Sunex Tools 5008 User manual

5008 1 Rev. 02/06/06
Operating Instructions • Warning Information • Parts Breakdown
Capacity......................................90˚
8" (200mm)
8" x 11" (200 x 280mm)
2.4" x 13.8" (60 x 350mm)
Capacity......................................45˚
5.5" (140mm)
5.5" x 6" (140 x 155mm)
Blade Size .............1" x 0.035"x107"
(27 x 0.9 x 2720mm)
Blade Speed ..... 86/128/175/244 FPM
(26/39/53/74 MPM)
Motor..............1.5HP 1 Phase, 18 Amp,
1732 RPM
Shipping 62.5" x 31.3" x 45"
Measurement.. (1588 x 795 x 1143mm)
Net Weight....................517lbs (235kg)
Gross Weight............. 594 lbs (270kgs)
SPECIFICATIONS
AlwAys reAd
instructions
before using
power tools
AlwAys weAr
sAfety goggles
weAr heAring
protection
5008
8"x14"
Horizontal
Band Saw
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5008 2 Rev. 02/06/06
This Instruction Manual Contains
Important Safety Information.
READTHISINSTRUCTIONMANUALCAREFULLY
ANDUNDERSTANDALLINFORMATIONBEFORE
OPERATING THIS TOOL.
1. KEEP GUARDS IN PLACE and in working order.
2. REMOVE ADJUSTING KEYS AND WRENCHES.
Always ensure keys and adjusting wrenches are
removed from tool before turning it on.
3. KEEP WORK AREA CLEAN. Cluttered areas and
benches invite accidents.
4. DO NOT USE IN DANGEROUS ENVIRONMENT.
Do not use power tools in damp or wet locations, or
expose them to rain. Keep work area well lighted.
5. KEEP CHILDREN AWAY. All visitors should be kept safe
distance from work area.
6. MAKE WORKSHOP CHILD PROOF with padlocks,
master switches, or by removing starter keys.
7. DO NOT FORCE TOOL. It will do the job better and
safer at the rate for which it was designed.
8. USE RIGHT TOOL. Do not force tool or attachment to
do a job for which it was not designed.
9. USE PROPER EXTENSION CORD. Make sure your
extension cord is in good condition. When using an
extension cord, be sure to use one heavy enough to
carry the current your product will draw. An
undersized cord will cause a drop in line voltage
resulting in loss of power and overheating. Table 1
shows the correct size cord to use depending on cord
length and nameplate ampere rating. If in doubt, use
the next heavier gauge. The smaller the gauge number,
the heavier the cord.
10. WEAR PROPER APPAREL. Do not wear loose clothing,
gloves, neckties, rings, bracelets, or other jewelry
which may get caught in moving parts. Nonslip
footwear is recommended. Wear protective hair
covering to contain long hair.
11. ALWAYS USE SAFETY GLASSES. Use face or dust
mask if cutting operation is dusty. Remember, everyday
eyeglasses only have impact resistant lenses, they are
NOT safety glasses.
12. SECURE WORK. Use clamps or a vise to hold work
when practical. It is safer than using your hand and it
frees both hands to operate tool.
13. DO NOT OVERREACH. Keep proper footing and
balance at all times.
14. MAINTAIN TOOLS WITH CARE. Keep tools sharp and
clean for best and safest performance. Follow
instructions for lubricating and changing accessories.
15. DISCONNECT TOOLS from power source before
servicing, or when changing accessories, such as
blades, bits, cutters, etc.
16. REDUCE THE RISK OF UNINTENTIONAL STARTING.
Make sure switch is in OFF position before plugging in
power cord.
17. USE RECOMMENDED ACCESSORIES. Consult the
owner’s manual for recommended accessories. The use
of improper accessories may increase risk of injury to
persons.
18. NEVER STAND ON TOOL Serious injury could result
if the tool is tipped or if the cutting tool is
unintentionally contacted.
19. ALWAYS CHECK FOR DAMAGED PARTS. Before
each use of the tool, a guard or other part that is
damaged should be carefully checked to determine
that it will operate properly and perform its intended
function - check for alignment of moving parts, binding
of moving parts, breakage of parts, mounting, and any
other conditions that may affect its operation.
A guard or other part that is damaged
should be properly repaired or replaced.
20. DIRECTION OF FEED. Feed work into a blade or
cutter against the direction of rotation of the blade or
cutter only.
21. NEVER LEAVE TOOL UNATTENDED
WHILE RUNNING. TURN POWER OFF.
Do not leave tool until it comes to a complete stop.
For Your Own Safety Read Instruction Manual Before Operating This Tool
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5008 3 Rev. 02/06/06
Operating Instructions • Warning Information • Parts Breakdown
A. GROUNDING INSTRUCTIONS
1. All grounded, cord-connected tools:
In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This
tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching
outlet that is properly installed and grounded in accordance with all local codes and ordinances.
Do not modify the plug provided - if it will not fit the outlet, have the proper outlet installed by a qualified electrician.
Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer
surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is
necessary, do not connect the equipment-grounding conductor to a live terminal.
Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the
tool is properly grounded.
Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.
Repair or replace damaged or worn cord immediately.
2. Grounded, cord-connected tools intended for use on a supply circuit having a nominal rating less than 150 volts:
This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in Sketch A on page 4. The tool has a grounding plug
that looks like the plug illustrated in Sketch A. A temporary adapter, which looks like the adapter illustrated in Sketches B and C on page 4, may be
used to connect this plug to a 2-pole receptacle as shown in Sketch B, if a properly grounded outlet is not available. The temporary adapter should
be used only until a properly grounded outlet can be installed by a qualified electrician. NOTE: THIS ADAPTER IS NOT PERMITTED IN CANADA.
The green-colored rigid ear, lug, and the like, extending from the adapter must be connected to a permanent ground, such as a properly grounded
outlet box.
Table 1
Minimum gauge for cord
Volts Total length of cord in feet
120 V 25 ft. 50 ft. 100 ft. 150 ft.
Ampere Rating
Not
More More
Than Than AWG
0 6 18 16 16 14
6 10 18 16 14 12
10 12 16 16 14 12
12 16 14 12 Not Recommended
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5008 4 Rev. 02/06/06
Operating Instructions • Warning Information • Parts Breakdown
Grounding Methods
Electrical Schematic – Single Phase
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5008 5 Rev. 02/06/06
General Safety Information
1. Read the Instruction manual before operating the machine.
2. If you are not thoroughly familiar with the operation of horizontal
band saws, obtain advice from your supervisor, instructor or other
qualified person.
3. Remove tie, rings, watch and other jewelry, and roll up sleeves.
4. Always wear safety glasses or a face shield.
5. Make sure wiring codes and recommended electrical connection
instructions are followed and that machine is properly grounded.
6. Make all adjustments with the power shut-off.
7. Adjust and position the blade guide before start cutting.
8. Make sure that blade tension is properly adjusted before start
cutting.
9. Stop the saw before putting a workpiece in the vise.
10. Always keep hands and fingers away from the blade when the
machine is running.
11. Stop the machine before removing chips.
12. Always have stock firmly clamped in vise, before start cutting.
13. Disconnect machine from power source when making repairs.
14. Before leaving the machine, make sure the work area is clean.
Operating Instructions
1. Check Coolant: Low coolant level causes foaming and high blade
temperatures. Dirty or weak coolant can clog pump, causes
crooked cuts, low cutting rate and permanent blade failure. Dirty
coolant causes the growth of bacteria with ensuing skin irritation.
2. Keep vise slides clean and oiled.
3. Clean chips from blade wheels and the areas around wheels.
4. Saw Guide: Keep saw guides properly adjusted. Loose guides will
affect cutting accuracy.
5. Saw Blade: Ensure that the saw blade is sharp.
6. Blade Speed: Ensure blade speed is set correctly for workpiece
material and shape.
7. Check Blade Tension: Particularly after initial cuts with a new blade.
Blade Selection
1. Never use a blade so coarse that less than 3 teeth are engaged
in the workpiece at any time. (Too few teeth will cause teeth to
strip out.)
2. Never use a blade finer than required to obtain a satisfactory
surface finish or satisfactory flatness. (Too many teeth engaged
in the workpiece will prevent attainment of a satisfactory sawing
rate; frequently cause premature blade wear; frequently produce
“dished” cuts or the cuts are neither square nor parallel.)
3. The chart which follows is not expected to be exactly correct for all
cases. It is intended as a general guide to good sawing practices
Your blade supplier or the qualified engineers should be your most
reliable source of correct information for operational details of saw
blades and their use.
THE SELECTION OF SAWBLADES
<3mm >5mm >50mm >100mm >150mm >200mm
Sawblade <0.12" >0.2" >2" >4" >6" >8"
(HSS) 14T •
(HSS) 6/10T •
(HSS) 5/8T •
(HSS) 4/6T • •
(HSS) 3/4T •
(HSS) 2/3T ••
(HSS) 1/2T •
(HCS) 10T •
(HCS) 8T •
(HCS) 6T •
(HCS) 4T •
(HCS) 2T ••
Remarks: HSS-High Speed Steel Sawblade
HCS-High Carbon Steel Sawblade
NOTE:
1. When standard wall pipe, tubes, channel iron and angled "I"
beams are cut, a 10 pitch saw blade of wave-set type or
saw blade of (HSS) 6/10T is frequently used to good advantage.
2. Tubes or structure with wall thickness or web thickness of 1/2”
or more can usually use an 8 or 6 pitch blade or sawblade of
(HSS) 4/6T satisfactorily.
3. When rectangular solid bar is to be sawed, the work should,
whenever possible, be loaded with the thinnest cross section
exposed to the blade teeth. The pitch (or number of teeth per inch
of blade) selected must provide engagement of at least 3 teeth in
the workpiece. Should application of this rule not be possible
because the thinnest cross section is too thin, the piece must be
loaded with the wider dimension exposed to the saw teeth and a
coarser blade selected from the listing of recommendations for
round and square solid bars.
Operating Instructions • Warning Information • Parts Breakdown
Cutting
Material
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5008 6 Rev. 02/06/06
The controls – Fig. 1
A. Indicator light
B. Cycle start switch
C. Arm Descent Valve
D. Emergency stop button
E. Coolant pump
F. Flow control regulator
Single Phase
Refer to the wire drawing inside the electrical box and above for
proper motor and transformer connections, lead selection and wiring
connections from the motor to the power source for the voltage you are
using. (IMPORTANT: IMMEDIATELY AFTER WIRING THE MACHINE,
TURN ON THE POWER AND MAKE SURE THE MOTOR IS RUNNING
IN THE RIGHT DIRECTION, COUNTER-CLOCKWISE WHEN LOOKING
AT THE BLADE ROTATION.)
NOTE:
1. When standard wall pipe, tubes, channel iron and angle Ibeams
are cut, a 10 pitch saw blade of wave-set type or sawblade of
(HSS) 6/10T is frequently used to good advantage.
2. Tubes or structure with wall thickness or web thickness of 1/2”
or more can usually use an 8 or 6 pitch blade or sawblade of
(HSS) 4/6T satisfactorily.
3. When rectangular solid bar is to be sawed, the work should,
whenever possible, be loaded with the thinnest cross section
exposed to the blade teeth. The pitch (or number of teeth per inch
of blade) selected must provide engagement of at least 3 teeth in
the workpiece. Should application of this rule not be possible
because the thinnest cross section is too thin, the piece must be
loaded with the wider dimension exposed to the saw teeth and a
coarser blade selected from the listing of recommendations for
round and square solid bars.
Removing and Installing the Blade
When your machine was shipped, a blade was supplied and
assembled to the saw. When selecting a new blade refer to the
selection of saw blades.
1. Disconnect the machine from the power source.
2. Raise the saw frame about 6" and close the flow control regulator
(F) Fig. 1 to stop the saw frame from descending.
3. Open both wheel covers and clean the chips out of the machine.
4. Release blade tension by turning the blade tension hand wheel (G)
Fig. 2 counter-clockwise.
5. Slide left blade guide arm to the right as far as possible (I) Fig.2.
6. Remove the blade from both wheels (H) Fig. 2, guide wheels (J)
Fig.3, and out of each blade guide.
7. Make sure the teeth of the new blade are pointing in the direction
of travel. If necessary, turn the blade inside out.
Operating Instructions • Warning Information • Parts Breakdown
Fig. 1
Fig. 2
H
G
A
D C
F
B
E
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5008 7 Rev. 02/06/06
8. Place the blade in place on the wheels (H) Fig. 2, the guide wheels
(J) Fig. 3, and through the lower blade guard (I) Fig.4, and
bearings guide.
Note: Blade must run on the outside of the blade wheels as shown in
(J) Fig. 3.
9. Work the blade all the way up between the blade guide bearings
with the back of the blade against the back-up bearing, as shown
in (I) Fig.4.
Note: If bearings need adjustment, refer to the section adjusting blade
guide roller bearings.
10. Put light tension on the blade and work it on both wheels. Make
sure that the back of the blade is against the wheel flanges of both
wheels. This is very important.
11. When you are sure the back of the blade is against the wheel
flanges of both wheels and properly inserted into the guides, finish
putting tension on the blade.
Proper tension 1400kg/cm2 is achieved when the pointer (K) Fig.
5 is on the left mark of the blade tension scale behind the driven
wheel.
12. Jog the power “on” and “off” to be sure the blade is in place and
tracking properly. If blade is not tracking properly, refer to the
section tracking the blade.
Starting and Stopping the Machine
The saw frame must be in the raised position before starting the
machine. The machine is started by pushing the start button (B) Fig. 1,
and will continue to run until the saw frame is in the down position at
the end of the cut. In an emergency, press the emergency button (D)
Fig. 1.
Operating Instructions • Warning Information • Parts Breakdown
Fig. 3
Fig. 5
Fig. 4
J
J
I
K
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5008 8 Rev. 02/06/06
Blade Tracking Adjustment
Blade tracking has been set at the factory and should require no adjust-
ment. If a tracking problem occurs, adjust the machine as follows:
Since tracking can only be adjusted while machine is running, it is sug-
gested that this adjustment be accomplished by qualified personnel that
are familiar with this type of adjustment and the dangers associated
with it.
1. Raise saw arm to its highest position and close cutting pressure
control valve (F) Fig.1 to hold saw arm in place.
2. Run the blade at a slow speed.
3. Locate tracking adjustment plate on the back side of the driven
blade wheel.
4. Loosen the three bolts (L - Fig. 6) located on the top of the
tracking nuts.
5. Tracking adjustment is accomplished by either loosening or
tightening three adjusting nuts (O - Fig. 6).
6. Tracking is set properly when the back of the blade lightly touches
the wheel flange.
Note: Over-tracking (allowing blade back to rub hard against wheel
flange) will damage the blade wheels and blade.
7. Tighten locking bolts (L) once properly tracking is completed.
Adjusting Feed Rate
When the feed arm descent valve (C) Fig. 1 is turned clockwise as far
as it will go, the saw frame will not move down.
By turning the feed control valve counter-clockwise, you regulate the
flow of oil from the cylinder and determine the speed at which the saw
frame will lower and the blade will feed through the work.
Too many factors are involved to make tabulated data practical on
feed rates. As a general rule, an even pressure without forcing the
blade gives best results. Avoid forcing the blade at the start as this may
shorten blade life and produce a bad cut. By inspecting the chips while
the cut is being made will indicate whether the feed rate is correct.
Fine powdery chips indicate a feed rate which is too light. The teeth are
rubbing over the surface instead of cutting.
Burned chips indicate excessive feed which causes the teeth to break off
as the blade overheats.
The ideal feed rate is indicated by chips that have a free curl and this
will give the fastest cutting time and longest blade life.
Operating Instructions • Warning Information • Parts Breakdown
Fig. 6
LO
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5008 9 Rev. 02/06/06
Adjusting Blade Guide Brackets
The blade guides should be set as close to the vise jaws as possible. The
right blade guide bracket is not adjustable and is pre-set at the factory
to clear the right hand vise jaw. The left blade guide bracket can be
moved to the left or right depending on the position of the left hand vise
jaw. To move the left blade guide bracket (M) Fig. 7, loosen the hand
knob (N), position blade guide bracket and tighten hand knob (N).
Automatic Shut-Off Adjustment
The motor should shut off immediately after the blade has cut through
the material and just before the head comes to rest on the horizontal
stop bolt. If the machine continues to run after the workpiece has been
fully cut, or machine shuts off before the workpiece has been complete-
ly cut, loosen nut (U) Fig.8, adjust bolt (O) Fig. 8, to actuate the micro
switch at the proper height, and tighten the nut (U).
Adjusting the Blade Guide Bearings
1. Disconnect the machine from the power source.
2. Raise arm to vertical position and lock in place by turning off the
hydraulic cylinder valve (F) Fig. 1.
3. Loosen hex cap screw (V) Fig. 9, and turn eccentric nut (W) Fig.9
to adjust the bearing snug to the blade, approximately 0.08mm ~
0.12mm. Blade should still move up and down freely when
grasped.
WARNING! MAKE SURE POWER IS DISCONNECTED
AND HANDS ARE PROTECTED BEFORE
HANDLING BLADE. BE SURE THAT BLADE
TEETH DO NOT INTERFERE WITH THE
ROLLER BEARINGS.
4. Repeat for other blade guide assembly.
5. Connect machine to the power source.
Operating Instructions • Warning Information • Parts Breakdown
Fig. 7
Fig. 8
Fig. 9
N
M
OU
V
W
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5008 10 Rev. 02/06/06
Vise Adjustment
To position the moveable vise jaw:
1. Turn vise hand wheel (P) Fig. 10, 1/2 turn counter-clockwise.
2. Pull up fold handle (T) Fig. 11, to quickly move the vise jaw (Q)
Fig.10, to desired location by sliding along the bed. Lift handle (T)
back into position to connect it to the lead screw.
3. Turn the hand wheel (P) Fig. 10, to tighten or loosen the vise.
To adjust the vise for angle cutting:
1. Loosen bolts (S) Fig. 11 on the fixed vise jaw (R), and rotate vise
jaw (R) Fig. 10, to desired angle scale at side of base.
2. After setting the vise to desired angle, and tighten the nut (S) on the
fixed vise jaw.
3. Adjust the movable vise to be parallel to the fixed vise. Loosen bolts
(S) Fig. 11 on the movable vise and slide it flush with the set fixed
vise (R) Fig. 10. Then secure bolts (S) Fig. 11 on the movable vise.
Setting Up the Machine for
Operation
1. Select the proper speed and blade for the type of material you are
going to cut.
2. Make sure blade tension is adjusted properly.
3. Lift the saw frame up and turn off the oil regulating knob (F) Fig.1
to stop the saw bow, and turn the feed rate knob (C) Fig.1
clockwise to the zero position.
4. Place the stock between the vise jaws, set the stock for the desired
width of cut and tighten the vise.
5. Make sure the left blade guide bracket (M) Fig. 7, is adjusted as
close as possible to the left vise jaw (Q) Fig. 10.
6. Open the flow control knob (F) Fig.1 and turn the feed control valve
(C) Fig.1, counter-clockwise until the saw blade begins to lower by
the desired rate.
7. Proceed to cut through the workpiece. The machine will shut off
upon completion of cut.
Operating Instructions • Warning Information • Parts Breakdown
Fig. 10
Fig. 11
P
Q
R
Q
T
S
R
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