CHESTER HV128 User manual
IMPORTANT
SAFETYFIRST
ALLMACHINESAREDANGEROUS
1.Usethecorrecttoolforthejobathandnevermakeamachinedoajobitwasnotdesignedfor.
2.Neverforcethetoolinthemachineitwilldothequickerandsaferatthecorrectrate.
3.Alwaysuseclampsorvicestosecurework– yourhandisnotstrongenough!
4.Whenchangingtoolsorworkpiecesalwaysdisconnectthemachinefirst.
5.Servicethemachineregularly;acorrectlyoperatingmachineisasafermachine.
6.Alwaysreplacebeltcoversbeforestartingthemachine.
7.Understandthemachinefullybeforeoperationandalwaysreadthemanual.
8.Gettoknowthemachineslimitationsandapplications.
9.Ensurethatthemachineissecurelyboltedtothebenchandthatthebenchissecurelyboltedtothe
ground.
TAKEGREATCAREWHENOPERATINGTHISMACHINETOPROTECTYOURBODY
1.Alwayswearsafetyglasses–everydayglassesarenotsuitable.
2.Dustcanbecausedwhenmachiningcertainmaterials,alwayswearamask.
3.Makesureyouarenotwearinganylooseclothingsuchasties,rings,braceletsthatmaygetcaughtin
themovingpartsofthemachine.
4.Keepaproperfootingandbalancewhilstoperatingthemachine.
5.Neverleavecleaningrags,etconornearthemachine.
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SAFETYFIRST
ELECTRICS
1.Allelectricaltoolsmustbeearthed.
2.Neveruseelectricaltoolsindamporwetenvironment.
3.Makesurethemachineisintheoffpositionbeforeswitchingonatthemains.
4.Alwaysimmobilisethemachinebeforeservicingorsettingupworkinthemachine.
5.Greatcareshouldbetakenwhenusingcoolantfluidwithmachinetools.
6.Ensurethemachineiscorrectlyconnectedandafuseoftheproperratingisused.
CHILDREN
1.Keepchildrenawayfrommachines,ifnecessaryfitsafetylockstothemachineandmainsswitches.
2.Neverusemachinerywhilsttalkingtovisitors,alwaysconcentrateonthejobinhand!
REMEMBERALLMACHINESARE
DANGEROUSIFNOTUSED
CORRECTLY!
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CONTENTS
1. MachineSpecifications......................................................................................................................4
2. RecommendedSpeedsforCuttingofVariousMaterials...................................................................4
3. Troubleshooting.................................................................................................................................5
4. Features..............................................................................................................................................6
5. Delivery&Installation.......................................................................................................................6
6. MinimumSpaceforMachineOperation...........................................................................................7
7. Operation............................................................................................................................................7
8. TelltaleChips.....................................................................................................................................9
9. MachineElementsAdjustment..........................................................................................................9
10. Maintenance.....................................................................................................................................11
11. Lubrication.......................................................................................................................................12
12. PartDiagram....................................................................................................................................13
13. PartList............................................................................................................................................14
14. CircuitDiagrams&ElectricalSpecifications..................................................................................18
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MACHINESPECIFICATIONS
Motor 1/3HP(1/2HP),50HZ=1420RPM/60HZ=1725RPM
BladeSpeed 20,30,50m/min
Max.CuttingCapacity(@90°) Rounddeg128mm
Square115x150mm
Max.CuttingCapacity(@45°) Rounddeg76mm
Square76x115mm
BladeSizeLength 64½”
Teeth 14tpi(asstandard)
Thickness 0.025”
Width 12.7mm
SawBodyTiltingRange 0° 45°
BladeWheels 73/8”(187mm)HighStrengthFlangedCastIron
Length –1029mm
Width 457mm
Height 965mmCut/Off
Height 1378mmVertical
Net/GrossWeight 62/63Kgs
PackingSize 38”x13”x16”(965x330x406mm)
20’ContainerQ’ty 249sets(CE190sets)
RECOMMENDEDSPEEDSFORCUTTINGOFVARIOUS
MATERIALS
MOTORPULLEY SAWPULLEY
MATERIALCUTTINGCHART
Material Speed (SFM) BeltGrooveUsed
50Hz 60Hz MotorPulley SawPulley
Tool,Stainless 19MPM 24MPM SmallA LargeD
orAlloySteel (65FPM) (80FPM)
BearingBronzes,MildSteel, 28MPM 36MPM MediumB MediumE
HardBrassorBronze (95FPM) (120FPM)
SoftBrass,Aluminium 50MPM 60MPM LargeC SmallF
orOtherLightMaterials (165FPM) (200FPM)
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TROUBLESHOOTING
Symptom PossibleCauses CorrectiveAction
ExcessiveBladeDamage 1.Materialislooseinthevice. 1.Clampworksecurely.
2.Incorrectspeedorfeed. 2.Adjustthespeedorfeed.
3.Bladeteethspacingistoolarge. 3.ReplacewithasmallerTPIblade.
4.Materialistoocourse. 4.Usebladeatslowerspeed&TPI.
5.Incorrectbladetension. 5.Adjusttensionsoblade doesnot
sliponthewheel.
6.Bladeisincontactwithmaterial 6.Placebladeincontactwithwork
beforethesawisstarted. onlyafterthemotorhasstarted.
7.Bladerubsonthewheelflange. 7.Adjustthewheelalignment.
8.Misalignedguidepivots. 8.Adjustguidepivots.
9.Bladeistoothick. 9.Useathinnerblade.
PrematureBladeDulling 1.Bladeteetharetoocourse. 1.UseasmallerTPIblade.
2.Toomuchspeed. 2.Reducethespeed.
3.Inadequatebladetension. 3.Adjustthespring
4.Hardspotsorscaleonmaterial. 4.Reducespeed,increasefeedpressure.
5.Bladeistwisting. 5.Replaceblade,adjustbladetension.
6.Insufficientbladetension. 6.Tightenbladetension.
7.Bladeissliding. 7.Tightenbladetension,reducespeed.
UnusualWearonSideor 1.Bladeguidesareworn. 1.Replacebladeguides.
BackofBlade 2.Bladeguidepivotsaremisaligned. 2.Adjustguidepivots.
3.Bladeguidebracketsareloose. 3.Tightenbladeguidebrackets.
TeethRippingfromBlade 1.Bladeistoocourseforthework. 1.UseafineTPIblade.
2.Toomuchpressure,speedistooslow. 2.Decreasepressureandincreasespeed.
3.Workpieceisvibrating. 3.Clampworkmoresecurely.
4.Bladeistoofineforthe work. 4.UseacourseTPIblade.
MotorOverheating 1.Bladetensionistoohigh. 1.Reducethebladetension.
2.Drivebelttensionistoohigh. 2.Reducethedrivebelttension.
3.Bladeistoocourse. 3.UseasmallerTPIblade.
4.Bladeistoofine. 4.UseacourserTPIblade.
5.Gearsneedlubrication. 5.Lubricategears.
6.Cutisbindingblade. 6.Decreasethefeedandspeed.
Bad,CrookedorRoughCuts 1.Feedpressureistoogreat. 1.Adjustspringtoreducepressure.
2.Guidepivotsaremisaligned. 2.Adjustguidepivots.
3.Inadequatebladetension. 3.Increasebladetension.
4.Bladeisdull. 4.Replaceblade.
5.Incorrectspeed. 5.Adjustspeed.
6.Bladeguidesarespacedouttoomuch. 6.Adjustguidespacing.
7.Bladeguideassemblyisloose. 7.Tightenguideassembly.
8.Bladeistoocourse. 8.UseafinerTPIblade.
BladeisTwisting 1.Cutisbindingblade. 1.Decreasefeedpressure.
2.Bladetensionistoohigh. 2.Decreasethebladetension.
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FEATURES
1. Speciallydesignedhorizontalbandsaw.
2. Offersthreespeedsforcuttingmetal.
3. Shutsoffautomaticallywhenmaterialiscut.
4. Scaleforthemitringvice.
5. Lownoisewhilstinoperation.
6. Casters(optional)forquickandeasymoving.
DELIVERY&INSTALLATION
UNPACKING
1. Transporttothedesiredlocationbeforeunpacking,useliftingaliftingjack(Fig.B).
2. Transportafterunpacking,pleaseuseaheavydutyfibrebeltinordertoliftthemachine.
FIG.B
TRANSPORTRECOMMENDATIONS
1. Tighten alllocksbeforeoperating.
2. Alwayskeepaproperfooting&balancewhilemovingthebandsaw.
3. Disconnectthepowersupply,andmakesurethemachineisproperlygrounded.
4. Checktheblademakingsurethatitisrunninginacounterclockwisedirection
5. Keepthebandsawoutofdirectsunlight,dust,wetorwater.
INSTALLATION
1. Thesawmaybemountedonaworkbenchorstandusingsixbolts.
2. The rear end of the base must be mounted on the rear of the stand or bench to permit the
verticaloperationforthisbandsaw.
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MINIMUMROOMSPACEFORMACHINEOPERATION
OPERATION
OPERATIONSTEPS
1. Raisethesawheadtoaverticalposition.
2. Adjustthemotorautomaticstopkeysothemotorwillstopwhentheworkpieceiscutoff.
3. Adjustthestockstoptothedesiredlengthposition.
4. Openthevicetoaccepttheworkpiecetobecut.Ifthepieceislonginlength,itwillrequire
somesupport.
5. Rotatethehandwheeltotightentheworkpiece.
6. Turnontheswitch,andchangethebladespeedtobestsuittheworkpiecebeingcut.
7. Let the saw head down slowly to touch the workpiece lest the blade should be broken by
excessivepressure.
8. Rotatetheadjustingrodtoobtainthecorrectpressure.
HELPFULCUTTINGHINTS
1. Theharderthematerial,theslowerthecuttingspeedshouldbe.
2. Useofcuttingoilisrecommendedwhenthebladespeedishigher.
3. Toincreasethefeed,turnthefeedscrewadjustment(attheleftofthebase)counterclockwise:
todecreaseturnclockwise.Donotadjustmorethanoneturnatatime.
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BLADESELECTION
1. A14toothperinchgeneralusebladecomesasstandardwiththemachine.Additionalblades
arealsoavailable:6,10and18tpi.
2. Thechoiceofthebladepitchisgovernedbythethicknessoftheworktobecut.
3. Thethinnerworkpiece,themoreteethadvised.
4. Iftheteethofthebladearetoofarapart,itcanresultinseveredamagetotheworkpieceand
totheblade.
CHANGINGBLADES
Raisethesawheadtoaverticalposition.Loosenthebladetensionadjustableknobsufficientlytoallow
thesawbladetoslipoffthewheels.
Installthebladeasfollows:
1. Placethebladebetweeneachguidebearing.
2. Slipthebladearoundthemotorpulley(bottom)withthelefthandandholdinposition.
3. Holdthebladetautagainstthemotorpulleyandplacethebladeupwardwiththerighthand,
whichwillbeplaced,atthetopoftheblade.
4. Remove the left hand from the bottom pulley and place it at the topside of the blade to
continuetheapplicationontheupwardpullontheblade.
5. Removetherighthandfromthebladeandadjustthepositionofthetoppulleytopermitthe
lefthandtoslipthebladearoundthepulleyusingthethumb,indexandlittlefingerasguides.
6. Adjust the bladetensionknob clockwiseuntilcorrect, asto assure no slippageon the blade
occurs.Donottightenexcessively.
7. Place23dropsofoilonthetable.
8. Replacethebladeguard.
STARTINGTHESAW
1. Neveroperatethesawwithoutthebladeguardsinplace.
2. Besurethebladeisnotincontactwiththeworkwhenthemotorisstarted.
3. Startthemotor;allowthesawtoreachfullspeed.
4. Donotdroporforcethehead.Providethecuttingforcebylettingtheheaddownslowlyinto
thework.
5. Correctfeedisimportant,excessivepressurecanbreakthebladeorstallthesaw.Insufficient
pressuredullsthebladerapidly.
6. Neveruseanewbladetocompletepreviouslystartedcut.
7. Donotstartcuttingonthesharpcorners.
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TELLTALECHIPS
Chipsarethebestindicatorof correctfeedforce.Monitorthechipformationandadjustfeedaccordingly.
Thinorpowderedchips–increasethefeedrateorreducethebandspeed.
Burnedheavychips–reducethefeedrateand/orbandspeed.
Curlysilveryandwarmchips–optimumfeedrateandbandspeed.
MACHINEELEMENTSADJUSTMENT
VERTICALADJUSTMENTOFTHEBLADEWHEELS
1. Removethebladeguards.
2. Turn the blade tension adjustable knob counter clockwise so that the blade might loosen a
little.
3. Adjust the hexhole screw in the hole of the slide block, until the front blade wheel rises
backwardalittle,sothatthebladewillbekeptinposition.
4. Tightenthebladetensionadjustableknobuntilthebladeobtainsthecorrecttension.
5. Checkthetrackingbyturningonthebandsaw.Ifthebladeslidesforward,gobacktostep4
untiltherearbladetouchestheflangeofthebladewheel.
6. Disconnectthepowertothemachine.
7. Replacethebladeguards.
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BLADEGUIDEBEARINGADJUSTMENT
Attention: This isthe most important adjustment on yoursaw. Itis impossibleto get satisfactory work
fromyoursawifthebladeguidesarenotproperlyadjusted.
Note:Thereshouldbefrom0.000(justtouching)0.001clearancebetweenthebladeandguidebearing.
Toobtainthisclearanceadjustasfollows:
1. Eachofthetwoguidebearingsismountedtoaneccentricbushingthatcanbeadjusted.
2. Loosenthenutwhileholdingtheboltwithanallenkey.
3. Positiontheeccentricbyturningthebolttothedesiredpositionofclearance.(Theblademust
becompletelyverticalwhileitiscutting).
4. Tightenthenut,thentheadjustablebladeguidebearingwillbefixed.
5. Adjustthesecondbladeguidebearinginthesamemanner.
BLADETENSIONADJUSTMENT
1. Makesurethemotorisshutoff.
2. Pressthebladelightlywithlefthand,maketherearbladeagainsttheflangeofthebladewheel
andfeelthebladetension(sothatthebladedoesnotcomeofffromthewheel).
3. Adjustthebladetensionadjustableknobwiththerighthand,until thebladeobtainsthecorrect
tension.
FIG.1
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Placetherightanglegaugeonthebedtoadjustthebladeverticalangle.Ifthebladeisnotverticaltothe
rightanglegauge,adjustthebladeadjustableseataccordingtoFig.1.
Whenthebladeisverticaltothebed,adjustthemitringviceplatetotherightangle,onthebasisofright
anglegaugeagainsttheblade(asabove,theclampingfaceofthemitringvicemustbeonalinewiththe
scale).
Methodofadjustingtheblade:
A. Loosenthescrew#11.
B. Adjustthebladeadjustableseat#64tomakethebladeverticaltothebed.
C. Placethesquareonthebedtocheckifthebladeisvertical,ifnot,repeattheprocessA
toC.
D. Tightenthescrew#11.
MAINTENANCE
That’seasierto keep machine in good condition or best performance by meansof maintaining it, than
remedyitafteritisoutoforder.
1. DailyMaintenance(byoperator)
(a) Fillthelubricantbeforestartingmachineeveryday.
(b) If the temperature of the spindle caused overheating or a strange noise, stop the
machineimmediatelytocheck.
(c) Keepthework area clean, release vice, cutter,workpiece from table, switch offthe
powersourceandcleanchip/dustawayfromthemachine.Thenfollowinstructions
onlubricationbeforeleaving.
2. WeeklyMaintenance
(a) Cleanandcoattheleadingscrewwithoil.
(b) Checktoseeiftheslidingsurfacesandturningpartslacklubricant(lubricateifso).
3. MonthlyMaintenance
(a) Checkifthefixedpartsareloose.
(b) Lubricatebearing,wormandthewormshafttoavoidwear.
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4. YearlyMaintenance
(a) Adjustthetabletoahorizontalpositionformaintainingtheaccuracy.
(b) Checktheelectriccord,plugandswitchesatleastonceayear.Thiswillhelptoavoid
looseningorwear.
LUBRICATION
1. Cleanthebandsawaftereachoperationandcoatwithrustlessoil.
2. UseSAE30oiltolubricatecomponents.
3. Lubricatetheleadscrewontheviceasrequired.
4. Thedrivegearsareinanoilbath,theywillnotrequirealubricantchangemore oftenthan
onceayear,unlessaleakoroverheating.
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PARTSDIAGRAM
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PARTLIST
CodeNo. PartNo. Description Specification Quantity
1 S022 Hex.HeadScrew 5/16"x3/4"L 4
2 N003 Hex.Nut 1/4" 1
3 W005 Washer 1/4"x16xt1.5 3
8 W016 Washer 5/16"x23xt2 8
10 W005 Washer 1/4"x16xt1.5 1
11 S017 Hex.HeadScrew 5/16"x1"L 4
12 N007 Hex.Nut 5/16" 4
13 3013 FloorStand(left) 1
14 3014 LiftingHandle 1
15 3015 ViceNut 1
15_1 30151 PlasticBushing 1
16 MotorCable 1
17 3017 PivotingRod 1
19 3019 DistanceSetBracket 1
20 S610 Hex.SocketHeadlessScrew 5/16"x5/16"L 4
21 3021 StockStopRod §1/2"x216L 1
22 3022_1 WireReliefRetainer 2
23 MagneticSwitch 1
27 3027 HandleRod ForPlasticHandleWheel 1
27 3027_1 Handle ForCastingHandleWheel 1
28 3028 Wheel PlasticWheelwithHandle 1
28 3028_1 HandWheel PlasticWheelwithHandle 1
30 E001 ERetainingRing E10 1
31 S017 Hex.HeadScrew 5/16"x1"L 1
32 3022 LeadScrew 1
33 3033 ViceNut 1
34 3034 MovableVicePlate 1
35 W008 Washer 3/8"x25xt2 1
36 S013 Hex.HeadScrew 3/8"x11/4"L 3
37 3037 SwivelBase 1
38 S708 CrossRoundHeadScrew 3/16"x3/8" 2
39 3039_1 Scale 1
43 3043 WireProtector BlackColor 1
44 PowerCable 1
45 3045 SpringHandleBracket 1
45_1 3045_1 SpringHandleBracket 1
46 3046 SpringAdjustingScrew 1
47 3047 Spring 1
48 S708 CrossRoundHeadScrew 3/16"x3/8"L 4
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PARTLIST
CodeNo. PartNo. Description Specification Quantity
49 3049 MovableVicePlate 1
50 S022 Hex.Screw 5/16"x3/4"L 3
51 W018 Washer 5/16"x23xt3 3
52 S019 Hex.HeadScrew 5/16"x11/2"L 1
53 S001 Hex.HeadScrew 7/16"x2"L 1
54 3054A Pivot 1
55 3055 VerticalSawTable 1
55 3055_3 VerticalSawTable 1
56 3056 TableSupportingPlate 1
56 3056_2 TableSupportingPlate 1
57 32406 AdjustableBracket(Left) 1
59 3059_5 BladeBackSafetyCover Standard 1
59 3059_6 BladeBackSafetyCover ForCEOnly 1
60 C100 CRetainerRing ForS10AxleOnly 4
61 CA6000ZZ Bearing(6000ZZ) 600ZZ 6
62 3062 BearingShaft 2
62_1 3062_1 GuidePivot(Right) 2
63 3063 BearingPin §10x36L 2
64 3064 BladeAdjustable(Rear) WithHole 1
64 3064_2 BladeAdjustable(Rear) WithHole 1
64_1 3064_1 BladeAdjustable(Front) WithoutHole 1
64_1 3064_3 BladeAdjustable(Front) WithoutHole 1
65 32405 AdjustableBracket(Right) 1
66 3066_2 LockKnob 3/8"16UNCx31L 2
66 3066_3 GuideAdjustingKnob 3/8"16UNCx31L 2
67 W205 SpringWasher §5/16" 1
68 S302 FlatCrossHeadScrew 1/4"x3/8"L 2
69 3069 DeflectorPlate 1
70 N006 Hex.Nut 3/8"UNF 4
71 3071 BladeWheel(Front) 1
72 3072_2 BearingCover 2
73 K006 Key 5x5x25L 2
74 K008 Key 5x5x30L 1
75 S006 Hex.HeadScrew 1/4"x1/2"L 10
76 3076 SwitchCutOffTip ForON OFFSwitch 1
76 3076_1 SwitchCutOffTip ForToggleSwitch 1
76 3076_2 SwitchCutOffTip 1
77 3077 BladeWheel(Rear) 1
77 3077_1 BladeWheel(Rear) ForCustomerRequestOnly 1
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PARTLIST
CodeNo. PartNo. Description Specification Quantity
77_2 3077_2 Bushing ForCustomerRequestOnly 1
79 3079_2 BladeTensionAdjustableKnob 3/8"16UNCx94L 1
79 3079_3 BladeTensionAdjustableKnob 1
80 3080 Spring 1
81 3081A BodyFrame 1
83 S002 Hex.HeadScrew 1/2"x11/2"L 2
84 3084 MotorMountPlate 1
85 H99038 Motor 1
86 3086 MotorPulley 1
87 A6202ZZ Bearing(600ZZ) 620ZZ 4
88 3088 Bushing 1
88 30881 Bushing 1
89 OilSeal TC15x35x7 2
90 3090 TransmissionWheelShaft 1
91 3091 TransmissionGear 1
92 3092 GearBoxGasket 1
93 3093 GearBoxCover 1
93 3093_1 WormGearShaft 1
94 3094_1 WormGearShaft 1
95 P005 SpringPin §4x24L 1
96 3096_1 BearingBushing 1
98 3098 PlumScrew 5/16"18UNCx45L 1
98 3098_1 ThumbScrew 5/16"18UNCx35L 1
98 3098_2 PlumScrew 5/16"18UNCx50L 1
99 3099 Bushing 2
100 S304 FlatCrossHeadScrew 5/32"x 3/8"L 8
101 3101 WormGearPulley 1
102 W205 SpringWasher §5/16" 2
103 3103 BladeTensionSlidingPlate 1
104 S609 Hex.SocketHeadlessScrew 5/16"x5/8"L 2
105 P020 SpringPin §4x20L 1
106 3106 SlidingPlateDrawBlock 1
106 3106_1 AssemblyDrawing 1
107 3107_1 BladeWheelShaft 1
108 3108 ShaftBlock 1
109 3109 BladeTensionSlidingGuides 2
110 3110 MotorPulleyCover 1
111_1 3111S_1 MotorPulleyCover Plastic 1
112 Belt A22 1
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PARTLIST
CodeNo. PartNo. Description Specification Quantity
113 3113 BladeAdjustable(Rear) 0.65x12.7x14Tx1638 1
114 W204 SpringWasher §3/8" 4
117 W201 SpringWasher 1/4" 4
119 3119_1 BladeWheelBushing §19x§17x16 1
120 3120 Bushing §19x§17 x7 1
122 N010 Hex.Nut 7/16" 1
123 S009 Hex.HeadScrew 1/4"x3/4"L 1
124 S709 Screw 3/16"x7/8"L 2
132 3132 RightSafetyGuard(Optional) 1
132_1 3132_1 SafetyGuard(Left) 1
134 S502 Screw(Optional) M6x10L 4
140 N014 Hex.Nut M6 4
156 S708 CrossRoundHeadScrew 3/16"x3/8"L 3
157 StarWasher 3/16" 3
158 N004 Hex.Nut 3/16" 3
182 W018 Washer 5/16"x23xt3 2
189 W018 Washer 5/16"x23xt3 2
194 W004 Washer 1/4"x19xt1.5 1
196 S006 Hex.HeadScrew 1/4"x1/2"L 1
197 S009 Hex.HeadScrew 1/4"x3/4"L 1
198 C103 CRetainerRing S15 1
199 S017 Hex.HeadScrew 5/16"x1"L 1
200 S006 Hex.HeadScrew 1/4"x1/2"L 1
201 N007 Hex.Nut 5/16" 1
202 N003 Hex.Nut 1/4" 1
203 ToggleSwitch 1
204 3131 SwitchCover 1
205 Switch 1
206 Hex.Nut 1
207 32312 PositionPin 1
208 32310 PlumHandle 1
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CIRCUITDIAGRAM
ELECTRICALSPECIFICATION
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CIRCUITDIAGRAM
ELECTRICALSPECIFICATION
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