SIP 12" Metal Cutting Bandsaw - Gearbox Transmission

Safety Instructions

This manual provides essential safety information for operating the SIP 12" Metal Cutting Bandsaw. It is crucial to read and understand all instructions before assembly and operation to prevent personal injury and equipment damage.

General Safety Information

• Safety symbols (Danger/Caution, Warning, Note) are used to highlight potential hazards.
• Always follow proper accident prevention measures.
• Keep guards in place and in working order.
• Remove all adjusting keys and wrenches before operation.
• Maintain a clean and well-lit work area.
• Keep children and visitors away from the work area.
• Do not force the tool; use it for its intended purpose.
• Wear appropriate apparel (no loose clothing, jewelry) and safety glasses.
• Secure workpieces using clamps or a vise.
• Do not overreach; maintain proper footing and balance.
• Maintain tools with care, keeping them sharp and clean.
• Disconnect tools before servicing or changing accessories.
• Reduce the risk of unintentional starting by ensuring the switch is off before plugging in.
• Use only recommended accessories.
• Check for damaged parts before use and repair or replace as necessary.
• Never leave the tool running unattended.

Metal Cutting Bandsaw Specific Safety

• Do not operate with dull or worn blades.
• Ensure the blade is properly tensioned and tracking.
• Always support stock in the vise and secure it firmly.
• Keep belt guards and wheel covers in place.
• Never force the saw through the cut; allow the feed cylinder to control the rate.
• Do not position fingers or thumbs in line with the cut.
• Periodically check horizontal stop screw and automatic shutoff limit switch.
• Exercise caution when replacing blades, wearing protective gloves and safety glasses.
• Support long or heavy workpieces with a roller stand.
• Develop good shop habits for safety.
• Operating this equipment can propel debris; always wear safety glasses or goggles.

Electrical Connection

WARNING: Ensure the machine is safely connected to the power supply. Inspect power cables, plugs, and connectors for wear or damage. It is recommended to use a Residual Current Circuit Breaker (RCCB) or Residual Current Device (RCD).

The bandsaw is fitted with a standard 230V ~ 13 Amp plug. Before use, inspect the mains lead and plug.

Wiring for 1 Phase Plug:

• Yellow/Green: Earth
• Blue: Neutral
• Brown: Live

If wire colors do not match your plug markings: Connect the blue wire to the terminal marked 'N' or black. Connect the brown wire to the terminal marked 'L' or red. Connect the yellow/green wire to the terminal marked with the same color or earth symbol.

Notes:

• Always ensure the mains supply is of the correct voltage and fuse protection is used.
• If using an extension lead, ensure its cross-section is sufficient to prevent voltage drops and always unwind it fully during use.

Getting to Know Your Bandsaw

Familiarize yourself with the main components of the bandsaw:

• Bow Lock: Secures the bow.
• Base: The main support structure.
• Vice Hand Wheel: Used to operate the vice.
• Blade Guide Adjuster: For adjusting blade guides.
• Blade Tension Knob: Adjusts blade tension.
• Coolant Valve Control: Controls coolant flow.
• Blade Bearing Guides: Support the blade.
• Emergency Stop: Immediately cuts power to the system and motor.
• Coolant On/Off Switch: Controls the coolant pump.
• Motor Off Button: Stops the motor.
• Motor On Button: Starts the motor.
• Speed Adjustment Lever: Selects blade speed.
• 1100watt Motor: The power source for the bandsaw.
• Bow Feed Control Knob: Adjusts the feed rate of the bow.
• Auto Cut Off Micro Switch: Detects end of cut.
• Main On/Off Switch & Control Box: Master power control.

Control Panel

The control panel features:

1. Emergency Stop Button: Press to interrupt power and stop the motor. Reset by twisting.
2. Coolant Pump Switch: Turns the coolant pump ON/OFF.
3. Stop Button: Stops the machine.
4. Start Button: Starts the machine.

Technical Specification

Guarantee

This SIP Bandsaw is covered by a 24-month parts and labour warranty for manufacturer defects. It does not cover failure due to misuse or operating the machine outside the scope of this manual. Consumable items like blades are not covered. Contact your distributor for warranty claims. Proof of purchase is required.

Assembly

Unpacking

Carefully remove packaging materials and inspect the machine for any damage. Contact your SIP distributor if damage is found. Inventory all contents.

SUFFOCATION HAZARD: Keep children and pets away from plastic bags or packing materials.

Cleaning

The machine's unpainted surfaces may be coated with a rust preventative. Clean using a cleaner/degreaser, rags, and safety glasses. For stubborn residue, a plastic paint scraper may be used. After cleaning, apply a quality metal protectant to prevent rust.

Shipping Bracket

A shipping bracket is installed to protect the bow alignment. Remove it before operation and store it safely for future use when moving or shipping the bandsaw.

Hydraulic Cylinder Installation

Follow the steps to fit the hydraulic unit, including removing the nut and washer, actuator shaft, and securing the bottom and top connections. Adjust the cut-off microswitch using screws C if needed.

Wheel Installation

Wheels can be installed to facilitate moving the bandsaw. The wheel kit includes wheels, axle shafts, split pins, and washers. Slide the axle through the cabinet, attach a washer, then a wheel, and secure with cotter pins.

Test Run

After assembly, perform a test run to ensure proper connection to power and functioning of safety components. If any unusual problems occur, stop the machine immediately, disconnect power, and fix the issue before operating again. Ensure all setup instructions are completed before starting.

1. Clear setup tools from the machine.
2. Connect the machine to the power supply.
3. Turn the power switch ON, press the motor ON button, verify operation, then press the motor OFF button. The motor should run smoothly.

Operating Instructions

Operation Overview

This section provides a basic understanding of machine operation. For detailed information, refer to the entire manual and seek additional training.

Operation

1. Examine the workpiece for suitability.
2. Adjust the swivel head for the desired cut angle.
3. Set and lock the material stop for the desired width of cut.
4. Check the out-feed side for proper support and clearance for the workpiece.
5. Wear appropriate Personal Protective Equipment (PPE).
6. Start the saw.
7. Set the feed speed, ensuring even pressure on the blade.
8. Switch on coolant.
9. The saw will stop automatically once the cut is complete.
10. Isolate the machine from the mains supply before making any changes (e.g., to the blade).

Vice Operation

The vice holds material up to six inches wide and can be set for angles from 0 to 45 degrees.

To Square Blade to Vice:

1. Loosen the lock nut.
2. Use a scale or machinist's square to set the blade angle.
3. Tighten the lock nut.

To Adjust Vice Angle:

1. Loosen the lock nut on the rear jaw.
2. Use the scale to set the desired angle.
3. Tighten the lock nut.
4. Loosen the lock nut on the opposite jaw to allow it to float and match the workpiece angle.
5. Tighten the vice against the workpiece.

Blade Selection

Choosing the correct blade is crucial for efficient cutting.

Tooth Pitch:

Measured in TPI (teeth per inch). Fine pitch cuts slower but smoother; coarse pitch cuts rougher but faster. Ensure at least three teeth are in contact with the material at all times. Use fine pitch for harder metals and coarse pitch for softer metals.

Tooth Style:

Includes Standard (even teeth, smooth cut), Skip (larger gullets, faster cut, rougher finish), Hook (digs into material, good for thick stock), and Variable Pitch (combines qualities).

Tooth Set:

Common sets include Alternate, Wavy, and Raker.

Choosing Blade TPI:

Consider material thickness, type, hardness, and shape. A chart (Figure 13) provides recommendations based on material width and thickness. Ensure at least 3 teeth contact the workpiece.

Choosing Blade Cutting Speeds:

A chart (Figure 14) provides recommended cutting speeds (FPM/M/min) for various metals. Select the speed closest to the chart recommendation. Adjust the speed using the lever on the machine.

Blade Guides

Position blade guides approximately 1/4" away from the workpiece to prevent twisting and drifting. Loosen the guide knob, slide the guide close to the workpiece, and tighten the knob.

Using the Coolant Pump

Use water-soluble coolant to prolong blade life and improve cutting efficiency.

1. Slide out the coolant tank.
2. Ensure the filter is fitted and fill with fresh coolant.
3. Slide the tank back into the base.
4. Ensure the coolant hose is over the filter.
5. Place the metal swarf filter over the coolant return hole.
6. Open the coolant tap.
7. Turn the coolant ON at the control panel.
8. Coolant pumps when the saw start button is pressed.
9. Adjust flow using the lever on the coolant tap.

Feed Rate

The speed of cut is controlled by blade type, feed rate, and feed pressure.

To Set Feed Rate:

1. Raise the bow to maximum height to remove spring tension. Close the ON/OFF valve.
2. Adjust the feed pressure tension spring using the adjustment nut. Tighten to remove play but not apply tension.
3. Clamp the workpiece in the vice.
4. Close the feed ON/OFF valve to lock the bow. Position the blade above the workpiece.
5. Turn the saw and lubricant pump ON.
6. Open the ON/OFF valve and slowly rotate the feed rate dial clockwise until the saw begins to cut.
7. Observe the metal swarf: tightly curled, warm, brown/black shavings indicate too much pressure; blue swarf indicates blade speed is too high; thin, powder-like swarf indicates insufficient pressure. Aim for evenly shaped curls.

Operation Tips

• Use a work stop for accurate multiple cuts.
• Clamp material firmly in the vice jaws.
• Let the blade reach full speed before engaging the workpiece.
• Wait for the blade to stop completely before removing the workpiece. Avoid touching the cut end as it may be hot.
• Support long workpieces and flag ends to alert others.
• Position blade guides approximately 1/4" from the workpiece.
• Use coolant to increase blade life.
• Loosen blade tension at the end of each day to prolong blade life.

Maintenance

Disconnect the machine from the power supply before any adjustments, maintenance, or service.

Schedule

Daily Check:

• Loose mounting bolts.
• Damaged saw blade.
• Worn or damaged wires.
• Any other unsafe condition.
• Clean after each use.
• Proper blade tension.

Monthly Check:

• Lubricate vise screw.
• Check gear box lubrication.

Cleaning

Vacuum excess chips and swarf, then wipe with a dry cloth. Use a cleaner for residue. Treat unpainted cast iron and steel with a non-staining lubricant. Always wear correct PPE.

Lubrication

Gears:

Use NLGI #2 equivalent grease. Apply a thin coat to headstock gears. Lubricate every 90 hours of operation. Check gearbox oil level (GL4 lubricant) every 90 hours.

Vice Leadscrew:

Clean the leadscrew with mineral spirits and a brush. Apply a thin coat of ISO 68 machine oil to exposed threads and move the vice several times to disperse the oil. Lubricate every 40 hours of operation.

Blade Change

Change blades when dull, damaged, or for different material requirements.

1. Disconnect power.
2. Raise bow, close feed valve, remove wheel access cover.
3. Remove blade guards.
4. Loosen tension handle and slip blade off wheels.
5. Install new blade around bottom wheel and through guides.
6. Slip blade around top wheel, keeping it between guides.
7. Ensure blade back is against the wheel shoulder.
8. Complete by following Blade Tension & Tracking steps.

Note: Check blade teeth direction; they should face the workpiece.

Blade Tension & Tracking

Proper blade tension is essential for blade life, straight cuts, and efficiency. A blade tension indicator is provided.

To Loosen and Tension Blade:

• Turn tension handle clockwise to tension, anti-clockwise to loosen.

To Adjust Blade Tracking:

1. Disconnect power.
2. Position bandsaw vertically.
3. Open wheel access cover.
4. Loosen lower hex bolt in wheel tilting mechanism.
5. Loosen blade tension.
6. Adjust set screw with a 4mm hex wrench: tightening moves blade closer to wheel shoulder; loosening moves it away.
7. Tension the blade.
8. Reconnect power and turn ON. Check if the blade tracks along the wheel shoulder without rubbing. Repeat steps 4-7 if necessary.
9. Turn OFF bandsaw.
10. Close blade guard and wheel access cover.

Note: Loosen blade tension at the end of each day.

Squaring the Blade

Periodically check and adjust blade squaring to the table for improved cutting results and blade life.

1. Disconnect power.
2. Lower head until it contacts the horizontal stop.
3. Place a square on the table bed against the blade edge and check different points.
4. Loosen hex bolt and rotate blade guide until the blade is vertical to the bed.
5. Tighten cap screw.

Blade Guide Bearings

Blade guide bearings are factory adjusted. Improper adjustment can lead to uneven wear or crooked cuts. Adjust eccentric bushings to set the distance between the blade and bearings. Ensure bearings make light contact with the blade.

Troubleshooting

Review this section for common problems and solutions.

Motor & Electrical

• Machine does not start or breaker trips: Check plug/receptacle wiring, power supply, motor wiring, start capacitor, fuse/breaker, ON/OFF switch, wiring integrity, or motor fault.
• Machine stalls or is underpowered: Ensure correct blade/material, appropriate feed rate/cutting speed, proper blade tension/tracking, sufficient power supply voltage, and check motor bearings or connections.
• Machine has vibration or noisy operation: Check for motor fan rubbing, blade issues, gearbox faults, or incorrect blade/speed settings.

Bandsaw Operations

• Machine is loud or bogs down: Check feed rate, blade TPI, or material coarseness.
• Blades break often: Verify blade tension, workpiece security, feed rate, blade TPI, blade rubbing on flange, starting method, guide bearing alignment, or blade quality.
• Blade dulls prematurely: Adjust cutting speed, blade TPI, feed rate, or check workpiece for hard spots/scale. Replace blade if twisted or slipping.
• Teeth ripping from blade: Check feed pressure, blade speed, TPI, workpiece vibration, or chip loading in gullets.
• Cuts are crooked: Adjust feed pressure, blade guides, blade tension, or check if the blade is dull or speed is incorrect.

Exploded Drawings and Parts Lists

This manual includes detailed exploded drawings (Parts Drawing A, B, and C) and corresponding parts lists. These sections are essential for identifying all components of the bandsaw and its gear driving system for maintenance, repair, or replacement purposes. They provide comprehensive visual and numerical references for every part of the machine.

Declarations of Conformity

The UK and EU Declarations of Conformity confirm that the SIP 12" Metal Cutting Bandsaw Gearbox Transmission meets the requirements of relevant directives and harmonized standards, including those related to Machinery Safety, Electrical Equipment Safety, Electromagnetic Compatibility, and Restriction of Hazardous Substances.

Disposal Information

Please dispose of packaging responsibly in an appropriate recycling bin. Never dispose of electrical equipment or batteries with domestic waste. Utilize disposal facilities or recycling agents to help protect the environment and recycle raw materials.