Starrett S1101 Band Saw Machine Manual by The L.S. Starrett Company Ltd

Instruction manual for the installation and maintenance of band saw machine model:

S1101 The Original Manual was written in Portuguese

Serial Number: Date:

220-230V

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CONTENTS 1. GENERAL AND REFERENCES 1.1 General 1.2 Figure and Part References

2. APPLICATION, GENERAL DESCRIPTION AND TECHNICAL CHARACTERISTICS 2.1 Application 2.2 General Description 2.3 Technical Characteristics 2.4 Optional

3. HANDLING AND INSTALLATION INSTRUCTIONS 3.1 Handling 3.2 Installation

01 01 03

05 05 06 13 14

15 15 15

4. USING THE MACHINE

4.1 Limits and Recommendations 4.2 Band Saw Selection Criteria 4.3 Adjustment Procedure and Machine Start-up 4.4 Band Saw Replacement and Adjustment Procedures 4.5 Angular Cutting Procedure 4.6 Blade Adjustment to Blade Guides 4.7 User Safety

5. SYSTEMS AND OVERALL MAINTENANCE

23 23 26 29 33 34 37

5.1 Cleaning 5.2 Electrical System 5.3 Machine Safety System 5.4 Measuring Rod System 5.5 Periodic Maintenance 5.6 Troubleshooting and Solutions

41 42 44 45 46 49

6. MACHINE IDENTIFICATION

7. CERTIFICATE OF COMPLIANCE

8. WARRANTY

9. SPARE PARTS

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1 . GENERAL AND REFERENCES: 1.1 General This Instructions Manual consists of 9 Sections containing relevant and important information to be observed. Such information will be "namedâ&#x20AC;? in accordance with the symbols appearing below in boldface.

WARNING:

Operation, technical and other procedures likely to cause physical damages to operator and/or to equipment;

OBSERVATION:

Operation, technical and other procedures that must be emphasized and observed;

ELECTRICAL INSTALLATION:

Important Electrical procedures.

Installation

For any doubts a user could have on the Starrett machine, the Customer Service Center, through its Technical Support Service, will be at your disposal to promptly assist you in your cutting needs. This Manual presents a serial number that coincides with the machine serial number. Should you experience any problem within the machine warranty period please mention this number (See Warranty terms in Section 8).

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1.2 Figure and Part References

Figure 01A

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Figure 01B

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S1101 / 220-230V ING POS. 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

DESCRIPTION Complete Machine S1101 Cutting table Vise Handle Clamp Lock Lever Band Saw Blade Mobile Guide-Lock Lever Vise Set Blade tension device Bow Carry handle Motor Electromagnetic switch (ON/OFF/EMERGENCY) Jaws Bow lock knob Technical Instruction - technical characteristics Technical Instruction-cutting direction Spring force adjustment hand Flywheel Spring system Drive Flywheel Back Cover Lifting handle Driven Flywheel Mobile guide Ball bearings Fixed Guide Vise Spindle Screw Bow swivel lock bolt Chip collection box Protractor Blade protection cover Moving guide support Micro Switch Microswitch drive pin Tool Panel Technical Instruction - tension directions Measuring rod Stopper Technical instruction – Bow lock Spring setting lock pin Cutting Force Adjustment Scale (L, M, H) Adjustable Mobile Guide Protection Power cord Starter key cover Bow swivel scale Nameplate Ball bearing fastening screw Nut Eccentric Bolt Lifting lock bow Technical instruction – Bow Lock Moving Guide protection cover Back Cover Screw Back Cover Fixed Pin Fixed Pin Micro Switch Pin Back Cover Micro Switch Technical Instruction

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2 . APPLICATION, GENERAL DESCRIPTION AND TECHNICAL CHARACTERISTICS: 2.1. Application (adequate use):

THE STARRETT–S1101 HORIZONTAL BAND SAW was developed to meet the quality, safety, modernity and technology criteria, in response to user needs, in conformity with directives EC and European standards.

This machine is intended for PROFESSIONAL and/or HOBBY, PORTABLE use, recommended for cutting structural shapes, thin-wall tubes, made of low-carbon ferrous or non-ferrous materials (bronze and aluminum alloys, among others). The physical characteristics of such materials, such as hardness, tenacity and density, should pose no safety problems for users during cutting operations.

This equipment IS NOT recommended for cutting materials whose production volumes are high and continuous, i e., involving several operating hours each day. In such cases, Starrett recommends one of its other machine models more specifically developed and designed for large volume cutting operations.

If used in INDUSTRY, the technical characteristics and machine cutting capability limits shall be complied with item 2.2 –Technical Characteristics, or else stand liable for LOSING THE WARRANTY granted by Starrett.

If in doubts,

Starrett will be at your disposal for any clarifications.

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2.2. General Description: 2.2.1. Bow Set: The machine consists a rigid Bow (10) provided with 2 Flywheels: one Driven Flywheel (25) and one Drive Flywheel (21), the latter coupled to a Speed Reducer. The Driven Flywheel (25) is mounted on the shaft of a Band Saw Blade Tension Device (09). A welded Band Saw Blade (06) is mounted around the two Flywheels and conveniently tensioned by the Tension Device (09), to keep the blade properly tensioned by the Flywheels (21)(25). The Bow (10), in turn, is mounted on the Vise Set (08) through a shaft that allows the Bow to pivot on the saw plane, thus creating a cutting plane (figure 01A). The Blade (06) and Flywheels (21)(25) are protected at the back of Bow (10) by a Protection Cover (23) (figure 02). In order to move the Bow (10) upwards (figure 04), it should be first unlocked by the Bow Lock Knob (15). The machine is so designed as to cause the Bow (10) to swivel around a fixed point on the Vise Set (08), i.e., along a plane at right angles to the Cutting Table (03), to allow for angular cuts to be made on the material to be cut (figure 10). The cutting pressure of the Band Saw Blade (06) on the material is set through a Spring System (20) (figure 07), which is part of the Bow assembly (10). Such spring system allows for 3 settings to be available: HIGH (H), MEDIUM (M) and LOW (L), duly marked on the Flywheel (19), as can be seen in figure 08. The Band Saw Blade cutting segment (06) is supported by two Guides (26)(28). Such Guides are provided with Ball Bearings (27), which allow the blade to be twisted by 45Âş relative to the rotation plane of Flywheels (21) (25), to form the cutting plane. Such Ball Bearings (27) are intended to align and prevent the Band Saw Blade (06) from laterally deflecting around the axis of its track movement. The Mobile Guide Support (35), close to the driven Flywheel (25), can be manually

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S1101 / 220-230V - ING adjusted by loosening Lever (07), to set its distance relative to the material to be cut (figure 03). The S1101 has a special protection used together the Mobile Guide (26). This Adjustable Mobile Guide Protection (45) can be used in all conditions of cutting capacity. When the user needs to cut a material with small dimensions, the Adjustable Mobile Guide Protection (45) must be slide forward (figure 05C). The user needs to check if this protection will not interfere in the operation or touch in the material to be cut, preventing the movement down of the Bow (10). Also, if the user needs to cut in the maximum cutting capacity, with the Bow (10) in 45o, this protection can move up, to allow the material will be free of interference this safety device (figure 05D).

2.2.2. Vise Set: The Vise Set (08) (figure 01A) is intended to securely clamp the material to be cut to the Cutting Table (03) and forms the base of the machine, made of injected aluminum alloy. Such assembly is comprised of: - Cutting Table (03); - Jaws (14); - Vise Spindle Screw (29); - Handle (04). - Clamp Lock Lever (05).

2.2.3. Electrical System: An Electrical Panel (13A, 13B and 13C) is coupled to the Bow Assembly (10), as shown in figure 01 A. This electrical system comprises an electromagnetic ONOFF switch that drives the machine (13A, 13B), and a Emergency Button (13C). The machine operates on SINGLE PHASE 220-230V, at 50/60 Hz frequencies. It allows for one single cutting speed, which changes according to the mains frequency: 45 m/min under 50 Hz or 54m/min under 60 Hz. REV. 4 JAN/11 (TĂ&#x153;V SUD/CE)

S1101 / 220-230V ING For safety, this model is equipped with a device that turn off the electrical system if the Back Cover (23) is disconnected of the Bow (10). When the Back Cover (23) is connected again, the cover touches in the Micro Switch Pin (59), it allows that electrical system turned on by Electromagnetic Switch (13) (see figure 5B and item 5.2).

Figure 02

Figure 03 8

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2.2.4. Machine operation: With the machine duly adjusted, electrically connected, with the material to be cut properly positioned and locked on the Cutting Table (03) and with the Bow (10) in its raised position, open the yellow cover containing the Switch Assembly (13 A, B, C) (figures 01, 09D), and actuate the green Button ON (13A). Manually position the Band Saw Blade (06) over the material to be cut, by means of the Lifting Handle (24). This operation will start the Band Saw Blade (06) cutting motion on the material. At the end of the cutting operation, the Drive Pin (37) will touch the Limit Micro switch (36) (figure 07), automatically switching off the Electric Motor (12). For being portable equipment for professional and/or hobby use, the STARRETT–S1101 Horizontal Band Saw Machine does not have a cooling system included. Therefore, in order to guarantee its safe and quality operation, the operator must observe the cutting conditions. As an OPTIONAL item, the STARRETT – S1101 can be provided with a Portable Bench Demountable called BPM 1101 (see Section 2.4 and figure 04).

NOTE: The Band Saw Blade cutting segment (06) (between Guides (26)(28)), obviously has no protection, being the responsibility of the machine operator to act carefully and taking the necessary precautions. All necessary details of the systems comprising this machine will be described in their relevant Sections.

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NOTE: O maximum opening angle of the Bow (10) (maximum height) with Cutting Table (03) is limited in 60ยบ, as figure 04.

Figure 04

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Figure 05A

Figure 05B

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Figure 05C

Figure 05D 12

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2.3. Technical Characteristics: Net Weight (kg):

Dimensions (m):

0.73 x 0.38 x 0.46 (height)

Main Motor (hp / kW)

0.5 / 0.37

Cutting Speed (m/min):

45 (under 50 Hz) 54 (under 60 Hz)

Band Saw Blade Dimensions (mm):

1470 (± 2) x 13 x 0.50 or 1470 (± 2) x 13 x 0.65 (*)

SINGLE PHASE voltage (V):

220-230

Motor operating frequency (Hz):

50 or 60

Capacity Cutting (mm):

The S1101 IS NOT provided with a cooling system. The cutting process is DRY. Noise Level as EN ISO 3744:

Lw = 91,7 dB(A) Lp = 78,7 dB(A)

Noise Declaration (EN 13898:2003+A1:2009 (E) item 7.3): "The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of the workforce include characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes. Also the permissible exposure level can vary from country to country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk."

Degree of Protection (IEC 60529):

IP 21

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2.4. Optional: BPM1101 – Portable Bench Demountable (*) the S1101 comes equipped and adjusted with a band saw blade with 0.50 thickness. If willing to equip it with a 0.65mm-thick blade, see the instructions in item 4.6.

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3 . HANDLING AND INSTALLATION INSTRUCTIONS: 3.1. Handling: WARNING: To properly install this machine, CAREFULLY READ this Instructions Manual, after unpacking. The S1101 is supplied within a reinforced carton box, internally protected by another box made of expanded polystyrene, containing the machine, its accessories, tools and instructions manual.

The machine gross weight is 29.5 Kg, but should be moved, if possible, with the help of a hauling device, to avoid any possible inconvenience when moving it over large distances.

3.2. Installation: The machine should be installed in a well lit work environment, over a flat, properly fastened workbench. If using the Portable Bench Demountable BPM1101, the floor shall be suitable, safe, and free from imperfections that could render the machine unstable.

WARNING: The machine should not be installed in environments subject to explosion of fire hazards.

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S1101 / 220-230V ING There is no need to fasten the machine to the workbench but, should this be required, there are 3 points (Ă&#x2DC;7mm holes), located on the 2 rear corners and 1 on the right-hand corner, which could be used as fastening points. In the event of lengthy and heavy materials being handled, our recommendation is for the machine to be fastened to the workbench. If using the Portable Bench Demountable BPM1101, we also recommend having it adequately fastened to the floor. Upon completing the installation, the installer or whoever did it, should check that all machine parts are:

Perfectly complete (no cracks or any other damages), particularly, the Emergency Switch (13C), Electric Motor (12), Jaws (14) and Vise Handle (04), and the Tool Panel (38);

In conformity with what is mentioned in the manual and as requested by customer (optional).

NOTE: In the event of any part not being intact or not in conformity with customer order and/or with the manual, the customer (or installer) should immediately notify Starrett, in writing, to receive the directives, also in writing, on what should be done to solve the problem.

However, after detecting the problem, the installer shall not proceed with the installation until the problem is fully solved and clarified.

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S1101 / 220-230V - ING The connection of the machine to the customer electric system supplier shall be carried out by qualified technician. Prior to connecting the machine to the electric network, the user should check: 1. that the power cord supplied with the machine is intact along the whole of its length; 2. that the power mains is of the same voltage (Volts) and frequency (Hz) as specified on the machine;

NOTE: The user external electric system must have been wired with cables whose cross section is equal to or greater than 1.5mm2. Also, it must be externally protected by 5A fuses or circuit breakers.

NOTE: The use of cable extensions can cause loss of power. To prevent extension cables from overheating, a condition that could lead to damages to the machine motor, the following cable gauges should be used for 220-230V: - up to a length of 15m

Æ use a 1.5 mm2 cross-section cable;

- from 15 to 40 m

Æ use a 2.5 mm2 cross-section cable.

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Starrett has many options to the power cord for different standards and countries. See the table below:

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WARNING: DANGER! To avoid electric shocks: Do not use the machine under the rain or on a wet floor. The S1101 should be used indoors and on dry environments.

WARNING: Always check that the grounding cable is properly connected and that there are no connections in common with the user electric system supplier Neutral.

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4. USING THE MACHINE: 4.1. Limits and Recommendations Before starting any type of machine work, check that the service to be performed

falls

within

the

limits

specified

the

chart

for

TECHNICAL

CHARACTERISTICS (Section 2). If being off-spec, our recommendation is for the user to query Starrett in writing on the possibility of changing some of the technical specifications. Starrett will reply in writing whether or not the solution may be adopted.

WARNING: Starrett shall not be liable for damages caused to people or objects, being the user responsibility to carefully check the characteristics of the material to be cut to avoid any and all risks to the operator and/or to third parties. If within the machine specified capabilities, the selection of the blade will become the second most important factor toward a satisfactory performance of the work to be carried out.

4.2. Band Saw Selection Criteria: In order to properly select the Band Saw Blade to be used, refer to the table below for the type and shape of the material to be cut off.

- CUTTING OF STRUCTURAL TUBES AND SHAPES: 1. Measure the average thickness (S) of the tube or shape to be cut off; 2. Depending on the thickness (S), select the corresponding welded blade code (CAT #) from table 01;

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S1101 / 220-230V ING 3. The selected blade will be found in Starrett distributors, in 1-unit packages, as indicated in figure 06. Should some particular product not be found, please refer to Starrett Customer Service Center.

- CUTTING SOLID MATERIALS: 1. Measure the material diameter or base and compare with the figures in table 01.

NOTE: Make sure the Band Saw Blade (06), is tracking in the same direction indicated on the Technical Instruction (17) located on the Bow (10). Should the direction of rotation be contrary to that indicated in the nameplate, please call Starrett Technical Support. 2. CHECK if the capacity is within the limits indicated in the table; 3. Depending on the measurement (L), select the corresponding welded blade code (CAT No) from table 01; Cortes de materiais maciços com L > 50mm, consultar manual de instruções ou assistência técnica Starrett.

Cortes de materiales macizos con L > 50mm consulte el manual de instrucciones o la asistencia técnica Starrett.

Cutting of solid materials with L > 50mm refer to instruction manual or call for Starrett technical support. Coupes de matériels massifs ave L > 50mm, voir le manuel d’instructions ou appeler l’assistance technique Starrett.

Für den Schnitt von massigen Materialien mit L>50mm bitte die Anweisungen im Handbuch beachten oder den Technischen Kundendienst von Starrett befragen.

CAT Nº

<2 mm

1101-4

2-4 mm

3-6 mm

S S S

TABLE 01 Should a replacement blade be required, notify the Starrett Distributor on the most indicated reference CAT # for the cutting operation to be performed.

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5-12 8-25 15-50 mm mm mm

1101-1 1101-2 1101-3

L L

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Figure 06

CAT #

Specification:

1101-1

UNZ 13x6-10 P-1,47

1101-2

UNZ 13x10-14 S-1,47

1101-3

UNZ 13x14-18 S-1,47

1101-4

UNZ 13x24 S-1,47

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4.3. Adjustment Procedure and Machine Start-up: 4.3.1. Adjustments and Checks: Prior to starting any type of work on the machine, check: 1. The conditions of Band Saw Blade (06), as to their teeth and body integrity; 2. The tension of Band Saw Blade (06), by rotating Lever of Tensioning Device (09) to check for the conditions indicated on the Technical Instruction (39) located on Bow (10); 3. If the tooth count and design are the most indicated for the cutting operation to be performed. Check that the selection conforms to the provisions of item Band Saw Blade Selection Criteria in this Section; 4. That the piece to be cut is well positioned on the Cutting Table (03), i.e., duly supported and flat on table surface; 5. After such adjustments and checks, select the cutting pressure, as per table 2 below.

TABLE 02

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S1101 / 220-230V - ING The Cutting Pressure adjustment is very important. For its conception, the S1101 is a gravitational machine, whose cutting force is exercised downwards by the weight of Bow (10). However, such cutting pressure of Band Saw Blade (06) on the material to be cut can be set by Spring (20). Therefore, select one of the options in TABLE 02 (42), and then unlock the system by pulling out Pin (43) (figure 07). Turn the Set Flywheel (19) until the desired letter L, M or H on Scale (44) (figure 08), matches the white line. The Pin (43) will automatically relock the Set Flywheel (19). This action will result in a proper cutting performance avoiding, among other problems, any cutting deviations.

Figure 07

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4.3.2. Machine Start-Up: Lift the Bow (10) to its upright position by unlocking Knob (15). In the upright position, lock Bow (10) again in that position, through Knob (15). Then, to fix the material to be cut, uncouple Vise Spindle Screw (29) to let it free, by moving Lever (05) to its upright position. Adjust the Vise Spindle Screw (29) to open the vise to place the material on the Cutting Table (03) and adjust it to the desired cutting position. By placing Lever (05) back to its horizontal position, couple Vise Spindle Screw (29) to the vise tightening nut. Turn the Vise Handle (04), in the tightening direction, the material will be securely clamped. After adjust the Mobile Guide Protection (45), as the dimensions of material that is cutting. If the dimension is smaller pull the Mobile Guide (26) forward position, and protection must be cover the zone that is not in contact with material. (figure 5C). Also, if the material that is being cutting has big dimensions, the Mobile Guide (26) must be push to back position. In this case the Mobile Guide Protection (45) must move up, as figure 5D.

NOTE: In all adjustment of Mobile Guide Protection (45), check the clamping this part by Mobile Guide Lock Lever (07). NEVER try to remove the Fixed Pin (58). This part is permanent fixed together with Bow (10).

NOTE: The cutting operation must be carried out with the cutting pressure adjusted according to item 4.3.1 line 5, in addition to the proper Blade (06) tooth count and design, which depends on the thickness of the material being cut.

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S1101 / 220-230V - ING It is very important to try and keep the cutting conditions within the parameters established by Starrett. By doing this, the Band Saw Blade efficiency and operating life will be higher.

For proper machine use, it is important to keep Guides (28) (26) always clean â&#x20AC;&#x201C; stop the machine and use Micro-Oil Starrett M1 for cleaning.

Figure 08

4.4. Band Saw Blade Replacement and Adjustment Procedures: To change the Band Saw Blade (06) requires that the Bow (10) to be placed in its upright position, and then: 1. TURN-OFF the machine - electrically powering down the machine by disconnecting the Power Cord (46) from the power mains; 2. Remove the Back Cover (23), by loosening the 5 Screws (56) located under the Bow (10) (figure 05A). The Screws must remain connect the body the Bow (10);

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S1101 / 220-230V ING 3. Move up the Back Cover (23), and after rotate it to the left side around the Fixed Pin (57), as showed in the figures 09A, 09B and 09C.

WARNING: The Fixed Pin (57) CAN NOT BE REMOVED. ItÂ´s fixed in the body of the Bow (10). NEVER try to remove it. The Back Cover (23) must remain connected with machine every time, for safety of its user.

4. Unlock through the Knob of the Tension Device (09) to release the tension of Band Saw Blade (06), checking the direction through the Technical Tension Directions (39) (figure 01B); 5. Carefully remove the Band Saw Blade, while wearing leather scraped gloves;

6. Before installing a new blade, thoroughly clean the surface where the blade touches the 2 Flywheels (21)(25) and the inside of Guides (26)(28), and inject Micro-Oil M1 into Ball Bearings (27); 7. Mount the new Band Saw Blade (06), making sure its teeth are intact and compatible with the material be cut, checking that the teeth are in the proper direction indicated in the Technical Directions (16) (figure 01B) or in Table 01. Firstly, fit the blade within the gap of both Guides (26) (28) (between Ball Bearings (27)) and then around the Drive Flywheel (21) and, finally, around the Driven Flywheel (25) (figure 05);

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Figure 09 A

Figure 09B

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Figure 09C

Figure 09D 8. With the Band Saw Blade (06) in place, tension it by turning the lever of Blade Tension Device

(09) in the direction indicated in the Technical Instruction

(39)(stretch); 9. Mount the Back Cover (23) fitting it through of 5 Screws (56). Tighten them with Phillips screw driver that is in the Tool Panel (38). Check if the machine is running.

After this sequence of operations the MACHINE WILL BE READY TO GO.

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4.5. Angular cutting procedure: Should an angular cut (â&#x2030; 0o) be required to the right side of the operator (0o to +60o maximum), proceed as follows: 1. Keep Bow (10) in its upright position, as per figure 04; 2. Loosen the Bow Swivel Lock Bolt (30) (figure 07), using a 13mm open-end wrench. Turn the Bow (10) to the desired angle, as visualized in Scale (48) by Protractor (32) (figure 11). Then, tighten the Bow Swivel Lock Bolt (30).

WARNING: Before starting the cut operation, MAKE SURE Bolt that the Bolt (30) is locked (the Bow swivel (10)), to avoid any inconvenience when in operation (figure 11).

Figure 10

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4.6. Blade Adjustment to Blade Guides: The S1101 machine is capable of operating with 2 standardized Band Saw Blade thicknesses. From factory, all machines are fitted with 0.50mm thick Band Saw Blades. Should user desire, or be recommended by Starrett, a 0.65mm-thick Band Saw Blade could also be used. To this end, itÂ´s necessary to make a quick adjustment to seat the Ball Bearings (27) on the sides of the Band Saw Blade (06) simply follow this procedure (Figures 12B and 12C). Before all, in turn counter-clockwise lever tensioning Tension Device (09) to loosen and release the tension, following the adjustments instructions below. Remove the Protections (34) and (55) (Figure 12A). Then, loosen it slightly with the help of a 13mm wrench, Hex Nut M8 (51) located at the top of Guide Fixed Support (28) and Mobile (26). With a 4mm Allen wrench, turn the Eccentric Bolt (52) to bring the Ball Bearings (27) saw blade (06). The cover of the bearings (27) must touch all the side of the Band Saw Blade (06). Then, retighten the hex nut M8 (51) to lock the Eccentric Bolt (52) and tensioning again the Band Saw Blade (06) by turning the lever of Blade Tension Device(09) clockwise. Replace the Protections (34) and (55). To accomplish this, the user may use standardized thickness of the saw blade (06). Figures 12B and 12C show clearly the sequence of this procedure. To facilitate the procedure sets up the Guide (28) and Mobile (26), remove the letter of Protections (34) and (55) with a key type Phillips, who is sent along with the machine, as illustrated in Figure 12D.

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Figure 12A

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Figure 12B

Figure 12C

Figure 12D

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4.7. User Safety: The STARRETT – S1101 machine was designed to provide full SAFETY during its use. To avoid unnecessary risks of accident, please observe a few important details: • Always wear duly approved SAFETY GLASSES and EAR PLUGS;

• Wear LEATHER SCRAPED GLOVES, whenever changing the machine Band

Saw Blade (06);

• To carry the machine by the Carry Handle (11), make sure the security lock (53)

is positioned as shown below and in the Technical Instruction (54) fixed on the basis of the Cutting Table (03);

• NEVER permanently remove the Saw Protective Cover (23), to avoid

accidents and to prevent possible pieces (chips) of material from being thrown toward you, in particular to protect your face and eyes.

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AVOID cut of small pieces, as these can easily let loose causing some

damage to the operator or to the machine;

•

NEVER ALLOW this machine to be used by unqualified and/or untrained

operators; •

OBSERVE the instructions contained in item Installations, Section 3, when

operating the machine near unprotected people;

•

During cutting operations, NEVER loosen Vise Set (08), or manually force the

Bow (10), or perform any operation other than in an emergency; •

MAKE SURE the loading of the material to be cut is made in a safe manner.

Such operation can be performed either manually or with the help of a traveling crane. In this case, make sure a safe distance will be kept between the operator and the material, and that the material will be carefully placed on the machine; •

OBSERVE and TAKE CARE in the area behind the Vise Set (08), near the

Drive Flywheel (21), as this is not provided with a protective cover, thus being exposed to possible hand contact. The Technical Instruction (61) fastened to Bow (10) emphasizes such hazard and the need for due care. Extreme care must be taken when handling pieces and all necessary precautions should be adopted;

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CAREFULLY READ this Instructions Manual and COMPLY WITH all technical

directions attached to the machine.

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WARNING: Under no circumstances should any of the Technical Instructions (Plates) attached to the machine be removed or changed.

WARNING: At the end of each cutting operation, the section of cut process, the material may, due to their very size, cast loose and drop on the floor, thus causing risks to the operator upper and/or lower limbs. In order to avoid accidents and increase the operator safety, it is its responsibility to see that resources such as supports, rollers, tables, etc., will be available during cutting operations, and to comply with all applicable Safety Standards, in addition to wearing IPE (Individual Protection Equipment), such as leather scraped gloves, safety shoes and safety glasses.

WARNING: RISK OF ACCIDENT! DEFINITION OF WORK DESK USER :

During the cutting process, the user should be mandatory in front of the machine, attentive to the main cutting parameter settings, and with your free hand to immediately access the button EMERGENCY (13C)

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5 . SYSTEMS AND OVERALL MAINTENANCE:

This purpose of this Section is to describe the main systems comprising this machine, in addition to the key periodic maintenance procedures. By keeping such inspections updated, a proper and continued machine performance will be obtained.

5.1. Cleaning It is very important:

To clean and eliminate, on a daily basis, all chips remaining on the Flywheels (21) (25) and on Guide assemblies (26) (28);

At certain intervals during the day, remove any built-up chips from the Cutting Table (03) and from the chip Collecting Box (31);

Periodically monitor the status of the Electric Power Cord (46).

WARNING: Should compressed air or equivalent systems be used for cleaning, the user should WEAR SAFETY GLASSES to avoid serious accidents.

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5.2. Electrical System: The electric system was developed and designed in compliance with EC technical standards. The standard machine is designed to operate with 1 single-phase motor top move the Band Saw Blade (06). All machine commands, including switches and other components operate on 220-230V.

SYMBOL

DESCRIPTION AND FUNCTION

TECHNICAL DATA

Power socket outlet

250VAC 10 - 16A

Power Cord

1.0mm x 3G HO5W-F

SQ1

Limit Switch

SB1

Electromagnetic Switch (ON/OFF/EMERGENCY)

Motor starter capacitor

Motor (12)

MS2

Back Cover Micro Switch (60)

Ui=500V Uimp=6kW AC-15 240V / 3A IP 65 KEDU – KJD12 16(12)A/250V 2P 50/60Hz – IP54 5E4 Capacitance: 100μF 220-240VAC 50/60Hz Single-phase -220-230V 50/ 60Hz 4P 0.38 KW -1700 rpm KEDU - HY-50-4 6A/250VAC EN61058

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ELECTRIC WIRING DIAGRAM

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5.3. Machine Safety System: This machine is equipped with the following safety devices: Emergency (13C) – A red Button can be actuated to disable the machine and stop the motor. The machine will only resume its operation after the Cover (47) is opened and the green Button (13A) is pressed (figure 13A); Regular Stop (13B) – Upon the red Button being depressed by the operator, it will automatically activate the movement of the Band Saw Blade (06). Safety Micro Switch (60) – This model is equipped with a safety device, that disable the electrical system, and permit that the user change the Band Saw blade with safety. The machine only can turn on, if the Back Cover (23) is connected with Bow (10) (Figure 13B).

Figure 13A

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Figure 13B

5.4. Measuring Rod System: The S1101 machine is fitted with a standard Measuring Rod system, comprising a 500 mm Measuring Rod (40) and one Stopper (41). First, the tip the Measuring Rod (40) is installed by threading it to the Vise Set (08). Then, the Stopper (41) is installed, as shown in figure 01B. To cut the material to a given length, use a ruler or a tape measure to adjust the distance of the Stopper (41) tip to the face of the Band Saw Blade (06), follow the steps: 1. Touches the material to be cut in the top of the Stop (41), 2. Clamp the vise by Vise Handle (04) to lock the material; 3. Start the electric motor by Switch (13), and start up the cutting process by the Band Saw Blade (06).

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Figure 14

5.5. Periodic Maintenance: For the STARRETT S1101 to have a proper cutting performance, and to increase its durability, it must be kept on adequate operating conditions, by periodically checking the items below: 1) Internal and external CLEANING, by removing chips and other objects resulting from the cut operation. It is also advisable to clean the rubberized surface of both Driven and Drive Flywheels (25) (21), in addition to their corresponding Cutting Guides (28) (26). This must be a daily procedure; 2) DAILY CLEANING of the Vise Set (08), by removing chips from the Chip Collection Box (31) fitting; 3) LUBRICATION, every 2 months, of the Drive Flywheel (21), as per the following procedure: - Using a 5mm hex wrench, loosen the internally centered hexagon head screw fastening the corresponding Flywheel (21) (figure 15 A); - Then, lubricate with high durability GREASE each of the points indicated in figures 15B and 15C, i.e., the internal gear of the Drive Flywheel (21) and the reducing gear pinion; - Upon such operation being performed, reassemble the Drive Flywheel (21) using the internally centered hexagon screw and the 5 mm hex wrench 5 mm.

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Figure 15A

Speed Reducer Pinion (GREASE Lubricated)

Figure 15B

Lubricate the internal gear with GREASE every 2 months

Figure 15C

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S1101 / 220-230V ING 4) ADJUST the Band Saw Blade (06) tension, as required. However, if required, follow the procedure below (figures 16 A and 16 B): - Disassemble the Driven Flywheel (25) by removing its center screw with a 5 mm hex wrench. Note the existence of a spring system fitted with 10mm hexagon nuts at either end (figure 16 B) with the help of a Starrett tensiometer (OPTIONAL) model 682 EMZ / EDP 57075, the Band Saw Blade (06) tension can be adjusted. The recommended value for the Band Saw Blade tension is 14,000 pound sq.in = 14 KSI (= 985 Kgf/cm2). - We recommend such a procedure to be made by the Starrett Technical Support sector or by one of its Authorized dealers. Please contact Starrett for greater safety.

Figure 16 A

Figure16 B

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5.6. Troubleshooting:

PROBLEM Blade does not move

PROBABLE CAUSES AND SOLUTIONS

The 0 to 45º tilt is catching

Check if: - emergency (13C) is disabled; - safety micro switch (60) is disabled, because the back cover is opening or is not fitting correctly in the bow (10).

The blade does not stretch

- Too much dirt on machine surface; - Clean and lubricate areas between moving surfaces;

The blade will not stay on Flywheel

Check if the length of blade (06) is 1470 ± 2 mm; Check for: - blade (06) tension; - clearance between Flywheel bearings;

Crooked cut Check if: - ball bearings of blade guide assembly (27) are in good conditions or if there is no clearance (item 4.6); - blade guide (35) too close the material being cut; - the material to be cut is not too irregular to the extent of causing a crooked cut; - the blade (06) is properly tensioned; Check that the length of blade (06) is 1470 ± 2 mm;

Blade tooth breaks

- Excessive cutting pressure (see item. 4.3.1); - Excessive feed; - Wrong blade (06) tooth pitch (see item 4.2) - Broken bearings (27)

Premature wear of blade tooth profile Blade breaks on weld section

- Inadequate Band Saw Blade (06) for the material to be cut; - Insufficient cutting pressure (see item 4.3.1) - Insufficient cutting feed

Blade breaks off weld section

- Defective blade weld Causes: - machine problems if occurring prematurely; - normal wear and tear (caused by rotation) if occurring after several hours of operation.

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WARNING: NEVER USE COOLING OIL in S1101. The machine was not developed to use such cutting means, and this can significantly impair the machine cutting performance, as well as damage some other machine part.

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6 . MACHINE IDENTIFICATION: Each Starrett machine can be identified by its nameplate attached to the side of the Vise Set (08). Data such as Model, Year of Manufacture, Serial Number, Voltage (V), Frequency (Hz) and Weight (kg) will all be engraved on the nameplate. The figure below shows the Starrett nameplate format.

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Figure 17

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7 . CERTIFICATE OF COMPLIANCE:

DECLARATION OF CONFORMITY

The Manufacturer:

Starrett Indústria e Comércio Ltda. Av. Laroy Starrett, 1880 13306-900 – Itu – SP – Brazil

Hereby warrants and represents, under its sole responsibility, that the band saw machine model:

S1101 complies with the following Directives: ¾ DIRECTIVE 2006/42/CE ¾ DIRECTIVE 2004/108/CE and that the following Harmonized Standards shall apply •

EN 13898:2009+A1

Machine Tools, Safety, Sawing Machine for cold metals;

•

EN 61029-1:2003

Safety of Transportable motor/operated tools – general requirements

•

EN 292-1

Safety of Machinery – Base concepts, general principles for design – Part 1: Basic terminology, methodology;

•

EN 292-2

Safety of Machinery – Electrical equipment of machines – Part 1 : General requirements;

•

ISO 7000

Graphic symbols.

March, 2010th Itu/SP – Brasil

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8 . WARRANTY:

WARRANTY CERTIFICATE PRODUCT S1101

Every equipment manufactured and/or commercialized by Starrett Ind. e Com. Ltda is covered by a year (12) months warranty, counted from the effective product delivery to purchaser, irrespective of whether or not the equipment has been used. All Technical Support services shall be provided by Starrett itself, or by any other company duly appointed by Starrett to render this type of service. The replacement of parts or components demonstrably showing material and/or workmanship defects shall be free of charge to purchaser, including the necessary labor, unless originated from: III III IV VVI VIIVII-

parts subject to normal wear and tear, such as ball bearings, gaskets, seals, lamp bulbs, hardmetal pads, etc.; improper and undue handling for the product intended purposes; inadequate transportation, drops, impacts, shocks or improper storage; Inadequate power supply or utilization; act of nature (lightning, floods, fire, etc); failing to comply with the Instructions Manual; interventions performed by third parties without the consent of Starrett Ind. e Com. Ltda; long periods of product inactivity.

The Technical Support provided during the warranty period shall no longer be free and shall be charged to purchaser if, after service execution, the occurrence of any of the aforementioned events will have been detected (items I through VII). This warranty shall not include such regular machine maintenance services as adjustments, cleaning, band saw replacements, etc. All defective parts or components replaced under this warranty shall be returned to Starrett, to whom they will then belong.

Starrett Indústria e Comércio Ltda.

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9 . SPARE PARTS: POS

CODE

4 5 6 7 10 12 13 14 15 16 17 18 20 21 22 23 24 25 27 30 31 32 33 35 36 37 38 39 40 41 42 43 44 45 46 47 48 48‐1

‐ 1101‐005 ‐ 1101‐007 1101‐010 1101‐012 1101‐013 1101‐014 1101‐015 ‐ ‐ ‐ ‐ ‐ 1101‐022 1101‐023 1101‐024 1101‐025 ‐ ‐ 1101‐031 1101‐032 ‐ ‐ ‐ 1101‐037 1101‐038 1101‐039 1101‐040 ‐ ‐ ‐ 1101‐044 ‐ 1101‐046 1101‐047 1101‐048 ‐

DESCRIPTION HEX BOLT M5X25 DIN933 8.8 BOW BASE FASTENING BUSHING ALLEN HEAD CAP SCREW M6X12 DIN912 ECCENTRIC SPECIAL WASHER CLAMPING LEVER CLAMPING VISE SPRING SPINDLE SCREW NUT CLAMPING HANDLE VISE FLYWHEEL ALLEN SET SCREW FLAT POINT M6X6 DIN913 HEX BOLT 8X16 DIN933 8.8 LOCK WASHER M8 ALLEN SET SCREW FLAT POINT M5X10 DIN913 HEX NUT M5 ECCENTRIC SPINDLE VISE SPINDLE SCREW CLAMPING LEVER KEYWAY JOINT 5X5X15 VISE SPINDLE SCREW ALLEN SET SCREW FLAT POINT M5X12 DIN913 LOCK WASHER M6 SET PLATE BASE PROTECTION PROFILE ALLEN FLAT SCREW M6X30 DIN 7991 LOCK WASHER M10 SCREW CAB SEXT M10X20 DIN933 8.8 BUTTON NUT BUSHING SPRING SPINDLE LOCK ALLEN HEAD CAP SCREW M6X10 DIN912 FLAT WASHER M6 HEX NUT M8 BELLEVILLE SPRING (DISC SPRING) ALLEN HEAD CAP SCREW M8X30 DIN912 SPRING BUSHING SUPPORT SPRING PIN DRIVE ALLEN SET SCREW FLAT POINT M8X10 DIN913

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POS

CODE

DESCRIPTION

49 50 51 52 53 55 57 58 60 63 64 65 66 67 69 70 71 72 73 74 75 76 77 78 79 80 82 84 85 87 88 91 92 93 94 95 96 97 99

1101‐049 1101‐050‐CH 1101‐051 ‐ 1101‐053 ‐ ‐ ‐ ‐ 1101‐063 ‐ 1101‐065‐CH 1101‐066 1101‐067 ‐ 1101‐070‐CH 1101‐071‐CH 1101‐072 1101‐073‐CH ‐ 1101‐075‐CH 1101‐076 ‐ ‐ 1101‐079‐CH 1101‐080‐CH ‐ ‐ ‐ 1101‐087‐CH 1101‐088‐CH 1101‐091 1101‐092 ‐ 1101‐094 1101‐095 1101‐096 1101‐097 1101‐099

KEYWAY POINT 4x4x20 BOW SHAFT KEYWAY JOINT 4X4X12 ALLEN COUNTERSUNK SCREW M6X10 DIN912 SUPPORT PLATE ALLEN HEAD CAP SCREW M8X20 DIN912 ALLEN HEAD CAP SCREW M8X40 DIN912 FLAT WASHER 8X25X3 HEX BOLT M8X45 DIN912 HEX BOLT MACHINED PHILLIPS BUTTON HEAD SCREW M5X15 SHAFT SEAT SELF LUBRIFICATING BUSHING FLAT WASHER 26X43X1.4 SPRING‐TYPE STRAIGHT PIN 3mm DIN1481 SWIVEL BOW LOCK PIN SPRING BASE BOW CLAMPING HANDLE PHILLIPS BUTTON HEAD SCREW M5X10 ANGULAR INDICATOR COVER PHILLIPS BUTTON HEAD SCREW M4X10 PHILLIPS BUTTON HEAD SCREW M5X30 MICRO SWITCH UPPER BOW MICRO SWITCH SUPPORT ALLEN HEAD CAP SCREW M6X25 LOCK WASHER M5 PHILLIPS BUTTON HEAD SCREW M4X6 MOBILE GUIDE SUPPORT LEVER BUSHING MOBILE FLYWHEEL SHAFT BASE HEX NUT M6 BUSHING Ø11 COMPRESSION SCREW COMPRESSION DEVICE COMPRESSION SPRING GUIDE

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POS

CODE

DESCRIPTION

100 101 102 103 107 110 111 114 115 119 120 121 123 125 125‐1 125‐2 125‐3

1101‐100 1101‐101‐CH ‐ ‐ ‐ 1101‐110 1101‐111 ‐ ‐ 1101‐119‐CH 1101‐120 1101‐121‐CH 1101‐123 1101‐125‐CH 1101‐125‐1‐CH 1101‐125‐2‐CH ‐ 1101‐126‐CH‐110V 1101‐126‐CH‐220V ‐ 1101‐126‐4‐CH‐110V 1101‐126‐4‐CH‐220V ‐ ‐ 1101‐131‐CH‐110V 1101‐131‐CH‐220V 1101‐131‐1‐CH 1101‐132 ‐ ‐ ‐ 1101‐138 ‐ 1101‐140 1101‐141 1101‐146‐CH 1101‐148 ‐ 1101‐153 1101‐156‐CH 1101‐157 ‐

DRIVEN FLYWHEEL SHAFT DRIVEN FLYWHEEL BALL BEARING 6003 INTERNAL CIRCLIP Ø35 PHILLIPS BUTTON HEAD SCREW M5X6 STOPPER BAR STOPPER FLAT WASHER M8 BAND SAW BLADE DRIVER FLYWHEEL FELT PAD GEAR DRIVER FLYWHEEL SHAFT ARMATURE WAVE SPRING DIN 137 CENTRIFUGAL CONTACT SLOTTED CAP HEAD SCREW M4X10 MOTOR SET 110‐127V MOTOR SET 220‐230V PHILLIPS BUTTON HEAD SCREW M6X8 STATOR 110V STATOR 220V HEX NUT M10 ALLEN HEAD CAP SCREW M5X16 DIN912 ELECTROMAGNETIC SWITCH 110‐127V ELECTROMAGNETIC SWITCH 220‐230V CAPACITOR SWITCH BOX HEX NUT M12 FLAT WASHER 12X28X3 BALL BEARING 625ZZ VERTICAL POSITION STOPPER SCREW CUTTING DIRECTION INSTRUCTION STICKER TRANSPORT HOOK FIXED GUIDE GUARD FIXED GUIDE HARDENED GROUND DOWEL PIN Ø 5X14 mm ALLEN CAP HEAD SCREW M6X30 FIXED GUIDE PROTECTION TENSIONING BLADE HANDLE BUSHING ALLEN HEAD CAP SCREW M8X12 DIN912

126 126‐3 126‐4 128 129 131 131‐1 132 134 135 136 138 139 140 141 146 148 149 153 156 157 159

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POS

CODE

160

1101‐160‐CH 1101‐162/BR 1101‐162/CH 1101‐162/EU 1101‐162/US 1101‐162/UK ‐ 1101‐163‐CH 1101‐164 1101‐169 1101‐170 1101‐171 ‐ ‐ ‐ ‐ ‐ 1101‐181 ‐ 1101‐184 ‐ 1101‐187 ‐ 1101‐190 1101‐191 1101‐192 1101‐193 1101‐194 1101‐195 1101‐200 ‐ 1101‐205 1101‐206 1101‐207 ‐ ‐ ‐ ‐ ‐

162

162‐1 163 164 169 170 171 174 176 177 178 179 181 182 184 186 187 188 190 191 192 193 194 195 200 204 205 206 207 208 209 210 211 212

DESCRIPTION MOBILE GUIDE ADJUSTMENT LEVER POWER CORD STD NBR 14136 BR POWER CORD STD GB 2099 POWER CORD STD CEE 7/7 HYBRID POWER CORD STD NEMA 5/15 POWER CORD STD BS 1363 ELECTRIC WHIP SET ANGULAR SCALE CHIP BOX CHIP BOX SUPPORT TOOLS SUPPORT TRANSPORT PIN ALLEN BUTTON HEAD SCREW BAND STICKER S1101 STICKER BEARING 6200Z BEARING 7200B GUIDE ECCENTRIC SPINDLE ALLEN SET SCREW FLAT POINT M5X20 DIN913 MOBILE JAW MACHINE´S SPEC STICKER BOW BACK COVER SERIAL NUMBER PLATE TENSIONING SHAFT CARRY HANDLE BOW MOTOR SCREEN MOTOR COVER MOTOR´S SPEC STICKER ADJUSTMENT PRESSURE SPRING CLAMPING SET ALLEN SET SCREW FLAT POINT M6X10 DIN 913 KEYWAY JOINT STOP VERTICAL FLAT WASHER 17X50X3 VISE SPINDLE SUPPORT TRANSPORT INSTRUCTION STICKER SECURITY INSTRUCTION STICKER WARNING ELECTRIC SHOCK STICKER TENSIONING INSTRUCTION STICKER CRUSH WARNING STICKER

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POS

CODE

213 214 215 216 217 219 220 221 222 223 225 226 227 229 230 231 232 233 234 235 236 237

1101‐213 1101‐214 1101‐215 1101‐216 1101‐217 1101‐219 1101‐220 ‐ 1101‐222 1101‐223 1101‐225 1101‐226 1101‐227 ‐ 1101‐230 1101‐231 ‐ ‐ ‐ ‐ 1101‐236 1101‐237

DESCRIPTION BUSHING BOW SPECIAL SCREW MOBILE GUIDE FIXED GUARD SWIVEL SUPPORT SWIVEL BASE COVER FIXED JAW WASHER M4 SPRING PROTECTION SCREW TELESCOPIC PROTECTION TELESCOPIC STEM KNOB PHILIPS BUTON HEAD M4X35 ISO 704 SPRING BUSHING HEX NUT M4 ISO 4032 PHILIPS BUTON HEAD M3X16 ISO 704 HEX NUT M3 ISO 4032 PHILIPS BUTON HEAD M4X6 ISO 704 BOW SAFETY SWITCH SAFETY SWITCH BRACKET

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