OPERATORS MANUAL

HORIZONTAL BAND SAW

Model: BS-250M
Baileigh Industrial, Inc.
P.O. Box 531
Manitowoc, WI 54221-0531
Phone: 920.684.4990
Fax: 920.684.3944
[email protected]

03/2010

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 TABLE OF CONTENTS

Thank you and Warranty................................................................. 3, 4, 5

Introduction / General Notes .......................................................... 6, 7

Safety Instructions .......................................................................... 8, 9, 10

Technical Specifications................................................................. 11

Transporting and Lifting the Machine ........................................... 11

Getting to Know Your Machine ...................................................... 12, 13, 14, 15

Getting Started................................................................................. 16

Adjusting the Machine .................................................................... 17, 18, 19

The Operation Cycle........................................................................ 20, 21, 22

Lubrication and Maintenance ......................................................... 23, 24, 25

Choosing a Saw Blade .................................................................... 26, 27

Parts Identification Drawings ......................................................... 28, 29, 30, 31, 32,

33, 34, 35

Electrical Schematic........................................................................ 36

Troubleshooting .............................................................................. 37, 38, 39, 40

Machine Acknowlegement.............................................................. 41

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 THANK YOU & WARRANTY

1. Thank you for your purchase of a Baileigh Industrial Band Saw. We hope that you find it
productive and useful to you for a long time to come.

2. Inspection & Acceptance. Buyer shall inspect all Goods within a reasonable period of time
after delivery, not to exceed ten (10) days. If Buyer rejects any Goods, Buyer must first obtain a
Return Authorization Number (“RAN”) before returning any goods to Seller. Goods returned
without a RAN will be refused. Seller will not be responsible for any freight costs, damages to
goods, or any other costs or liabilities pertaining to goods returned without a RAN. Seller shall
have the right to substitute a conforming tender. Buyer will be responsible for all freight costs to
and from Buyer and repackaging costs, if any, if Buyer refuses to accept shipment. If Goods are
returned in unsaleable condition, Buyer shall be responsible for full value of the Goods. Buyer
may not return any special order Goods. Any Goods returned hereunder shall be subject to a
restocking fee equal to 30% of the invoice price.

3. Specifications. Seller may, at its option, make changes in the designs, specifications or
components of the Goods to improve the safety of such Goods, or if in Seller’s judgment, such
changes will be beneficial to their operation or use. Buyer may not make any changes in the
specifications for the Goods unless Seller approves of such changes in writing, in which event
Seller may impose additional charges to implement such changes.

4. Limited Warranty. Seller warrants to the original end-user that the Goods manufactured or
provided by Seller under this Agreement shall be free of defects in material or workmanship for a
period of twelve (12) months from the date of purchase, provided that the Goods are installed,
used, and maintained in accordance with any instruction manual or technical guidelines provided
by the Seller or supplied with the Goods, if applicable. The original end-user must give written
notice to Seller of any suspected defect in the Goods prior to the expiration of the warranty period.
The original end-user must also obtain a RAN from Seller prior to returning any Goods to Seller
for warranty service under this paragraph. Seller will not accept any responsibility for Goods
returned without a RAN. The original end-user shall be responsible for all costs and expenses
associated with returning the Goods to Seller for warranty service. In the event of a
defect, Seller, at its sole option, shall repair or replace the defective Goods or refund to the
original end-user the purchase price for such defective Goods. The foregoing warranty is Seller’s
sole obligation, and the original end-user’s exclusive remedy, with regard to any defective Goods.
This limited warranty does not apply to: (a) die sets, tooling, and saw blades; (b) periodic or
routine maintenance and setup, (c) repair or replacement of the Goods due to normal wear and
tear, (d) defects or damage to the Goods resulting from misuse, abuse, neglect, or accidents, (f)
defects or damage to the Goods resulting from improper or unauthorized alterations,
modifications, or changes; and (f) any Goods that has not been installed and/or maintained in
accordance with the instruction manual or technical guidelines provided by Seller.

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5. EXCLUSION OF OTHER WARRANTIES. THE FOREGOING LIMITED WARRANTY
IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. ANY AND ALL
OTHER EXPRESS, STATUTORY OR IMPLIED WARRANTIES, INCLUDING BUT NOT
LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. NO WARRANTY IS MADE
WHICH EXTENDS BEYOND THAT WHICH IS EXPRESSLY CONTAINED HEREIN.

6. LIMITATION OF LIABILITY. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER

OR ANY OTHER PARTY FOR ANY INCIDENTIAL, CONSEQUENTIAL OR SPECIAL
DAMAGES (INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR DOWN TIME)
ARISING FROM OR IN MANNER CONNECTED WITH THE GOODS, ANY BREACH BY
SELLER OR ITS AGENTS OF THIS AGREEMENT, OR ANY OTHER CAUSE
WHATSOEVER, WHETHER BASED ON CONTRACT, TORT OR ANY OTHER THEORY
OF LIABILITY. BUYER’S REMEDY WITH
RESPECT TO ANY CLAIM ARISING UNDER THIS AGREEMENT IS STRICTLY LIMITED
TO NO MORE THAN THE AMOUNT PAID BY THE BUYER FOR THE GOODS.

7. Force Majuere. Seller shall not be responsible for any delay in the delivery of, or failure to
deliver, Goods due to causes beyond Seller’s reasonable control including, without limitation, acts
of God, acts of war or terrorism, enemy actions, hostilities, strikes, labor difficulties, embargoes,
non-delivery or late delivery of materials, parts and equipment or transportation delays not caused
by the fault of Seller, delays caused by civil authorities, governmental regulations or
orders, fire, lightening, natural disasters or any other cause beyond Seller's reasonable control. In
the event of any such delay, performance will be postponed by such length of time as may be
reasonably necessary to compensate for the delay.

8. Installation. If Buyer purchases any Goods that require installation, Buyer shall, at its expense,
make all arrangements and connections necessary to install and operate the Goods. Buyer shall
install the Goods in accordance with any Seller instructions and shall indemnify Seller against any
and all damages, demands, suits, causes of action, claims and expenses (including actual
attorneys’ fees and costs) arising directly or indirectly out of Buyer’s failure to properly install the
Goods.

9. Work By Others; Safety Devices. Unless agreed to in writing by Seller, Seller has no
responsibility for labor or work performed by Buyer or others, of any nature, relating to design,
manufacture, fabrication, use, installation or provision of Goods. Buyer is solely responsible for
furnishing, and requiring its employees and customers to use all safety devices, guards and safe
operating procedures required by law and/or as set forth in manuals and instruction sheets
furnished by Seller. Buyer is responsible for consulting all operator’s manuals, ANSI or
comparable safety standards, OSHA regulations and other sources of safety standards and
regulations applicable to the use and operation of the Goods.

10. Remedies. Each of the rights and remedies of Seller under this Agreement is cumulative and
in addition to any other or further remedies provided under this Agreement or at law or equity.

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11. Attorney’s Fees. In the event legal action is necessary to recover monies due from Buyer or to
enforce any provision of this Agreement, Buyer shall be liable to Seller for all costs and expenses
associated therewith, including Seller’s actual attorneys' fees
and costs.

12. Governing Law/Venue. This Agreement shall be construed and governed under the laws of
the State of Wisconsin, without application of conflict of law principles. Each party agrees that all
actions or proceedings arising out of or in connection with this Agreement shall be commenced,
tried, and litigated only in the state courts sitting in Manitowoc County, Wisconsin or the U.S.
Federal Court for the Eastern District of Wisconsin. Each party waives any right it may have to
assert the doctrine of “forum non conveniens” or to object to venue to the extent that any
proceeding is brought in accordance with this section. Each party consents to and waives any
objection to the exercise of personal jurisdiction over it by courts described in this section. EACH
PARTY WAIVES TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW THE
RIGHT TO A TRIAL BY JURY.

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INTRODUCTION

The quality and reliability of the components assembled on a Baileigh Industrial machine
guarantee near perfect functioning, free from problems, even under the most demanding
working conditions. However if a situation arises, refer to the manual first. If a solution
cannot be found, contact the distributor where you purchased our product. Make sure
you have the serial number and production year of the machine. (stamped on the
nameplate). For replacement parts refer to the assembly numbers on the parts list
drawings.

Our technical staff will do their best to help you get your machine back in working order.

In this manual you will find:

• Safety procedures
• Correct installation guidelines
• Description of the functional parts of the machine
• Capacity charts
• Set-up and start-up instructions
• Machine operation
• Scheduled maintenance
• Parts lists

GENERAL NOTES
• After receiving your equipment remove the protective crating. Do a complete
visual inspection, and if damage is noted, photograph it for insurance claims
and contact your carrier at once, requesting inspection. Also contact Baileigh
Industrial and inform them of the unexpected occurrence. Temporarily suspend
installation.

• Take necessary precautions while loading / unloading or moving the machine to

avoid any injuries.

• Always check that the work piece is securely clamped and that long pieces are
properly supported.

• If the blade gets stuck in the cut, press the emergency stop button immediately,
and disconnect the power to the machine. Slowly open the vise and remove the
piece part. Check the blade for any broken teeth and replace blade if necessary.

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 The operator should stand in front
of the machine while the saw is
cutting.

PLEASE READ THIS OPERATORS MANUAL CAREFULLY

It contains important safety information, instructions, and necessary operating

procedures. The continual observance of these procedures will help increase
your production and extend the life of the equipment.

Your machine is designed and manufactured to work smoothly and efficiently. Following
proper maintenance instructions will help ensure this. Try and use original spare parts,
whenever possible, and most importantly; DO NOT overload the machine or make any
unauthorized modifications.

TECHNICAL SUPPORT

Our technical support department can be reached at 920.684.4990, and asking for the
support desk for purchased machines. Tech Support handles questions on machine
setup, schematics, warranty issues, and individual parts needs.

For specific application needs or future machine purchases contact the Sales
Department.
at: [email protected] or phone: 920.684.4990

Note: This symbol refers to useful information throughout the manual.

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 SAFETY INSTRUCTIONS

LEARN TO RECOGNIZE SAFETY INFORMATION

This is the safety alert symbol. When you see this symbol
on your machine or in this manual, BE ALERT TO THE
POTENTIAL FOR PERSONAL INJURY!

Follow recommended precautions and safe operating

practices.

UNDERSTAND SIGNAL WORDS

A signal word – DANGER, WARNING, or CAUTION

is used with the safety alert symbol. DANGER identifies
a hazard or unsafe practice that will result in severe
Injury or Death.

Safety signs with signal word DANGER or WARNING

are typically near specific hazards.

General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this
manual.

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PROTECT EYES

Wear safety glasses or suitable eye protection when

working on or around machinery.

BEWARE OF CUT AND PINCH POINTS

Keep hands and fingers away from the saw

blade when the machine is in operation.

HIGH VOLTAGE

USE CAUTION IN HIGH VOLTAGE AREAS.

DO NOT assume the power to be off.

(MAKE SURE PROPER LOCKOUT

PROCEDURES ARE FOLLOWED)

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment

or loss of hearing. Wear suitable hearing protective devices
such as ear muffs or earplugs to protect against objectionable
or uncomfortable loud noises.

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 Additional Safety Precautions
• Turn off main power to the machine when changing the saw blade or performing
any maintenance work.
• Never expose your hands or limbs to the cutting area while the machine is
operating.
• Steel toe shoes should be worn when using this machine.
• Make sure it is possible to move freely around the machine and associated
equipment. The floor should be kept clean and dry, and the surrounding area well
illuminated, so that work can be performed safely.
• Never wear loose fitting garments or jewelry, and avoid long loose hair when
operating machine.
• When the machine is not in use, the saw blade should not be moving.
• Do not remove any warning signs.
• Check safety equipment, such as safety covers, emergency stop buttons, safety
mats, railings, light booms, ramps, and warning signs.
• Make sure electrical cables are well protected from damage. Check insulation
periodically for wear.
• When moving the saw ALWAYS have the head lowered to the horizontal position.
• DO NOT overreach. Maintain proper footing and balance at all times.
• Make sure the machine is properly grounded.
• Learn the function and proper use of the “ON-OFF” start switch, trigger switch,
blade speed knob, and the emergency stop button.
• Use the right tool. Do not force a tool or attachment to do a job it was not designed
for.
• Keep visitors a safe distance from the work area.
• Safety is a combination of common sense and alertness at all times when the saw
is being used.

UNPACKING AND CHECKING CONTENTS

Your Baileigh band saw is shipped complete in one carton. Separate all parts from
packing material and check each item carefully. Make certain all items are accounted
for, before discarding any packing material.

WARNING: If any parts are missing, do not try to assemble the band saw,
plug in the power cable, or turn the power switch on until the missing parts are
obtained and installed correctly.

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 Technical Specifications

Cutting
Capacity

0°

45°

60°

M otor 2 HP / 110V / 1 PH / 60HZ

Drive G ear
Blade Speed 66-280 fpm (variable)
Blade Size (H / W / L) 1" / .035" / 96.85"
Descent Control Hydraulic w/speed adjustm ent
Return M anual
Shipping W eight 475 lbs.

Features

1. Designed for horizontal cutting.

2. Variable speed for cutting various metals and plastics.
3. Saw shuts off automatically when material is cut.
4. Mitering vise scale (0-60° Right)
5. 1” Blade (standard)
6. Quick vise feature for fast and easy clamping.
7. Direct gear drive

TRANSPORTING AND LIFTING THE MACHINE

Caution: Lifting and carrying operations should be carried out by skilled workers,
such as truck operator, crane operator, etc. Also, it is necessary to keep in mind
that having a large clearance area around the machine is important for efficient
and safe working conditions.

Note: The specifications and dimensions presented here are subject to

change without prior notice due to improvements of our products.

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GETTING TO KNOW YOUR MACHINE

H
F I
E
G
J
D

C
B
L

Q
A O

12
GETTING TO KNOW YOUR MACHINE (cont.)

A Vise hand wheel Turning hand-wheel opens and closes vise

B Vise lever To quickly clamp and unclamp piece parts
C Vise Holds front and rear jaws for clamping
D Blade tension hand wheel For applying and releasing blade tension
E Blade tension gauge Reads tension in Kgs/cm2
F Trigger switch For starting saw motor in manual mode
G Blade adjustment ass'y. Adjusts front end of blade
H Blade adjustment ass'y. Adjusts rear end of blade
I Ball valve Starts and stops the blade descent
J Control box Houses the operator controls
K Motor/gearbox Drives the saw blade
L Spring adjustment knob Sets spring tension
M Microswitch Shuts off saw when finished cutting
N Coolant pump Recirculates blade coolant
O Stop rod assembly For setting the length of cut
P Saw stand Supports the saw assembly
Q Angle indicator Shows angular cutting degrees
R Miter lock lever Tightens and loosens table to set angles

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GETTING TO KNOW YOUR MACHINE (cont.)

1 2 3 4

5 6 7

(1) Power Indicator Light (Lights “white” when power is on)

(2) Blade Start Indicator Light (Lights green when blade is moving)
(3) Start Pushbutton (Starts saw motor in Auto mode)
(4) Speed Control (Sets blade speed from 66-280 fpm) Has an OFF position
to shut off power
(5) Main Disconnect Switch (Turns power ON to the saw) Can be locked
out in the OFF position for Safety or Security
(6) 2-Position Mode Switch (Selects between auto mode, clockwise (cw)
and trigger control, counterclockwise (ccw)
(7) E-Stop Pushbutton (Saw can be stopped immediately by pressing the
red palm button) Twist the button clockwise (cw) to reset. Resetting the
E-Stop will not start the saw.

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GETTING TO KNOW YOUR MACHINE (cont.)

Machine Base (figure 1)

After assembly, the machine base becomes the

structure that supports the saw bow, the vise, the
coolant pump, the bar stop, and the swing arm.

figure 1

Quick Clamp Vise (figure 2) B

A
Place the piece part between the vise jaws and have it
rest next to the fixed vise jaw. Rotate the hand wheel
(A) clockwise (cw) to close the front jaw onto the piece
and tighten. Rotate the hand wheel counterclockwise
(ccw) to release. Vise lever (B) can be used to quickly
lock and release the piece part by allowing a small gap
between the vise and part. Then rotate lever (B)
counterclockwise (ccw) to lock and clockwise (cw) to figure 2
release.

Cutting Angle Adjustment (figure 3)

Angles can be cut up to 60°. Unlock the rotating saw Q

head by pushing the miter lock lever (R) to the left.
Rotate the saw head to the desired angle as shown on
the angle indicator (Q). Lock the saw head by pushing
the lock lever (R) to the right. R
figure 3

WARNING Check that the saw blade clears all parts of the vise assembly before
cutting. The blade can strike parts of the assembly (especially during miter cuts) if
not properly adjusted. Make sure saw bow is in a down or horizontal position
when moving or mitering, to avoid tipping over machine.

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 GETTING STARTED

ATTENTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE

BY A CERTIFIED ELECTRICIAN !

Your Baileigh Machine is approved

Check if the available power supply is the same as required by the Band Saw
(consult nameplate on machine base)

WARNING
Make sure the grounding wire (green) is properly connected to avoid electric
shock. DO NOT switch the position of the green grounding wire if any electrical
plug wires are switched during hookup.

Anchoring the Machine: Position the saw on a firm

and level concrete floor. Maintain a min. distance of
32.00” from the wall to the rear of the machine. Anchor
the saw stand to the floor as shown in the diagram to
the left using bolts and expansion plugs, or tie rods
sunken into the concrete.

Assembly and Setup

Assemble the stand as shown in the Parts Identification Drawing A, page 28 of this
manual. (Make sure all nuts and bolts are properly tightened). Use a sling capable of
lifting 500 lbs. (min.) and make sure the load is properly balanced. Pick up the saw
and carefully set it onto the stand and bolt together. Attach D
D electrical control box (J) to
the pedestal (S) with (4) hex socket capscrews.

figure 4

16
 G
ADJUSTING THE MACHINE

BEFORE PERFORMING THE FOLLOWING OPERATIONS,

THE ELECTRIC POWER SUPPLY AND THE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.

Replacing the saw blade: (Wear gloves when handling the saw blade.)

BLADE DIRECTION OF TRAVEL

1. Raise the saw bow. (figure 5)

2. Remove the front blade guard (T) and the (4) knobs (U) holding on the main blade
guard. Carefully pull out the tongue from the safety interlock switch (V)
3. Loosen the saw blade with the tension hand wheel (D) and remove it from the
flywheels and the blade guide blocks.
4. Assemble the new blade by placing it first between the guide blocks and then on
the face of the flywheels. (note blade direction)
5. Tension the blade, making sure it seats properly on the flywheels.
6. Reassemble the front blade guide (T) and the main blade guard (W), making sure
the switch tongue engages the switch or the saw will not start.

W
U

U
T
V
figure 5

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ADJUSTING THE MACHINE (cont.)

Setting Blade Tension

Blade tension is important to the proper operation of the saw.

Correct blade tension is 120 kg/cm² as measured on the saws
tension gauge. (figure 6) Turning the handwheel clockwise (cw)
will increase the tension. Counterclockwise (ccw) will decrease
tension of the saw blade.

figure 6

Adjusting the Blade Tracking

The flywheels alignment may need some adjustment to

allow the saw blade to track correctly. Improper flywheel
alignment can cause damage to the saw blade or cause
it to ride off the blade wheel bearings.

1. Disconnect power from the saw

2. Raise the saw bow to a usable work height.
X Y Z AA
3. Loosen the hex socket cap screws (X, Y, & Z) (see
figure 7)
4. Use an allen wrench on setscrew (AA) to adjust the figure 7
blade as shown in (fig. 7a).
5. Turning the setscrew (AA) clockwise (cw) will tilt
flywheel so that the blade will ride closer to the approx.
flange. Blade 0.19"
6. Turning the setscrew (AA) counterclockwise (ccw) Wheel
will tilt the flywheel so that the blade will ride away
from the flange. (If it rides too far away it will come
off). Blade
7. After the adjustment is finished, tighten the socket Teeth
cap screws in this order: (X, Y, & Z)
figure 7a

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ADJUSTING THE MACHINE (cont.)

Adjusting the Blade Guide (figure 8)

AB AD
1. Disconnect Power From the Saw
2. Release the extension bar for the blade guide
block by turning clamp handle (AC)
counterclockwise (ccw) to loosen the clamping
block (AD).
3. Hold the revolving handle (AB) and slide the
blade guide block as close as possible to the
piece part without interfering with the cut.
4. Tighten clamp handle (AC) clockwise (cw). figure 8
AC

Blade Guide Bearing Adjustment (figure 9)

ATTENTION: This is the most important adjustment on
your saw. It is impossible to get satisfactory work from AF
your saw if the blade guides are not properly adjusted.
Your Baileigh Band Saw has been adjusted and power
tested before leaving the factory to insure proper
setting. If the guides do get out of adjustment, it is
extremely important to re-adjust immediately. An AG
improperly adjusted blade will not cut straight and
serious blade damage may result. It is always best to
try a new blade to see if this will correct poor cutting
before beginning to adjust the blade guide bearings. If
the blade becomes dull on one side and not the other, AE
for example, it will begin cutting crooked. A blade
change will correct this problem; the guide adjustment
will not. If a new blade does not correct the problem, figure 9
check the clearance between the blade and guides.
Clearance should be from just touching to .001”. Adjust
as follows:

1. Disconnect Power From the Saw

2. Remove guard (AE) for access to the bearing.
3. Loosen nut (AF) on the eccentric bearing.
4. Turn adjusting nut (AG) clockwise (cw) to move the bearing away from the blade.
5. Turn the adjusting nut counterclockwise (ccw) to move the bearing closer to the
blade.
6. After adjustment, retighten nut (AF) and replace guard (AE).

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 I
THE OPERATION CYCLE AH

Manual Operation (figures 10, 11, & 12)

• Close the handle on the hydraulic ball valve (I) by turning

it counterclockwise (ccw).
• Turn the flow control knob (AH) clockwise (cw) to shut off
the hydraulic flow. This will prevent the saw bow from M
dropping when the ball valve is opened.
• Reduce the bow weight. Rotate the wing nut (AI)
clockwise (cw) to increase the tension on the spring.
• Load piece part and clamp securely.
• Turn the main switch (5) to “ON”.
(Check to see that the indicator light (1) is lit)
• Set the blade speed with control knob (4)
• Set switch (6) to manual mode for trigger operation.
• While firmly holding the control handle of the saw bow,
open ball valve (I) clockwise (cw).
• Fully open the flow control knob (AH) counterclockwise
(ccw).
• Squeeze the start trigger to energize the blade motor and
lower saw bow to begin cutting. (Light (2) will be green) figure 10
• When saw bow reaches bottom limit, the microswitch (M)
is actuated and shuts off the saw motor.
• Return the saw bow to its start position and close ball
valve (I).
• Unclamp and reset the piece part to continue the next
cutting cycle.

1 2 3 6 4 AI

5 figure 11 7 figure 12

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 THE OPERATION CYCLE (cont.)

If an emergency situation should occur:

Press the emergency STOP button (7) to immediately shut off all functions of the
saw. To release the stop button, rotate the mushroom head clockwise (cw) to reset.

(Note: Resetting the E-STOP button will not start the machine.)

Auto Mode Operation

• Close the handle on the hydraulic ball valve (I) by turning it counterclockwise
(ccw).
• Turn the flow control knob (AH) clockwise (cw) to shut off the hydraulic flow. This
will prevent the saw bow from dropping when the ball valve is opened.
• Increase the bow weight. Rotate the wing nut (AI) counterclockwise (ccw) to
decrease the tension on the spring.
• Load piece part and clamp securely.
• Turn the main switch (5) to “ON”.
(Check to see that indicator light (1) is lit)
• Set the blade speed with control knob (4)
• Set switch (6) clockwise (cw) to auto mode for hydraulic cylinder operation.
• Press the green start button (3). The saw motor and the coolant pump motor
should both start.
• Open the ball valve (I) clockwise (cw).
• Turn the flow control knob (AH) clockwise (cw) to slow down the descent or
counterclockwise (ccw) to speed it up.
• When saw bow reaches bottom limit, microswitch (M) is actuated and shuts off the
saw and pump motors.
• Grasp the control handle and lift the saw bow to a height slightly above the piece
part to minimize the next cut entry time.
• Close ball valve (I).
• Unclamp and reset the piece part to continue the next cutting cycle.

21
THE OPERATION CYCLE (cont.)

These examples below show ways to clamp a variety of cross sections. Always
keep in mind the cutting capacity of the saw to achieve efficient saw cuts and long
blade life. Do not use blades of a size different from that shown in the technical
specification chart on page 11.

figure 13

22
 LUBRICATION AND MAINTENANCE

MAINTENANCE SHOULD BE PERFORMED ON A REGULAR BASIS

BY QUALIFIED PERSONNEL

CAUTION: Always follow proper safety precautions when working around machinery

MAKE CERTAIN POWER IS DISCONNECTED TO SAW.

Daily Maintenance
• Do a general cleaning by removing dust and metal chips from the machine.
• Inspect the saw blade for wear.
• Top off the coolant tank.
• Clean the lubricating coolant drain screen.
• Check that the blade guards and emergency stop button are in good working order.
• When through using machine, raise the saw head to its up position and release some
tension on the saw blade.

Weekly Maintenance
• Thoroughly clean the machine.
• Wipe and re-grease the vise screw and sliding surfaces.
• Remove chips from inside the guard housing for the saw blade.
• Use compressed air to clean the blade guides and guide bearings.

Monthly Maintenance
• Check the tightening of the motor flywheel screws.
• Check the blade guide bearings for wear. (replace if necessary)
• Tighten any loose bolts or screws on the gear motor, pump, and safety switches.
• Clean coolant tank (see procedure on page 24)

Six month maintenance

• Do a continuity check of the safety circuit

23
LUBRICATION AND MAINTENANCE (cont.)

Oils for Lubricating Coolant

Any 10:1 (water to coolant) solution will work, however we recommend Baileigh
B-Cool 20:1 (water to coolant) biodegradable metal cutting fluid. It has excellent
cooling and heat transfer characteristics, is non-flammable, and extends blade and
machine life. Each gallon of concentrate makes 21 gallons of coolant .

Oil Disposal
Used oil products must be disposed of in a proper manner following your local
regulations.

Coolant System Maintenance (figures 14 & 15) AL

• Disconnect Power From the Saw

• To clean the tank, first remove the pipe plug (AK)
to drain the coolant.
• Take off the screen (AL) by removing (4) screws.
• Remove the pump (AM) by taking out (2) socket
cap screws.
• After tank is completely drained use a vacuum
cleaner to remove all chips and debris.
• Replace the plug. figure 14
• Thoroughly clean the pump (AM) and replace. AK AN
• Fill the tank with coolant to approximately 1” below
the screen.
• Replace the screen (AL)
AM
Removeable drip tray (AN) shown in place

figure 15

24
LUBRICATION AND MAINTENANCE (cont.)

Gearbox Maintenance (figure 16)

The gearbox requires periodic changing of the oil. Initially after 6 months and then
every year thereafter. Follow the procedure below:

• Disconnect Power From the Saw

• Raise the saw bow to a vertical position. Note: You may have to back off the
upper travel adjusting bolt.
• Remove the oil drain plug (AO) and drain the oil into a catch basin. Loosening
oil fill plug (AP) will help oil to drain.
• After draining, replace drain plug (AO).
• Return the saw bow to a horizontal position.
• Remove the fill plug (AP) and add .32 quart of gear oil. (For reference use
SHELL type gear oil or Mobil gear oil #90).

AP

figure 16

AO

Storing Machine for Extended Period of Time

If the Band Saw is to be inactive for a long period of time, prepare the machine as
follows:
• Detach the plug from the electrical supply panel.
• Clean and grease the machine.
• Release tension on the blade or remove blade.
• Cover the machine
• Drain coolant

25
CHOOSING A SAW BLADE
(A general purpose blade is furnished with this band saw.)

To achieve a quality, economical, and efficient saw cut, the following points must be
taken into consideration:
• Type of material being cut (ferrous or non ferrous)
• Material hardness and physical dimensions
• Blade descent rate
• Longitudinal speed of blade
• Blade tooth profile

Choose a tooth pitch that is suitable for the workpiece. Thin walled profiles,
including tubes and pipes require close toothing. At least 3-6 teeth should be in
contact with the material while cutting. Large solid or transverse sections require
widely spaced toothing to allow for greater volume of chips and better tooth
penetration. Soft materials such as plastics, light alloys, mild bronze, Teflon, etc
require widely spaced toothing to avoid clogging.

Metal Chip Indicators

Chips are the best indicator of correct material feed force. Monitor chip information
and adjust feed accordingly.

a.) Thin or Powdered Chips – increase feed rate or reduce saw speed
b.) Burned Chips – reduce feed rate and / or saw speed
c.) Curly Silvery and Warm Chips – optimum feed rate and saw speed

26
 CHOOSING A SAW BLADE (cont.)

Breaking in a Band Saw Blade

Sharp cutting edges with extremely small edge radii are required for high cutting
capacity. To achieve the optimal tool life we recommend breaking-in the blade
accordingly.The correct cutting speed is determined by the material being cut and
its dimensions. It is very important that the new blade is first used with only 50% of
the determined feed rate. This will avoid micro-breakages of the blade because of
too large chip thicknesses. New band saw blades may tend toward vibrations and
vibration sounds. In this case a slight reduction of the cutting speed is helpful. With
small workpiece dimensions approximately 300cm² of the material should be cut
for breaking-in. If large work piece dimensions are to be cut we recommend a
breaking-in period of about 15 minutes. After breaking-in you may slowly increase
the feed rate up to the determined value.

Baileigh Industrial offers a wide selection of tooth styles for various cutting
applications. Please phone Baileigh Industrial at (920.684.4990) or fax to
(920.684.3944) to have one of our technicians assist you in selecting the proper
band saw blade for your cutting applications.

27
PARTS IDENTIFICATION DRAWING A

28
PARTS IDENTIFICATION DRAWING B

29
PARTS IDENTIFICATION DRAWING C

30
PARTS IDENTIFICATION DRAWING D

31
PARTS IDENTIFICATION DRAWING E

32
 SHEET A

Item Description Qty Item Description Qty

1 Base (right part) 1 33 Hex. soc. cap screw M5x8 4
2 Nut M12 2 34 Base front plate 1
3 Hex. cap bolt M12x40 2 38 Hand wheel 1
4 Nut M8 8 39 Set screw M8x10 1
5 Washer M8x18x2 8 40 Nut M20 1
6 Hex. cap bolt M8x16 8 41 Bearing bushing 1
7 Base plate 2 42 Thrust ball bearing #51104 1
8 Base (left part) 1 43 Lock handle 1
9 Hex. soc. cap screw M8x20 2 44 Bushing 1
10 Spring washer M8 2 45 Hex. soc. cap screw M6x100x28 2
10-1 Nut M8 2 46 Table 1
10-2 Washer M8x18x2 2 47 Plate 1
11 Hex. soc. cap screw M8x20 2 48 Flat head mach. screw M6x15 2
12 Spring washer M8 2 49 Compressed spring 1
13 Washer M8x18x2 2 50 Lead screw 1
14 Supporting plate 1 51 Hex. soc. cap screw M8x20 4
15 Roller stand bracket 1 52 Spring washer M8 4
16 Washer M10x21x2 2 53 Treaded nut 1
17 Spring washer M10 2 54 Vise 1
18 Hex. cap bolt M10x20 2 55 Bar stop rod 1
19 Roller 1 56 Bracket 1
19-1 Roller shaft 1 57 Butterfly screw 5/16x3/4 1
20 Washer M8x18x2 2 58 Washer M8x18x2 1
21 Spring washer M8 2 59 Spring washer M8 1
22 Hex. soc. cap screw M8x20 2 60 Hex. cap bolt 5/16”x1” 1
23 Filter net 1 61 Rod 1
24 Round head screw M5x10 4 62 Nut 5/16 1
25 Hex. soc. cap screw M6x25 2 63 Hex. cap bolt 5/16”x2 1
26 Washer M6 2 64 Set screw M8x10 1
27 Hose clamp 13mm 1 64-1 Hex. soc. cap screw M5x8 2
27-1 Hose 5/16x52” 1 64-2 Scale point 1
28 Pump WE90 1 65 Pivot 1
29 Hex. cap bolt M10x20 4 66 Anti dust cover M30 2
30 Coolant and chip tray 1 67 Ball bearing #32006ZZ 2
30-1 Black plate 1 68 Nut M10 2
31 Hex. cap bolt M12x40 2 69 Hex. cap bolt M10x30 2
32 Nut M12 2 69-1 Hex. cap bolt M10x25 1

33
 SHEET B

Item Description Qty Item Description Qty

70 Spring hook 1 100 Hex. soc. cap screw M8x25 4
72 Star washer M30 1 101 Spring washer M8 4
73 Nut M30 1 102 Set screw M8x10 1
74 Blade start indicator light 1 103 Hex. soc. cap screw M10x35 1
75 Emergency pushbutton 1 104 Spring washer M10 1
76 Main connect switch 1 105 Set screw M10x16 1
77 Power indicator light 1 106 Locking lever 1
78 Round head screw M5x10 6 107 Nut M12 1
79 Blade speed knob 1 108 Handle 1
80 Round head screw M5x10 4 109 Hex. soc. cap screw M10x30 4
81HV Control box cover 1 110 Spring washer M10 4
82 Hex. soc. cap screw M5x8 4 111 Gib 2
83HV Control box bottom plate 1 112 Spring washer M8 6
83-1 Transformer 1 113 Hex. soc. cap screw M8x20 6
83-2 Contacts 1 115 Front ball bearing bracket 1
83-3 Power in fuses 12A 2 116 Set screw M6x12 4
83-4 Control circuit fuses 1A 2 117 Hex. soc. cap screw M8x20 2
83-5 Magnetic connector 1 118 Hex. soc. cap screw M12x50 1
83-6 PC board 1 119 Setting bracket 1
84HV Control box bottom part 1 120 Hex. soc. cap screw M6x8 2
85HV Control box panel 1 121 Plastic handle 1
85HV-1 Manual/hydraulic brake selector 1 122 Hex. soc. cap screw M6x8 2
85HV-2 Start pushbutton 1 123 Cover plate 1
86 Support 1 127A Slide 1
88 Hex. soc. cap screw M5x8 4 127A-1 Spring washer M10 3
89 Hex. soc. cap screw M8x20 2 127A-2 Hex. soc. cap screw M10x45 3
90 Spring washer M8 2 127A-3 Set screw M10x25 1
91 Setting bracket 1 128 Nut M16x2x8 1
92 Spring washer M8 4 131 Handle 2
93 Hex. soc. cap screw M8x20 4 132 Handle wheel 1
94 Swivel arm 1 133 Thrust spring washer 10
94-1 Scale 1 134 Tension shaft 1
94-2 Rivet 2mm 2 137 Set screw M8x30 2
95 Disk 1 138 Rod 1
97 Oil seal 4mm 1 139 Nut M16x2x8 1
98 Shaft 1 140 Trigger switch 1
99 Nut 1 141A Shaft 1

34
 SHEET C

Item Description Qty Item Description Qty

142 Ball bearing #32006ZZ 2 172-H7 Spring 1
143 Idle flywheel 1 172-H8 Set screw M8x10 3
144 Anti-dust cover M30 2 173 Spring 1
145 Star washer M30 1 174 Key 6x6x30 1
146 Jam nut M30 1 175V DC Motor 1
147 Oil inlet 1/16(1/4x28T) 1 176 Spring washer M8 4
148 Blade 1 177 Hex. cap bolt M8x30 4
149 Blade cover 1 178V Gear box 1
150 Knob bolt M6x10 4 178-1 Vent screw 1
151 Round head screw M4x8 2 178-2 Key 8x8x35 1
153 Spring washer M4 2 179 Set screw M6x12 4
154 Nut M4 2 181 Hex. soc. cap screw M8x20 2
155 Hex. cap bolt M10x25 1 182 Front blade guard 1
156 Spring washer M10 1 183 Round head screw M6x8 3
157 Washer 1 185 Bolt 2
158 Drive flywheel 1 186 Front ball bearing seat 1
159 Hex. soc. cap screw M10x40 4 187 Pipe fitting 1
160 Spring washer M10 4 188 Rear blade guard 1
161 Hose 5/16x40” 1 189 Blade guide(B) 2
162 Pipe fitting 1/4Px5/16 1 190 Hex. soc. cap screw M6x12 2
163 Pipe fitting seat 1 191 Rear ball bearing seat 1
164 Hex. soc. cap screw M5x30 2 192 Pipe fitting 1/4Px5/16 1
165 Coolant valve 1/4Px5/16 1 193 Set screw M6x12 2
166 Hose clamp 1 193-1 Nut M6 2
167 Pipe fitting 1/4Px5/16 1 194 Hex. cap bolt M6x12 2
168 Hose 5/16x16” 1 195 Washer M6 2
169 Saw arm 1 196 Brush set ring 1
170 Limit switch AZD-S11-SA 1 197 Set screw M5x5 1
170-1 Switch pin 1 198 Bracket 1
171 Hex. soc. cap screw M4x35 2 199 Brush 1 1/2” 1
172 Spring shaft 1 200 Eccentric shaft 2
172-H1 Spring shaft 1 201 Ball bearing #608ZZ 8
172-H2 Setting plate 1 202 Blade guide (A) 2
172-H3 Handle 1 203 Hex. soc. cap screw M6x25 2
172-H4 Nut M16x2x8 2 204 E-ring 7Ø 4
172-H5 Bushing 1 205 Concentric shaft 2
172-H6 Adjustable shaft 1 206 Ball bearing #608ZZ 2

35
ELECTRICAL SCHEMATIC

36
 TROUBLESHOOTING

WARNING Disconnect the machine from power source before

troubleshooting.

SYMPTOM POSSIBLE CAUSE (S) CORRECTIVE ACTION

The Blade Drive 1. Fuses FU1, FU2, FU3, or FU4 Switch off main power. Replace
may have burned out. defective fuse(s).
Motor Does Not Work

2. Defective transformer (Power at Replace T1 (transformer).

input – no power at output).

3. If there is no voltage between

wires 11 & 13 of K1 and fuses
FU3, FU4 & transformer T1 are
ok :

Speed switch is not in “OFF” Turn speed switch (ccw) to “OFF”

position. position.

Speed switch is not at the “OFF” Replace speed switch.

position and contact is not closed.

E-stop pushed. Twist the button (cw) to reset or

replace the switch.

Blade guard limit switch SQ1 Replace blade guard or replace switch
open. SQ1.

Broken blade limit switch SQ2 Replace broken blade or replace switch
Open. SQ2.

Bow down limit switch SQ3 Raise saw bow or replace switch SQ3.
opened.

Move select switch SA2 has Replace move select switch SA2.
been turned to right position,
but contact is not closed.

Cycle start switch SB2 opened. Check that cycle start button SB2 has
been pressed in correct position or
replace button SB2.

Overload on the DC driver PCB1. Too fast of advance causes overload.

Switch “OFF” main disconnect switch
SA1, Then switch “ON” SA1.
Replace PCB1.
Replace motor.

37
 TROUBLESHOOTING (cont.)

SYMPTOM POSSIBLE CAUSE (S) CORRECTIVE ACTION

The Blade Drive 4. Overload relay switch K1 bad Replace overload relay switch K1.
Wires 11 & 13 of K1 have 24VAC
Motor Does Not Work but no response.

There are no voltage outputs at

(54 and 55 ) to the PCB1 when
K1 is actuated.

No. 61 and 62 (wire code) do not Contact Baileigh Service at

close after K1 actuated. (920.684.4990)

5. Check 24VAC on wires 1 & 10

(either below 22 volts or above 27
volts)

Saw Motor Does Not Actuator on cylinder does not Re-adjust actuator or switch.
contact switch properly.
Stop When Cut is
Finished Bow down limit switch SQ3 Replace SQ3
damaged

Coolant Motor Does Coolant motor M2 damaged. Replace M2 motor.

Not Run With Band
Saw Motor

No Power Indicator Fuses FU1, FU2, FU3,or FU4 may Switch off main power. Replace
have burned out. defective fuse(s)
Light When Main
Power Turned On Transformer T1 damaged Replace Transformer

Power LED HL1 damaged Replace (white) power LED

PCB1 damaged Replace PCB1

Operating Indicator Run LED HL2 damaged Replace (green) run LED
Light Does Not Work PCB1 damaged Replace PCB1
When Saw Motor is
Running

38
 TROUBLESHOOTING (cont.)

SYMPTOM POSSIBLE CAUSE (S) CORRECTIVE ACTION

1. Material loose in vise 1. Clamp work securely

2. Incorrect speed or feed 2. Adjust speed or feed
3. Blade tooth spacing too large 3. Replace with a small tooth spacing
blade
Excessive Blade 4. Material too coarse 4. Use a slow speed blade an small
Breakage tooth spacing
5. Incorrect blade tension 5. Adjust to where blade does not slip
on wheel
6. Teeth in contact with material 6. Start saw and lower into work
before saw is started piece
7. Blade rubs on wheel flange 7. Adjust wheel alignment
8. Misaligned guide bearings 8. Adjust guide bearings
9. Cracking at weld 9. Weld again, note quality of weld

1. Teeth too coarse 1. Use finer teeth

2. Too much speed 2. Decrease speed
3. Inadequate feed pressure 3. Decrease spring tension on side of
saw
Premature Blade 4. Hard spots or scale on material 4. Reduce speed, increase feed
Dulling pressure
5. Work hardening of material 5. Increase feed pressure by reducing
spring tension
6. Blade twist 6. Replace with a new blade, and
adjust blade tension
7. Insufficient blade 7. Tighten blade tension adjustable
knob

1. Blade guides worn 1. Replace

2. Blade guide bearings not adjusted 2. Adjust as per operators manual
Unusual Wear on properly
Side/Back of Blade 3. Blade guide bearing bracket is 3. Tighten
loose

Teeth Ripping 1. Teeth too coarse for work 1. Use finer tooth blade
2. Too heavy pressure, too slow 2. Decrease pressure, increase
From Blade speed speed
3. Vibrating work piece 3. Clamp work piece securely
4. Gullets loading 4. Use coarse tooth blade or brush to
remove chips

39
 TROUBLESHOOTING (cont.)

SYMPTOM POSSIBLE CAUSE (S) CORRECTIVE ACTION

1. Blade tension too high 1. Reduce tension on blade

2. Drive belt tension too high 2. Reduce tension on drive belt
Motor Running 3. Gears need lubrication 3. Check oil bath
Too Hot 4. Cut is binding blade 4. Decrease feed and speed
5. Gears aligned improperly 5. Adjust gears so that worm is in
center

1. Feed pressure too great 1. Reduce pressure by increasing

spring tension on side of saw
2. Guide bearing not adjusted 2. Adjust guide bearing, the clearance
properly can not be greater than .001mm
3. Inadequate blade tension 3. Increase blade tension with tension
Poor Cuts knob
4. Dull blade 4. Replace blade
5. Speed incorrect 5. Adjust speed
6. Blade guide spaced out too much 6. Adjust guide space
7. Blade guide assembly loose 7. Tighten blade guide assembly
8. Blade truck too far away from 8. Re-track blade according to
wheel flanges operating instructions

Poor Cuts 1. Too much speed or feed 1. Decrease speed or feed

2. Blade is too coarse 2. Replace with finer blade
(Rough) 3. Blade tension loose 3. Adjust blade tension

Blade is Twisting 1. Cut is binding blade 1. Decrease feed pressure

2. Too much blade tension 2. Decrease blade tension

40
P.O. Box 531 Manitowoc WI 54221-0531
Phone: 920.684.4990 Fax: 920.684.3944
Web: bii1.com

41
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