4/29/03 JOHNSON VERTICAL BAND SAWS INSTRUCTION MANUAL AND PARTS LIST SECTION I – Manual FOR MODELS E-16 V-16 V-24 VH-24 V-40 VH-40 MODEL: ________________________________________ SERIAL NUMBER: ________________________________ N MANUAL AND PARTS LIST DATE PURCHASED: ______________________________ Manual V-16, V-24, VH-24, V-40 & VH-40 DAKE Division of JSJ 724 Robbins Road Grand Haven, Michigan 49417 616.842.7110 Phone 800-937-3253 616.842.0859 Fax 800-846-3253 Web: www.dakecorp.
4/29/03 If machine is to be operated At 440 volt 3 phase power, please read the following warning. WARNING! This machine must be wired by a qualified electrician. Do not connect 440-volt power directly to this machine. The use of the step down transformer supplied with this machine must be used. Failure to do so may affect warranty, if damage occurs from improper wiring. FOREWORD These instructions cover the installation and operation of vertical band saws.
4/29/03 SECTION I - TABLE OF CONTENTS Specifications ....................................................................................... Machine Features ................................................................................ Unloading ............................................................................................. Installation ............................................................................................ Electrical ...................................................
/29/03 SPECIFICATIONS Model Number: V-16 V-24/VH-24 V-40/VH-40 Capacity: Throat Work Height Inches Inches 16 11 23-1/2 12-1/2 41 12-1/2 Table: Work Table Auxiliary Height from Floor Travel-Manual or Hydraulic Tilt-Left Tilt-Right Table Weight Capacity Inches Inches Inches Inches Degree Degree Lbs.
4/29/03 Manual V-16, V-24, VH-24, V-40 & VH-40 5 – Section I
4/29/03 Manual V-16, V-24, VH-24, V-40 & VH-40 6 – Section I
4/29/03 MACHINE UNPACKING AND INSTALLATION UNLOADING: Remove the shrink-wrap covering the machine, carefully as not to damage painted surfaces, electrical or hydraulic parts. Carefully inspect the machine for physical damage. If damage is noted, notify the truck line at once. They may require inspection, and that a claim be filed. Check that all standard accessories are with the machine. Some accessories may be boxed or placed behind access doors or chip drawer.
4/29/03 FILLING THE SPEED REGULATOR 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Turn the saw on. Screw the handwheel in. Turn the saw off once handwheel is in. Remove the mounting screws (item 6). Remove the plug from the cylinder (Item 3). Turn screw out. Add oil (Lightweight hydraulic oil) slowly while turning the wheel out. When it is completely full, replace the plug (Item 3). Re-mount the cylinder to the saw body. Turn on the saw and adjust to the desired speed.
4/29/03 WHEEL ALIGNMENT V-16 & V / VH-24 Note: This alignment is factory set, but may need adjustment when replacing blade. Two wheel machines have a bottom wheel that drives the saw blade and a top idle wheel that is adjustable to facilitate blade tracking. The edges of the wheels are fitted with a composite material to accommodate the tooth set. The idle wheel may be adjusted by loosening the knurled locking collar and turning the black knob in the center of the wheel.
4/29/03 BLADE TENSIONING The blade indicator is located inside the upper wheel compartment, on the lower left side of the idle wheel. (See machine features graphic) The indicator has an arrow mounted on the horizontal plane, with a corresponding scale for blade tensioning. The scale has two legends, one reads inches from 0 1”, the second reads mm 0 - 25 mm. This allows tensioning either standard or metric blade widths. With out tension on the blade, the indicator should read zero.
4/29/03 An analysis of the work to be performed should be made and the proper blade selected. The blade should always be inspected before installing on the machine. Things to look for should be the smoothness on the sides and back edge of the weld, look for any missing teeth, or impacted chips. The blade guides may now be selected and inserted into both the upper and lower guide holders.
4/29/03 HIGH SPEED ROLLER GUIDES Applications and Advantages: Friction and abrasive cutting, filing operations, aluminum and woodcutting. These guides eliminate having to change inserts when changing to blades of different widths. Requirements for Installation: These roller guides must be installed using a new 1/2” blade width band for proper alignment. The 1/2” band should be tracked within the approximate center line of the band wheels.
4/29/03 4: Insert the mounting stud (B) into the guide casting (A). Keep the stud flush with the front of the casting. Keeping the mounting stud flat area on the bottom, tighten securely the set screw (C) on the bottom of the casting. 5: Insert this stud and guide assembly into the 7/16” hole in the guidepost. Make sure upper roller guide is plumb with the guidepost. Lightly tighten set screw you installed in the guidepost. Lower Guide Installation: 6: Remove lower blade guide.
4/29/03 Repeat this process for the lower guide assembly. Note: Upper guide stud may be adjusted in or out in the guide post to allow proper clearance for blade, and for alignment with lower guide. Align backup bearing as previously described for upper guide. Tighten both set screws when alignment is confirmed. Re-adjust side rollers. (Graphic in previous column) Set the side clearance distance between rollers and saw blade, leaving about a .004 gap.
4/29/03 Note: Occasionally the drive wheel may have to be jogged by hand to engage the transmission lever. The variable speed is achieved through the use of a variable regulator. (Figure 3) This is turned clockwise or counter clockwise to obtain an increase or decrease in blade speed, in either range. Adjust until desired speed is reached as read on the blade speed gauge.
4/29/03 SAW BLADE SELECTION MATERIAL SHAPE MATERIAL SHAPE MATERIAL SHAPE INCHES TOOTH SELECTION TOOTH SELECTION TOOTH SELECTION 0 .1 .2 .3 .4 .5 .6 .7 .8 .9 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4 4 5 6 7 8 9 10 11 12 14 / 18 14 / 18 14 / 18 10 / 14 8 / 12 8 / 12 6 / 10 6 / 10 5/8 5/8 5/8 4/6 4/6 4/6 4/6 4/6 3/4 3/4 3/4 3/4 3/4 3/4 3/4 2/3 2/3 2/3 1.4 / 2.5 1.4 / 2.5 1.4 / 2.5 1.4 / 2.5 1.4 / 2.
4/29/03 MATERIAL ALUMINUM ALLOY COPPER ALLOY ALLOY 1/2" 1" 2" 4" 7" 12" 1100,2011,2017,2024 fpm 568 sipm 7 fpm 577 sipm 11 fpm 536 sipm 16 fpm 498 sipm 21 fpm 451sipm 23 fpm 389 sipm 24 3003,5052,5086,6061 fpm 568 sipm 7 fpm 577 sipm 11 fpm 536 sipm 16 fpm 498 sipm 21 fpm 451sipm 23 fpm 389 sipm 24 6063,6101,6262,7075 fpm 568 sipm 7 fpm 577 sipm 11 fpm 536 sipm 16 fpm 498 sipm 21 fpm 451sipm 23 fpm 389 sipm 24 356,360 fpm 511 sipm 7 fpm 501 sipm 10 fpm 482 sipm 14 fpm 448
4/29/03 MATERIAL ALLOY 1/2" 1" 2" 4" 7" 12" A-6 fpm 227 sipm 3 fpm 223 sipm 4 fpm 214 sipm 6 fpm 199 sipm 9 fpm 180 sipm 9 fpm 156 sipm 10 COLD-WORK A-2 fpm 204 sipm 3 fpm 200 sipm 4 fpm 193 sipm 6 fpm 179 sipm 8 fpm 162 sipm 8 fpm 140 sipm 9 TOOL STEEL A-10 fpm 182 sipm 2 fpm 178 sipm 3 fpm 171 sipm 5 fpm 159 sipm 7 fpm 144 sipm 7 fpm 125 sipm 8 D-2 fpm 102 sipm 1 fpm 100 sipm 2 fpm 96 sipm 3 fpm 90 sipm 4 fpm 81 sipm 4 fpm 70 sipm 4 HOT-WORK TOOL H-11,H-12,H-13 fpm
4/29/03 MATERIAL NITRONIC 50,60 fpm 68 sipm 1 fpm 67 sipm 1 fpm 64 sipm 2 fpm 60 sipm 3 fpm 54 sipm 3 fpm 47 sipm 3 ALLOY 1/2" 1" 2" 4" 7" 12" GREEK ASCOLOY fpm 108 sipm 1 fpm 106 sipm 2 fpm 102 sipm 3 fpm 95 sipm 4 fpm 86 sipm 4 fpm 74 sipm 5 416 fpm 216 sipm 3 fpm 212 sipm 4 fpm 204 sipm 6 fpm 189 sipm 8 fpm 171 sipm 9 fpm 148 sipm 9 MARTENSITIC STAINLESS STEEL FREE MACHINING 440 F fpm 182 sipm 2 fpm 178 sipm 3 fpm 171 sipm 5 fpm 159 sipm 7 fpm 144 sipm 7 fpm 125 sipm
4/29/03 MATERIAL ALLOY 1/2" 1" 2" 4" 7" 12" INCONEL 751,X750 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 WASPALOY fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 fpm 79 sipm 1 ALLOY MONEL K500 fpm 74 sipm 1 fpm 72 sipm 1 fpm 70 sipm 2 fpm 65 sipm 3 fpm 59 sipm 3 fpm 51 sipm 3 (*HASTELLOY) INCOLOY 901,903,926 fpm 68 sipm 1 fpm 67 sipm 1 fpm 64 sipm 2 fpm 60 sipm 3 fpm 54 sipm 3 fpm 47 sipm 3 INCONEL 600,718 f
4/29/03 38 353 40% HYDRAULIC FEED TABLE Machines equipped with a hydraulic feed table (VH models) have a pumping unit in the base. The system has an adjustable relief valve, which is factory preset at 400 p.s.i. This setting may be reduced to afford greater sensitivity for cutting soft or thin materials. Pressures may be lowered by turning the square nut located on the top right hand side of the reservoir.
4/29/03 Cut the blade ends accurately and at right angles. (See graphic below) Check abutment against the stop for a cut at right angles. Proper welding can only be achieved if the blade ends are cut with out a burr and at right angles. (Also see trouble shooting section) 2. ADJUSTMENT The initial jaw gap and upset force must be adjusted and proportioned to the cross sectional area of the blade being welded. A greater jaw gap will allow a wider or thicker blade to reach proper welding temperature.
4/29/03 After welding loosen the pressure clamps (7 fig. 1) and set the jaws to the wide annealing position by turning the upsetting pressure switch (2 fig. 1) counter clockwise. Re-clamp the blade so that the weld is in the center between the jaws. Operate the annealing switch (8 fig.1) until the weld becomes dark cherry red. This will take from 1 to 5 seconds depending on the blade width. Allow blade to cool until the blade returns to a dark color. Repeat this process at least three times.
4/29/03 If incoming voltage is high reverse this procedure. If incoming voltage is low, the welder transformer has taps that can be set to a 10% increase or decrease. SHOCK HAZARD! ONLY A QUALIFIED ELECTRICIAN SHOULD ATTEMPT THIS. ALWAYS CONTACT DAKE BEFORE REMOVING THE WELDER. If the welder does not shut off, after the welding cycle, or will not start the welding cycle, a limit switch adjustment is needed. THE WELDER MUST BE REMOVED FOR THIS ADJUSTMENT.
4/29/03 RIP FENCE Standard all models (figure 2) (Part number 714805 – Model 24/40) (Part number 714869 – Model 16) Used for cutting material in accurate straight lines. To attach, insert T-bolt provided in the T-slot in the front of the table. Slide into the desired position and tighten handle. PROFILE CUTTING ATTACHMENT Standard on VH-24 / VH-40 models (figure 3) (Part number 714821) This device is used for cutting irregular shapes with the use of the hydraulic table.
