Table Op...

Page 6: ...op Bracket 4 10 Unrolling Installing the Blade 4 11 Adjusting Blade Tension 4 12 Adjusting Wire Brush 4 12 Adjusting Saw Arm 4 12 Adjusting Horizontal Stop Spring Cushion 4 13 Section 5 Electrical System 5 1 Electrical Circuit Diagrams 5 1 Section 6 Hydraulic System 6 1 Hydraulic Diagrams 6 1 Section 7 Bandsaw Cutting A Practical Guide 7 1 Introduction 7 2 Saw Blade Selection 7 2 VISE LOADING 7 3 ...

Page 7: ... Recommendation for Maintenance 8 4 Section 9 Troubleshooting 9 1 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 9 12 Section 10 Parts 10 1 Spare Parts Recommendations 10 1 Part List 10 2 ...

Page 8: ...l you will also see various safety related symbols indicating important information that you should take note of prior to use of the machine or part of its functions These important safety instructions do not cover all possible situations that might occur It is your responsibility to take caution and follow procedures stated in this manual when installing maintaining and operating your machine SAF...

Page 9: ...ted with a roller table recommended Do not use the machine to cut explosive material or high pressure vessels as it will generate great amount of heat during the sawing process and may Wear proper apparel during operation and when servicing the machine Some personal protective equipment is required for the safe use of the machine e g protection goggles Never operate while under the influence of dr...

Page 10: ...ese safeguard devices under any circumstances except when servicing the machine Even skilled service technicians should still take cautions when performing repairs or service on the machine with any of these protectors removed It is the responsibility of the user to make sure all these elements are not lost and damaged Take note of the following main moving parts on the machine prior to and during...

Page 11: ... that the machine will stop whenever the wheel covers are open This device is to protect users from being cut by the running saw blades Among all these safety switches some of them are used to protect the users and some of them are used to prevent damage to saw blades the workpiece and the machine itself etc We have taken every precaution to prevent injury or damage and to provide safe and economi...

Page 12: ...Illustration Emergency Stop Emergency Stop Button ...

Page 13: ...n the accessories DANGER Running Blade Blade runs through this area Keep your hands away from a running blade to avoid severe injury The arrow indicates direction of the blade Cutting Hazard KEEP COVER CLOSED KEEP HAND OFF while the blade is running Turn power off before opening cover Failure to follow the warning can result in severe injury Hazardous Voltage TURN POWER OFF before servicing Failur...

Page 14: ...Illustration Safety Labels SW 100T SafetyLabels ...

Page 15: ...our machine produces an undesirable noise while it is running you should 1 Make sure all maintenance tasks have been performed following the prescribed maintenance schedule Refer to Section 6 2 If maintenance does not seem to solve the problem follow the troubleshooting procedures under Section 7 RISK ASSESSMENT Risk assessment generally takes account of intended use and foreseeable misuse includi...

Page 16: ...lly when the saw blade is broken protecting both the operator and the machine Convenience High Performance The machine is designed in the way that the operation and adjustment can be easily performed The machine will stop automatically when out of stock Dual valve system is designed to achieve optimal cutting performance with the simple setting of feed rate and perspective cutting pressure for dif...

Page 17: ... x 27 x 0 9 mm 132 x 1 06 x 0 035 Tension Hydraulic with automatic blade breakage detection Guide Interchangeable tungsten carbide Cleaning Steel wire brush with flexible drive shaft driven by main motor Motor Output Saw Blade 2 HP 1 5 kW Hydraulic 1 4 HP 0 2 kW Coolant Pump 1 8 HP 0 1 kW Coolant Tank Capacity 20 L 5 28 gal Vise Control Method Manual Feeding Mode Manual Workbed Height 640 mm 25 We...

Page 18: ...N Fixed vise Guide arm handle Dovetail slide guide Control box Dovetail gauge plate Idle wheel cover Movable vise Stopper Motor Variable blade speed control Blae tension handwheel Blade tension device Bed Hydraulic feed cylinder ...

Page 19: ...FLOOR PLAN Machine top view Machine front view ...

Page 20: ...Machine front view ...

Page 21: ...d inspection Refer to Section 2 General Informattion for machine dimensions and floor space Environment Well lighted 500 lumen at minimum Floor kept dry at all times in order to prevent operators from slipping Away from direct exposure to the sunlight Room temperature between 5C to 40C Humidity level kept at 30 95 without condensation to avoid dew on electric installation and machine Away from vib...

Page 22: ...tention to machine surface equipments furnished and the electrical and hydraulic systems for damaged cords hoses and fluid leaks In the event of damage caused during shipping please contact your dealer and consult about filing a damage claim with the carrier Your machine comes in with a set of tools for you to maintain the machine The accessories furnished are as follows 1 Tool box 1 pc 2 Grease g...

Page 23: ...If there is any doubt on missing hanging points on your machine please consult with the original manufacturer or its qualified agent before hanging the machine Machine lifting is likely to damage the machine if not performed properly Warning You must have a qualified crane operator to perform the job You must use tools and equipment with the proper tensile strength and use proper method when movin...

Page 24: ...2 General Information for Specifications Machine lifting with a forklift should be done strictly according to the lifting points designated by the original manufacturer If there is any doubt on missing lifting points on your machine please consult with the original manufacturer or its qualified agent before lifting the machine Machine lifting is likely to damage the machine if not performed proper...

Page 25: ...w user guide of your forklift 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 or stickers please contact your local agent immediately ...

Page 26: ...Illustration Lifting Points Minimum weight capacity for each wire rope 1 ton Total number of wire ropes required 4 ...

Page 27: ...ve the rust preventive grease with a metal scraper and do not wipe the painted surfaces with solvent as doing so would damage surface paint INSTALLING Our bandsaw machine is relatively easy to install Follow these six easy steps to install your machine Supplying hydraulic oil Open the filler cap and fill the hydraulic oil tank to above 2 3 or full level Check the sight gauge to make sure the oil l...

Page 28: ...t level remaining in the tank Always check the coolant supply before starting the machine If the coolant pump is started without enough coolant supply in the tank the pump and its drive motor may be damaged Refer to specification chart under Section 2 General Information for tank capacity Consult your coolant supplier for bandsaw use regarding coolant type and mix ratio ...

Page 29: ...e motors and make sure your shop circuit breaker is capable of this consumption amount Also use a power supply cable of proper size to suit the power supply voltage 1 Turn off the shop circuit breaker 2 Make sure the machine circuit breaker switch on the electrical compartment door is turned to OFF 3 Remove the screw securing the electrical compartment and then open the door 4 Pull the power suppl...

Page 30: ...lectrical connections are in the right order Leveling Place spirit level on the vise slide plates and the work feed table Level the machine in both directions i e along and across the machine Adjust the level of the machine by turning the leveling bolts Make sure all leveling bolts evenly support the machine weight Anchoring the machine Normally there is no need to anchor the machine If the machin...

Page 31: ...ATING We recommend you follow these procedures when relocating or shipping your machine to other place 1 Descend the saw frame to its lowest position then turn off the power 2 Fix the saw frame using the shipping bracket that originally came with the machine 3 If you are shipping the machine pack the machine carefully with industrial plastic wraps to protect it from dust 4 Use a crane or forklift ...

Page 32: ...NS 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: ...terial in place before cutting long workpieces Always make sure the material is clamped firmly in place before starting to cut Do not remove jammed or cut off pieces until the blade has come to a full stop Keep fingers away from the path of the blade Protection devices should be in place at all times For your own safety never remove these devices Disconnect machine from the power source before mak...

Page 34: ... material is flammable Never take your eyes off the machine while in operation Cutting fluid For cooling and lubrication purpose we recommend you use water soluble cutting fluids The following table lists out its pros and cons for your reference Pro Con Have a high cooling effect Not flammable Economical Does not require cleaning of the cut products Remove machine paint Lose its rust protection ef...

Page 35: ...in an emergency When the button is pressed it brings the machine to a full stop The button locks when pressed In order to unlock it please turn the button clockwise 3 Saw bow up button When this button is pressed the saw bow rises until the operator lets go of the button 4 Saw bow down button When this button is pressed the saw bow descends 5 Flow control valve This valve is used to adjust the des...

Page 36: ...eel bearing bronze 100 120 Small Medium Cast iron mild steel hard brass bronze 164 196 Medium Small Plastic copper soft brass aluminum other light materials 277 330 Large Smallest Some materials due to manufacturing processes such as certain types of cast iron pipe or materials containing certain types of welds cannot be cut on the machine Changing Blade Speed 4 Speed Step Pulley Fig 1 Step 1 Remo...

Page 37: ... 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 A finer blade tooth is used when cutting thin sections and harder materials Coarse teeth are for sawing large work and tough gummy metals ...

Page 38: ...r regulates the rate at which the blade is lowered into the material being cut Adjusting the blade descend speed control knob provides an infinite choice for feed rate When cutting workpiece of 2 mm thick or below please adjust the blade descend speed control knob to between 1 2 gradually when cutting workpiece of 3 mm and above to 3 4 gradually The by pass valve Fig 3 2 has been factory adjusted ...

Page 39: ...Angle Cutting The vise offers the user great flexibility in angle cutting from 0 Position 1 to 45 Position 2 ...

Page 40: ...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 to saw blade with an accurate protractor See Fig 6 below Tighten the two lock bolts Step 4 Clamp the workpiece with the movable vise jaw Fig 4 4 Step 5 When repositioning the vise for 90 cutting make sure it is square with an accurate square instrument ...

Page 41: ... Adjusting Coolant Flow Step 1 Press the power on button to start the saw blade drive motor Step 2 Lower the saw bow 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...

Page 42: ...between saw blade teeth edge and the top of the material Then measure your desired cutoff length Step 4 Loosen the fastening bolt Fig 9 3 Step 5 Slide and position the stopper Fig 9 6 so that the end of stopper faces the direction of the front end of the material Then tighten the stopper handle Fig 9 5 to fix the stopper in the bracket Fig 9 4 Step 6 Move the stopper bracket Fig 9 4 toward the wor...

Page 43: ...tep 1 Elevate the saw bow until it is positioned vertically Step 2 Open the idle and drive wheel covers Step 3 Release blade tension by turning the blade tension handle lever counterclockwise see below Adjusting Blade Tension and remove the blade Step 4 Install the new blade with teeth pointing downward and place the blade around the wheel consecutively following the direction of the teeth Step 5 ...

Page 44: ... while cutting Do not apply excessive tension ADJUSTING WIRE BRUSH Follow these steps to adjust wire brush to appropriate position Step 1 Open the drive wheel cover Step 2 Adjust the screw to make brush move up down until it makes proper contact with the saw blade see below illustration Step 3 Close the drive wheel cover Proper Improper ADJUSTING SAW ARM Adjust the blade guide guide arm position b...

Page 45: ... steps to adjust the horizontal stop spring cushion Step 1 Place a level on the workbed Fig 10 4 to make sure the bed is level Step 2 Loosen the lock nut Fig 10 3 and lower down the saw bow Place the level on top of the saw blade Fig 10 A to check its leveling against the bed horizontal line Adjust the screw Fig 10 2 until the blade is level Step 3 Tighten the lock nut Fig 10 3 when leveling is ob...

Page 46: ... right before the head comes to rest on the horizontal stop spring cushion If it does not the spring cushion must be adjusted 1 Check the horizontal stop spring cushion Refer to Complete Cut Adjusting Horizontal Stop Spring Cushion 2 Raise the saw head and press the power on button to ON Lower the saw head slowly and observe the switch mechanism ...

Page 47: ...Section 5 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS ...

Page 48: ......

Page 49: ...Section 6 HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM ...

Page 50: ......

Page 51: ...Section 7 BANDSAW CUTTING A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BladeBreak In SOLUTIONS TO SAWING PROBLEMS ...

Page 52: ...s for the minimum tooth distance in the toothing interval Constant Variable Min Max 4 Set The bending of teeth to right or left to allow clearance of the back of the blade through the cut 5 Width The nominal dimension of a saw blade as measured from the tip of the tooth to the back of the band 6 Thickness The dimension from side to side on the blade 7 Gullet The curved area at the base of the toot...

Page 53: ...ade from binding in the cut It may be either a regular set also called a raker set or a wavy set The regular or raker set is most common and consists of a pattern of one tooth to the left one tooth to the right and one which is straight or unset This type of set is generally used where the material to be cut is uniform in size and for contour cutting Wavy set has groups of teeth set alternately to...

Page 54: ...nd speed for the material to be cut 2 Reduce the feed force rate to achieve a cutting rate 20 to 50 of normal soft materials require a larger feed rate reduction than harder materials 3 Begin the first cut at the reduced rate Make sure the teeth are forming a chip Small adjustments to the band speed may be made in the event of excessive noise vibration During the first cut increase feed rate force...

Page 55: ...est performance and longer life of the band saw machine a maintenance schedule is necessary Some of the daily maintenance usually takes just a little time but will give remarkable results for the efficient and proper operation of cutting BASIC MAINTENANCE It is always easy and takes just a little effort to do the basic maintenance But it always turns out to be a very essential process to assure th...

Page 56: ...ck the wire brush for proper contact with the saw blade Replace the wire brush if it is worn out After ending a day s work Please remove saw chips and clean the machine with discharging the cutting fluid when work has been completed Do not discharge cutting fluid while the saw blade is operating because it will cause severe injury on operator s hand Be sure the saw blade is fully stop it will be p...

Page 57: ...wing conditions in future 1 Turn off the power 2 Ambient temperature 5 40 3 Relative humidity 30 95 without condensation 4 Atmosphere use a plastic canvas to cover machine to avoid excessive dust acid fume corrosive gases and salt 5 Avoid exposing to direct sunlight or heat rays which can change the environmental temperature 6 Avoid exposing to abnormal vibration 7 Must be connected to earth TERMI...

Page 58: ...oil of 600 hours of using Change it every year Regularly Omala oil HD220 Mobil Gear 630 Hydraulic system Inspect half a year Change oil every year Regularly Shell Tellus 32 Mobil DTE oil Light Hydraulic 24 Bearing Inserts Oil with lubricant but not excess Daily Shell R2 Band wheel Oil with lubricant but not excess Weekly Cylinder Oil with lubricant but not excess 6 Monthly Wire brush Oil with lubr...

Page 59: ...S and BLADE TROUBLES Although you may have other troubles which can not be recognized in advance such as malfunctions due to the limited life span of mechanical electric or hydraulic parts of the machine We have accumulated enough experiences and technical data to handle all of the regular system troubles Meanwhile our engineering department had been continuously improving the machines to prevent ...

Page 60: ...s Blade Selection Cannot make square cut Dull blade Replace blade Guide rollers not adjusted properly Refer to Adjustments Rear vise jaw not adjusted properly Set fixed vise jaw 90 to blade Excessive head pressure Reduce head pressure Refer to operating instructions Adjusting Feed Increased cutting time Dull blade Replace blade Insufficient head pressure Increase head pressure Refer to Operating I...

Page 61: ...shorted terminals or worn insulation on wires Incorrect fuses or circuit breakers in power line Install correct fuses or circuit breakers Motor fail to develop full power Power output of motor decreases rapidly with decrease in voltage at motor terminals Power line overloaded with lights appliances and other motors Reduce the load on the power line Undersize wires or circuit too long Increase wire...

Page 62: ...utting lubricant Excessive speed Lower speed See Operating Instructions Speed selection Excessive speed Reduce feed pressure Refer to Operating Instructions Adjusting Feed Excessive tension Tension blade to prevent slippage on drive wheel while cutting Wheels out of line Adjust wheels Blade line Run out or Run in Guides out of line For a straight and true cut realign guides check bearings for wear...

Page 63: ... feed pressure Premature tooth wear Dry cutting Use lubricant on all materials except cast iron Blade too coarse Use finer tooth blade Not enough feed Increase feed so that blade does not ride in cut Excessive speed Decrease speed ...

Page 64: ...improperly positioned Relocate Blade improperly clamped by insert Check and correct Improperly clamped workpiece Check and correct Excessively hard material surface Soften material surface Excessive cutting rate Reduce cutting rate Non annealed workpiece Replace with suitable workpiece Insufficient or lean cutting fluid Add fluid or replace Vibration near machine Relocate machine Non water soluble...

Page 65: ...e 3 Wear On One Side Of Teeth 13 Butt Weld Breakage 4 Chipped Or Broken Teeth 14 Heavy Wear In Only The Smallest Gullets 5 Body Breakage Or Cracks From Back Edge 15 Body Breaking Fracture Traveling In An Angular Direction 6 Tooth Strippage 16 Body Breakage Or Cracks From Gullets 7 Chips Welded To Tooth Tips 17 Band is Twisted Into A Figure 8 Configuration 8 Gullets Loading Up With Material 18 Used...

Page 66: ...nsufficient sawing fluid due to inadequate supply improper ratio and or improper application 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 Worn wheel flange allowing side of teeth to contact wheel...

Page 67: ...e C Improper band tracking back edge rubbing heavy on wheel flange D Worn or defective back up guides E Improper band tension F Notches in back edge from handling damage 6 Tooth Strippage Probable Cause A Improper or lack of break in procedure B Worn missing or improperly positioned chip brush C Excessive feeding rate or feed pressure D Movement or vibration of material being cut E Improper tooth ...

Page 68: ...ine 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 9 Discolored Tips Of Teeth Due To Excessive Frictional Heat Probable Cause A Insufficient sawing fluid due to inadequate supply improper ratio and o...

Page 69: ... application 11 Uneven Wear Or Scoring On The Sides Of Band Probable Cause A Loose side guides B Chipped worn or defective side guides C Band is rubbing on part of the machine D Guide arms spread to maximum capacity E Accumulation of chips in side guides 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 e...

Page 70: ...aking Fracture Traveling In An Angular Direction Probable Cause A An excessive twist type of stress existed B Guide arms spread to capacity causing excessive twist from band wheel to guides C Guide arms spread too wide while cutting small cross sections D Excessive back up guide preload 16 Body Breakage Or Cracks From Gullets Probable Cause A Excessive back up guide preload B Improper band tension...

Page 71: ...oo tight rubbing near gullets B Excessive preload band riding heavily against back up guides C Worn band wheels causing uneven tension D Excessive feeding rate E Guide arms are spread to maximum capacity F Improper band tracking back edge rubbing heavy on wheel flange 19 Used Band Is Short On The Tooth Edge Probable Cause A Side guides are too tight rubbing near back edge B Worn band wheels causin...

Page 72: ...just TOOL measuring Measurement Horizontal balance Procedure 1 Screw or loosen the adjusting bolt to attain the horizontal balance leveling between the roller table and the machine frame 2 Ensure that the machine frame is not struck by the loaded material on the feeding table 3 Check the leveling by the measuring tool 4 After finished the adjusting fix the roller table If the feeding table and the...

Page 73: ...wing 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 Hydraulic tank leak proof gasket Duster seal Rubber washer Oil seal O ring Snap ring Drive wheel Idle wheel ...

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