Starrett S3120 Band Saw Machine Manual by The L.S. Starrett Company Ltd

Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Service Center: 55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br

Instruction Manual for installation and maintenance band saw machine models:

S3120 The Original Manual was written in Portuguese

serial number: date:

Prior to installing or performing any operation, carefully read this Instructions Manual on the use of this machine. For further informations or clarifications, please contact Starrett. REV.05 - MAI/13

S3120 - ENG

GENERAL INDEX 1. COMPLIANCE CERTIFICATE ..................................................................................... 1 2. WARRANTY............................................................................................................ 5 3. MACHINE IDENTIFICATION ..................................................................................... 7 4. TECHNICAL DATA .................................................................................................... 9 4.1. STANDARD ITEM ........................................................................................................................... 9 4.2. FIGURE AND PART REFERENCES ................................................................................................ 10 4.3. APPLICABLE LEGISLATION AND TECHNICAL STANDARD .......................................................... 11

5. SAFETY RECOMMENDATIONS ............................................................................... 13 6. MACHINE DESCRIPTION ....................................................................................... 19 6.1. DESCRIPTION ............................................................................................................................... 19

7. INSTRUCTION FOR USE AND OPERATION ............................................................. 25 7.1. ADJUSTMENTS AND CHECKS ...................................................................................................... 25 7.2. MACHINE START ͳ UP .................................................................................................................. 27 7.3. BAND SAW BLADE CONSIDERATION .......................................................................................... 29 7.4. BAND SAW BLADE REPLACEMENT AND ADJUTMENT PROCEDURE ........................................ 34 7.5. ANGLE CUT PROCEDURE ............................................................................................................ 36

8. CRITERIA FOR BAND SAW SELECTION ................................................................... 39 8.1. LIMITS AND RECOMMENDATIONS ............................................................................................. 39 8.2. CRITERIA FOR BAND SAW SELECTION ........................................................................................ 39 8.2.1. TEETH ΈPITCHΉ ...................................................................................................................... 40 8.2.2. CUTTING FEEDING AND BLADE SPEEDS ............................................................................ 40

9. TRANSPORTION INSTRUCTION ............................................................................. 41 9.1. HANDLING ................................................................................................................................... 41

10. INSTALLATION INSTRUCTION ............................................................................ 43 10.1. INSTALLATION INSTRUCTION .................................................................................................. 43 10.2. DISASSEMBLY AND DISPOSAL OF THE MACHINE ................................................................... 46 10.2.1. DISPOSAL............................................................................................................................ 46 10.2.2. DISASSEMBLY .................................................................................................................... 46

REV.05 - MAI/13

III

S3120 - ENG 11. SISTEMS ............................................................................................................. 47 11.1. ELECTRICAL SYSTEM .................................................................................................................. 47 11.2. MACHINE SAFETY SYSTEM ........................................................................................................ 49 11.3. MEASURING ROD SYSTEM ........................................................................................................ 49

12. GEAR BOX ......................................................................................................... 51 12.1. OPERATING PRINCIPLE .............................................................................................................. 51 12.2. MAINTENANCE INSTRUCTIONS .............................................................................................. 51

13. GENERAL MAINTENANCE .................................................................................. 53 13.1. CLEANING .................................................................................................................................. 53 13.2. GUIDES SET ADJUSTMENT AND MAINTENANCE ................................................................... 53 13.3. CAMBER OF DRIVEN FLYWHEEL ADJUSTMENT ...................................................................... 56 13.4. HYDRAULIC CYLINDER REPLACEMENT ..................................................................................... 58 13.5. SPRING SET REPLACEMENT ...................................................................................................... 59 13.6. MAINTENANCE TABLE .............................................................................................................. 60 13.7. TROUBLE, CAUSES AND SOLUTION .......................................................................................... 61

14. SPARE PARTS...................................................................................................... 63 14.1. CABINET SET AND COOLANT SYSTEM ...................................................................................... 63 14.2. VISE SET AND SWIVEL SUPPORT .............................................................................................. 64 14.3. BOW SET AND ELECTRIC PANEL ............................................................................................... 65 14.4. GUIDE SET .................................................................................................................................. 66 14.5. HYDRAULIC CYLINDER SET ....................................................................................................... 67

BAND SAW BLANDE CATALOG .................................................................................. 69 NOTES

REV. 05 - MAI/13

S3120 - ENG

WARNING! •

BEFORE TO START any kind of operation on the machine S3120, READ WITH ATTENTION all instructions in this manual, so that the use is familiarize with the equipament;

•

OBSERVE carefully the INSTRUCTIONS for TRANSPORT (Chapter 9);

•

OBSERVE carefully the INSTRUCTIONS for INSTALLATION (Chapter 10). CHECKED the voltage (Volts) of tje machine being delivered;

•

All opetations for transportation, installation, operation, maintenance, assembly, disassembly and repair should be performed by skilled, trained and trained for these types of services. A Starrett will give all assistance and technical support to the user or to the owner of machine, always when requested in writing;

•

Observe and understand all signs contained in the machine;

•

If the standard machine (delivered to the user) was modified or altered their technical characteristics, without the prior knowledge and approval of Starrett, the user or the owner will lose all WARRANTIES, and the civil and criminal liabilities will fall on the owner of the machine.

.Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Service Center: 0055 11 2118 8000 falecom@starrett.com.br www.starrett.com.br

REV.05 - MAI/13

S3120 - ENG

REV. 05 - MAI/13

S3120 - ING

1. CERTIFICADO DE CONFORMIDAD: DECLARAÇÃO DE CONFORMIDADE CE DECLARATION EC-CONFORMITY DECLARACIÓN DE CONFORMIDAD CE ATTESTATION DE CONFORMITÉ CE Starrett Indústria e Comércio Ltda. Av. Laroy Starrett, 1880 13306-900 – Itu – SP – Brazil Declara, sob sua exclusiva responsabilidade que o Declara bajo su exclusiva responsabilidad que lo Declare that it is our sole responsibility that the Déclaro sous la seule responsabilité que le produto, producto, produto, produit,

Máquina de serra de fita, Máquina de sierra de cinta, Bandsaw machine, Scie à ruban,

modelo: modelo: modelo: modèle:

S3120 O qual se refere a esta declaração está de acordo com as seguintes diretivas: La cual se refiere esta declaración está de acuerdo con las siguientes directivas: Which refers this declaration is in accordance with the following directives: Qui se réfère à cette déclaration est en conformité avec les directives suivantes: DIRECTIVE 2006/42/CE DIRECTIVE 2004/108/CE e que estão em conformidade com as normas y que están de acuerdo con las normas and are in conformity with the following standards et qui est conforme aux normes EN 13898:2003+A1:2009 EN ISO 12100-1:2003+A1:2009 EN ISO 12100-2:2003+A1:2009 EN 60204-1:2006+A1:2009 EN ISO 14121-1:2007 EN 61000-6-2:2005 EN 61000-6-4:2007

Itu/SP, may de 2013. REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

2. WARRANTY: Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 13306-900 – Itu – SP – Brazil Starrett Call Center: 0055 11 2118.8000 falecom@starrett.com.br www.starrett.com.br

WARRANTY CERTIFICATE

PRODUCT S3120. The equipment manufactured and marketed by Starrett Ind. e Com. Ltda is covered by 12 months warranty from the issuance of invoice, regardeless or not the use of equipment. During the warranty period, the Technical Support of Starrett provided will loose its free characteristic if the defect allegation is unfounded. The replacement of parts or components, which are proven to have factory defects, shall be free of charge, not including the labor required, except when in reference to: •

Parts with foreseen natural wear caused by usage, such as bearings, protections, sealing, lamps, bearings of guides, etc;

•

Improper and undue handling for the purposes to which the product is intended;

•

Transport, falls, collisions, shocks, or improper storage;

•

Supply or usage of improper electric power;

•

Supply or usage of improper electric power;

•

Lack of observance of the instruction manual;

•

Interventions performed by third parties without Starrett Ind. e Com. Ltda;

•

Extended lack of product usage.

Changes in the technical specifi cations of the machine, structural, electrical or any unauthorized modifi cation written by Starrett Ind. e Com. Ltda will result also in loss of warranty. The warranty does not include regular machine maintenance service, such as adjustments, cleaning, and band replacement. Parts or equipment eventually replaced during the fulfillment of such warranty are the property of Starrett. Starrett Indústria e Comércio Ltda.

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

3. MACHINE IDENTIFICATION: All machinesStarrett can be identified with Identification Plate attached in the Cabinet (06). Data such as Model, Year of Manufacture, Serial Number, Power (kW / hp), Voltage (V) Frequency (Hz) and Weight (kg) are all recorded.

The figure below shows the Starrett Identification Plate format. .

S3120 U-0002-12/TW-S S3120-H2 2013 156 1,0 220

(ILLUSTRATIVE DATA)

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

4. TECHNICAL DATA: StarreƩ

S3120

Net Weight Dimensions (mm) Blade Motor (hp / kW) Coolant Motor (hp / kW) Blade Speed (m/min) Band Saw Blade Dimensions (mm) Available Voltage - 3 phases (V)(*) Motor opera on frequency (Hz)

156 Kg. 1,5 x 0,8 x 1,6 (height) 1,0/0,75 0,12/0,09 35 and 70 2110 ( + 2) x 20 x 0,9 220 or 380 50 or 60 (*) specification according to purchase order of customer

CUTTING CAPACITY DIMENSIONS (mm)

Noise emmited by the machine Machine no cu ng = 78 dBA Machine in cu ng = 82 dBA

NOISE DECLARATION (EN 13898:2003+A1:2009(E) – ITEM 7.3): “The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of the workforce include characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes. Also the permissible exposure level can vary from country to country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk.”

4.1. STANDARD ITEM Band Saw Blade

REV. 05 - MAI/13

S3120 - ING

4.2. FIGURE AND PART REFERENCES 01 10 11

09 12 08

06 Figure 01

INDEX OF FIGURES:

REV.05- MAI/13

S3120 - ING

4.3. APPLICABLE LEGISLATION AND TECHNICAL STANDARDS APPLICABLE LEGISLATION: ( From European Parliament and of the Council:) Directive 2006/42 /EC - On Machinery; Directive 2004/108/EC - Electromagnetic Compatibility; Directive 2006/95/EC - Electrical equipment designed for use within certain voltage limits. EUROPEAN TECHNICAL STANDARDS: EN 13898:2009+A1 Machine Tools - Safety - Sawing machines for cold metal; EN 12100:2010 Safety of Machnery - General Principles for design - Risk Assessment and Risk Reduction; EN 60204-1:2006 - A1:2009 Safety of machinery - Electrical Equipment of Machines - General Requirements; EN ISO 13857:2008 Safety Distances to Prevent Danger Zones being reached by Upper and Lower Limbs; IEC 61000-6-2: 2007 Electromagnetic compatibility (EMC) - Part 6.2 - Generic standards - Immunity for industrial environments; IEC 61000-6-4: 2007 Electromagnetic compatibility (EMC) - Part 6.4 - Generic standard - Emission standards for industrual environments; EN ISO 14121- & - 2:2007 Safety of machinery - Risk Assesment.

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

5. SAFETY RECOMMENDATIONS: The S3120 is equipped with safety protections to operator and to the equipment. However, all safety aspects cannot be summed by this way.Therefore, each user should pay attention to the machine’s configuration, maintenance, and repair, and also carefully read all parts of this Instruction Manual. In addition, the user or the owner of the machine must observe the conditions and contexts of risk that the equipment will operate through analyzing through mandatory requirements of Laws and Technical Standards of his country. Obligatorily observe the following: •

ONLY qualified personnel with express authorization may operate and maintain this machine. These people must be trained regarding occupational safety standards of each country;

•

Without express authorization, it is strictly forbidden to perform changes or alterations to machine components that may compromise user or machine safety, exposing both to unnecessary risk. For the afore-mentioned changes, it is obligatory to request the authorization and approval of Starrett Technical Support;

•

All machine problems must be immediately communicated to the responsible personnel, that is, Starrett Technical Support;

•

ONLY persons authorized by the company owning the machine may handle, operate, feed material to be cut, prepare for cutting, do the maintenance, remove moving parts, change permanent components, and replace periodic maintenance components, such as: oil, filter, bearings, coolant liquid, etc.;

•

To perform maintenance, changes, and repairs, or replace components of the machine’s electric system, the responsible and authorized person of the owner company must be qualified for such purpose, according to the pertinent law.It is implicit that only qualified persons must connect the machine to the electric power supplier and perform any works for this purpose.This service should be according to the standards and laws valid in the country in which the machine is installed.

•

When there is intervention of maintenance or any other service, it´s necessary to position the General Switch (02) inOFF, and disconnected from the electrical grid.This way, the machine will not offer risk of electric discharge;

•

To avoid machine operation irregularities, the operator must be well informed and trained on the operation of the machine before putting it into operation;

REV. 05 - MAI/13

S3120 - ING •

OBSERVE and ENSURE that the personnel responsible for handling, operating, feeding material to be cut, preparing for cutting, performing maintenance, repairing, removing moving parts, changing permanent components, replacing machine components, are NOT working under the influence of medicine, alcohol, or drugs that act on the central nervous system;

•

In case of machine problems, do NOT put it in operation before Starrett Technical Support;

•

In case of accidents, problems, or danger, quickly activate the EMERGENCY Button (05);

WARNING RISK OF AMPUTATION OR SEVERE INJURY! • OBSERVE all signaling that are on the Bow (09) of machine. It is very important that the operator is familiarized with these indications; • DO NOT DAMAGE the machine´s technical plate; • NEVER touch machine moving parts with your hands or any other part of the body when it is in operation; • ALWAYS KEEP the machine and the surrounding area clean. This way, it will prevent accidents to operator and also for people who are close to it; • Before to start the cleaning of machine or the maintenance, put the Main Switch (02) in OFF. NEVER remove material chips and other residues with the machine in operation. DO NOT leave chips , and other residues to accumulate on or around the machine, because this may cause severe accidents or damage; • All the humidity generated by the cooling fl uid around the machine must be cleaned and removed to avoid operator or other people accidents. If immediate cleaning is not possible, indicate the risk locations; • USE lifting and transport devices to handle the materials to be cut according to appropriate weight and dimension limitations for a safe and ergonomic work. This operation must be performed by responsible and qualified persons; • The operator must USE always the protective personal equipment (PPE) legally approved in the country. The operator must use the following PPEs: safety glasses, earplugs and industrial shoes. OBSERVE Plate (38) in the Electrical Panel (01) (figure 02A).

REV.05- MAI/13

S3120 - ING

Leather Gloves, use them ONLY to replace the band saw blade, and NEVER use them during the operation. Besides that, the company owner the machine must guide and train each operator appropriately on how to use and keep each PPE, creating or indicating other individual protections especially for the operator;

• Also it is necessary to observe the selection of the type of band saw blade. Observe: tooth, feeding and cutting speed, appropriate for the type of material to be cut. This definition avoids problems during the cutting operation ( seer Chapter 8 this Manual); • Long materials to be cut that exceed the Table Cutting (22) of the machine should be supported by roller tables in the machine feed positi on (see the following figure); • In case of machine maintenance, OBSERVE the safety recommendations; • Before any maintenance in the Hydraulic Cylinder (12), keep the Bow (09) completely in the lower position, so that there is no pressure in the hydraulic system due to the weight of Bow (09); • Before any maintenance in the Spring System (37), keep the Bow (09) completely in the upper position, so that there isn't potential energy accumulated in the spring; • ALWAYS USE originals and new spare parts. Other spare parts or works not approved by the manufacturer, that present risks or cause accidents and damage are not under Starrett responsability; • ENSURE suffi cient free space (1.2m minimum) around the machine, in order to provide work space and for people passage; Observe the recomendations of safety technical statndards; • DO NOT PUT or LEAVE tools or others objects on the machine parts;

REV. 05 - MAI/13

S3120 - ING

DANGER â&#x20AC;&#x201C; risk of electric shock

WARNING - danger of injury or damage to the machine DANGER - hands crushed

DANGER - RISK OF AMPUTATION

DANGER - projection of chips material USE LEATHER GLOVES APPROPRIATE FOR THIS PURPOSE, ONLY TO REPLACE THE BAND SAW BLADE USE PROTECTIVE SHOES APPROPRIATE FOR THIS PURPOSE USE EARPLUGS APPROPRIATE FOR THIS PURPOSE USE PROTECTIVE EYEWEAR APPROPRIATE FOR THIS PURPOSE

Input and Output Roller Table (Optional)

REV.05- MAI/13

S3120 - ING

ATTENTION: RISK OF INJURY! DEFINITION OF MACHINE´S WORKSTATION POSITION: During the cu ng process, the operator must be MANDATORILY near General Switch (03), observing the cutng parameters, and with his hands free, to access, immediately the EMERGENCY Bu on (05)

DANGER ZONE

ATTENTION:RISK OF INJURY! The Band Saw Blade (32) has a region that isn´t protected, called de DANGER ZONE. The operator of machine must be aten ve to this area.

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

6. MACHINE DESCRIPTION: 6.1. DESCRIPTION The STARRETT HORIZONTAL BAND SAW MACHINE â&#x20AC;&#x201C; S3120 was developed by quality, safety, modernity, and technology criterias to meet the userâ&#x20AC;&#x2122;s needs, according to the harmonized EC directives and standards. It is a machine designed for cutting ferrous (steel and its alloys) and nonferrous (bronze, aluminum alloys, etc.) bars having various shapes and dimensions. The physical characteristics of these materials such as hardness, toughness and density should not pose any safety problem to the user during the cutting operation. Due to its project conception, this equipment can work in 2 operation modes:MANUAL a GRAVITATIONAL. In MANUAL mode the operator is responsible for the speed and feeding force, and keep running the Blade Motor. In the GRAVITATIONAL mode, the operator simply presses the Trigger (25), opens the Shutoff Valve (36) and begins the feeding movement by pressure of the weight of Bow (09).At the end of cutting operation, the machine will stop automatically. Following, this model is composed of a rigid Bow (09) that it has 2 Flywheels: one is Driven Flywheel (42) and the other, Driver Flywheel (41). The Driver Wheel (41) is coupled to a WORM-type Gear Box (11). The Driven Wheel (42) is mounted on the shaft of a dynamometric system called Tensioning Set (21). A welded Band Saw Blade (32) is mounted on two flywheels and adequately tensioned through Tensioning Set (21) in order to keep the blade properly tensioned on Flywheels (41)(42). The Bow (09) in turn is mounted on the vise set through a shaft, which allows it to tilt on the blade plane, i.e., on the cutting plane (figure 01). The Band Saw Blade (32) and the Flywheels (41)(42) are protected in the rear side of the Bow (09) by a Back Cover (14) (figure 07B). The Vise Set (08) (figure 01) is responsible for securely fastening the material to be cut on the Cutting Table (22). This set has a longitudinal moviment, in the sense of fixing the material, controlled manually through the Handle (23). The tightening or loosening of the vise on the material is also manually controlled by the Quick Clamping Lever (24) (figure 06). By construction of machine, the Bow (09) can rotate about a fixed point of the set of Vise (08), ie on the perpendicular axis of the Cutting Table (22), to allow miter cuttings on the material to be cut.

REV. 05 - MAI/13

S3120 - ING The feeding speed of the Band Saw Blade (32) on the material is controled by a Hydraulic Cylinder (12) (figure 11), solidary with the Bow Set (09). Opening or closing the Regulator Valve (35), it can control the feeding, in order to adjust the desired feeding speed.The Shutoff Valve (36) will allow to keep the Bow (09) in any position, when it is in the CLOSED position (horizontal lever). The machine is supported on the rigid Cabinet (06) made from steel plate and shapes. The structure is protected by epoxy-based painting that is highly resistant to weather. Attached with the Bow Set (09) there is the Electrical Panel (01), positioned ergonomically (figure 02A). The electrical system was developed, following specifics standards. The system is composed by 2 lines: the power and another of control. The power line is sized to allow the load of electric motors, protected against short circuits or overloads. The motor are switced by por 1 contactor. The electric supply line can be in 220 or 380 or 400 or 440VAC, as purchase order of equipment. The command line operates with 24VAC, ie, in extra low voltage. On the Electrical Panel (01) is installed a General Switch (02), which the purpose is to disable the electrical system of the machine in case of disuse and to protect the user in case of maintenance (figure 02B). In the left side of Electrical Panel (01) is installed the EMERGENCY Button (05), which objective is to stop the machine in the cases of abnormalities.

REV.05- MAI/13

S3120 - ING

01 03

31 04 20

15 38

32 17

70 19 Figure 02A

05 01

33 Figure 02B

REV. 05 - MAI/13

S3120 - ING The Band Saw Blade (32) segment that performs the cutting is supported by 2 Guides (18) (19). These Guides have Lateral Bearings (51) and the Back (50), that allow the blade twist to define the cutting plane.The Lateral Berings (51) have the function to align and no allow that the Band Saw Blade (32) rotates laterally on the movement axis (figures 07A and 07C). The Mobile Guide Support (16), close the Driven Flywheel (42), can be manually adjusted. Releasing the Lever (17), can adjust the distance of it to the material being cut (figures 04 and 07A). With the machine adjusted, electrically connected and the material to be cut properly positioned and clamped on the Cutting Table (22), the operator must select the operation mode: MANUAL or GRAVITATIONAL, by Selector Switch (31), as required. Then, select the most appropriate cutting speed to the process, by Speed Control Switch (04) (figure 03). Made the cutting plan, the operator presses the Trigger (25) to start the cut, regulating the first time the feeding by Regulator Valve (35) (figura 11), if it is operating in the GRAVITATIONAL mode. At the end of the cut the Micro Switch (34) will be pressed by Drive Rod (30), stopping the machine automatically. In MANUAL mode the operator is responsible for the foce and speed feeding, and keep running the Blade Motor (32). Always that the machine is connected to the electrical grid and the General Switch (02) in ON (Switched), the WHITE Pilot Lamp (03) will remain lighted.

34 30 12

47 46

Figure 03

REV.05- MAI/13

S3120 - ING Also is installed in this model a safety system to user and to the equipment, which will be described in detail in the Chapter 11 - Systems. The safety systems presents are: -

General Switch (02) to disable the electrical circuit, allowing the operator perform the maintenance operation without risk of electric shocks;

EMERGENCY Button (05), on the electric panel, for any stops no normals;

Opening of the protection cover, or Back Cover (14), turnning-off the Micro Switch (33);

Ligth indicator, i.e. Pilot Lamp (03), indicating the presence of electric power in 24VAC in the electric panel of machine.

OBSERVATION: The segment of Band Saw Blade (32) that performs the cu ng opera on (between the Guides (18)(19)), obviously, do not have protec on, leaving the machine's operator to take all due care.

01 09

10 11

24 12 23

08 06

Figure 04

All details of the systems making up these machines are described in their respective Sections.

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

7. INSTRUCTION FOR USE AND OPERATION: 7.1. ADJUSTMENTS AND CHECKS Before starting any kind of job with the machine, check it: 1.

The volume of coolant (oil + water) in the Tank (44) is approximately 20 liters. The oil concentration in the cutting fluid mixture must follow the instructions as specifications from the oil manufacturer (figure 05);

OBSERVATION: Check if the coolant oil to be employed is not obnoxious to the operator, the environment and the machine itself.. Disposal of the coolant oil must be provided in compliance with current environmental regula ons and the product manufacturer standards.

44 06

Figure 05

REV. 05 - MAI/13

S3120 - ING 2.

Check the Band Saw Blade (32) conditions regarding integrity of its teeth and band;

The tension of Band Saw Blade (32), turning the handle of Tensioning Nut (52) until that the conditions indicated on the Plate (39), located on the Bow (09) (figure 02B) are presents, i.e., touching the edge of Tensioning Nut (52) on the head of Stop Screw (53) (figure 07B), as showed bellow.

If the teeth type is the most appropriate for the kind of cuting to be done. Check selection for conformity to item Band Saw Blade Selection Criteria in this Section;

If the cutting speed (m/min) selection is compatible with the characteristics of the material to be cut. . Select the cutting speed through the Speed Control Switch(04) located on the electric panel. As guidance Starrett Cutting Recommendation Table may be used as reference only.

If the distance of Band Saw Blade (32) from the material to be cut is suitable as follows below (figure 07A): – Position the Bow (09), as close as possible to the material to be cut; – Release the Lever (15) and slide the Mobile Support (16) of Mobile Guide (17), such as cause the distance between the Guides (18)(19) to be least possible. Thereafter, lock the Mobile Guide Suport (16) by Lever (15);

If the part to be cut is well positioned on the Cutting Table (22), i.e., properly supported in all surface of table and perfectly flat;

After these adjustments and check, select the working cutting speed through Speed Control Switch (04): – “ 1 ” (speed = 35 m/ ') to hard materials; – “ 2 ” (speed = 70 m/ ') to soft materials.

REV.05- MAI/13

S3120 - ING

43 15

42 47 46 08 41 24 23 54

Figure 06

7.2. MACHINE START-UP ATTENTION: ALL cu ng opera on must be performance ONLY by qualified operators to this purpose.In ALL cu ng opera on use PPEs duly approved for this purpose. Before starting any operation, observe if the machine is switched off, checking if the General Switch (02) is in OFF position and the EMERGENCY Button (05) is pressed (figure 03). Next, lift the Bow (09) until the upper position by Lever (15). Lock the Shutoff Valve (36), positioning it horizontally, as ilustrated in figure 11. After, to close the Regulator Valve (35) turning it clockwise until meets resistance to close. So, the machine will be safe before handling or adjustment of it. With the Handle (23), approach the Vise (08) until the material to be cut. Touch the jaws against the material and turn the Handle (23) Âź turn back. With this, it will have a small clearance enough to move longitudinally the part by operator. The loosening and tightening the vise on the material will be done manually, turning the Lever (24) to down (figure 06). Make sure that the material to be cut is properly fixed and secure on the Vise (08).

REV. 05 - MAI/13

S3120 - ING Selected cutting speed through the Speed Control Switch (04), as the characteristics of material to be cut. From this point, the operator must select the operation mode: MANUAL or GRAVITATIONAL by Mode Selector Switch (31).

MANUAL MODE: (SWITCH (31) - TO RIGHT): In this operation mode, the operator is responsable to exercise the feeding force and the control its the speed. It is a operation that requires the operator remain in his working station. Before start any cutting operation, the operator must keep the Bow (09) completely in its the upper position.After, to tension the Spring Set (37) through the Handle (49), until that the Bow Set remain in the upper position, ie with the Valve (35) and (36) fully open. The both Valves must be OPENED during all cutting operation. Then, position in ON the General Switch (02) and the EMERGENCY (05) Button in order to unlock (pull). Also it must be opened the Tap (75) (figure 02A) of coolant liquid, if necessary. In this condition, the operator must keep the Trigger (25) pressed, and start the cut of the material pulling the Lever (15) to down, until to the end of operation. At the end of the cut, the operador stops to press the Trigger (25) and slowly releases the Lever (15). Open the vise by Lever (24) pulling it to up. Following, remove the cut part and replace the material to a new cut.

GRAVITATIONAL MODE: MANUAL MODE: (SWITCH (31) - TO LEFT): In this condition, it will be the weight of the bow, who will exercise the feeding force, with the controlled speed by Regulator Valve (35). For this, the operator must relieve the tension of Spring Set (37), release it by Handle (49).This set should not exercise a against force to feeding movement of the bow. Before relieve the tension of spring, keep the Bow (09) in the upper position, with the Valves (35) and (36) in the CLOSED positions. Then, position in ON the General Switch (02) and the EMERGENCY (05) Button in order to unlock (pull). Also it must be opened the Tap (75) (figure 02A) of coolant liquid, if necessary.

REV.05- MAI/13

S3120 - ING The material clamped and positioned, press the Trigger (25) and release it. With care, open the Shutoff Valve (36). Following, slowly, open the Regulate Valve (35) until to reach a proper cutting speed (figure 11). In the first cuts, use low feeding speeds and each operation, if necessary, increase it according to the cutting performance. If so, any abnormal noise in the process, the operator should stop the operation and check what may be occuring. In case of doubt, the Technical Assistance of Starrett can give all informations to help. At the end of the cut, the machine will stop automatically. Open the vise by Lever (24) pulling it to up. Following, remove the cut part and replace the material to a new cut.

MANUAL MODE: 49

TENSION THE SPRING SET (37), UNTIL THAT THE BOW (09) REMAIN IN THE UPPER POSITION WITH THE VALVES (35) AND (36) FULLY OPEN.

GRAVITATIONAL MODE: RELIEVE THE TENSION OF SPRING SET (37) UNTIL THAT THE BOW (09) CAN EXERCISE ENOUGH FORCE TO CUT THE MATERIAL.

REV. 05 - MAI/13

S3120 - ING

7.3. BAND SAW BLADE CONSIDERATIONS: Some advices to keep the good performance of the band saw blade 1.

Properly tension the band saw blade, as instruction of item 7.1., point 3.

Know very well the material to be cut, mainly the hardness and homogeneity;

Choose a speed cutting that is compatible with the geometry, dimensions and physical characteristics (hardness) of the material to be cut;

Use blade with good quality, with correct teeth type and íntact (no broken teeth);

Use the recommendations above for the first cuts;

Frequently clean the Guides (18)(19) – with the machine stopped and use Micro-Oil Starrett M1, to clean the Lateral (50) and Rear(50) Bearings;

Check the conditions of Bearings (50)(51);

Check periodically the clearances between the Bearings (51) (0.95 mm) and the distance between the back of band saw blade and the Rear Bearing (50) as showed in the figures 14A and 14B.

OBSERVATION: For be er performance of the Band Saw Blade, it´s recommended to make the break-in while the blade is new upon its installa on on the machine. This break-in is a prac ce that purpose an arrangement of the tooth cu ng edge before the blade will be put into full opera on. The break-in consists to make that the Band Saw Blade works for a period with twice the me required for cu ng and at a suitable speed cu ng, as intruc on of the Starre ´s Cu ng Recommenda ons Table. AVOID THAT THE BLADE SLIDE ON THE MATERIAL WITHOUT REMOVING THE CHIPS. (PREVENT VIBRATION)

REV.05- MAI/13

S3120 - ING

Figure 07A

51 43

52 13 53

09 40 14 Figure 07B

19 59

73 56 51 58

34 Figure 07C

REV. 05 - MAI/13

S3120 - ING RECOMMENDATIONS OF BEST WAY TO CLAMP THE MATERIAL:

OBSERVATION: The cu ng opera on must be realized with force and speed perfectly suited to teeth type of Blade (32), the thickness of the material to be cut and the blade wear.

ItÂ´s vey important to try to keep the cutting conditions within the parameters established by Starrett. Thus, the efficiency and the lifetime it will be larger. For a good use of the machine is important to keep The Guides (18) (19) cleans and make sure that the both receive abundant coolant liquid. Increase or decrease the flow of coolant liquid just open or close the tap located in the Oil Distributor (20), installed on the Bow (09).

REV.05- MAI/13

S3120 - ING

49 37

Figure 08A

08 26

Travar Figure 08B - Corte a 0o

Figure 08C - Corte a 60o

REV. 05 - MAI/13

S3120 - ING

7.4. BAND SAW BLADE REPLACEMENT AND ADJUSTMENT PROCEDURE: To replace or change the Band Saw Blade (32) correctly, it´s necessary to keep the Bow (09) on highest position and at 0º angle; thereafter: 1.

Disable electrically the machine keeping the General Switch (02) in the OFF position, the EMERGENCY (05) pressed (locked);

Remove the Back Cover (14) protection tightening the 4 Toggle Latches (40) located in the rear part of the bow (figure 07B);

Remove the Protection (43) , installed in the Support (16) of Mobile Guide (18) (figure 09);

Removing the Back Cover (14) the protection automatically disable the electric system through Micro-Switch (33) attached in the Bow (09), installed to protect user against possible accidents with the machine (figure 09) – UNDER NO CIRCUMSTANCES NEVER ACTUATE THE MICRO SWITCH (33) IN THIS SITUATION;;

Turn the Tensioning Handle (13) to reduce (loosening) the tension of Band Saw Blade (32), in order to reduce the distance between centerlines of Flywheels (41) (42);(figura 06);

Remove the Blade with care, wearing leather gloves, only this situation;

Before to install a new blade, clean thoroughly the area touched by the blade of the two Flywheels (41)(42) and also inside the Guides (18)(19) by injecting Micro-Oil M1 between the Lateral (51) and Rear (50) Bearings;

Assemble the new Band Saw Blade (32) making sure that the teeth are intacts and compatible with the material to be cut, observing if the teeth are towards the direction indicated on Plate (39)(figure 02A).First, put in the gap of the Guides (18) (19) (between the Bearings (51) and after in the Driver Flywheel (41) and, then, in the Driven Flywheel (42). (figura 06);

Make the pre-tensioning turning the Levers (13) of Tensioning Nut (52) towards to tension the blade (stretch);

10. Assemble the Back Cover (14) clamp it by Toggle Latches (40) and reset the Micro Switch (33) (figure 09); 11. Install the Mobile Guide Protection (43) with its respectives screws;

REV.05- MAI/13

S3120 - ING 12. Select one of the cutting speeds by Speed Selector Switch (04), unlock the EMERGENCY Switch (05) and position the General Switch (02) in ON. With a Select Switch (31) in MANUAL mode, press the Trigger (25) to start momentarilly the Motor (10). Repeat this operation for 4 to 5 times to seat the blade on the flywheels and the guides. 13.

Make the tensioning permanent of Band Saw Blade (32), turning the handles of Tensioning Nut (52) as described in the section 7.1 pont 3.

Figure 09

01 09 10

54 33 33

ATTENTION: The recommended limit is 20,000 PSI -pounds sq.inches (20kSI) or ~1400 Kgf/cm2. However, it is advisable to use a Saw Tension Gage Starre 682 EMZ (EDP 57075) â&#x20AC;&#x201C; SAW TENSION GAGE), as seen below, to check and to adjust the tensioning set from supplier.

Following this sequence of opera ons, the MACHINE WILL BE READY FOR USE.

REV. 05 - MAI/13

S3120 - ING

7.5. ANGLE CUT PROCEDURE When intending to carry out some cut at an angle /( (= 0º) to the operator’s right (0º to +60º maximum), the following procedure must be done: 1.

Keep the Bow (09) in the highest position;

Push the Bow Rotation Clamp Lever (60) in the counterclockwise (figure 08B). Turn the Bow (09) until the desired angle viewed in the Angular Scale (26) (figure 08C). Push the Bow Rotation Clamp Lever (60) in the counterclockwise (figure 08B).

ATTENTION: Before star ng the cu ng opera on, MAKE SURE that the Lever (60) is locked the rota on of Bow (09), it is dully ghted and locked, totally posi oned to operator’s le , thus preven ng injuries during opera on.

However, to cuts with angle more than 45º (>45º), the rear of the bow can stay positioned in the lateral of the Cabinet (06). In order to avoid leakage of coolant outside the limit of the table, a removable Lateral Collector (54) can be fitted, to collect the coolant liquid, as showed in the figure 10.

Figure 10

REV.05- MAI/13

S3120 - ING

12 36

Figure 11

WARNING Always OBSERVE the Opera on Instruc ons of Cylinder (12), as described in the Instruc on Plate beside, installed in the Bow (09), beside the Motor (10) (figure 04).

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

8. CRITERIA FOR BAND SAW SELECTION: 8.1. LIMITS AND RECOMMENDATIONS: Prior to beginning any kind of work with the machine, see that the job to be carried out is within the limits specified in table TECHNICAL DATA (Section 2). If it is out of the specified values, we recommend that an inquiry in writing be addressed to Starrett on the possibility of changing some technical specification. The Starrett will answer in writing the appropriate solution or not.

ATTENTION: The StarreĆŠ is not responsible for damages caused to persons or objects, being forced the user's machine to check with a en on the characteris cs of the material to be cut in order to avoid any risk to the operator and / or third par es.

If it is within the specified capabilities of the machine, selection of the blade will be another important aspect to improve the cutting performance.

8.2. CRITERIA FOR BAND SAW BLADE SELECTION: To chose correctty a blde for a givbem application should be considerd some factores: type of material, hardness, cutting section, capability of the machine itself, etc. Four basic variables exist in selecting the band saw blade: 1-

Blade Type;

Tooth Shape;

Pitch;

Cutting Feeding and Blade Speeds.

REV. 05 - MAI/13

S3120 - ING 8.2.1. TEETH (PITCH): The pitch is number of teeth per inch (25,4 mm), that operator must be choose in function of material cutting section. The normal or annealed materials require at least 3 teeth inside cross section to be cut. It is ideal between 6-12 teeth. In general, materials with thin section require a band saw blade with a larger number of teeth per inch (25,4mm), or a band saw blade with “teeth thinner” being this opposite for materials with larger section.

8.2.2. CUTTING FEEDING AND BLADE SPEEDS. It´s important that the feed and cutting speed will be corrects. Starrett can to send a table “slide chart” type, to fast and easy selection of band saw blade, with specification of feeding and cutting speed for each kind of material. The same information are available in the Starrett Band Saw Catalog attached.

OBSERVATION: The best condi ons to cut are 3 to 12 teeth inside in the cross sec on to be cut, in the same me.

REV.05- MAI/13

S3120 - ING

9. TRANSPORTION INSTRUCTIONS: 9.1. HANDLING:

ATTENTION: To install correctly this machine it´s necessary, a er removing it from packaging, CAREFULLY READ this Instruc on Manual, during the machine opera on and on maintenance ac ons.

When the machine leaves the factory, it´s fixed on a wooden pallet, which allows it to be carried by a lift truck or other moving system. Also, in case of transportation by traveling crane, it can lifted by steel cables fastened along with it, as showed in the figure below. To lift the machine will be necessary to use appropriate cables with resistance to support 170 kg (gross weight) of it.Thereafter, the machine must be lifted just the minimum required to move it. During this operation, must be regarded the safety conditions that the traveling offer, in function of characteristics (distances, maximum height and load-lifting capacity). The same care should be taken in case that lift trucks are employed.

OBSERVATION: 1. Use steel cables (mininum diamenter = ø 8 mm) with enough resistance to support 170 kg , and pass by hook eye, as indicated in the following figure; 2. The user must make sure that the steel cable or rope are intacts, before to start the li ing opera on; 3. Make sure that the 4 hooks are intacts before li the machine; 4. Make sure that the machine is well balanced during the li ing opera on; 5. Li the machine the minimum required to enable moving the same; 6. Do not permit to shake the machine during movement of traveling crane.

REV. 05 - MAI/13

S3120 - ING

â&#x2013;º

REV.05- MAI/13

S3120 - ING

10. INSTALLATION INSTRUCTION: 10.1. INSTALLATION INSTRUCTION: The machine must be installed in a normally lighted working environment on an industrial type floor having the strength required to hold up the weight of the machine itself plus the weight of the material to be cut.

ATTENTION: The machine may not be installed in environments where the risk of explosion or fire exists. It is advisable that the machine be fixed by screws "anchor" in the floor according to the type illustrated below, especially when to handle the long and heavy materials.These attachments must be through the points of support.

Also, in this case, it´s recommended to install supports devices and/or roller tables to support the material. When the installation has been completed, the installer or whoever shall have carried out the same will check if all parts of the machine: –

Perfectly intacts ( free from cracks or any other defects, in particular the EMERGENCY Button (05), the Speed Control Switch (04), Moto Reducer(10) (11), the Coolant Pump (45), the Vise (08) and the Handle (23). Check also for the condition of the Cabinet (06), Mobile Guide (18), Control Panel (01), etc

–

In conformity with what is specified in the manual and on its order (optional items).

REV. 05 - MAI/13

S3120 - ING

OBSERVATION: In case that some parts are not intact or fail to conform to the order and/or the manual, customer (installer) shall promptly no fy Starre in wriƟng to obtain clarificaƟons, also in wriƟng, on what is to be done to solve the problem. However, a er the problem is detected, the installer must not proceed with the installa on un l such me as the problem has been solved and clarified.

ENVIRONMENTAL CONDITIONS: - Environmental temperature: from -10 to +50 oC.; - Relative humidity: cannot be over 90% The installation of machine in the electrical grid must be done by individuals qualified for this kind of service. Also, must be observed the electrical diagram, in this Manual, that electrical connection to be properly made. The Electric Panel (01) is on the Bow (09) of machine. The Cooling Pump (45) is located inside the Cabinet (06), it is ready for operation. Before connecting the machine in the electrical grid, check: 1.

If the power cable provided with the machine is intact in all extension;

If user’s main electrical grid has the same voltage (V) and frequency (Hz) as required.

OBSERVATION: In case that the voltage and/or frequency is not compa ble with user’s electrical grid, due the mistake of the client, immediately, the Starre must be advised of it, so that components can be replaced, by its decision, under warranty or not, the Motor (10), the Cooling Pump (45), the transformer and the overload fuses by appropriate values. User’s electrical grid shall use cables or wires whose cross sec on area is equal to or larger than 2.5mm2.

In the extremity of electric cable must be installed a plug with 4-pins, being 3 used for phases R, S and T, and the fourth pin for Grounding (Earth), always conform specifications and recommendations of manufacter of plug. When the installation of plug is ready, connect in the user´s electrical grid. Immediately, a Pilot Lamp (03) (WHITE) in the command panel will light indicating that machine is switch on. 44

REV.05- MAI/13

S3120 - ING

Then, turn the Speed Control Switch (04) to position "1" (Turtle), the Selector Switch (31) in the MANUAL mode, and press momentarily the Trigger (25) to check if the Band Saw Blade (32) is running in the direction indicated in the Plate (70), installed in the Bow(09) (figure 02A).

OBSERVATION: Make sure if the Band Saw Blade (32) is running in the same direc on indicated in the Plate (39), located on the Bow (09) (figure (02B). If the blade direcons is opposite as indicated, exchange 2 or 3 phases (cables) in the plug that is connected in the machine of user´s electrical grid.

ATTENTION: – For the electric installa on, use the following color codes or numbering: OPTION 1 BLUE WHITE BLACK RED

OPTION 2 GREEN/YELLOW BLACK 1 BLACK 2 BLACK 3

Cables funcƟon Ground R S T

– Always check if the GROUND connec ng cable is well connected and that does not have connec on in common with NEUTRAL of user’s electrical grid. – Connect the machine electrical cables on an outlet of an independent panel board with a three-pole thermomagne c switch of 16A and a diﬀeren al of 40A with a 0.3A sensi vity at 220V.

WARNING (IMPORTANT INFORMATION): NEVER perform any welding opera on (common electric weld type, MIG or TIG) with the machine switched on, or connected to electrical grid, with General Switch (02) in ON, the Pilot Lamp (WHITE) (03) ligthed.NO use the machine itself as a point of grounding welding equipment.Even with the machine without the above condi ons, NO PERFORM ANY OPERATION of welding on the machine. NEVER WELD in any material that will be cut on the machine, even if it is necessary to repair the same, because it may cause irreparable damage to electrical, machine and this will not be covered under warranty.

REV. 05 - MAI/13

S3120 - ING

10.2 DISASSEMBLY AND DISPOSAL OF THE MACHINE: 10.2.1. DISPOSAL In the case, if it´s necessary to disposal the machine for some reason, some cares should be taken: 1.

Power off and remove the machine are tasks that should be carried out by a person duly qualified and authorized to do it and having experience and expertise to do that job;

Correctly disconnect it from user’s power line in a safe way, making sure that the same is totally powered off;

Clean the machine completely, removing the coolant liquid (oil + water) from the cooling system contained in Tank (44). Drain all liquid and do not dispose of it in the environment;

Remove completely all chips contained in the Tank (44) and on Cabinet (06);

Parts susceptible to oxidation and that have been exposed to weather for long time must be smeared with oil for protection.

10.2.2. DISASSEMBLY

OBSERVATION: Before star ng the disassembly or decommissioning opera on of the machine or its components, INQUIRE Starre for all instrucƟons required in respect of the subject. If need to disassembly the machine, follow these instructions: 1.

Avoid direct contact with cutting oil and other lubricants. Wear appropriate SAFETY GLASSES.

Avoid and pay a attention to do not to discard any type of oil in the environment;

For the step involving moving the machine and/or parts, observe the instructions contained in the item9.1 - Handling this Section;

When disassembly the machine or part of it, follow a sequence that will later on enable you to properly re-assemble it. To that end, take down notes on this manual on the operations carried out.

REV.05- MAI/13

S3120 - ING

11. SISTEMS: 11.1. ELECTRICAL SYSTEM: The electric system was developed and designed in order to to keep the userÂ´s safe and the equippment. The standard machine is designed to operate with 2 motors, being the Blade Motor M1(10) three-phases and the other to Cooling Pump M2 (45) single-phase, dully developed, according to working capacity of it.A General Switch QS1 (02) of isolator type is installed at the input of circuit to disable it, when the cover of Electric Panel (01) is opened to maintenance. A Contactor KM1 (56) has the function to start the Motors (10) and (45), as soon as the Trigger SB2 (25) is pressed (figure 02A). The Speed Control Switch CH1 (04), of the three position type (1[ turtle ] -0-2 [ rabbit ] ) has a function to change the speed of Motor M1 (10), according to operatorÂ´s choice. In the 0 (ZERO) position or neutral the Motors (10)(45) do not start. The Motor (10) of the band saw blade is protected by a Thermal Relay FR1 (66). The Motor (45) of coolant pump has protection by Fuses FU4 (64) and FU5 (65). A Transformer TC (67), dully sized, it has the function to reduce the voltage to command line of electric panel to 24VAC, i.e., to extra low voltage. This tramsformer is protected by 2 Fuses FU1(61) and FU2(62) in the input and 1 Fuse FU3 (63) in the output. As a safety device, the machine presents a EMERGENCY Button SB1 (05) installed in a visible position and accessible to the operator in case of abnormality. In addition, in the rear position of the Bow (09) is installed a Micro Switch (33) (figure (09), of the electromechanical type, which disables all electrical circuit when the Back Cover (14) is removed. Also, by a Selector Switch SA3 (31), of the 2 positions type, it has the function to select the operation mode of machine: MANUAL or GRAVITATIONAL A Micro Switch SQ1 (34) installed in the Hydraulic Cylinder (12) has the function to switch off automatically the machine at the end of cut, i.e., when the Bow (09) is in the lower position. This function is only valid when the Selector Switch SA3 (31) is positioned in the GRAVITATIONAL mode. All components have EC mark, certified as IEC european standars. The cables for motors (power cables) are black and 1.5 mm2 gage. The command wires are in red color with section of 1.0mm2. All cables are identified pursuant to the enclosed electric diagram.

REV. 05 - MAI/13

L1 (R) - BLACK L2 (S) - BLACK L3 (T) - BLACK PE - YELLOW/GREEN

48 BLADE MOTOR

COOLANT PUMP MOTOR

S3120 - ING

REV.05- MAI/13

S3120 - ING ELECTRIC COMPONENTS:

11.2. MACHINE SAFETY SYSTEM: This machine is equipped with safety devices. They are: 1-

Pilot Lamp (03) (white color) - It is a white light signal indicating that the electric circuit has energy and that the can be operating;

EMERGENCY (05) â&#x20AC;&#x201C; Red switch with mushroom- shaped , when actuated, it disables all commands of the machine and the motor stops working. The machine will only resume operation by turning the button clockwise so as to unlock it;

Back Cover Micro Switch (33) â&#x20AC;&#x201C; When the Back Cover (14) is uncoupled or removed from the Bow (09), the Micro Switch (33) will disable all controls of the machine, no allowing that the motor runs, however, the Pilot Lamp (03) (white color) will remain turned on. Only the correct installation of Back Cover (14) in the Bow (09), the machine will be available to start.

11.3. MEASURING ROD SYSTEM: The S3120 has a starndard measuring system, compound it by a Measuring Rod of 500 mm (46) and a Stop Rod (47). Firstly, screw it the tip of Measuring Rod (46) in the Vise Set (08). Then, fit the Stop Rod (47) in the Measuring Rod (46) and fix it, as figure 12, by Knob (48). With the help of a measuring tape, measure the desired dimension from the Blade (32) to the tip of the Stop Rod (47). Every time the material to be cut touching the tip of the stop, the piece will be cut to desired size.

REV. 05 - MAI/13

S3120 - ING

Figure 12

08 47

06 48

REV.05- MAI/13

S3120 - ING

12. GEAR BOX: TheS3120 was designed to offer 2 cutting speeds in order to handle the cutting of a number of different types of materials.

The selection of speed is done electrically by a Speed Control Switch (04) of 3 positions (speeds “1 (Turtle)”, “2 (Rabbit)” and “O (Neutral)” – switched off) that control the Motoreducer (10)(11) (figure 09).

12.1. OPERATING PRINCIPLE: The Gear Box (11) is the WORM type, with permanent lubrication. Coupled to it, there is a double-speed, 4- and 8-poles, three-phases, DAHLANDER type motor, which the voltage must be chosen by user: 220 or 380 or 400 or 440 V, in the frequencies of 50 and 60 Hz. For long operation periods in high temperature environments, the worm-type gear box, by its characteristics, it can operate at temperatures of between 60 and 80ºC. Within this range, the performance and the motor will not be affected.

12.2. MAINTENANCE INSTRUCTIONS: Assembling and Disassembling the Gear Box Reducer For assembly and disassembly of the motoreducer should follow these instructions (Observe figure 13): 1.

Before any maintenance operation, make sure that the machine is switched off with the General Switch (02) in OFF position and the EMERGENCY Button(05) locked;

Disconnect the cables of Motor (10), observing and noting the wiring diagram to avoid mistakes of assembly later;

Release the screws that attach the Motor (10) in the Gear Box (11);

On the inner side of the Bow (09), remove the Driver Flywheel (41), releasing it by removal of the central bolt;

Without the Driver Flywheel (41), release the screws that fix the Gear Box (11);

With care, remove the Gear Box (11) of the Bow Set (09);

Make the maintenance necessary, and if to drain the oil contained in the gear box, avoid to drop it in the envioronment;

REV. 05 - MAI/13

S3120 - ING 8.

After the maintenance necessary, remake the assembly of the Gear Box (11), following the opposite steps of the disassembly;

Assemble the Driver Flywheel (41) in the tip of Reducer (11) shaft. Check the tighten of the bolt;

10. Assemble the Motor (10) in the Gear Box (11), making sure the tightening of the respective screws; 11. Remake the original electric connection; 12. Turn the motor in the two directions for approximately 20 times, through the Fan, avoiding excess efforts on the shafts; 13. Check if the Motoreducer set is running without any abnormal noise. If happen this, contact the Starrett Technical Support.

OBSERVATION: User is advised to inquiry Starretâ&#x20AC;&#x2122;s Technical Support before performing any acĆ&#x;on.

Figure 13

Bolt of Driver Flywheel 41 10

Bolt of Gear Box in the Bow 11

Bolt of Motor in the Reducer

REV.05- MAI/13

S3120 - ING

13. GENERAL MAINTENANCE: This Section provides a description of the main systems that make up this machine,in addition to the main periodic maintenance procedures. Keepng the periodic inspections to date, certainly the machine will always get a good overall performance.

13.1. CLEANING It is very important: –

To clean and remove chips from Flywheels (41) (42) and from the Guide set (18)(19) on daily basis;

–

Periodically (at least once a week) clean the Tank (44) of coolant liquid. If necessary,complete or change the cutting coolant in the Tank (44) and keep its level to specification;

–

At given intervals during the day, remove chips from Vise Set (08) and Cabinet (06);

–

Periodically clean and provide adequate maintenance to the electric cables (whip).

ATTENTION: In the case the operator u lizes compressed air or equivalent cleaning systems, he shall USE SAFETY GLASSES, to avoid needless accidents.

13.2. GUIDES SETS ADJUSTMENT AND MAINTENANCE ATTENTION: Only qualified persons authorized by the owner of machine can perform this opera on.

The Guides Set should periodically be adjusted, so cutting performance is the most appropriate. Cleaning Daily, clear these two sets with its own coolant (water + oil cut), with the Bow (09) in the lower position, without material to be cut on the Cutting Table (22)

REV. 05 - MAI/13

S3120 - ING Run the machine for 5 minutes, at the end of the period of machine use, in order to that the coolant liquid wash the inside of the guides sets with abundance. Other way to clean these sets every day is washing under pressure with Micro Oil M1 of Starrett. Monthly, it is advisable to remove the Band Saw Blade (32), the machine completely disabled electrically, the Bow (09) in the lower position and to wash under pressure with Micro-Oil. With the aid of a clean brush remove all kinds of dirt on these Guides Sets (18)(19). Lateral Bearings Adjustments: (figures 14A and 14B)

ATTENTION:INJURIES DANGER! All repairs and adjustments required a qualified and trained person to perform any opera on on the machine, and necessarilly must be pressed the EMERGENCY Bu on (05) and the General Switch (02) in OFF. It is recommended to use the Technical Suppor Starre , to specialized repair.

MONTHLY, during cleaning of Guide Sets (18)(19), the Laterals Bearing (51) should be adjusted, in order to improve the performance of cutting process. With the machine electricaly in off, according to observed above, put the Bow (09) in upper position, keeping the Valves (35) and (36) in closed position. (figure11). Relieve the tension of Band Saw Blade (32), as item 4.4. (itens 1 to 4). After the cleaning procedure of the Guides (18)(19), loosen the Lock Nut (74) of Eccentric Shaft (71) (figure 14B). With help of fixed wrench, turn the Eccentric Shaft (71) ALWAYS clockwise as showed in figure 14A. The Lateral Bearings (51) should touch completely in the lateral of the Blade (32). The gap between the lateral bearings must be from 0.90 to 0.95mm. Then, tighten the Nut (74), otherwise will get the chance to loose and leave the Lateral Bearing (51) free, may be generating future problems. The pressure of Lateral Bearing (51) on the Blade (32) NOT can be excessive, as this will cause premature wear of bearings. Also, these bearings CAN NOT be too far away of the blade's lateral, which may cause cutting deviations.

REV.05- MAI/13

S3120 - ING

Figure - 14A - LATERAL BEARING Adjustment

Fixed Wrench

18 or 19

51 Adjustment Nut

ATTENTION:INJURIES DANGER! For this adjustmen requires a qualified and trained person to perform this opera on on the machine. Necessarily it must have the EMERGENCY Bu on (05) pressed and the General Switch (02) in OFF.

It should be observed DAILY the position of the Rear Bearing (50) against the back of the Band Saw Blade (32). The distance must be between 0.5 to 1.0mm of clearance. If the blade is outside these limits, adjust the guides by loosening the Screws (73) (figure 07C), moving up or down the Guide Sets (18) or (19), installed in the Guides Support (16) and (59), respectively. Also check the height of Protection of Fixed Guide (58) in relation to the teeth of the Band Saw Blade (32), ie, the protection to cover the teeth, not to be exposed.

REV. 05 - MAI/13

S3120 - ING

Figure 14B

18 or 19

50 71

13.3. CAMBER OF DRIVEN FLYWHEEL ADJUSTMENT

ATTENTION: Only qualified persons authorized by the owner of machine can perform this opera on.

The life of a blade will depend of the adjustment with driver and driven flywheels. The Band Saw Blade (32) running on the Driven (42) and Driver Flywheel (41) should touch lightly in the ledge these flywheels. For this, the camber adjustment of Driven Flywheel (42) can relieve the pressure of the blade on the ledge. PROCEDURE: 56

REV.05- MAI/13

S3120 - ING 1. Disconnect the machine from the electrical grid, keep the Bow (09) in the upper position and closing the Valves (35) and (36); 2. Position the General Switch (02) in OFF and the EMERGENCY Button (05) pressed; 3. With Allen screwdriver, loosen ( relieve the tighting ) the Screws A, B e C, without removal them from Tensioning System (21); 4. By screw D, adjust the camber of Driven Flywheel (42), this way: - in clockwise the back of the blade touches the ledge; - in counterclockwise the back of the blade away from the ledge; The intensity of the turn of the screw D should be small, around 1/4 to 1/3 turning to each setting,until you reach the ideal condition, as illustrated in the figures below; 5. At the end of the adjustment, tighten the screws A, B and C and connect the machine to the power grid, position the Speed Control Switch(04) in the speed 1 and the Selector Switch (31) in the MANUAL mode.Then, switch on the machine, position in ON the General Switch (02) and pull the EMERGENCY (05) Button; 6. Check if the tension of the blade is correct; 7. With light touches on the Trigger (25), run the Motor (10) of band saw blade; 8. Remove the Back Cover (14) of the Bow (09) and check the position of the blade's back against the ledges of the Flywheels (41)(42); 9. As reference measure the back of the blade should be 0.2 to 0.5 mm from the ledges of the flywheels; 10. If it maintain beyond these measures, reinstall the Back Cover (14) and repeat the procedure from 1 to 8; 11. Reaching the measured according to item 9, installing Back Cover (14, enable it electrically and put it to use; 12. Perform this procedure MONTHLY or when there is a problem of breaking the blade or wear on the ledge of the flywheels.

REV. 05 - MAI/13

S3120 - ING

LEDGE

D 21

C 09

13.4. HYDRAULIC CYLINDER REPLACEMENT

ATTENTION: Only qualified persons authorized by the owner of machine can perform this opera on.

For replacement and repair of the Hydraulic Cylinder (12) is required for some safety procedures to avoid any risk to user. PROCEDURE: 1. Disconnect the machine from the power grid, keep the Bow (09) in lower position; 2. Position the General Switch (02) in OFF and the EMERGENCY Button (05) pressed;

REV.05- MAI/13

S3120 - ING 3. With the Cylinder (12) fully retracted, remove and replace it, loosening their respective bolts that fix it; 4. NEVER try work with machine without the Cylinder (12) properly installed, as this can cause risks and damages to the operator or to the equipment; 5. With the Cylinder (12) installed, connect electrically the machine and test it if it is performing properly.

13.5. SPRING SET REPLACEMENT

ATTENTION: Only qualified persons authorized by the owner of machine can perform this opera on.

To change or repair the Spring Set (37) ) is required for some safety procedures to avoid any risk to user. PROCEDURE: 1. Disconnect the machine from electrical grid; 2. Position the General Switch (02) in OFF and the EMERGENCY Button (05) pressed; 3. Lift the Bow (09) in the upper position, close the Valves (35) and (36) - MAKE SURE if the Bow (09) is safe in this position; 4. Relieve completely the tension of Spring Set (37) by Handle (49); 5. Disassemble the set and replace the items necessaries; 6. Assemble again the Spring Set (37) and tension the spring; 7. Connect the electrically the machine and test it to check if it is performing properly.

REV. 05 - MAI/13

S3120 - ING

13.6. MAINTENANCE TABLE POS 18 e 19 50 e 51 11 44 14, 41 e 42 13, 52 e 53 08 e 22 13, 52 e 53 32

DescripĆ&#x;on Guide cleaning (Rear and Lateral Bearings) Check the wear of Bearings(gaps) Check the gear box

Frequency Daily

AcĆ&#x;on Clean with M1 Micro Oil, or Coolant Coolant, and/or compressed air. Monthly Measure with feeler gauge. See figure 14A Semiannual Repair if necessary

Check the tank level coolant liquid Flywheels and Back Cover cleaning

Daily

Complete with

Daily Weekly Daily

Clean, lubricate the sha s of flywheels, by injec on of grease Adjust

Check the tension blade the Band Saw Blade Clean the surface of cu ng table, Daily the vise and others surface of machine Tensioning System Montly Band Saw Blade Daily

Clean Change, if it is the case Replace, if it is the case

ATTENTION: All periodic and correc ve maintenance should be performed by qualified and trained professionals for this purpose. The owner of machine must check all safety laws and standards of each country.

REV.05- MAI/13

S3120 - ING

13.7. TROUBLE, CAUSES AND SOLUTIONS Problems Pilot Lamp(03) is out The blade no run

Causes and SoluƟons • if the General Switch(02) is in the ON posi on; • the micro switch (33) of back cover (14) is disabling the system system (the Back Cover must be closed); • the speed control switch (04) is in posi on 1 or 2; • the emergency (05) is disabled; • the lamp (03) is lighted; The rota on of the Bow (09) in the • The quality is not good of coolant oil; • There is too much dirt on machine surface; angle 0o, +60o is hard • Clean and lubricate between the surface of movement. The blade do not tension • if the lenght of blade (32) is 2110 + 2 mm. The blade leaves onthe flywheel • the tension of blade (13); • if there is clearance between the bearings of flywheels (41)(42); • if the driven flywheel (42) has taper. The coolant liquid • if there is coolant liquid in the tank (44); does not arrive in the blade • if the tap (75) is open; • the hoses of pump and the tap(75) are not clogged. Cu ng crooked • If the bearings (51) of guide set (18)(19) are in good condi ons; • if the distance between Lateral Bearings (51) (0,95mm); • the mobile guide support of blade (16) is nearest of the material to be cut; • if the material to be cut is too irregular causing crooked cuts; • if the cu ng speed and the coolant are according with the specifica on of material to be cut (check the hardness of material); • if the blade has the correct tension; • the supports with roller are misaligned with the cu ng table (22) surface; • Excess of cu ng feed rate of Bow (09) – reduce by Regulator Valve (35). the teeth of blade is broken • Excessive Pressure; • High cu ng feed rate – decrease the cu ng feed rate; • The teeth of blade(32) is not correct; • bearings (51) are broken; • Cu ng speed is lower – increase the speed (04) Premature wear of the teeth • The blade is not correct to the material be cut (28); • Excess cu ng speed (04); • The low cu ng feed rate (35). Rupture of the weld blade • Defec ve blade welding. Blade rupture outside weld • problem with machine if occuring a er a few opera on hours; • natural wear (caused by material fa gue) is occurring a er many hours of service.

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

14 SPARE PARTS 14.1. CABINET SET AND COOLANT SYSTEM

REV. 05 - MAI/13

S3120 - ING

14.2. VISE SET AND SWIVEL SUPPORT

205

REV.05- MAI/13

S3120 - ING

14.3. BOW SET AND ELECTRIC PANEL

REV. 05 - MAI/13

S3120 - ING

14.4. GUIDES SET

REV.05- MAI/13

S3120 - ING

14.5. HYDRAULIC CYLINDER SET

REV. 05 - MAI/13

S3120 - ING

REV.05- MAI/13

S3120 - ING

BAND SAW BLADE CATALOG: NOTAS:

REV. 05 - MAI/13

170% MORE WELD CONTACT AREA

A - WIDTH Tip of the cutting edge to the back of the blade. B - LENGTH Measurement along the back edge of the blade.

MULTIPLE CUTTING EDGES

C - THICKNESS Measurement of the body of the blade. D - BACK EDGE Opposite side of the blade from the teeth. E - TOOTH PITCH Distance from the tip of one tooth to the next tip. F - TEETH PER INCH/25MM Number of teeth per inch/25mm. G - GULLET The curved area between two teeth. H - TOOTH FACE Surface of the tooth where the chip is formed. The tooth can have a positive or straight angle when measured against a line perpendicular from the back of the blade.

SPLIT CHIP ADVANTAGE

Â®

I - TOOTH SET The bending of the teeth, right and left, to allow blade clearance through the cut.

starrett.com

Constant Pitch

INTENSS

.8-1.3 to 14-18

INTENSS PRO-VTH

VERSATIX MP

REGULAR

HOOK

SKIP

Variable Pitch

6 to 32

1-2 to 4-6

Positive rake (up to 12º) product with a patented surging cutting action. Use with nickel alloys, stainless steels, and heat treated steels (up to HRc 45).

2-3 to 6-10

Computer designed product with a resultant robust positive rake tooth aimed specifically for intercept cuts on beams, channels, and tubes. Works well for all general cutting. M-42 - 8% cobalt teeth.

8-12 to 14-18

A standard 0º rake tooth form good for general and light duty cutting applications.

2 to 6

A 10º rake angle available in the carbon line. Good for fast cutting of hardwoods and nonferrous materials.

3 to 6

0º rake tooth with expanded gullet area. Works well in soft woods, nonferrous and non-metallics.

1 to 3

CNC ground triple chip tooth form. Excellent for high production rates on hard metallic and abrasive nonmetallics. Advanz™ FS is for shock, foundry applications. Advanz™ TS is for heat treated, difficult to machine materials.

ADVANZ FS & TS (Carbide Tipped)

Aggressive positive rake (up to 12º). Use for high production cutting of solids or heavy wall profiles. M-42 high speed edge with 8% cobalt.

.9-1.1 to 3-4

TOOTH CONSTANT PITCH

All teeth on the blade have uniform spacing, gullet depth and rake angle throughout the full length. Typically for general purpose cutting. Identified by one pitch number.

VARIABLE PITCH

Size of tooth and depth of gullet varies to substantially reduce noise levels and vibrations. Cuts all structurals, tubing and solids smoothly and quickly. Identified by two pitch numbers.

SETS RAKER SET

A recurring sequence of teeth set left and right, followed by one tooth unset. Frequency of unset teeth on variable pitch blades varies depends on the tooth configurations.

WAVY SET

Groups of teeth set to each side of the blade, with varying amounts of set in a controlled pattern.

ALTERNATE SET

A recurring sequence of teeth set alternately left and right.

TRAPEZOIDAL

Special carbide cylinder welded in the tooth edge, being slightly thicker than the blade, and triple chip grind.

starrett.com

BLADE TYPE Use this guide to choose the blade that will work best for the material to be cut, or provide an acceptable result, as necessary.

BLADE WIDTH Use the widest blade your machine will take except for contour cutting. Use this chart for cutting radii:

EXOTIC & NICKEL-BASED ALLOYS Intenss™ PRO or Intenss™ VTH TOOL & STAINLESS STEEL Intenss™ PRO or Intenss™ VTH ALLOY & HIGH CARBON STEEL Intenss™ PRO GENERAL PURPOSE Intenss™ PRO CARBON STEEL Intenss™ PRO-DIE STRUCTURAL STEEL Intenss™ PRO-ST or Versatix™ MP ALUMINUM Intenss™ PRO or Intenss™ PRO-DIE or Duratec™ FB CAST ALUMINUM Advanz™ FS THIN FERROUS SECTIONS Duratec™ FC COMPOSITES, FIBERGLASS, GRAPHITE & CERAMICS Advanz™ CG or Advanz™ DG WOOD & PLASTIC Woodpecker™ Premium or Woodpecker XF™ FOAM, PAPER PRODUCTS & RUBBER Band Knives FRESH OR FROZEN MEAT OR FISH (WITH OR WITHOUT BONES) Meatkutter™ Premium or Meatkutter™ Stainless

TOOTH SHAPE Regular - A conventional tooth used for general purpose sawing, straight or zero rake. Intenss™ PRO - Large teeth, up to 12º positive rake angle, for optimum production cutting of steels up to HRc 45, stainless, nickel based and nonferrous alloys. Hook - A positive rake for fast cutting of nonferrous metals and non-metallics. Skip - Zero rake and shallow gullets for cutting large sections of soft, nonferrous material.

BLADE LENGTH The blade length varies according to the band saw machine type and specifications. Please find the correct blade length on your band saw machine user manual.

PITCH Pitch is the number of teeth per inch or 25mm. Cutting thinner sections requires a finer pitch (more teeth per inch/25mm). Thick sections require coarser pitches (fewer teeth per inch/25mm). The charts are good guidelines. Because the cross section limits in the chart are broad and overlap, choose a coarser pitch if the speed of cut is most important. Choose a finer pitch if finish is most important. Section Size (Inch)

Constant Pitch (TPI)

Variable Pitch (TPI)

5/32 - 3/8

32 or 24

14-18

1/4 - 1/2

18 or 14

10-14

1/2 - 3/4

14 or 10

8-12

3/4 - 1

10 or 8

6-10

1 - 1-1/2

8 or 6

5-8

1-1/2 - 3-1/2

6 or 4

4-6

3-1/2 - 7

4 or 3

3-4

7 - 10

2-3

10 - 16

1.4-2

14 - 20

1-2

16 - 32

1-1.2

Over 30

.8-1.3

Wall Thickness

Outside diameter of tube or maximum profile section length (Inch)

(Inch)

3/8

3/4

1-5/8

2-3/8

3-1/4

4-3/4

3/32

14-18

10-14

8-12

6-10

5-8

1/8

10-14

8-12

6-10

5-8

5/32

8-12

6-10

5-8

4-6

3/16

6-10

5-8

4-6

1/4

5-8

4-6

3-4

5/16

4-6

3-4

3/8

4-6

3-4

2-3

1/2

4-6

3-4

2-3

5/8

4-6

3-4

2-3

3/4

4-6

3-4

2-3

3-4

2-3

1.4-2

1-1/4

3-4

2-3

1.4-2

1-5/8 2 2-3/8

starrett.com

3-4

2-3

1.4-2

3-4

2-3

1.4-2

1-2

2-3

1.4-2

1-2

Intenssâ&#x201E;˘ Pro Blade Width x Thickness

Blade Pitch with Material Numbers (all are Positive Rake)

Inch

.8-1.3/P

3/4 x .035

19 x 0.90mm

1 x .035

25 x 0.90mm

1-1/4 x .042

32 x 1.10mm

1-1/2 x .050

38 x 1.30mm

2 x .063

50 x 1.60mm

99928

2-5/8 x .063

67 x 1.60mm

3-1/8 x .063

79 x 1.60mm

1-1.2/P

1-2/P

1.4-2/P

2-3/P

3-4/P

4-6/P

5-8/P

6-10/P

8-12/P

10-14/P

99191

99902

99903

99206

99222

99234

99905

99906

99907

99908

99318

99329

99334

99500

99911

99096

99912

99913

99914

99915

99917

99919

99921

99923

99924

99926

99927

99929

99930

99931

99932

99933

99962

99934

99937

99939

99941

99942

99943

99945

99947

3/4 to 1-1/4 sizes available in 250 (76m) coils. 1-1/2 to 2 sizes available in 150 (45m) coils. 2-5/8 and larger available in welded bands only.

starrett.com

POCKET LASER TACHOMETER KIT WITH CASE Cat. No. S7793Z • EDP No. 68930 The Pocket Laser Tachometer is a digital, battery-powered portable optical tachometer that can operate up to 25 feet from a reflective target using a laser light source. This powerful 32 function Tachometer/ Ratemeter, Totalizer/Counter and Timer is programmable in both inch and metric rates. It has TTL compatible pulse output to trigger devices such as data collectors or strobocopes. Ergonomic design makes measurement of speed and RPM simple.

RANGE Optical: 5 to 200,000 RPM Contact: 0.5 to 20,000 RPM Accuracy: Optical: ±0.01% of reading Contact: ±0.05% of reading Kit includes: Tachometer, RCA, contact tips,10cm linear contact wheel, 5 of T-5 reflective tape, (2) AA batteries, carrying case

SAW TENSION GAGE Cat. No. 682EMZ • EDP No. 57075 The Saw Tension Gage will check for proper blade tension in either English or metric, and is graduated both in pounds and kilograms. The tension gage can be read directly on either band saws of any type, or power hacksaws. It is graduated to read up to 60,000 PSI or 4,000kg per cm2 and is furnished with instructions, including suggested tensions.

BAND SAW BLADE ALIGNMENT GAGE Cat. No. PT92925 • EDP No. 65049 The alignment of your band saw blade is a key factor to guarantee blade life and accuracy with Starrett Band Saw Blades. This gage enables you to make sure your blade is running square to the cut.

187 SLIDE CHART FOR BAND SAW SELECTION AND OPERATING GUIDE Our popular band saw slide chart selection and operating guide includes a wealth of useful information printed on both sides. This slide chart recommends the pitch suitable for the cross section to be cut as well as surface feet per minute speed plus the optimum cutting rate. This tool was developed by our R & D group from actual tests.

193 CUTTING RATE SELECTION CHART This cutting rate selection chart is a heavy-weight, laminated, two sided sheet with a chain for easy attachment to a band saw machine. It also includes recommended tension for Starrett band saw blades and a quick reference troubleshooting table.

starrett.com

121 CRESCENT STREET ATHOL, MA 01331 978 249 3551

starrett.com M1, M2, M7, M10, M50 M3, M4, M30-M47 High Speed Steels

T1, T2, T6 T4, T5 T15

Free Machining Stainless Steels

303 416, 420F, 430F

Austenitic Stainless Steels

201, 202, 301-304 305, 308, 321, 347, 348

Ferritic

Monel K500 Hastelloy, Rene 41 99% Titanium

Molybdenum Refractory Metal

405, 409, 430, 434, 436, 442, 446

99% Copper

Martensitic Stainless Steels

403, 410, 420, 422, 501, 502 440A-C, 414, 431 15-5PH, 17-4PH, 17-7PH

INSTRUCTIONS: Set ARROW on slide at material to be cut. Check ARROW in lower right corner for correct blade type. For Intenss™ PRO-VTH increase scale speed/feed by 15%. For Advanz™ carbide tipped, increase scale speed/feed by 25%-30%. Use Versatix™ MP for structurals, pipe, tube, channel and small diameters. Instructions on reverse side. CUTTING STRUCTURALS SPEEDS: 250-325 wet; 200-250 dry NOTE: Break in blade at about 1/2 normal cutting rate for the ﬁrst 50-100 square inches on easy to cut material. Tough work hardening material, break in at about 3/4 normal cutting rate for the ﬁrst 25 square inches, gradually increasing feed to reach maximum cutting rate after 50 square inches. Always remove a chip and maintain recommended band speed. (Avoid vibration.)

Free Cutting Brass Yellow/Red Brass Copper Alloys

Phosphor Bronze

Class 20

Aluminum Bronze

Class 40

Aluminum Bronze (Hardened)

Free Machining Carbon Steels

Beryllium Copper

Ductile 80-55-06, 225HB

Beryllium Copper (Hardened)

Medium Carbon Steels

Most Aluminums

High Carbon Steels

1/2"-1"

1"-2"

320 5-7

300 6-8

270 8-10

10-14

8-12 6-10

5-8 4-6

TEETH PER INCH

SPEED ft./min. sq. in./min. CUTTING RATE

1211-1215

5040-5060

1110, 1117-1118

5115-5120

1137-1151

5130-5160

1005-1012

50100, 51100, 52100

1015-1026

6118

1030-1055, A36

6150

Low Carbon Steels

Ductile 60-40-18, 150HB

MATERIAL WIDTH <1/2"

Titanium Alloys

Alpha, Alpha-Beta, Beta

Tantalum Columbium

Prec. Hardening

Nickel Alloys

Monel 400, 401

A286, 309, 310, 314, 316, 317, 330

Cast Iron

Front

Inconel 625, 718, X-750 Waspaloy Inconel 600, 601

MATERIAL WIDTH 2"-5"

5"-10"

250 8-10

250 6-7

4-6 3-4

3-4 2-3

>10"

Intenss™ PRO

PREFERRED 180 BAND TYPE 4-6 Intenss™ 1-2 3/4 - 1-1/4 PRO-VTH

TEETH PER INCH

Manganese Steels

8115, 8615-8622

1330-1345

8720, 8822

1513-1527

8145, 8625-8637

1536-1552

8640-8660, 8740

1561-1572

9310

4012-4024

9430-9445

4030-4042

9255-9262

4047-4068

A2-A6, A8-A10

or Advanz™

Molybdenum Steels Intenss™ PRO-VTH recommended for cutting these materials GENERAL INFORMATION Consult our technical dept. for appropriate Advanz™ carbide style 1) When cutting materials of various hardness other than normal listing on speed chart, multiply speed or cutting rate given on chart by these factors to arrive at speeds and cutting rates for hardened material. Rockwell Brinell SPEED FACTOR CUTTING RATE FACTOR Up to 20Rc 225Bhn 0 0 20-28Rc 225-275Bhn .75 .75 HARDNESS 28-35Rc 275-325Bhn .60 .54 35-40Rc 325-375Bhn .50 .40 2) Cutting normal or annealed materials requires at least 3 teeth to be in contact with the work, with the optimum being 6-12 teeth, and 24 teeth being too many. 3) When using Duratec™ PH or Duratec™ FB, reduce speed by 50% and cutting rate by 85%. 4) When cutting dry, reduce band speed 40-50%, and cutting rate 40-50%. Blade life will also be shorter by approximately 40-50%. 5) To choose correct Versatix™ MP for cutting tubing, pipe and structurals, first find the total square inches and divide by the distance the saw blade must travel to finish cut. This figure can be used as material width to determine Teeth Per Inch (Pitch). 6) To find estimated cutting rate for pipe, tubing and structurals, multiply factor for minimum wall thickness of section to be cut by the cutting rate shown for the same size solid material. 7) For foundry applications (aluminum, non-ferrous) use Advanz™ FS carbide tipped at 1000-5000FPM 8) For case hardened & hardened steels, use Advanz™ CS. (+) Up to 3/16 .4

3/16 - 3/8 .5

3/8 - 5/8 .6

5/8 - 1 .7

1 and Over .8

1/2 3/4 1 1-1/4 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4

.20 .44 .79 1.22 1.76 2.40 3.14 3.97 4.90 5.93 7.06 8.25 9.62 11.04 12.56

4-1/4 4-1/2 4-3/4 5 5-1/4 5-1/2 5-3/4 6 6-1/2 7 7-1/2 8 8-1/2 9 9-1/2

14.18 15.90 17.72 19.63 21.64 23.75 25.96 28.27 33.18 38.48 44.17 50.26 56.74 63.61 71.00

10 10-1/2 11 11-1/2 12 12-1/2 13 13-1/2 14 14-1/2 15 15-1/2 16 16-1/2 17

78.53 86.60 95.00 104.00 113.00 122.75 132.00 143.06 153.86 165.04 176.62 188.59 200.96 213.71 226.86

17-1/2 18 18-1/2 19 19-1/2 20 20-1/2 21 21-1/2 22 22-1/2 23 23-1/2 24 24-1/2

240.40 254.36 268.66 283.43 298.49 314.00 330.09 346.18 362.86 379.94 397.40 415.26 433.51 452.16 471.19

4142-4161

L2, L6 S1-S7

4815-4820

1/2"-1"

1"-2"

Tool Steels (Air and Oil Hardening)

D2, D3, A7 W1-W5

4340

MATERIAL WIDTH <1/2"

Nickel Chrome Moly Steels

Silicone Steels

O1, O2, O6, O7, P20

4320

4615-4626

Intenss™ PRO-VTH recommended for cutting these materials

Carbon Tool Steel

Special Purpose Shock Resistant Hot Work Steel

H10-H19 H21-H42

SPEED

MATERIAL WIDTH 2"-5"

5"-10"

4-6 3-4

3-4 2-3

>10"

Intenss™ PRO

ft./min. sq. in./min. 10-14

WALL THICKNESS FACTOR

Diameter Area in Diameter Area in Diameter Area in Diameter Area in in inches Sq. Inches in inches Sq. Inches in inches Sq. Inches in inches Sq. Inches

4130-4140

Chrome Moly Steels

Nickel Chrome Moly Steels

Nickel Moly Steels

Chrome Steels

Chrome Vanadium Steels

1060-1095

8-12 6-10

TEETH PER INCH

5-8 4-6

CUTTING RATE

PREFERRED BAND TYPE Intenss™ 1-2 3/4 - 1-1/4 PRO-VTH

TEETH PER INCH

starrett.com

or Advanz™

SPECIFICATIONS SUBJECT TO CHANGE BULLETIN 110-25M/PG-04/09

No Varnish Area

BLADE BREAK-IN Using the right break-in procedures for a bimetal blade assures longer blade life, faster cuts for a longer period of time and consistent performance. Conversely, blade life can be significantly compromised if the proper break-in procedures are not followed.

LONGER BLADE LIFE

NEW BLADE WITH RAZOR SHARP TEETH

TOOTH CORRECTLY BROKEN IN

The teeth on a new band saw blade are razor sharp. To withstand the cutting pressures of band sawing, the tip of each tooth should be honed to create an extremely small radius on its tip. Easy-to-cut material such as carbon steel and aluminum: A. Run the normal surface feet per minute (SFPM). B. Adjust the feed pressure to about one-half the normal cutting rate for the first few cuts or for 50-100 square inches (323-645 sq.cm). C. Increase to the normal cutting rate. D. Avoid vibration. Hard-to-cut materials such as nickel-based alloys like inconel, hardened steels,tool steels and stainless steels: A. Run the normal surface feet per minute (SFPM). B. Adjust the feed pressure to about threequarters of the normal cutting rate for the first few cuts or for 25-75 square inches (161-484 sq.cm). C. Then increase the cutting rate part way to normal for the next few cuts. D. Then increase to the normal cutting rate. E. Avoid vibration.

BAND SAW SERVICE & SUPPORT Starrett service technicians are available to tune up and perform preventative maintenance on your production sawing machine using Starrett Band Saw Blades, at no additional cost. They fully review machine condition, blade mounting and operation in detail, making adjustments, as required, to help maintain good sawing and long life for both the machine and blades.

TRAINING

TOOTH INCORRECTLY BROKEN IN

starrett.com

START TO CUT MATERIAL AT REDUCED CUTTING RATE

Starrett service technicians can also instruct saw operators on achieving the best performance of blade and machine for your applications. Contact your Starrett Band Saw distributor about arranging a visit to your workplace by a Starrett service technician.

AFTER BREAK-IN WHEN THE BLADE HAS FULLY ENTERED THE WORKPIECE, INCREASE THE FEED RATE OVER A SERIES OF CUTS UNTIL THE RECOMMENDED CUTTING RATE IS ACHIEVED

BAND SAW BLADE INSTALLATION GUIDELINES Always follow the machine manufacturer’s instructions and recommendations for blade changes and the safe operation for the band saw machine. The guidelines are not intended to replace the machine manufacturer’s instructions or recommendations. The general information contained in the guidelines is intended to assist in the proper installation of band saw blades. Proper blade installation achieves more efficient blade performance. Please contact your machine manufacturer for appropriate procedures for blade changes for your specific machine and your saw blade manufacturer for appropriate cutting recommendations. The L. S. Starrett Co. nor its employees, shall not be held responsible for the accuracy or completeness of these guidelines. Wear gloves when handling band saw blades.

Wear eye protection, safety shoes, and hearing protection.

FOLLOW INSTRUCTIONS CAREFULLY Follow all the safety instructions shown in the band saw machine operator’s manual and on the machine labels. Recognize and read safety and warning signs such as Danger, Warning and Caution. Follow the saw blade installation instructions for the make and model of the band saw machine.

BASIC BLADE CHANGE GUIDELINES Position saw head to appropriate location to facilitate ease of blade change. Follow required lock out tag out procedures. Position chip brush away from saw blade. Relieve saw blade tension and remove blade. Remove any chips from saw guides and band wheels. Select appropriate blade for cutting application. (Refer to saw blade selection chart) Unfold blade properly. Do Not Throw. Throwing the blade will result in tooth damage that will reduce saw blade performance. (Refer to unfolding procedure) Install blade with saw teeth pointing in proper direction.

Apply appropriate tension to the blade. Be aware of pinch points and keep hands and clothing clear of rotating blade.

Adjust guide arms to appropriate positions to workpiece. Adjust blade guides for proper blade support. Adjust chip brush to fully engage saw blade teeth to ensure proper chip removal. Check hydraulic fluid levels if applicable. Ensure appropriate cutting fluid placement and mix ratios as applicable per machine, cutting fluid, and blade manufacturer’s recommendations. Break in blade properly before reaching desired cutting rates.

Steel Specification USA (AISI)

Feet per Minute

Meters per Minute

Sq Inch per Minute

Sq cm per Minute

1211-1215

230 - 310

69 - 93

12 - 18

78 - 117

1110, 1117-1118

220 - 300

66 - 90

9 - 15

58 - 97

1137-1151

165 - 245

50 - 74

5 - 11

32 - 71

1005-1012

220 - 300

66 - 90

9 - 14

58 - 97

1015-1026

210 - 290

63 - 87

8 - 13

52 - 91

1030-1055, A36

140 - 220

42 - 66

5-9

32 - 58

1060-1095

120 - 200

36 - 60

5-8

32 - 52

1330-1345

140 - 220

42 - 66

4-8

26 - 52

1513-1527

220 - 300

66 - 90

8 - 12

52 - 91

1536-1552

165 - 245

50 - 74

6 - 10

39 - 65

1561-1572

120 - 200

36 - 60

5-8

32 - 52

4012-4024

150 - 230

45 - 69

4-9

26 - 58

4030-4042

140 - 220

42 - 66

4-8

26 - 52

4047-4068

130 - 210

39 - 63

4-8

26 - 52

4130-4140

130 - 210

39 - 63

4-8

26 - 58

4142-4161

120 - 200

36 - 60

3-7

20 - 45

4320

130 - 210

39 - 63

4-8

26 - 52

4340

120 - 200

36 - 60

3-7

20 - 45

4615-4626

140 - 220

42 - 66

4-8

26 - 52

4815-4820

130 - 210

39 - 63

4-8

26 - 52

5040-5060

130 - 210

39 - 63

4-8

26 - 52

5115-5120

150 - 230

45 - 69

5-9

32 - 56

5130-5160

130 - 210

39 - 63

4-8

26 - 52

50100, 51100, 52100

90 - 160

27 - 48

3-5

20 - 32

6118

150 - 230

45 - 69

5-9

32 - 58

6150

130 - 210

39 - 63

4-8

26 - 52

8115, 8615-8622, 8720, 8820

130 - 210

39 - 63

5-9

32 - 58

8145, 8625-8637

130 - 210

39 - 63

5-9

32 - 58

8640-8660, 8740, 9430-9445

130 - 210

39 - 63

4-8

26 - 52

9310

110 - 190

33 - 57

2-4

13 - 26

Work Material Type

Free Machining Carbon Steels

Low Carbon Steels Medium Carbon Steels High Carbon Steels

Manganese Steels

Molybdenum Steels

Chrome Moly Steels

Nickel Chrome Moly Steels

Nickel Moly Steels

Chrome Steels

Chrome Vanadium Steels

Nickel Chrome Moly Steels

starrett.com

Steel Specification USA (AISI)

Feet per Minute

Meters per Minute

Sq Inch per Minute

Sq cm per Minute

130 - 210

39 - 63

4-8

26 - 52

140 - 220

42 - 66

3-6

20 - 39

A2-A6, A8-A10

130 - 210

39 - 63

2-4

13 - 26

01, 02, 06, 07

130 - 210

39 - 63

2-6

13 - 29

D2, D3, D7 (CUT DRY)

50 - 100

15 - 30

2-3

13 - 20

W1-W5

130 - 210

39 - 63

2-6

13 - 39

L2, L6

120 - 200

36 - 60

2-6

13 - 39

S1 - S7

90 - 160

27 - 48

2-4

13 - 26

H10 - H19

130 - 210

39 - 63

2-5

13 - 32

H21 - H42

90 - 160

27 - 48

2-4

13 - 26

M1, M2, M7, M10

75 - 130

22 - 39

2-4

13 - 26

M3, M4, M30 - M47

50 - 100

15 - 30

1-3

7 - 20

T1, T2, T6

75 - 130

22 - 39

2-4

13 - 26

T4, T5

60 - 120

18 - 36

1-3

7 - 20

T15

50 - 90

15 - 27

1-3

7 - 20

303

75 - 140

22 - 42

2-5

13 - 32

416, 420F, 430F

100 - 180

30 - 54

3-6

20 - 39

201, 202, 301-304, 305, 308

70 - 120

21 - 36

2-4

13 - 26

321, 347, 348

70 - 120

21 - 36

2-4

13 - 26

A286, 309, 310, 314

50 - 80

15 - 24

1-2

7 - 13

316, 317, 330

50 - 80

15 - 24

1-2

7 - 13

405, 409, 430, 434

60 - 100

18 - 30

1-3

7 - 20

436, 422, 446

60 - 100

18 - 30

1-3

7 - 20

403, 410, 420, 422, 501, 502

70 - 130

21 - 39

2-4

13 - 26

440A-C, 414, 431

60 - 100

18 - 30

1-3

7 - 20

15-5PH, 17-4PH, 17-7PH

50 - 90

15 - 27

1-3

7 - 20

CLASS 30

120 - 200

36 - 60

8 - 14

52 - 91

CLASS 40

80 - 160

24 - 48

5 - 11

32 - 71

DUCTILE 60-40-18 150HB

160 - 240

48 - 72

4 - 10

26 - 65

DUCTILE 80-55-06 225HB

80 - 160

24 - 48

2-7

13 - 45

Work Material Type Silicon Steels

9255-9262

Nitriding Steels

Tool Steels (Air & Oil Hardening)

Carbon Tool Steel

Special Purpose Shock Resistant Hot Work Steel

High Speed Steels

Free Machining Stainless Steels

Austenitic Stainless Steels

Ferritic Stainless Steels

Martensitic Stainless Steels Precision Hardening Stainless Steels

Cast Iron

Diameter

AREA CALCULATION

Area

Inches

Centimeters

Square Inches

Square Centimeters

1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 24

2.5 3.8 5.1 6.4 7.6 8.9 10.2 11.4 12.7 14 15.2 16.5 17.8 19.1 20.3 21.6 22.9 24.1 25.4 26.7 27.9 29.2 30.5 31.8 33.0 34.3 35.6 36.8 38.1 39.4 40.6 41.9 43.2 44.5 45.7 47.0 48.3 49.5 50.8 52.1 53.3 54.6 55.9 57.2 58.4 61.0

0.8 1.8 3.1 4.9 7.1 9.6 12.6 15.9 19.6 23.8 28.3 33.2 38.5 44.2 50.3 56.7 63.6 70.9 78.5 86.6 95.0 104.0 113 123 133 143 154 165 177 189 201 214 227 241 254 269 284 299 314 330 346 363 380 398 415 452

4.9 11.3 20 32 45 62 82 102 127 154 186 214 249 287 324 366 412 456 507 560 611 670 731 794 855 924 995 1064 1140 1219 1295 1379 1466 1555 1640 1735 1832 1924 2029 2132 2231 2341 2454 2570 2679 2922

In order to calculate the best cutting progress, you can select an option from the charts below.

ATTENTION Make all the measurements in centimeters to get the area in cm2

SQUARE area = L2

ROUND area = D2 x 0,7854

ROUND TUBE area = (De2 - Di2) x 0,7854

SQUARE TUBE area = = Le2 - Li2

RECTANGULAR area = E x L

HEXAGONAL area = L2 x 2,598 E2 x 0,866

Blade Effect

Blade Breakage

Straight break indicates fatigue.

Prematurely Dull Teeth

Inaccurate Cut

Band Leading in Cut

Chip Welding

Teeth Fracturing - Back

Probable Cause

Solution

Incorrect blade

Check tooth selection

Band tension too high

Reduce band tension, refer to operator’s manual

Excessive feed

Reduce feed pressure

Incorrect cutting fluid

Check coolant recommendations

Wheel diameter too small for blade width

Use narrower blade

Worn or chipped pressure block

Replace worn pressure blocks

Blade rubbing on wheel flange

Adjust wheel alignment

Teeth in contact with work before starting saw

Allow blade clearance above work

Side guides too tight

Refer to operator’s manual

Blade on machine backwards

Install blade correctly

Improper blade break-in procedure

Refer to recommended procedures

Hard material or heavy surface scale

Check material hardness and surface condition

Material is work-hardening

Increase feed pressure

Improper cutting fluid or mix ratio

Follow coolant mixing procedures

Speed or feed too high

Check cutting recommendations

Guide arms too far apart

Adjust guide arms closer to material

Blade worn out

Replace blade

Over or under feeding

Check cutting recommendations

Improper tooth pitch

Use proper tooth selection

Cutting fluid not applied properly

Adjust coolant nozzles

Too many teeth for material cross section

Use proper tooth selection

Guides worn or loose

Tighten or replace guides

Over feeding

Check cutting recommendations

Low band tension

Refer to operator’s manual

Tooth set damaged

Check material hardness

Guide arms loose or space too wide

Adjust guides and guide arms

Worn or missing chip brush

Replace or adjust chip brush

Improper or lack of cutting fluid

Check coolant flow and fluid type

Wrong coolant ratio

Check coolant type and ratio

Excessive feed or speed

Reduce feed or speed

Incorrect blade pitch

Use proper tooth selection

Saw guides not properly adjusted

Align or adjust saw guides

Incorrect feed or speed

Refer to cutting recommendations

Incorrect blade

Use proper blade type and pitch

Material moved in vise

Inspect and adjust vise

Indexing while blade in work

Adjust index sequence

Blade not high enough before index

Adjust height selector

Saw head drifts into work while neutral

Check hydraulic cylinder

Back of tooth indicates spinning in vise.

Irregular Break

Indicates material movement.

starrett.com

Blade Effect

Teeth Stripping

Wear on Back of Blade

Rough Cut

Washboard surface, vibration and/or chatter

Wear Lines - Loss of Set

Twisted Blade

Contour sawing

Blade Wear

Teeth blued.

Teeth Fracturing - Front

Front of tooth indicates work spinning in vise.

Probable Cause

Solution

Improper blade break-in procedure

Follow proper break-in procedure

Speed too slow

Refer to cutting recommendations

Feed pressure too high

Reduce feed pressure

Tooth jammed in cut

Do not enter new blade in that cut

Poor cutting fluid application or ratio

Adjust coolant flow and ratio

Hard material or heavy scale

Check material or surface hardness

Wrong blade pitch

Use proper tooth selection

Work spinning or loose nested bundles

Tighten vises or use nesting clamps

Blade on backwards

Install blade correctly

Excessive back-up guide preload

Adjust pressure blocks

Low blade tension

Refer to operator’s manual

Incorrect blade (carbon steel type)

Switch to a bi-metal blade

Excessive feed rate or pressure

Reduce feed rate or pressure

Damaged or worn pressure block

Replace pressure block

Guide arms spaced too far apart

Adjust guide arms closer to work

Blade rubbing band wheel flanges

Adjust wheel alignment

Dull or damaged blade

Install new blade

Incorrect feed or speed

Refer to cutting recommendations

Blade not supported properly

Adjust or tighten guide arms

Low blade tension

Refer to operator’s manual

Incorrect tooth pitch

Use proper tooth selection

Guide arms too far apart

Adjust guide arms closer to material

Saw side guides too tight

Adjust guides properly

Blade riding too high in guide

Adjust rollers or pressure blocks

Blade teeth riding on band wheel surface

Adjust tracking or replace wheel

Wrong blade width for machine

Refer to operator’s manual

Chips being carried back into cut

Replace or adjust chip brush

Worn or damaged pressure block

Replace pressure block

Insufficient coolant flow

Adjust coolant flow

Blade binding in cut

Adjust feed or use heavy set blades

Side guides are too tight

Adjust guides

Work loose in vise

Adjust vise

Feed too heavy

Reduce feed pressure

Guide arms too far apart

Adjust guide arms closer to material

Incorrect blade

Use proper tooth selection

Heavy feed or too fast speed

Refer to cutting recommendations

Lack of cutting fluid

Adjust coolant flow or ratio

Blade installed backwards

Install blade correctly

Material loose in vise

Adjust vise

Incorrect tooth pitch

Use proper tooth selection

Feed too heavy

Reduce feed rate

Speed too fast

Refer to cutting recommendations

NOTAS: