Pilous FORESTOR OR 50 User manual

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INSTRUCTION MANUAL
SEMI-AUTOMATIC BAND SAW
GRINDING MACHINE
OR 50

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Certificate of EU - Conformity
OR 50
We,
kind of product:
model designation:
serial number:
year of make:
PILOUS - pásové pily, spol. s r.o., Kšírova 118b, 619 00 Brno,
declare hereby on our own exclusive responsibility that the machine
complies with the EU 89/392 Guidelines for Machines, as amended by the EU 91/368
and 93/44 Guidelines, and with EN 1807;EN 292-1, EN 292-2, EN 418, EN 60204-1,
EN 60529, IEC 417, EN 294, EN 349, ISO 3864.
Surname:Eng. Mašek
First name: Petr
Position:Executive
Brno, …………………..… ……………………………
Place and date Signature
Semi-automatic band saw sharpener
PILOUS - pásové pily, spol. s r.o., Kšírova 118b, 619 00 Brno, Czech Republic

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1999
Pilous pásové pily spol.s r.o.
Vranovská 5
614 00 BRNO
TSCHECHISCHE REPUBLIK
All rights, particularly the right to make copies of, to distribute and translate this
instruction manual, are reserved.
No part of this instruction manual may in any form (printing, microfilm or others) be
reproduced or stored, processed, copied or distributed by using electronic systems
without permission of PILOUS.
Letter of Guarantee – Service
The Letter of Guarantee is a separate annex to the instruction manual.
Guarantee period – see Letter of Guarantee
Conditions for Maintenance of Claims under Guarantee
Use and attendance of the machine in conformity with the instruction manual.
Connection of the machine to voltage corresponding to that mentioned in the instruction
manual
The guarantee does not apply to:
Violent and mechanical damage of the machine caused by interference of the user or
other persons.
Unavoidable event (natural disaster)
Damage of machine during transport
Storage or installation of machine in humid, chemical or any other unsuitable environment
Any claims concerning guarantee and after-guarantee repairs should be sent by fax,
post or phone to the address: refer to the Letter of Guarantee.
Instruction for the User:
The Seller is obliged to hand over to the User the Letter of Guarantee immediately when
the product is being purchased. The Letter of Guarantee must be carefully and legibly
completed and provided with the Seller’s stamp, signature and data of sale.
The Seller is obliged to inform the Buyer about the use and handling the product.
Data Necessary for Claiming Guarantee (After-Guarantee) Repair
Machine type
Number of Letter of Guarantee (identical with serial number)
Date of issue of Letter of Guarantee
C

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CONTENTS
0. IN GENERAL
0.1. Safety Provisions
0.2. Requirements Concerning Operators
1. TECHNICAL PARAMETERS
1.1. Scope of Use
2. INSTALLATION – DISMANTLING
2.1 Space Requirements
2.2 Machine Installation
2.3 Connection to Energy Supplies (Wiring Diagram)
2.4. Dismantling
2.5. Disposal
3. SAW BANDS – MAIN PRINCIPLES
4. MACHINE DESCRIPTION
5. SETTING OF SHAPE OF TOOTH TO BE GROUND
5.1 Tooth shape setting
5.2 Preparation and adjustment of grinding machine
5.3 Grinding wheel exchange
6. LUBRICATION, CLEANING, MAINTENANCE
0. IN GENERAL
This instruction manual provides the users assistance and information about the PILOUS
band saw grinding machine and the possibilities of use as directed.
The instruction manual contains important instructions on a safe, adequate and
economically efficient operation. Observing the operating instructions will prevent risks,
the repair and outage time costs will be reduced and the machine reliability and life
increased.
The instruction manual contains instructions based on the valid national safety regulations
and environmental standards.
The instruction manual must be always available at the machine site.
The instruction manual must be read and used by the staff entrusted with the machine
installation, transport and storage, use / operation, maintenance and disposal.
In addition to the instruction manual and the binding safety regulations in force in the
user’s country and at the service site, it is also necessary to observe the approved rules
for safe and professional work.

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0.1 Safety Provisions
The machine design complies with the technical status and the approved safety and
technical rules. In spite of this, the user’s or the third persons’ health can be endangered
and/or the machine or other tangible goods may be unfavorably influenced during the
operation of the machine.
In order to prevent such hazards, it is unconditionally necessary to observe the safety
instructions in this instruction manual.
These safety instructions must be read and understood by the respective persons before
the machine has been put into operation.
Failure to observe these instructions may cause serious health and property damage!
The safety instructions are marked in this instruction manual with safety symbols / danger
spot signs.
Danger spot
Proceed with maximum caution
Dangerous voltage
Use goggles
Use protective gloves when handling the
saw band
0.2 Requirements Concerning Operators
The machine may only be operated by persons instructed in safety at work and
appropriately trained.
The machine may only be operated if in perfect condition with respect to technical safety.
The user is obliged to check the machine for visually detectable damages and failures at
least once per shift. Any changes, failures and damages of protective covers, changes of
the machine behavior endangering the safety should be immediately reported to the
supervisor. Wait for the decision about the repair and the putting into operation.
No safety devices may be removed, moved, put out of operation or changed during the
machine operation.
If any safety device has to be removed during operation or maintenance, secure the main
switch in the „OFF“ position by a padlock or disconnect the machine from the mains.

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Only electricians or persons instructed in electromechanical
work under the supervision of electrical specialists are
allowed to open the electric equipment housings and to work
on the electric equipment!
Caution! Danger of injury!
The grinding disk is not covered at the grinding point!
Never use the grinding machine when you are tired,
exhausted, under the influence of medicaments,
drugs or alcohol!
Protective shields may only be removed when the machine is disconnected from the
power supply and the grinding disk is at a standstill.
An emergency shutdown is done by the TOTAL STOP push-button.
For putting the machine into operation again, unlock the push-button by turning it
manually.
Manual cleaning, removal of waste (e.g. sawdust,
wood chips, bark) are not allowed during the machine
run and running down.
Observe all valid fire prevention rules.
A first-aid kit must be available at the workplace.
Use suitable working clothes, shoes and
appropriate
safety devices (goggles, protective gloves)
-remove loose parts of clothes, cover long hair
-make sure that other persons are at least 5 m from the band saw
-all people present at the site muse be made familiar with all safety rules
-the safety rules must be provided on a visible place at site
-keep hands at safe distance from the saw band; never adjust any saw band when the
motor is running. Switch off the motor securing it against restarting before you start
handling the saw band

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1. ENGINEERING DATA
- Width of sharpened saw bands 20 – 50 mm
- Length of sharpened saw band 2 000 – 5 000 mm
- Saw band thickness up to 2 mm
- Tooth pitch 8 - 30 mm
- Manual band feed 5 teeth/min
- Band feed by motor 35 teeth/min
- Motor of grinding disk drive 0,25 kW/230V, 50Hz
- Motor of saw band drive 0,18 kW/230V, 50 Hz
- Cooling pump motor 0,09 kW/230V, 50 Hz
- Outside dimensions of grinding machine 750 x 750 x 350 mm
-Weight 33kg
-Total power input 0,52 kW/230V, 50 Hz
- Grinding disk size 175 x 6 x 20 mm
1.1 Scope of Use
The machine is designed exclusively for the grinding of saw bands.
Any other use is considered as not adequate to the purpose. The manufacturer is not
responsible for damages due to such a use. The user himself has to bear the risk.
The use complying with the purpose includes also observing the operating instructions
and the check and maintenance conditions.
2. Installation
2.1 Space Requirements
To obtain an optimal function and the maximum accuracy of grinding, it is recommended
to install the machine on a flat solid base, in a hall or under a shelter.
Recommendations / assumptions:
a) Allow for sufficient space for the ground band saw and its maintenance.
b) The workplace of the grinding machine and its operator must be even, clean, it must
endanger neither the operation nor the operator.
c) Provide for good lighting of the workplace.
Observe all standards and hygienic regulations in force for the arrangement of the
machines at the workplace.
The arrangement of the machines must exclude that other operators are put at risk.

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2.2 Machine Installation
Protect the machine against humidity, rain and dust!
The machine may be operated in the ambient temperature between + 5° and + 40°C.
In temperatures below + 5°C the conventional coolants should be replaced by coolants
designed for respective temperatures.
2.3 Connection to Energy Supplies
Connect the supply cable to
a protected 6A socket.
Make sure that the grid voltage, the voltage
protection and the connection voltage comply
with the power requirements specified in the
Technical parameters.
Wiring Diagram of Electrical Installation
Stop Stop
Start Start
230 V
50 Hz
H.V. Tot a l. S t op
Schliff Vorschub
Kühlung

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Destription Title Typ Manufacturer
K4732 Box Gewiss GW 44 207 Gewiss
L0961 Ledge DIN perforated ABO
H09743 Head -On-Off 800 EP Allen-Bradley
H4236 ZB5 –AD2 CE Telemecanique
H4282 ZB5 – AG2 Telemecanique
H4103 ZB5 – A2 102 Telemecanique
R03012 Relay RP 730 2P/230V
AC Kuhnke
R15046 Patina for relay RP Kuhnke
V40101 Bushing PG 9 Bimed
V40102 Bushing PG 11 Bimed
V40328 Nut for bushing PG 9 Bimed
V40329 Nut for bushing PG 11 Bimed
V0506 Line wire CYA 1,5 schwarz Draka Cables
Š0042 Flex kabel 3x1,5 3m schwarz Draka Cables
Š0276 Cable HOS VVF
3Gx0,75č.
Draka Cables
K40070 Case isolation 1/14 Band GPH
K40090 Case isolation 1,5/14 Band GPH
K3790 Cable eye 4x1,5 RF – M4 Cembre
S36021 Grip serial RSA 4 PE Elektro Bečov
S36022 Grip serial RSA 4 dunkel blau Elektro Bečov
S36025 Grip serial RSP 4 Elektro Bečov
P1574 Safety fuse Skl. 4A Omega

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Control desk
2.4. Dismantling
1. Disconnect the machine from power supply.
Machines may be disconnected
from power supply only by electricians!
2. Clean the machine.
3. Provide sliding surfaces with anticorrosive oil.
4. Check whether all safety devices of the machine are screwed on.
5. Enclose machine accessories.
2.5. Disposal
When the machine has been definitely put out of operation, it should be
disposed of in accordance with the provisions valid in the respective country.
It is recommended to contact a company specialized in disposal.
01
TOTAL STOP
OR
50
Při práci na stroji používejte ochranné pomůcky !
Use protective means while working on the machine !
Bei Arbeit an der Machine Unfallverhütungsmittel tragen !
Výměna pilového pásu a brusného kotouče se smí provádět
pouze s vypnutým hlavním vypínačem !
Saw band and grinding wheel exchange may only by done
with the master switch off !
Sägeband - und Schleifscheibewechsel dür fen nur bei
ausgeschaltetem Hauptschalter durchgeführt werden !
Nepouživejte stroj bez ochranných krytů!
Do not use the machine without protective shiel ds !
Machine ohne Schutzhauben nicht benutzen !!
Při práci na stroji dodržujte bezpečnostní předpisy !
Observe safety regulations while working on the machine !
Bei Arbeiten an der Machine Sicherheitsvorschriften beachten !
Start - Stop
Grinding disk motor
Start - Stop
Saw band feed
Main switch
(lockable)
For emergency
shutdown
Start - Stop
Cooling pump (option)

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3. SAW BANDS – MAIN PRINCIPLES
CAUTION!
The saw band surface is sharp. Be careful in order
to prevent injury. Wear protective gloves whenever
handling of the saw band.
For a proper performance of the machine and accurate timber dimensions, the most
important is to use quality, correctly sharpened and set saw bands.
You can start cutting the log only when the specified sawing speed of the saw band has
been achieved.
When sawing a log, start slowly increasing the sawing speed step-by-step until the speed
optimum for the specific material is achieved.
If the saw band is blunt, the slow sawing feed is of no use because if the feed is too small,
the chip removal per one tooth is small and the band saw is sawing still worse. The saw
band becomes blunt and warms up more quickly.
A too strong sawing pressure does not result in any performance increase either; just the
life of the overloaded and overheated saw band will be shorter.
A good maintenance of the band is vital for the sawing quality.
Inaccurate cuts and slow sawing are by 90 % caused by the saw band. Only 10 % of
problems may be caused by incorrect setting of the machine.
TERMINOLOGY OF TEETH
Pitch – point-to-point distance of two adjacent teeth.
Tooth space – distance between tooth point and its lower part (tooth gullet). This distance
is important to enable chip disposal. The depth of the tooth space must be kept when the
tooth is being re-ground.
Tooth face angle – a value measured in degrees expressing the tooth face angle. The
tooth angle must be observed when the band is being re-sharpened. The same applies to
the grinding wheel angle.
Front angle –angle between the tooth front face and the band body. This angle must
remain 90 degrees. This is the critical moment for achieving a good cut and the primary
factor when a new band is being sharpened.
Raker – an absolutely straight tooth whose shape removes saw dust from the cut.
Tooth setting – incline of a tooth to one side measured from the raker (straight tooth).

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Sharpening and Setting
There is no definite recommendation for an ideal saw band because each kind of timber
needs a specific ideal saw band to achieve the optimum efficiency.
This, however, can be also very different in the same kind of timber as a result of the
landscape origin.
Because of a permanent bend change when running on the running wheels and due to
the sawing pressure, enormous loads and forces are exerted on the relatively thin saw
band.
The teeth roots are critical saw band points.
A timely sharpening of the tooth root is important because very small hair cracks expand
inevitably causing saw band cracks. Avoid long idle runs because tooth root cracks may
develop during idle run rather than during cutting.
Do not let the machine run idle, if it is not necessary.
Important: Do not use the same saw band for more than approximately 2 hours and let it
“have a rest” then allowing for recovering of the steel structure. The saw band life
substantially increases in this way. Slacken the saw band in the machine after shift end.
Adherence to the rules and instructions for saw band maintenance will bring high sawing
performances, accurate cuts and a long life of the tool.
If there are suddenly bad sawing results or if the saw bands break more frequently, it is
usually difficult to find out the reason. The most frequent reason for breaks is wrong
handling of the saw band. The breaks can also be caused by operators. You can find
below the most frequent causes of cracks. Consider all items because there are often
several of them acting simultaneously.
1. Using blunt saw bands is the most frequent cause of saw band breaking, blunt bands
are excessively tensioned and hair cracks develop. Change saw bands on time!
2. The tooth shape is not observed when the tooth is being sharpened.
3. The saw band has been set in a wrong manner.
4. Excessive sawing pressure does not result in any increase in performance. The saw
band is overloaded and warms up.
5. Do not let the machine run idle, if it is not necessary.
6. Make a correct setting of the saw band guide.
7. The grinding wheel hardness or the particle size are unsuitable – microcracks on the
tooth root.
8. The grinding wheels are not trued up on time.
9. Excessive feed (of grinding wheel) causes heating of the tooth root (grinding until blue
color develops).
Cleaning and Ascertaining of Cracks
Remove saw dust and deposits from the saw band. Check the saw band for cracks
between the teeth. Small cracks may be ground while the saw band teeth are being set. If
the cracks are too big to be eliminated by grinding, the saw band must be rejected.
The cracks in saw bands are the most frequent cause of saw band break.

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ANGLES
The convergence angle must be 10 – 12° and the tooth face angle (F) differs only
depending on the different kinds of wood as follows:
Frozen wood 9°
Hardwood 11°
Medium hardwood 17°
Softwood 19°
The above values are approximate only and can differ depending on the origin of
the wood.
4. MACHINE DESCRIPTION
The grinding machine is intended for sharpening band saws in semi-automatic cycle. The
change of pitch and the shape of the sharpened teeth are made manually.
The grinding disk and the saw band shift are driven by electric motors. The grinding machine
is equipped with a pump, which enables cooling during turning.
The infinitely variable control of grinding disk lift (up – down) enables setting of different tooth
heights and the size of the feeder step enables setting of different tooth pitches.
The grinding machine is provided with a cam allowing for grinding Wood – Mizer teeth. If you
wish to grind other than Wood – Mizer teeth, you have to exchange the cam. The cam is
available by order from our company.
9°,11°,17°,19°
10-12°
90°

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COMPONENT SPECIFICATION
0
0
I
I

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Standardized bearings
6002 2ZR 2 pcs component No. 23 Feeder holder
608 2Z 1 pc component No. 11 Arm
6000 2ZR 2 pcs component No. 1 Grinding arm
Special accessories are not included in the basic grinder version.
32
1.Grinding arm
2.Base
3.Saw band holding plate
4.Setting screws of saw band width
5.Lock nut
6.Holding plate screws
7.Tooth face angle setting screw
8.Setting screw of tooth material removal
9.Setting screw of tooth face removal
10.Crank
11.Arm
12.Eccentric shifter
13.Control box
14.Setting feet
15.Band cover
16.Feed electric motor
17.Grinding machine el. motor
18.Supporting arm
19.Band guide
20.Clamp
21.Gearbox
22.Cam
23.Feeder holder
24.Feeder arm
25.Cam lock screw
26.Tooth length setting screw
27.Tooth length lock screw
28.Cooling fluid vessel
29.Pump
30.Shut-off cock
31.Hose
32.Flange

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5. SETTING OF SHAPE OF TOOTH TO BE GROUND
Note: The standard setting of the grinding machine is a tooth pitch of 22 mm and the
WOOD-MIZER tooth profile.
The setting of grinding machine may be changed in three ways:
5.1 Tooth Shape Setting
Tooth Form Depth
Increase and/or decrease the tooth depth by moving the screw /8/ to another lever recess
/11/.
By moving to the left /when looking from the front/, the tooth depth increases, by moving to
the right, the tooth depth decreases and the steepness of the tooth back surface changes
at the same time.
deeper identical shallow
Tooth Pitch – Change of Feed Length
When the shifter /12/ eccentricity is changed, the elevation of the feeding mechanism
changes.
The elevation should be always bigger than the actual tooth pitch.
-Loosen the feed elevation lock screw (27).
-Turning the feed elevation setting screw (26), set the elevation to be bigger than the
tooth pitch. Loosening the screw, the elevation increases, tightening the screw, the
elevation decreases.
-Secure the set elevation by tightening the screw (27).
33

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Change of Tooth Form - Contour
Turn the flange /32/ clockwise towards the cam /22/ (when looking from the front) to
change the tooth shape grinding:
5.2 Grinding Machine Preparation and Adjustment
Set the grinding machine in horizontal position. Eliminate any unevenness by means of
adjusting feet. If you use the base, screw the grinding machine to the base.
If cooling is used (option), connect the pump hose to the 1/4” cock and fit the discharge
hose on the socket, inserting the free end into the collecting vessel. Connect the pump to
the control box.
Fit the saw band supporting arms with adjusting shifters on the pins of the grinding
machine frame and tighten with sleeves. Set the adjustable shifters according to the saw
band size.
CAUTION!!! Carry out the items 1-6 while the
machine is at standstill and the main switch
locked.
1. Raise the grinding arm /1/, raise the feeder arm /24/, unscrew the saw band cover
/15/. Depressing the plastic pin /20/, loosen the saw band guide /3/ and insert the saw
band. Screw on the saw band cover /15/ again.
2. Adjust the saw band height with screws /4/ so that the tooth gullet is approx. 2 mm
above the upper guide surface /3/. Concurrently, the saw band must be guided in parallel
to the upper guide surface /3/.
3. If necessary, set the guides /19/ on the supporting arms /18/ so that the saw band
is supported at all supporting points.
4. Adjust the screws /6/ so that the saw band may move easily and be at the same
time sufficiently held in the desired position.
5. Loosen the screw /7/ to set a correct tooth face angle. Tighten the screw /7/ after
setting.
6. Lower the grinding arm /1/.
7. Shape the grinding wheel with a dressing diamond; a new grinding wheel should be
shaped according to the figure below:

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8. Using the screw /8/ (control of tooth material removal) and the screw /9/ (setting
screw of tooth face removal) and turning the crank /10/, set the tooth shape
copying.
Note: Turning the screw /8/
to the right – the grinding arms lowers
to the left – the grinding arm raises
Turning the screw /9/
to the right – the shifter shifts back
to the left – the shifter shifts forward
9. If the tooth profile does not comply with the desired form, choose another lever
recess /11/ for the screw /8/. Should in spite of this the tooth contour not be copied,
it is necessary to change the tooth form. See item “Change of Tooth Form”.
optimum
10. Switch on the turning of the grinding wheel and correct the grinding setting by
means of the screws /8/ and /9/ while turning the crank /10/.
Caution: The face surface should get less sharpening than the back
surface.
This is the basic rule for sharpening all kinds of teeth!

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11. Switch on the electric feed.
12. In new or extremely blunt saw bands the tooth space /form/ grinding should be
repeated several times.
Be careful when grinding the tooth face. A too big face surface removal during grinding will
cause a slow change of the face angle until zero degree and greater changes in root
radius.
(Excessive grinding will cause extreme deterioration of the grinding wheel.)
13. The screws (33) are used to set the coupling force. Adjust the screws (33) to allow
the crank (10) to be turned by hand and the saw band to be moved when the el.
band feed is switched on.
Carry out the adjustment while the machine is at standstill.
5.3 Grinding Disk Exchange
Cut the machine off the mains securing it
against starting before you begin the work
(lubrication, cleaning, maintenance)
1. Raise the grinding arm.
2. Unscrew the side cover.
3. Hold the grinding wheel in place and loosen the grinding wheel flange with a
wrench.
4. Remove the grinding wheel, fit on a new one and tighten the flange.
5. Screw on the side cover.
6. Lower the grinding wheel.
7. Switch on the grinding machine motor and leave it run idle for about 2 minutes.
8. Shape the grinding wheel profile with a dressing diamond.
1 grinding
2 grinding
3 grinding
st
nd
rd

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6. Lubrication, Cleaning, Maintenance
Grinding dust develops during grinding; therefore, it is very important to observe
recommendations concerning lubrication.
Current maintenance of the grinding machine should be always done daily after finishing
the work.
Remove grinding dust from the protective shield and the grinding disk cover space.
Clean the grinding disk bottom and remove dust from all parts.
Apply grease to sliding bearings on the arm /11/, setting screws /8,9,4/.
Cut the machine off the mains securing it
against starting before you begin the work
(lubrication, cleaning, maintenance)