Starrett S4240 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

Instructions Manual for installation and maintenance band saw machine model:

S4240 MANUAL ORIGINAL The Original Manual was written in Portuguese MANUAL ORIGINAL

serial number: date:

Prior to installing or performing any operation, carefully read this Instructions Manual on the use of this machine. For fither information or clarifications, please contact Starrett. 220/380V - 50/60Hz

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S4240 200/380V - ENG

GENERAL INDEX 1. COMPLIANCE CERTIFICATE ..................................................................................... 1 2. WARRANTY............................................................................................................ 3 3. MACHINE IDENTIFICATION ..................................................................................... 5 4. TECHNICAL DATA .................................................................................................... 7 4.1. STANDARD ITEM ........................................................................................................................... 7 4.2. REFERENCES FOR FIGURES AND PARTIES .................................................................................... 8 4.3. APPLICABLE LEGISLATION AND TECHNICAL STANDARD .......................................................... 10

5. SAFETY RECOMMENDATIONS ............................................................................... 11 6. MACHINE DESCRIPTION ....................................................................................... 17 7. INSTRUCTION FOR USE AND OPERATION ............................................................. 27 7.1. OPERATION ADJUSTMENTS ........................................................................................................ 27 7.1.1. CUTTING ANGLE ADJUSTMENT ......................................................................................... 27 7.1.2. CUTTING FEED HYDRAULIC ADJUSTMENT ....................................................................... 29 7.1.3. BOW HEIGHT ADJUSTMENT ............................................................................................... 29 7.1.4. CLAMPING OF MATERIAL ................................................................................................... 31 7.1.5. REPLACE AND TENSION OF THE BAND SAW BLADE ........................................................ 32 7.1.6. GUIDE OF BAND SAW BLADE .............................................................................................. 34 7.2. CONTROL PANEL Í³ BASIC FUNCTIONS ....................................................................................... 35 7.3. COOLANT SYSTEM ........................................................................................................................ 37 7.3.1. OIL OF CUTTING COOLING .................................................................................................. 38 7.4. HYDRAULIC UNIT .......................................................................................................................... 38 7.4.1. PRESSURE ADJUSTMENT OF MOBILE VISE ........................................................................ 38 7.4.2. TYPES OF HYDRAULIC OOL ................................................................................................. 38 7.5. FIRST CUT ...................................................................................................................................... 41

8. CRITERIA FOR BAND SAW SELECTION ................................................................... 43 8.1. LIMITS AND RECOMMENDATIONS ............................................................................................. 43 8.2. CRITERIA FOR BAND SAW SELECTION ........................................................................................ 43 8.2.1. TERMINOLOGY ..................................................................................................................... 44 8.2.2. TEETH SHAPES .................................................................................................................... 45 8.2.3. CHARACTERISTTCS ............................................................................................................. 46 8.2.4. BLADE SELECTION IN 5 STEPS ............................................................................................ 47 8.2.5. PRODUCTS ........................................................................................................................... 49 8.2.6. RECOMENDATIONS ............................................................................................................. 56 8.2.7. CUTTING CALCULATION ..................................................................................................... 58 8.2.8. PROBLEMS SOLUTION ........................................................................................................ 59

9. TRANSPORTION INSTRUCTION ............................................................................. 61 10.INSTALLATION INSTRUCTIONS ............................................................................ 63

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S4240 220/380V - ENG 10.1.INSTALLATION INSTRUCCTIONS ................................................................................................ 63 10.2. DISASSEMBLY AND DISPOSAL OF THE MACHINE ................................................................... 66 10.2.1. DISPOSAL............................................................................................................................ 66 10.2.2. DISASSEMBLY .................................................................................................................... 66

11. SISTEMS ............................................................................................................. 67 11.1. ELECTRICAL SYSTEM .................................................................................................................. 67 11.2. HYDRAULIC SYSTEM ................................................................................................................... 71

12. GEAR BOX ......................................................................................................... 73 12.1. OPERATING PRINCIPLE .............................................................................................................. 73 12.2. MAINTENANCE INSTRUCTIONS ............................................................................................... 73

13. MAINTENANCE AND CONTROL........................................................................... 75 13.1. CLEANING .................................................................................................................................. 75 13.2. GUIDES SETS ADJUSTMENT AND MAINTENANCE .................................................................. 75 13.3. CAMBER OF DRIVEN FLYWHEEL ADJUSTMENT ....................................................................... 79 13.4. BOW CYLINDER REPLACEMENT ................................................................................................ 81 13.5. SPRING SET REPLACEMENT ...................................................................................................... 81 13.6. MAINTENANCE TABLE ............................................................................................................... 82 13.7. TROUBLE, CAUSES AND SOLUTIONS ......................................................................................... 83

14. SPARE PARTS...................................................................................................... 85 14.1. CABINET SET AND HYDRAULIC UNIT ....................................................................................... 85 14.2. VISE SET AND SWIVEL SUPPORT .............................................................................................. 86 14.3. BOW SET AND MOTO REDUCER ............................................................................................... 87 14.4. GUIDES SET ................................................................................................................................. 88 14.5. HYDRAULIC SET ......................................................................................................................... 91

APENDIX.................................................................................................................. 93 NOTES ..................................................................................................................... 95

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WARNING! •

BEFORE TO START any kind of operation on the machine S4240, 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: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br

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S4240 220/380V - ENG

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S4240 - 220/380V - ING

1. COMPLIANCE CERTIFICATE: DECLARAÇÃO DE CONFORMIDADE CE DECLARATION EC-CONFORMITY ATTESTATION DE CONFORMITÉ CE Starrett Indústria e Comércio Ltda. Av. Laroy Starrett, 1880 13306-900 – Itu – SP – Brazil Declara, sob sua exclusiva responsabilidade, que os Declara bajo su exclusiva responsabilidad que los We declare that it is our sole responsibility that the Nous déclaro ns sous notre exclusive responsabilité que produtos, productos, produtcs, produits,

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

modelos: modelos: modelos: modèles:

S4240 Os quais se referem a esta declaração, estão de acordo com as seguintes diretivas: Al cual se refiere esta declaración, están de acuerdo con las siguientes directivas: To which this declaration relate are in accordance with the provision of following directives: Auxquels se rapporte la présente déclaration sont conformes aux dispositions des directives suivantes: DIRECTIVA 2006/42/EC DIRECTIVA 2004/108/EC DIRECTIVA 2006/95/EC e que estão em conformidade com as normas y que están en conformidad con las normas and are in conformity with the following standards et sont conformes aux normes suivantes EN 13898:2009+A1 EN 12100:2010 EN 60204-1:2006 EN ISO 13857 : 2008 IEC 61000-6-2: 2007 IEC 61000-6-4: 2007

IEC 61000-6-2:2007 IEC 61000-6-4:2007

Itu/SP, novembro de 2011.

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2. WARRANTY: 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

WARRANTY CERTIFICATE

PRODUCT S4240. The equipments manufactured and marketed by Starrett Ind. e Com. Ltda are 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, carbide plates, 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 ofwarranty; 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.

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3. MACHINE IDENTIFICATION: All Starrett machines are provided with a Identification Plate attached to the Base or Cabinet. The following data in engraved in the ID plate: Model, serial number, code, manufacturing year, weight, power and voltge. Below is showed an ID plate type:

S4240 11080019 S4240-H4 2011 600 3,0 220

(ILLUSTRATIVE DATA)

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4. TECHNICAL DATA: StarreƩ

S4240

Net Weight

600 Kg.

Dimensions (mm)

1,5 x 0,8 x 1,6 (height)

Blade Motor (hp /kW)

3,0/2,25

Hydraulic Unit Motor (hp / kW)

1,0/0,75

Blade Speed (m/min)

20 - 85

Band Saw Dimensions (mm)

3490 ( +/- 2) x 27 x 0,9

Available Voltage - 3 phasis (V)

220 or 380

Motor opera on frequency (Hz)

50 or 60

CUTTING CAPACITY DIMENSIONS (MM)

0 o 45 60o

300 300 170

B AxB 300 x 300 240 x 240 170 x 170

75o o -45

80 270

80 x 80 160 x 160

A B AxB 180 x 450 170 x 190

3490 x 27 x 0,9

MOTOR

160 x 210 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) – SECTION 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

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4.2. FIGURE AND PART REFERENCES

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General View

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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.

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5. SAFETY RECOMMENDATIONS

The S4240 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 these 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 (09) in OFF, 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.01 - JAN/12

S4240 - 220/380V - 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, areNOT 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 (04);

ATTENTION: RISK OF AMPUTATION OR SEVERE INJURY!

• NO is authorized to use this machine, UNDER ANY CIRCUMSTANCES, for CHILD(REN) or person(s) NOT qualified; • During the cu ng opera on, MUST NOT BE USED by the operator, UNDER NO CIRCUMSTANCES: short jacket or shirt or any kind of long-sleeved sweater, chain (s) or e or neck scarf, long hair loose, ring (s) in any finger, or any other object in the body that can pull the operator from the machine. • OBSERVE all signaling that are on the bow and the cabinet of machine. It is very important that the operator is familiarized with these indica ons; • 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 operaƟon; • 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 General Switch (09) in OFF. NEVER REMOVE material chips and other residues with the machine in operaon.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 loca ons; 12

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• USE li ing and transport devices to handle the materials to be cut according to appropriate weight and dimension limita ons for a safe and ergonomic work. This opera on must be performed by responsible and qualified persons; • The operator mustUSE always the protec ve personal equipment (PPE) legally approved in the country.The operator must use the following PPEs: safety glasses, earplugs and industrial shoes. OBSERVE the Plate (55) on the Bow (24) figure 03. Leather Gloves, use them ONLY to replace the band saw blade, and NEVER use them during the opera on. Besides that, the company owner the machine must guide and train each operator appropriately on how to use and keep each PPE, crea ng or indica ng other individual protec ons especially for the operator;

• Also it is necessary to observe the selec on of the type of Band Saw Blade.(41). Observe: tooth, feeding and cu ng speed, appropriate for the type of material to be cut. This defini on avoids problems during the cu ng opera on ( see Chapter 8 this Manual ); • Long materials to be cut that exceed the Table Cu ng (35) of the machine should be supported by Roller Tables (54) in the machine feed posi on; • Before any maintenance of Bow Cylinder (48), keep the bow completely downward so that there is no pressure on the hydraulic system due to the weight of the bow (see 13.3); • If it's necessary to displace the Spring (49), USE a li ing device to move up the Bow (24) to the highest posi on, to eliminate all the poten al energy accumulated by the springs, avoiding therefore the risk of injury (see 13.4); • 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 underStarreƩ responsability; • USE the hydraulic oils recommended in this manual. Such oils must be disposed oﬀ according to the local legisla on; • DO NOT PUT or LEAVE tools or others objects on the machine parts; • ENSURE suﬃ cient free space around the machine, in order to provide work space and space for people passage.

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DANGER – 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)

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ATTENTION:DANGER! IN DANGER ZONE, THE BAND SAW BLADE (41) IS NOT PROTECTED! The operator should be alert andNEVER to approach this area when the machine is on operaƟon.

DANGER ZONE

ATTENTION: RISK OF INJURY! DEFINITION OF MACHINE´S WORKSTATION POSITION: During the cu ng process the operator must be in front of Control Panel (20), observing the parameter se ngs of cutng, and with the hand free to access immediately the EMERGENCY Bu on (04).

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6. MACHINE DESCRIPTION: The STARRETT BAND SAW MACHINE - S4240 was developed by quality, safety, modernity, and technology criterias to meet the user’s needs, according to the harmonized EC directives and standards.

This is a SEMI-AUTOMATIC, designed exclusively for cutting parts, usually metal materials and should be used only by qualified persons.Any other form of use is considered incorrect and dangerous, voids warranty, and exempts the manufacturer from responsibility in case of accidents. For correct usage should be observed the instructions of application, and the maintenance and control conditions, in order to meet the occupational safety standards of each country.

Examples of materials to be cut: • construc on steels

• carbon steels

• alloy steels

• cupper

• stainless steels

• brass

• iron cas ng

• other metals

• aluminum alloys

• plas cs

The machine shouldn't be used by unqualified personnel, and it is NOT made to cut:Wood, Teflon, meat, bones, ceramic materials, etc.

REV.01 - JAN/12

S4240 - 220/380V - ING BASIC CHARACTERISTICS: •

Worm type gear box, theree phases (2,25 kW) a blade speed controlled by frequency inverter;

•

Hydraulic Unit with three phases motor;

•

Hydraulic Unit with three phases motor;

•

Stop device in case of rupture of the blade;

•

SEMI AUTOMATIC mode: closing vise, runing of the blade, moving down the bow controlled by flow regulator, cutting of material, stop the blade, move up the bow and opening the vise;

•

Combined guides with carbide plates and bearings guides;

•

Cutting cooling by the both guides;

•

Band Saw Blade;

•

Dynamometer Tension of Band Saw Blade;

•

Cutting Angle to both sides: 0-75° right and 45° left;

•

Power supply:220 or 380V in 50 or 60Hz (*) - voltage factory default is 220V/60Hz;

•

Manufacturing according to EC directives.

(*) machine assembled according to Purchase Order OF user. The S4240 consists of one rigid Bow (24) provided with two fl ywheels:one is Driven Flywheel (33) and the other, Driver Flywheel (34). The Driver Flywheel (34) is coupled in a Gear Box (23), which it is coupled in a three phase electric Motor (22).The Driven Flywheel is mounted in the Tensioning System (39) (figures 01 and 02). One Band Saw Blade (41) is mounted on the two Flywheels (33) (34), conveniently tensioned by Tensioning System (39). The Bow (24) is mounted on the vise set by a shaft, that enables it to turn in the blade plane, that is the cutting plane. The Blade (41) and the Flywheels (33) (34) are protected in the rear part of the Bow (24) by Bow Doors (25) (figure 03). Basically, the vise set is consisted: one Cutting Table (35) and one Vise Set (36), responsible to fix rigidly the material to be cut. The Mobile Vise (36) has a longituidinal movement, in the material’s clamping direction. transversally in the cutting angle direction, commanded manually.The clamping of vise on the material is commanded hydraulically, by MANUAL mode (Selector Switch (03), and by Buttons (11A) and (11B) in the Control Panel (20). According to the machine’s construction, the Bow (24) rotates on a fixed point of the 18

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24 48

41 53

Figure 01

Cutting Table (35), allowing angled cuts (45째 to the left, 0째, 45째, 60째 and 75o to the right) on the material to be cut (figures 05A and 05B). One extremely rigid Cabinet (53), constructed in steel plates, supports all set described above, and that incorporates inside it the Electric Box (21), Hydraulic Unit (47), and Coolant Pump (45).The design of this cabinet allows the operator to work in an position ergonomically correct. The segment of the Band Saw Blade (41) that performs the cutting operation is supported by two guides: Mobile (27) and Fixed (30). (figures 04 and 07). These guides are provided with Bearings (31) and Carbide Plates (32) that allow twist the blade in respect to the rotation plane of the Flywheels (33) (34), in order to form the cutting plane. The Carbide Plates (32) have a function to align and to keep the stability of the Band Saw Blade (41) in the cutting plane.The Mobile Guide (27), closed of Driven Flywheel (33), can be adjusted manually by positioning of Mobile Guide Support (37), in order to adjust the distance from the material to be cut (figure 04). To release the Mobile Guide Support (37) use the Lever (39).

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33 34

36 20

Figure 02

40 51

Figure 03

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Figure 03

This machine has commands that allows to perform all movements of the Bow (24), of the Vise (36), Coolant Pump (45) (figure 06). The S4240 has 2 operation modes: MANUAL and SEMI-AUTOMATIC. In the MANUAL mode, the operator can only perform the adjustments of machine, as opening and closing of Vise (36), to go up and go down of the Bow (24), running the blade with Button (07) pressed.All adjustment operation should be performed in this mode, not allowing the cutting operation. In SEMI AUTOMATIC mode, the machine adjusted in the MANUAL mode, and electrically connected and the material to be cut properly positioned on the Cutting Table (35), press the Cycle Start Button (10A) to start the cutting operation. The Pilot Lamp (10B) (GREEN) will light.Thus, the Vise(36) closes automatically, locking the material, and begining the down movement of the Bow (24) with the Band Saw Blade (41) running. At the end of the cut, the Micro Switch (13) is pressed by Screw (19), stopping automatically the movement of the blade and moving up the Bow (24), until the height previously adjusted by the operator. In case of normal stop of the cycle, just press the Button (10C). All these commands are on the Control Panel (20) as selector switches, buttons and lights are operated under the voltage of 24VAC (figure 06).The Electric Box (21), located on the left and inside the Cabinet (53), is found the electric components of power and control, such as the General Switch QS1 (09), Contactors KM2 (67) and KM3 (68) , Thermal Relay FR1 (73), timers, auxiliary relays, Transformer CT (66) and Frequency Inverter INV (65) (figure 08). The movements of the Bow (24) and the Vise (36) are realized hydraulically by the Hydraulic Unit (47) installed inside the cabinet (figure 09), where are the Motor M3 (74) and Tank (76) of the hydraulic oil.

Figure 04

15 39 37

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62 61

Figure 05 A CUT AT +75o RIGHT side

09 48

24 48

36 35 Figure 05 B CUT AT - 45o LEFT side

83 58

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Figure 06

12A

11A

10A

10B

10C

02 06

12B

11B

Figure 07

23 52

45 44 38

93 81

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71 09

65 66

Figure 08

Figure 09

Figure 07 47

76 77

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S4240 - 220/380V - ING This machine is also provided with a safety systems to operator and motors.The safety systems are: •

EMERGENCY Button (04) RED, mushroom type, installed on the control panel: under any abnormal condition while in operation, in case of problems or risks of accidents, should be pressed.This action will instantly stop the movement of the blade, the coolant system and the hydraulic system;

•

NORMAL Stop Button (10C) RED, installed on the control panel, to be pressed in cases of normal stops;

•

Safety Micro Switch (16) of Doors (25). When opening the Doors of Bow (25), for maintenance or replacement band saw, this micro switch will disable the electrical system in order to protect the operator against accidental injury;

•

Blade Rupture Micro Switch (15): in case of breaking of the Band Saw Blade (41) during the cutting operation. This micro switch is installed on the Tensioning System (39) of the Band Saw Blade (41), which pressed will stop the movement of the blade, coolant pump and hydraulic system, protecting the operator against risk of accident.

•

Thermal Relay FR1 (73) to protect the Motor M3 (74) against possible overloads on this component, forcing the stopping of the machine and disabling the electrical system;

•

Frequency Inverter INV (65) against short circuit and overload on the Motor M1 (22);

•

Fuses of protection FU1, FU2 e FU3 (70)(71)(72) in the input and output of Transformer TC (66) and FU4 (72) protecting the valves' coils of Hydraulic Unit (47).

All details of the systems that compose this machine will be described in their respective sections.

ATTENTION! RISK OF AMPUTATION OR SEVERE INJURY! The length of the Band Saw Blade (41) that perform the cu ng opera on between Guides (27) (30),obviously does not have protec on, then: NEVER touch machine moving parts with your hands or any other part of the body when it is in opera on, specially the Band Saw Blade (41).

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7. INSTRUCTION FOR USE AND OPERATION: Only qualified personnel with expressly authorized may operate and maintain this machine. These people must be trained according to the occupa onal safety standards, use PPE Personal Protec ve Equipment correctly, and be well informed on the contents of this manual.

7.1. OPERATION ADJUSTMENTS 7.1.1. CUUTTING ANGLE ADJUSTMENT

To cut in angle, above all, the operator should choose the correct value of the degree and the desired side of the cut. RIGHT SIDE ( from 0 to +75o ): With the Bow (24) at its maximum upper position, position Bow Rotation Lock Lever (42) to the left side to unlock the clamp system (figure 10A).Rotate the Bow (24) to right until the desired angle viewed in Angular Scale (79) in relation to the Pointer 0o (80) (figure 10B). . MAKE SURE if the Bow (24) is locking forcing the rota on. . CHECK if the Vise Set (36) is in the RIGHT side and locked (figure 05B); . OBSERVE if the Collector Tray (85) is installed as figure 05A. Then, lock the Bow (24), positioning the Lever (42) to right. LEFT SIDE ( de 0 a -45o ): With the Bow (24) at its maximum upper position, position Bow Rotation Lock Lever (42) to the left side to unlock the clamp system (figure 10A). After, remove the Stop Pin 0o (81) to allow the Bow (24) can rotate to the right side (figures 07, 10A and 12A). â&#x2013;ş REV.01 - JAN/12

S4240 - 220/380V - ING â&#x2013;ş

Rotate the Bow (24) to right until the desired angle viewed in Angular Scale (79) in relation to the Pointer 0o (80) (figure 10B). Next, unlock the Vise Lock Lever (43) position it of the left side. Position the Vise Set (36) to the right side, according to viewed in the figure 05B. Lock by Lever (43) the Vise Set (36). Electrically switch on the machine and start it to operate.

. MAKE SURE if the Bow (24) is locking forcing the rota on; . CHECK if the Vise Set (36) is in the RIGHT side and locked (figure 05B).

35 81 43 51 42 Figure 10A

80 Figure 10B

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S4240 - 220/380V - ING 7.1.2. CUTTING FEED HYDRAULIC ADJUSTMENT The Cutting Feed Regulator Valve (50), located on the Control Panel (20) modifies the descent speed of the bow (cutting feed) and allows retaining the bow in any position by closing the valve completely (figure 06 and 11). The best feeding can be determined by chip quality produced from material to be cut or by the procedures contained in the Band Saw Catalog (Chapter 8 this Instructions Manual) or by consulting of Starrett Technical Support. The movement of the bandsaw should be silent and with no vibration, and the chips must be wavy and shiny. The figure 11 indicates the Cutting Feed Regulator Valve (50), whose the sense of rise of feeding is indicated by red arrow of the left side. The clockwise indicates the rise of the feeding speed.In the 0 (ZERO) position the valve is closed and the Bow (24) stopped. Figure 11

7.1.3. BOW HEIGHT ADJUSTMENT: This machine allows the operator define and position the height that the Bow (24) will return after the cut of material. This reduces process time, especially in the serial cuts and continued, because the Band Saw Blade (41) will be positioned at least a minimum distance away from the material. PROCEDURE: 1. Position the material to be cut on the Cutting Table (35); 2. Loosen the Lever (63) leaving free the Trigger Plate (44) (figura 12A); 3. Lift the Bow (24) until the teeth of the Band Saw Blade (41) are 10 to 15 mm above the material to be cut.Make this movement by Buttons (11A or 11B), located on the Control Panel (20) (figure 06), in the MANUAL - Selector Switch (03) positioned in the left side; 4. Positioned the Bow (24) at the desired height, touch and press the Trigger Plate (44) on the Micro Switch Limit (14) (BOW UP) (figure 12B) in order to activate it. In this

REV.01 - JAN/12

â&#x2013;ş

S4240 - 220/380V - ING â&#x2013;ş position lock the Trigger Plate (44) by Lever (63); 5. Following, check by Buttons (11A and 11B) (MANUAL mode) if the Bow (24) stops in the adjusted and desired upper position; 6. If not, repeat the procedures from 1 to 5, to find the desired point.

44 Figure 12A

53 14

19 13

Figure 12B

REV.01 - JAN/12

S4240 - 220/380V - ING 7.1.4. CLAMPING OF MATERIAL The correct clamping of material to be cut can influence significantly in the operator safety, in the life of the band saw blade, in the quality and accuracy of the cutting. To the correct clamping. follow the procedure: 1. Open the Mobile Vise (27), to loose and to lift the Pawl Lock (83) that engages in the Rack Gear (58) (figure 05B) - MANUAL mode; 2. Position the material to be cut on the Cutting Table (35); 3. Manually, approach the Mobile Jaw (59) close to the material to be cut, leaving a space between 3 to 4mm; 4. Down the Pawl Lock (83) on the Rack Gear (58); 5. Press the CLOSE VISE Button (11B) - MANUAL mode; 6. Check if the material is properly clamped and without possible movements. For cases cutting in bundle, the material shall be clamped using a vertical vise device installed on the Mobile and Fixed Jaws (59) (60) - contact the Starrett. To make cuts in long bars or profiles, it is necessary to use Roller Tables (54) with height adjustment.The rollers must be aligned in the same level of the cutting table. It is recommended uses Roller Table to bar over 1 meter of lenght.

CLAMPING SYSTEMS OF THE RECOMMENDED MATERIAL(S):

â&#x2013;ş REV.01 - JAN/12

S4240 - 220/380V - ING â&#x2013;ş

7.1.5. REPLACE AND TENSION OF THE BAND SAW BLADE

ATTENTION!ACCIDENTS RISK To perform this opera on, wear appropriate leather gloves.

ATTENTION!ACCIDENTS RISK Only qualified persons authorized by the owner of machine can perform this opera on.These people must be trained according to the occupa onal safety standards, use PPE Personal Protec ve Equipment correctly, and be well informed on the contents of this manual.

To perform this procedure the Bow (24) should be at its maximum upper posi on. A er, the operator must press the EMERGENCY Bu on (04) and the General Switch (09) in the OFF posi on, un l the end of this adjustment of the sec on 7.1.5 . To obtain accurate cuts with good surface quality and to ensure operator safety, the bandsaw must be replaced at the right moment.A deteriorated bandsaw causes cut deviation, poor surface quality, and increases the consumption of power. One of the factors that determines cut quality and band saw useful life is the blade tension.

PROCEDURES: 32

REV.01 - JAN/12

S4240 - 220/380V - ING Close the Cutting Feed Regulator Valve (50) and lift the Bow (24) about 300 mm of the Cutting Table (35). Press the EMERGENCY Button (04) or disconnect electrically the machine of the electrical grid. Disassemble the Mobile Guide Protection (28), remove the Brush (38) and open the Bow Doors (25), releasing the Toggle Latches (57) (figures 03 and 07). Loosen the Band Saw Blade (41) by Tensor Handle (40), remove the blade of Flywheels (33)(34) and after of the Guides (27)(30) (figure 02). Insert a new Blade (41) in the guides and assemble it, firstly, on the Driver Flywheel (34) and after in the Driven (33). Tension it again until that the pointer of the Blade Pressure Gauge (56) reach the GREEN range between 2000 to 2500 Kg/cm2. Close the Bow Doors (25), install the Mobile Guide Protection (28) and the Brush (38). Electrically connect the machine, position in ON the General Switch (09) and start it by Control Panel (20). Lift the Bow (24) and adjust to cutting speed about to 10 m/min, viewed on the Indicator (01). Press The Blade Start Button (07) for few seconds, in order to make some turns. Press the EMERGENCY Button (04) and check if the blade is correctly positioned in the guides and on the Driven Flywheel (33), for this, open again the Bow Door (25) of side of the Driven Flywheel (33). If the band saw is away from 1,5mm of ledge of Driven Flywheel (33), or if the back of the blade is pressing much this ledge, the operator should perform an adjustment, according to instructions of section 13.2- Chapter of Maintenance.

OBSERVATION: The recommended limit is 25,000 PSI -pounds sq.inches (25kSI) or ~ 1750 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.

REV.01 - JAN/12

S4240 - 220/380V - ING 7.1.6 GUIDE OF BAND SAW BLADE The Band Saw Blade (41) is assembled on the Flywheels (33)(34), and inserted in the Guides (27)(30). The Fixed Guide (30) is mounted on the fixed support and the Mobile Guide (27) in the Mobile Support (37) (figure 04), which should be approached as much as possible of the material to be cut. The both supports have metallic protectors that cover the band saw and protect the operator against direct contact with the blade (figures 13A snd 13B).

28 41

Figure 13A

41 30 32 57

Figure 13B

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7.2. CONTROL PANEL - BASIC FUNCTIONS GENERAL SWITCH

ON – Enables electrically the machine

(09)

OFF – Disables eletrically the machine

EMERGENCY BUTTON (04)

CYCLE MAN/AUT (03) HYDRAULIC UNIT (06) BAND SAW START (07) (MANUAL mode) PILOT LAMP NO MATERIAL (17)

Pressed it will stop the blade motor, hydraulic unit motor and the coolant pump. Unlock the bu on to restart. SEMI AUTOMATIC – begin the cut, closing and opening automa cally the vise; MANUAL – this func on only to adjustment of machine START (GREEN Bu on illuminated) – Press it, start the motor of hydraulic system. START (GREEN Bu on) – When pressed, switch on the motor of Hydraulic Unit (47), allowing the movements of the Bow (24) and the Vise Set (36). RED color, when illuminated indicates that don't have material to be cut.

PILOT LAMP 24V (08)

WHITE color, when illuminated indicates that the electric system is switched on and the Control Panel (20) is supplied with 24VAC.

CUTTING SPEED SELCTOR POTENCIOMETER (02)

Select the cu ng speed turning the knob. The speed increases by turning it clockwise - from 20 to 85m/min.

CUTTING SPEED DISPLAY (01)

View the cu ng speed in m/min.

CYCLE START BUTTON (10A)

GREEN color, when pressed it start the cu ng cycle of material - close the vise, start the running of the blade, start the cu ng feeding, stop the cut, up the bow and open the vise - SEMI- AUTOMATIC mode.

CYCLE STOP BUTTON (10C)

RED color, when pressed it will stop the cu ng cycle of the material - will stop only the running of the blade motor, remaining the bow on posi on. The operator should set the Mode Selector Switch (03) in MANUAL.

OPEN VISE BUTTON (11A)

GREEN color, when pressed it will open the vise - MANUAL mode.

CLOSE VISE BUTTON (11B)

GREEN color, when pressed it will close the vise - MANUAL mode.

BOW UP BUTTON (12A)

GREEN color, when pressed it wil mve the bow to upper posi on - MANUAL mode.

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►

S4240 - 220/380V - ING â&#x2013;º

BOW DOWN BUTTON (12B)

GREEN color, when pressed it wil mve the bow to lower posi on - MANUAL mode.

SWITCH ON/OFF COOLANT MOTOR (18)

Switch 2 posi ons, which func on is ON and OFF the Coolant Pump (45) - SEMI-AUTOMATIC mode

Figure 14

12A 11A

10A

10B

10C

02 06

12B

11B

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S4240 - 220/380V - ING

7.3. COOLANT SYSTEM The coolant system is composed of a Coolant Pump (45), a Tank (84), installed inside of Cabinet (53) of machine (figure 15). The Pump (45) captures the coolant liquid from Tank (84) and send it through of the hoses to the Distributor (46) (figure 05B). This way, through other hoses, coolant is sent to both Guides (27) and (30). The quantity of coolant liquid that leaves the guides can be regulated by means of Taps (figura 13A). The emulsion coolant (cutting oil) ensures the blade cooling, a good disposal of wastes and avoid oxidation of the cut material. The Coolant Pump (45) is switched on or off automatically with the operation or stopping of Motor (22) of the blade, if the Switch (18) is in ON position. The level coolant liquid can be controlled through of the Oil Gauge (64) installed of rear side and external of Cabinet (53), as observed in the figure 15. Inside of Tank (84) has a reservoir of sediments that should be clean with regularly, preferably at each 2 days in the continuous use. To access the inside of Tank (84), remove the Filter Screen (86).

Figure 15

49 45

REV.01 - JAN/12

S4240 - 220/380V - ING 7.3.1. OIL OF CUTTING COOLING Use the cut cooling oils indicated for machines that operate with recirculating waterbased fluids. There are a large variety of cutting coolant oil, which can be vegetables, synthetics and semi-synthetics. However, the choice of product used is responsibility of the company that is the owner the machine, depending on the type of material to be cut, use conditions, the environment, environmental standards of each country, etc.The oil of cooling cutting must be handled by qualified persons..

ATTENTION!ACCIDENTS RISK NO INGEST the coolant liquid; AVOID contacts with the eyes; USE SAFETY GLASSES; HANDLE wearing appropriate protec on gloves; OBSERVE the environmental laws; DISPOSE the coolant, according to recommended by supplier of cu ng oil, and to be performed by a company duly authorized for this type of disposal service; KEEP away of children and animals.

ATTENTION!ALWAYS CHECK THE MANUFACTURERâ&#x20AC;&#x2122;S RECOMMENDTIONS!

7.4. HYDRAULIC UNIT The hydraulic unit is inside of cabinet of machine, wich allows the movements of the vise ( open and close ) and the bow ( up and down ), in the MANUAL mode as in the SEMI AUTOMATIC.

7.4.1. PRESSURE ADJUSTMENT OF MOBILE VISE The Hydraulic Unit (47) has the pressure factory set to 30 Bar, but is equipped with Pressure Regulator Valve 977) that allows to modify the pressure between 10 to 40 Bar. This feature reduces the pressure in necessary cases to cut tubes and profiles of very small thickness, which can be deformed by the pressure exerted by the vise. The pressure increase turning the Pressure Regulator Valve (77) in clockwise. In the opposite sense (counterclockwise), the pressure decrease. The figure 16 illustrates this instruction. The Hydraulic Pressure Gauge (75) allows to check the pressure in the Hydraulic Unit (47). The Oil Gauge (78) measures the level of hydraulic oil, and it is installed in the lateral of Tank (76). A Electric Motor M3 (74) is coupled with hydraulic pump and to mainfold set, which it is attached with directional valves of the system.

REV.01 - JAN/12

S4240 - 220/380V - ING When pressed the Button (06) in the Control Panel (20), the hydraulic unit switch off automatically if no command is activated, ie, after 15 minutes without operation of the machine.

7.4.2. TYPES OF HYDRAULIC OIL Use hydraulic oils according to recommended in the chapter. The maintenance operation of the hydraulic system and oil changes must be performed by qualified professionals.The Starrett uses PARAMOL HM 46 oil, and recommends the replacement before of 5,000 hours of operation. Safety conditions must be observed when handling hydraulic oils.

ATTENTION!DANGER OF ACCIDENTS: NO INGEST; AVOID contacts with the eyes; HANDLE wearing appropriate protec on gloves; OBSERVE the environmental laws for the disposal of this product; KEEP away of children and animals.

Figure 16 74

Figure 07 47

76 77

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S4240 - 220/380V - ING

ATTENTION! ALWAYS CHECK THE MANUFACTURER’S RECOMMENDATIONS

SpecificaƟon: Manufacture AGENA CASTROL ELF ESSO FUCHS GULF HOUGHTON IPIRANGA MARIS MICROQUÍMICA MOBIL PETROBRÁS ROCOL SHELL TEXACO TIRRENO UNI VALVOLINE REPSOL

HM 32 AGEFLUID AW 785/32 HYSPIN AWS 32 ELFONA 32 NUTO H32 RENOLIN B10 GULF HARMONY AW 32 HYDRODRIVE HP 32 IPITUR AW 32 HILLUS AW32 MICROFLUID AW32 MOBIL DTE 24 LUBRAX INDUSTRIAL HR-32-EP HO 32 TELLUS 32 RANDO HD32 TIRROIL AWSE 32 HIDRAMAX AW 32 HYDRAULIC AW 32 HIDRAULICO BP 32

With temperatures below +5 ° C should replace the oil type: PARAMOL H 46 by PARAMOL H 32.

REV.01 - JAN/12

HM 46 AGEFLUID AW 785/46 HYSPIN AWS 46 ELFONA 46 NUTO H 46 RENOLIN B10 GULF HARMONY AW 46 HYDRODRIVE HP 46 IPITUR AW 46 HILLUS AW 46 MICROFLUID AW 46 MOBIL DTE 25 LUBRAX INDUSTRIAL HR-46-EP HO 46 TELLUS 46 RANDO HD46 TIRROIL AWSE 46 HIDRAMAX AW 46 HYDRAULIC AW 46 HIDRAULICO BP 46

S4240 - 220/380V - ING

7.5. FIRST CUT ATTENTION! RISK OF ACCIDENTS This machine should be operated only by trained and qualified person for this purpose, and each one of them must OBSERVE all the Safety Recommenda ons and USE the PPEs. Before start any operation, check if the material to be cut is dully positioned. For heavy materials and with big difficulty of movement, use appropriate lifting device. To long material, use Roller Tables (54) (see section 7.1.4). To first cut. follow the procedure below: •

Position the General Switch (09) in ON, check if the EMERGENCY Button (04) is unlocked and press the Button (06) to start the hydraulic system in operation;

•

Adjust the equipement, positioning the Selector Switch (03) in MANUAL mode;

MANUAL MODE: •

Adjust the height of the bow (upper position), considering the height of the material to be cut (see section 7.1.3);

•

Position the bow in the desired cutting angle (see section 7.1.1);

•

Introduce the material to be cut in the vise and position it according to cutting lenght required. (It is possible move the vise to right and to left )(see section 7.1.4). Adjust the cutting length positioning the Stop (62) on the Measure Rod (61);

•

Adjust the Mobile Guide (27) in the distance as close as possible the material to be cut (see section 7.1.6);

•

Close completly the Cutting Feed Regulator Valve (50) (see section 7.1.2);

•

Select the cutting speed of the blade and position the Selector Switch (03) in SEMIAUTOMATIC mode;

SEMI-AUTOMATIC MODE: •

MAKE SURE that the material is dully fixed and the Lever (42) and (43) in LOCKED position (pad lock closed);

•

PRESS the Cycle Start Button (10A) (green) to start the cycle. The vise set will close, the blade will turn and the bow start move down after 2 seconds;

•

SELECT a correct descent speed of the bow (cutting feed) with the Cutting Feed Regulator Valve to get a good compromise between quality and life of cutting tool; REV.01 - JAN/12

S4240 - 220/380V - ING •

After finish the cut, the Bow (24) will move up to the previous preset position. The Mobile Vise (27) will open automatically;

•

REMOVE the cut part, REPOSITION the material, and start the cutting cycle again.

ATTENTION! RISK OF ACCIDENTS During the cu ng opera on, OBSERVE all Safety Recommenda on, keeping away from anyone outside the reach of the equipment and the operator remains in the posi on indicated previously.

ATTENTION! Missing material to be cut during the begining of cu ng cycle, a RED Lamp (10C) will illuminate, indica ng this occurrence, preven ng the machine to start the cycle.

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S4240 - 220/380V - ING

8. BAND SAW BLADE SELECTION: 8.1. LIMITS AND RECOMMENDATIONS Before starting any kind of operation with the machine, check if the service to be performed is within the limits specified in the Technical Data (see Chapter 4).If not, it is recommended to communicate in writing to Starrett regarding the possibility of changing any 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 capacitiesbilities of the machine, the selection of the blade will be another important aspect to improve the cutting performance.

8.2. CRITERIA FOR BAND SAW BLADE SELECTION: To choose correctly a blade for a given application should be considered some factors:type of material, hardness, cutting section, capacity of the machine itself, etc. Four basic variables exist in selecting the band saw blade: 1.

Blade Type;

Tooth Shape;

Pitch;

Cutting Feed and Blade Speeds;

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S4240 - 220/380V - ING 8.2.1. TERMINOLOGY

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.

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S4240 - 220/380V - ING 8.2.2. TEETH SHAPES

Constant Pitch

Variable Pitch

INTENSS .8-1.3 to 14-18

1-1.2 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 speci cally 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.

INTENSS PRO-VTH

VERSATIX MP

REGULAR 6 to 32

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, dif cult to machine materials.

HOOK

SKIP

ADVANZ FS & TS (Carbide Tipped)

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

.9-1.1 to 3-4

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S4240 - 220/380V - ING 8.2.3. CHARACTERISTICS

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.

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S4240 - 220/380V - ING 8.2.4. BLADE SELECTION IN 5 STEPS

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

TOOTH SHAPE

WOOD & PLASTIC Woodpecker™ Premium or Woodpecker XF™

Regular - A conventional tooth used for general purpose sawing, straight or zero rake.

FOAM, PAPER PRODUCTS & RUBBER Band Knives

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.

FRESH OR FROZEN MEAT OR FISH (WITH OR WITHOUT BONES) Meatkutter™ Premium or Meatkutter™ Stainless

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.

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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)

5/320 - 3/80

32 or 24

14-18

1/40 - 1/20

18 or 14

10-14

1/20 - 3/40

14 or 10

8-12

3/40 - 10

10 or 8

6-10

10 - 1-1/20

8 or 6

5-8

1-1/20 - 3-1/20

6 or 4

4-6

3-1/20 - 70

4 or 3

3-4

70 - 100

2-3

100 - 160

1.4-2

140 - 200

1-2

160 - 320

1-1.2

Over 300

.8-1.3

Wall Thickness

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

(Inch)

3/80

3/40

1-5/80

2-3/80

3-1/40

4-3/40

120

160

200

240

3/320

14-18

10-14

8-12

6-10

5-8

1/80

10-14

8-12

6-10

5-8

5/320

8-12

6-10

5-8

4-6

3/160

6-10

5-8

4-6

1/40

5-8

4-6

3-4

5/160

4-6

3-4

3/80

4-6

3-4

2-3

1/20

4-6

3-4

2-3

5/80

4-6

3-4

2-3

3/40

4-6

3-4

2-3

3-4

2-3

1.4-2

1-1/40

3-4

1-5/80 20

3-4

2-3

1.4-2

3-4

2-3

1.4-2

3-4

2-3

1.4-2

1-2

2-3

1.4-2

1-2

2-3/80

REV.01 - JAN/12

S4240 - 220/380V - ING

The Starrett line of band saw blades has been extensively revised, with several completely new blade lines including Versatix™ MP, Advanz™ CS, Advanz™ FS and Advanz™ TS. Our new family of blades offers exceptional performance solutions for virtually any band saw cutting requirement.

FOOD INDUSTRY

SOFT PLASTIC

BUTCHERS

PAPER

CATERING

FOAM

MEAT PACKERS

RUBBER

Low Alloy Steels Aluminum Stainless Steel Tool, Die & Mold Steels Carbon Steel Structural Steels Steels up to 45 HRc Nickel Based Alloys Non Ferrous Metals Case Hardened Chrome Shaft Wood Nail Embedded Wood Furniture Composition Board Plastic Acrylic Ceramic Glass Porcelain Fiberglass Stone Marble Granite Foam/ Fibrous Material Rubber Paper Meat Primary Application Secondary Application

REV.01 - JAN/12

Band Knives

Meatkutter™ Premium & Stainless

Woodpecker XF™

Woodpecker™ Premium

(Replaces Friction Cutting)

Duratec™ FC

(Replaces Flex-Back)

Duratec™ FB

Duratec™ PH

(Replaces Premium Hard-Back)

Advanz™ DG

(Replaces Diamond Grit)

(Replaces Carbide Grit)

Advanz™ CG

Advanz™ TS

(Replaces Carbide Tipped Type III)

Advanz™ FS

(Replaces Carbide Tipped Type I)

NEW PRODUCT

Advanz™ CS

Univerz™

(Replaces Portaband bi-metal unique®)

NEW PRODUCT

Versatix™ MP

(Replaces Gladiator Emperor)

Intenss™ PRO-ST

Intenss™ PRO-VTH

(Replaces Gladiator Pulsator)

(Replaces Die-Pro 1/4" - 1/2")

Intenss™ PRO-DIE

(Replaces Gladiator 3/4" - 3-1/8")

MATERIAL CUTTING GUIDE

Intenss™ PRO

8.2.5. PRODUCTS

S4240 - 220/380V - ING â&#x201E;˘

Replaces Gladiator Ideal for intensive production cutting operations across a wide range of metals.

Features Positive rake angle tooth design and variable pitch for optimum cutting efficiency in high-production cutting operations. Triple tempered M-42 cobalt high speed steel teeth combined with a fatigue resistant alloy steel backing strip.

Benefits Easy penetration, excellent chip clearance and reduced noise levels. High quality surface finish and faster, straighter cuts.

Applications Steels up to HRc 45. Tool and stainless steels. Nickel based and non-ferrous alloys.

Intenssâ&#x201E;˘ Pro (replaces Gladiator) Blade Width x Thickness

Blade Pitch with Material Numbers (all are Positive Rake)

Inch

.8-1.3/P

3/40 x .0350

19 x 0.90mm

10 x .0350

25 x 0.90mm

1-1/40 x .0420

32 x 1.10mm

1-1/20 x .0500

38 x 1.30mm

20 x .0630

50 x 1.60mm

99928

2-5/80 x .0630

67 x 1.60mm

3-1/80 x .0630

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

3/40 to 1-1/40 sizes available in 2509 (76m) coils. 1-1/20 to 20 sizes available in 1509 (45m) coils. 2-5/80 and larger available in welded bands only.

SOLID

TUBULAR

STRUCTURAL

BUNDLE

REV.01 - JAN/12

S4240 - 220/380V - ING

™

Replaces Die Pro bi-metal unique

Features: Triple tempered M-42 cobalt high speed steel teeth combined with a fatigue resistant alloy steel backing strip. Longevity and chip clearing advantages of bi-metal unique® saw technology. Available in a variety of tooth pitches up to a maximum width of 1/20.

Benefits: Ideal for contour and general purpose cutting. Resists heat, abrasion and shock, allowing faster cutting rates.

Applications: Horizontal and vertical machines. Tool, die and mold steels. Stainless steels. Nickel based and non-ferrous alloys.

Intenss™ Pro-Die (replaces Die Pro bi-metal unique) Blade Width x Thickness Inch

1/40 x .0250

6.5 x 0.65mm

Blade Pitch with Material Numbers 3/P

4/P

6/P

6-10/P

8-12/P

10/S

99032

10-14/P 10-14/S

14/S

14-18/W

18/W

24/W

99190

99173

99174

99188

99185

99079

99080

1/40 x .0350

6.5 x 0.90mm

99051

99078

99090

3/80 x .0250

10 x 0.65mm

99092

99122

99124

99125

3/80 x .0350

10 x 0.90mm

99093

99091

99127

1/20 x .0200

13 x 0.50mm

1/20 x .0250

13 x 0.65mm

1/20 x .0350

13 x 0.90mm

99087

99095 99175

99138

99143

99151

99102

99165

99144

99152

99154

99167

99172

99186 99176

99178

99181

Available in 1009 (30m) coils. P: Positive Rake. W: Wavy Set, Zero Rake. S: Straight (Zero) Rake.

SOLID

TUBULAR

STRUCTURAL

BUNDLE

REV.01 - JAN/12

S4240 - 220/380V - ING

™

Replaces Gladiator Pulsator High performance bi-metal band saw blade with a uniquely designed tooth edge that allows the teeth to cut in a fast, pulsating action.

Features: Triple tempered M-42 cobalt high speed steel teeth combined with a fatigue resistant alloy steel backing strip. Aggressive “surging” cutting action created by variable tooth height and set. Ground teeth for maximum blade performance.

Benefits: Ideal for the production cutting of a wide range of materials. Excellent heat and wear resistance.

Applications: Exotic and nickel based alloys. High hardness steels. Other solids.

Intenss™ Pro-VTH (replaces Gladiator Pulsator) Blade Width x Thickness

Blade Pitch with Material Numbers (all are Positive Rake/Tapered)

Inch

1-1.2P/T

2-3P/T

3-4P/T

10 x .0350

25 x 0.90mm

99948

99949

99950

1-1/40 x .0420

32 x 1.10mm

99953

99954

99956

1-1/20 x .0500

38 x 1.30mm

99958

99959

99989

1-2P/T

1.4-2P/T

99990

20 x .0630

50 x 1.60mm

99991

99961

99967

2-5/80 x .0630

67 x 1.60mm

99992

99968

99969

3-1/80 x .0630

79 x 1.60mm

99993

99987

99988

4-6P/T

10 & 1-1/40 sizes available in 2509 (76m) coils. 1-1/20 & 20 sizes available in 1509 (45m) coils. 2-5/80 and larger available in welded bands only.

SOLID

TUBULAR

STRUCTURAL

BUNDLE

REV.01 - JAN/12

S4240 - 220/380V - ING

™

NEW Patent-pending design developed and tested by Starrett, Versatix™ MP band saw blades set new standards in cutting structural steels, sections, tubes and small solids. The new tooth design ensures that the blades can easily cope with the shock loading conditions associated with intermittent cutting and uncontrolled feed rates.

Features: New tooth design resulting in a significant increase in tooth strength and consequent reduction in tooth strippage. Triple tempered M-42 cobalt high speed steel teeth combined with a fatigue resistant alloy steel backing strip.

Benefits: Ideal for use on manual “pull down” band saw machines where uncontrolled feed rates can easily overload the teeth with a standard blade.

Applications: Sections. Structurals. Tubes and small solids.

Versatix™ MP - NEW Blade Width x Thickness Inch

3/40 x .0350

19 x 0.90mm

10 x .0350

27 x 0.90mm

Blade Pitch with Material Numbers 2-3/P

3-4/P 99343

4-6/P

5-8/P

99212

99211

99210

99342

99341

99340 99498

1-1/40 x .0420

34 x 1.10mm

99494

99495

99496

99497

1-1/20 x .0500

41 x 1.30mm

99517

99518

99519

99520

20 x .0500

54 x 1.30mm

99551

99552

20 x .0630

54.5 x 0.62mm

99562

99563

2-5/80 x .0630

67.5 x 0.62mm

99564

99565

6-10/P

3/40 to 1-1/40 sizes available in 2509 (76m) coils. 1-1/20 & 20 sizes available in 1509 (45m) coils. 2-5/80 available in welded bands only. With Exclusive Starrett Structural Tooth Design.

SOLID

TUBULAR

STRUCTURAL

BUNDLE

REV.01 - JAN/12

S4240 - 220/380V - ING

™

Replaces Carbide Tipped Type I Advanz™ FS is made for sawing tough materials that bi-metal blades cannot cut.

Features: Teeth ground from high quality micro-grained carbide cylinders welded to a tough, ductile backing material. Improved carbide to back bonding. Triple chip tooth geometry.

Benefits: Exceptional resistance to fatigue, shock and wear.

Advanz™ FS (replaces Carbide Tipped Type I)

Improved tooth strip resistance. Smooth finish. Faster cutting speeds.

Applications: Aluminum castings. Fiberglass. Masonite. Plastics.

Blade Width x Thickness

Blade Pitch with Material Numbers 2-3/P

Inch

3/40 x .0350

19 x 0.90mm

10 x .0350

25 x 0.90mm

10 x .0500

25 x 1.30mm

92553

1-1/40 x .0420

32 x 1.10mm

92513

1-1/40 x .0500

54 x 1.30mm

92555

All sizes available in 1509 (45m) coils.

Composite materials. Abrasive wood.

SOLID

TUBULAR

STRUCTURAL

BUNDLE

REV.01 - JAN/12

3/P 92550

92507

92552

S4240 - 220/380V - ING

™

Replaces Carbide Tipped Type III Advanz™ TS is made for sawing tough materials that bi-metal blades cannot cut.

Features: Teeth ground from high quality micro-grained carbide cylinders welded to a tough, ductile backing material. Improved carbide to back bonding. Triple chip tooth geometry.

Benefits: Extreme resistance to heat and wear. Smooth surface finish. Improved strip resistance. Superior durability. Advanz™ TS offers exceptional resistance to fatigue, shock and wear.

Applications: Difficult to machine steels. High-alloy metals. Titanium. Stainless steel. Inconel.

Advanz™ TS (replaces Carbide Tipped Type III) Blade Width x Thickness Inch

3/40 x .0350

19 x 0.90mm

Blade Pitch with Material Numbers .9-1.1/P

1/P

1.3/P

1.4-2/P

2-3/P

10 x .0350

25 x 0.90mm

1-1/40 x .0420

32 x 1.10mm

92515

1-1/40 x .0500

32 x 1.30mm

92522

1-1/20 x .0500

54 x 1.30mm

92519

92521

92516

20 x .0630

50 x 1.60mm

92558

92559

92528

2-5/80 x .0630

54 x 1.30mm

92560

92561

92530

3-1/80 x .0630

79 x 1.60mm

92562

92531

3/P

3-4/P

92500

92503

92504

92509 92517

92512

92563

3/40 to 1-1/20 sizes available in 1509 (45m) coils. 20 sizes available in 1009 (30m) coils. 2-5/80 and larger available in welded bands only. With Exclusive Starrett Structural Tooth Design.

SOLID

TUBULAR

STRUCTURAL

BUNDLE

REV.01 - JAN/12

S4240 - 220/380V - ING 8.2.6. RECOMENDATIONS

BAND SAW BLADE INSTALLATION 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.

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.

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.

Follow the saw blade installation instructions for the make and model of the band saw machine.

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.

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. c Wear

gloves when handling band saw blades.

Wear eye protection, safety shoes, and hearing protection.

FOLLOW INSTRUCTIONS CAREFULLY c

BASIC BLADE CHANGE GUIDELINES

REV.01 - JAN/12

S4240 - 220/380V - ING

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.

START TO CUT MATERIAL AT REDUCED CUTTING RATE

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

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

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.

REV.01 - JAN/12

S4240 - 220/380V - ING 8.2.7. CUTTING CALCULATION

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

REV.01 - JAN/12

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

S4240 - 220/380V - ING 8.2.8. PROBLEMS SOLUTION

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

Back of tooth indicates spinning in vise.

Irregular Break

Blade not high enough before index

Adjust height selector

Saw head drifts into work while neutral

Check hydraulic cylinder

Indicates material movement.

REV.01 - JAN/12

S4240 - 220/380V - ING

Blade Effect

Probable Cause

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.

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

REV.01 - JAN/12

S4240 - 220/380V - ING

9. TRANSPORTION INSTRUCTIONS:

ATTENTION: . To install correctly this machine itÂ´s necessary, a er removing it from packaging, READ CAREFULLY this Instruc ons Manual, during the machine operaon and on maintenance ac ons. . Only persons trained and qualified for this of opera on of handling opera on are authorized to perform this service.

When the machine leaves the factory, itÂ´s fixed on a wooden pallet, which allows it to be carried by a lift truck or other moving system. These equipments of transport must have the capacity to support the 700Kg (Gross Weight) of machine. Thereafter, the machine must be lifted just the minimum required to move it. During this operation must be observed the safety conditions.

OBSERVATION and ATTENTION! 1. Use li ing equipment capable and with resistence enough to support the weight of machine of 700Kg; 2. The user should make sure that the pallet is intact, before to start the lifng; 3. Make sure that the machine is well balanced during the li ing opera on; 4. Li the machine the minimum required to enable moving the same; 5. Do not permit that the machine shake during the transport.

REV.01 - JAN/12

S4240 - 220/380V - ING

REV.01 - JAN/12

S4240 - 220/380V - ING

10. INSTALLATION INSTRUCTIONS: 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 (04), the General Switch (09), Moto Reducer (22) (23), the Coolant Pump (45), the Vise Set (36), the Levers (42)(43) and the Handle (40). Check also for the condition of the Cabinet (53), Mobile Guide (27), Control Panel (20), etc

–

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

ATTENTION! ALWAYS OBSERVE the Safety Recommenda ons when install the machine.

REV.01 - JAN/12

S4240 - 220/380V - 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 qualified persons for this kind of service. Also, must be observed the electrical diagram, in this Manual, that electrical connection to be properly made. Before connecting the machine in the electric line supplier, check: 1.

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

If user’s main electric line has the same voltage (V) and frequency (Hz) as required by machine.

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 Starre must be advised of it, so that components can be replaced, by its decision, under warranty or not, the Motor M1 (22), the Motor M3 (74) of hydraulic unit, the Coolabt Pump (45), the Frequency Inverter INV (65), the Thermal Relay FR1 (73), 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 6,0 mm2.

In the extremity of electric cable must be installed a plug with 5-pins, being 3 used for phases R, S and T,the fourth pin for Grounding (Earth) e and fifth to NEUTRAL, always conform specifications and recommendations of manufacter of plug. When the installation of plug is ready, connect in the user´s electric line. Immediately, a Pilot Lamp (08) (WHITE) in the control panel will light indicating that machine is switch on.

REV.01 - JAN/12

S4240 - 220/380V - ING Then, turn the Selector Switch (03) to MANUAL mode, and press the Button (06) to start the Hydraulic Unit. Press the Buttons (11A) or (11B) to check if the Bow (24) is moving according to commands. If no adequate answer, permute 2 of the 3 power wires (R, S, T) and make a new checking, until the commands answer properly.

OBSERVATION: Make sure if the Band Saw Blade (41) is running in the same sense as indicated in the Plate (26), located on the Bow (24) according to figure 04.

ATTENTION: For the electric installa on, use the following color codes or numbering: Color of CABLE YellowGreen

CABLE function GROUND

Black 1

Black 2

Black 3

Blue

NEUTRAL

– 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 electric panel with a three-pole thermomagne c switch (circuit breaker) of 30A and a diﬀeren al of 40A with a 0.3A sensi vity at 220V.

WARNING (IMPORTANT INFORMATION): NEVER PERFORMANCE any welding operation (common electric weld type, MIG or TIG) with the machine switched on, or connected to electrical grid, with General Switch (09) in ON, Pilot Lamp (WHITE) (08) illuminated.

NO USE the machine itself as a point of grounding welding equipment. Even with the machine without the above condiƟons, 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.01 - JAN/12

S4240 - 220/380V - 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 (84). Drain all liquid and do not dispose of it in the environment;

Remove completely all chips contained in the Tank (84) and on Cabinet (53);

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 Chapter 9 - TRANSPORT INSTRUCTIONS this Instructions Manual;

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.

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S4240 - 220/380V - ING

11. SYSTEMS: 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 3 three phases motors, being the Blade Motor M1 (22), M2 (74) of Hydraulic Unit and M3 (47) of Coolant Pump(45), dully sized, according to working capacity of it. A General Switch QS1 (09) of the isolator type is installed in the input of circuit to disable it, when the door of Electric Box (21) is opened to maintenance (figures 06 and 08). Two Contactors KM2 (67) and KM3 (68) have the function to start the Motors M2 (74) and M3 (45), when the Button SB2 (06) and the Switch SA2 (18) are actuated, respectivelly. The Motor M1(22) of blade is protected by Frequency Inverter INV (65) and the Motor (74) of hydraulic unit by Thermal Relay FR1 (73). A Transformer TC (66), dully sized, it has the function to reduce the voltage to command line of control panel to 24VAC, i.e., to extra low voltage. This transformer is protected by 2 Fuses FU1 (69) and FU2 (70) in input and 1 Fuse FU3 (71) in the ouput. As a safety device, the machine presents a EMERGENCY Button SB1 (04) installed in a visible position and accessible to the operator in case of abnormality. In addition, in the back position of the Bow (24) ĂŠ installed 2 Micro Switches SQ1 and SQ2(16) (figure 03), of the electromechanical, that disable all the electric circuit when the Doors (25) are opened. Also, by a Selector Switch SA3 (03) of 2 positions type, it has a function to select the operation mode of machine: MANUAL or SEMI AUTOMATIC A Micro Switch SQ14 (13) installed beside of Hydralic Unit (47) has the function to switched off automatically the machine at the end of cut, i.e., when the Bow (24) is in the lower position. Other Micro Switch SQ5 (14) stop the machine when the Bow (24) is in the upper position. The solenoid valves of Hydraulic Unit (47) are protected by Fuse FU4 (72). All components have EC mark, certified as IEC european standars.

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HYDRAULIC UNIT MOTOR

COOLANT PUMP MOTOR

68 BAND SAW BLADE MOTOR

INV

220 / 24VAC

S4240 - 220/380V - ING

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S4240 - 220/380V - ING

SOLENOID VALVE BOW DOWN

SOLENOID VALVE BOW UP

SOLENOID VALVE OPEN VISE

SOLENOID VALVE CLOSE VISE

BOW DOWN

BOW UP

OPEN VISE CLOSE VISE COOLANT PUMP

SB3

TIMER SEMI AUTOMATIC CYCLE CYCLE PILOT LAMP

HYD. UNIT PILOT LAMP

HYDRAULIC UNIT 24V PILOT LAMP

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S4240 - 220/380V - ING ELECTRIC COMPONENTS:

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11.2. HYDRAULIC SYSTEM: The S4240 has a hydraulic system responsable by power of movements of the Bow (24) and the Vise Set (36). This system is composed of a Hydraulic Unit (47) installed inside the Cabinet (53) (figure 16), by Hoses (52), by Bow Cylinder (48) (figure 07) and by Vise Cylinder (51) (figure 03). The Hydraulic Unit (47) is composed of the Hydraulic Oil Tank (76), a mainfold set that incorpores the solenoid valves, pump and the Motor M2 (74). By Buttons on the Control Panel (20) can command the movements of the Bow (24) and the Vise Set (36).

VISE CYLINDER (51) VISE CYLINDER (48)

PILOT CHECK VALVE SOLENOID VALVE 2D2 - 24VAC B

A A

B P

SOLENOID VALVE 3C4 - 24VAC

HYDRAULIC PRESSURE GAUGE (75)

ADJ PRESSURE VALVE (77)

OIL FILTER CAP

PUMP M2

FILTER TANK ( 76)

MOTOR M2 (74)

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12. MOTO REDUCER: A S4240 was developed with a moto reducer system composed of a Gear Box (23) connected with a Motor 1 (22) three phase. This motor is controled by a Frequency Inverter (65) that alows the moto reducer set vary its rotation in the output shaft of Gear Box (23), i.e., in the Driven Flywheel (34).

12.1. OPERATING PRINCIPLE: The Gear Box (23) is the WORM type, with oil lubrication. The Motor M1is of 4 poles, three-phases, of 2 voltages: 220 or 380V in the frequencies of 50 or 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 80ยบC.Within this range, neither its performance nor that of the motor will be impaired.

12.2. MAINTENANCE INSTRUCTIONS: Assembling and Disassembling the Gear Box Reducer For assembly and disassembly of the moto reducer should follow these instructions (Observe figure17). 1.

Before any maintenance operation, make sure that the machine is switched off with the General Switch (09) in OFF position and the EMERGENCY Button(04) locked;

Disconnect the cables of Motor (22) observing and noting the wiring diagram to avoid mistakes of assembly later;

Release the screws that attach the Motor (22) in the Gear Box (23);

On the inner side of the Bow (24), remove the Driver Flywheel (34), releasing it by removal of the central bolt;

Without the Driver Flywheel (34), release the screws that fix the Gear Box (23);

With care, remove the Gear Box (23) of the Bow Set (24);

Make the maintenance necessary, and if to drain the oil contained in the gear box, avoid to drop it in the envioronment - Replace each 6 month;

After the maintenance necessary, remake the assembly of the Gear Box (23), following the opposite steps of the disassembly; REV.01 - JAN/12

S4240 - 220/380V - ING 9.

Assemble the Driver Flywheel (34) in the tip of Reducer (23) shaft. Check the tighten of the bolt;

10. Assemble the Motor (22) in the Gear Box (23), 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 17

Bolt of Gear Box in the Bow

Bolt of Driver Flywheel

Bolt of Motor in the Reducer

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13. MAINTENANCE AND CONTROL 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 (33) (34) and from the Guide set (27)(30) on daily basis;

–

Periodically (at least each 2 days) clean the Tank(84) of cutting coolant liquid. Complete or change, if necessary, the emulsion of coolant liquid in the Tank (84) and keep the level;

–

At given intervals during the day, remove chips from Vise Set (36) and Cabinet (53);

–

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 (24) in the lower position, without material to be cut on the Cutting Table (35)

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S4240 - 220/380V - 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 (41), the machine completely disabled electrically, the Bow (24) 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 (27)(30). Lateral Bearings Adjustments: (figures 18A and 18B)

ATTENTION: DANGER OF INJURIES! All repairs and adjustments required a qualifi ed and trained person to perform any opera on on the machine, and necessarilly must be pressed the EMERGENCY Bu on (04) and the General Switch (09) posiĆ&#x;oned in OFF. It is recommended to use the Technical Suppor Starre , to specialized repair.

MONTHLY, during cleaning of Guide Sets (27)(30), the Lateral Bearings (31), Rear Bearings (95) and the Carbide Plates (32) must be adjusted, in order to improve the performance of the cutting process. With the machine electricaly in off, according to observed above, put the Bow (24) in upper position.Relieve the tension of Band Saw Blade (41), as section 7.1.5. Procedure to adjust the Carbide Plate (32): 1. After the procedure of cleaning of Guides (27)(30), loose the Lock Nut (88) (figure 18B); 2. With the help of an allen key tighten the Screw (89) in order to touch the Carbide Plate (32) against the side of the Blade (41); 3. Then, lock the Screw (89) with the Lock Nut (88). Procedure to Adjust of the Lateral Bearings (31): 1. Release the Lock Nuts (90) and loose the Screws (91); 2. With the help of a wrench, turn the nut of the Eccentric Shaft (87), ALWAYS clockwise as shown in figure 18A, until Lateral Bearings (31) touch completely the lateral of the Blade (41).The gap between the Lateral Bearings (31) must be from 0.90 to 0.95mm.. The pressure of Lateral Bearing (31) on the Blade (41) NOT can be excessive, as

REV.01 - JAN/12

S4240 - 220/380V - ING 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; 3. In following, tighten the Screw (91) and lock it with Lock Nut (90), otherwise will get the chance to loose and leave the Lateral Bearing (31) free, may be generating future problems.

Figure - 18A - LATERAL BEARING Adjustment

Fixed Wrench

18 or 19

27 or 30

Adjustment Nut 31 Adjustment Nut

ATTENTION: DANGER OF INJURIES! 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 (04) pressed and the General Switch (09) in OFF.

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S4240 - 220/380V - ING Procedure to adjust of Rear Bearing (95): It should be observedDAILY the position of the Rear Bearing (95) against the back of the Band Saw Blade (41). 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 (92) (figure 18B), moving up or down the Guide Sets (27) or (30), installed in the Guides Support (37) or (93) (figures 13B and 07), respectivelly. Also check the height of Protection of Fixed Guide (94) in relation to the teeth of the Band Saw Blade (41), ie, the protection to cover the teeth, not to be exposed.

Figure 18B

89 88

87 31

95 87

32 92

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S4240 - 220/380V - ING

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 (41) running on the Driven (33) and Driver Flywheel (34) should touch lightly in the ledge these flywheels. For this, the camber adjustment of Driven Flywheel (33) can relieve the pressure of the blade on the ledge. PROCEDURE: 1. Disconnect the machine from the power grid, keep the Bow (24) in upper position; 2. Position the General Switch (09) in OFF and the EMERGENCY Button (04) pressed; 3. With Allen screwdriver, loosen ( relieve the tighting ) the Screws A, B e C, without removal them from Tensioning System (39); 51

4. By screw D, adjust the camber of Driven Flywheel (33), 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 to 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 Selector Switch (03) in the MANUAL mode. Then, switch on the machine, position in ON the General Switch (09) and pull the EMERGENCY (04) Button; 6. Check if the tension of the blade is correct; 7. With light touches on the Button (07), run the Motor (22) of band saw blade; 8. Open the Doors (25) of the Bow (24) and check the position of the blade's back against the ledges of Flywheels (33)(34); 9. As reference measure the back of the blade should be 0.2 to 0.5 mm from the ledges of the flywheels;

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S4240 - 220/380V - ING 10. If it maintain beyond these measures, close again the Doors (25) and repeat the procedure from 1 to 8; 11. Reaching the measured according to item 9, close the Doors (25), 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.

LEDGE

D 24

B 33

D 39

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S4240 - 220/380V - ING

13.4. BOW 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 (48) is required for some safety procedures to avoid any risk to user. PROCEDURE: 1. Disconnect the machine from the power grid, keep the Bow (24) in lower position; 2. Position the General Switch (09) in OFF and the EMERGENCY Button (04) pressed; 3. With the Cylinder (48) fully retracted, remove and replace it, loosening their respective bolts that fix it; 4. NEVER try work with machine without the Cylinder (48) properly installed, as this can cause risks and damages to the operator or to the equipment; 5. With the Cylinder (48) installed, connect electrically the machine and test it, if the machine is performing adequately.

13.5. SPRING SET REPLACEMENT ATTENTION: Only qualified persons authorized by the owner of machine can perform this opera on. For replacement and repair of the Spring Set (49) is required for some safety procedures to avoid any risk to user. PROCEDURE: 1. Lift the Bow (24) until the upper position; 2. Disconnect the machine from electrical grid; 3. Position the General Switch (09) in OFF and the EMERGENCY Button (04) pressed; 4. With some device, lock the Bow (24) in the upper position, because if there is REV.01 - JAN/12

S4240 - 220/380V - ING some loss of pressure within of Bow Cylinder (48), the bow set will remain safe in the top. 5. Relieve completely the tension of Spring Set (49) by nuts that stretch them; 6. Disassemble the set and replace the items necessaries; 7. Assemble again the Spring Set (49) and give tension in the springs; 8. Remove the device of safety of the bow; 9. Electrically connectar the machine and put it in test to check if it is performancing adequately.

13.6. MAINTENANCE TABLE DescripĆ&#x;on

Freqquency

AcĆ&#x;on

Clean the guides (Bearings and Carbide Plate)

Daily

Clean with Micro Oil M1, or coolant liquid andor compressed air

Check the wear of Carbide Plate (clearance)

Monthly

Measure with a feeler gauge

Check the gear box lubricant

Half yearly

Replace

Check the gear box lubricant

Daily

Complete

Check the level of tank with coolant liquid

Daily

Complete

Clean the Doors of the Bow and the

Daily

Clean

Flywheels grease

Weekly

Lubricate flywheel sha of flywheels with

Check the band saw blade tension

Daily

Adjust

Clean the surface of cu ng table, vise and others surfaces of machine

Daily

Clean

Check the Spring Set

Monthly

Replace, if necessary

Tensioning system

Monthly

Grease and adjust

Band Saw Blade

Daily

Replace if necessary

Check the oil in the hydraulic tank

Monthly

Complete

Hydraulic Oil

Half yearly

Replace

Check the oil filter

Half-yearly

Replace if necessary

Monthly

Replace if necessary

Check the hydraulic hoses

each 3 years

Replace

Check the seals of cylinders

Monthly

Replace if necessary

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S4240 - 220/380V - ING

13.7. PROBLEMS, CAUSES AND SOLUTIONS Problem

Cause

24V Pilot not light Press the Cycle Switch the Blade no run

• General Switch posi oned in OFF • Fuse FU1, FU2 and FU3 burnt • Hydraulic Unit switched oﬀ • EMERGENCY pressed • Bow Doors opened • Bow down no press the Micro Switch • No Material • Vise no adjusted-Material loose • Irregular or crooked material • Length greater than specified of the blade • Slide on the Flywheels • Rupture of Driver Flywheel Sha

Pilot Lamp RED lighted - NO MATERIAL Blade Motor run, but the blade no No coolant o liquid arrives at the guides Rupture of blade's teeth

SoluƟon

• Tank is empty or low level • Dirty circuit • Motor is broken • It was not make break in in the blade • Excessive cu ng feed • Incorrect teeth

Cracks appear on the of the blade

• Blade no adjusted on the Flywheel • Excessive pressure of rear bearing • Mobile Guide Support too close to Driven Flywheel • High tension in the blade

Rupture on upper part of the blade

• Material to be cut no clamped • Mobile Guide Support too close of Driven Flywheel • High tension in the blade

Cracks appear in the gullet of the teeth

• Teeth too worn for the sec on to be cut • Excessive cu ng feed

REV.01 - JAN/12

• Posi on in ON • Replace • Switch on Hydraulic Unit • Unlock it • Close them correctly • Adjust the Micro Switch • Supply with Material • Clamp correctly the material • Improve the clamping • Replace (3490 x 27 x 0,9mm) • Tension correctly • Make maintenance of gear box • Fill it • Clean the circuit • Check and replace necessary • Make break in • Reduce the cu ng feed speed be cut • Choose the appropriate teeth for the sec on of material • Adjust the posi on • Posi on correctly in guides in the ver cal plan • Posi on as close as possible of the material •Apply tension according to the recommended values • Clamp it correctly • Posi on it as close as possible of material • Apply tension according to the recommended values • Choose an appropriate blade to sec on to be cut • Reduce the cu ng feed speed

S4240 - 220/380V - ING

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S4240 - 220/380V - ING

14. SPARE PARTS: 14.1. CABINET SET AND HYDRAULIC UNIT

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14.2. VISE SET AND SWIVEL SUPPORT

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14.3. BOW SET AND MOTO REDUCER

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14.4. GUIDES SET

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14.5. HYDRAULIC SET

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APENDIX OIL TO LUBRICAT AND CLEANING THE GUIDES Product: Micro-Oil Prevents Rust M1

Manufacter: Starrett

SpecificaĆ&#x;on: Color

Amber (clear)

Odor

pleasant

Specific Gravity

0,788 to 60 oF (15,5C)

Viscosity

2,2 cSt (cen Stokes) connverts to 10,5 SUS

Lubrifica on

680Kg (1500 lb) of pressure (independent tes ng)

Flash Point

Minimum 53 oC Toledo open cup

Percent Non-Vola le

15% by weight

Percent vola le maximum

85% by weight petroleum dis late

Pour Point

-73 oC Excelent low temperature stability

Evapora on Rate

0,7 (water = 1 )

Coverage

85 to 100 m2 / liter = 3500 to 4000 sq. per U.S Gal. (4,5 liters)

Bolling Point, Ini al

173 oC

Weight, Applied Coa ng

8 x 10 -3 Kg/m2

Film Tickness

0,010 mm average

Humity

According with ASTM-D 655. Zero rust a er 1000 hours

Salt Spray

According with ASTM-B 117. Zero rust a er 48 hours

Indoor Protec on

at lasts up to a year

Outdoor Protec on

reapply as needed

Packages Types

No catalogs

No EDP

Case of 12 / 12 oz. (0.3 liter) Aerosol Cans

M1.95173

95173

1 Gallon (3.8 liters) Containers

M1.01 - 5

93221

5 Gallons (19 liters) Pall

M1.05

93227

53 Gallons (200liters) Drum

M1.53

93233

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S4240 - 220/380V - ING

NOTES

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S4240 - 220/380V - ING

NOTES

REV.01 - JAN/12