Horizontal Band Saw Manual: Operating Controls, Adjustments, and Maintenance

You own a horizontal band saw and you want to know how to operate it. A horizontal band saw is a metal cutting band saw where the blade runs horizontally and the saw head descends into the material. You need to know the operating controls, adjustments, and maintenance.

A horizontal band saw is a metal cutting band saw where the blade runs horizontally. The saw head is hinged and descends into the material held in a vise. Horizontal saws are used for cutting metal pipe, tubing, bar stock, and structural shapes.

Operating Controls

1. Power Switch

Turns the saw on and off. Usually a toggle switch or push-button.

2. Blade Speed Control

Controls the blade speed in feet per minute (FPM).

Types:

• Step pulley: Change the belt position on the pulleys to change speed.
• Variable speed (mechanical): Turn a dial to adjust speed.
• Variable speed (hydraulic): Adjust a hydraulic speed control.

Recommended speeds:

• Mild steel: 80 to 200 FPM
• Stainless steel: 60 to 100 FPM
• Aluminum: 200 to 400 FPM
• Cast iron: 80 to 150 FPM

3. Feed Rate Control

Controls how fast the saw head descends into the material.

Types:

• Hydraulic feed: A hydraulic cylinder controls the descent rate. Adjust the flow control valve.
• Gravity feed: The saw head descends by gravity. Adjust a valve to control the rate.
• Manual feed: The operator pushes the saw head down. Not common on production saws.

How to set the feed rate:

1. Start with a light feed rate.
2. Increase the feed rate gradually.
3. Stop increasing when the saw starts to struggle or the motor loads.
4. Reduce the feed rate slightly from that point.

4. Coolant Control

Controls the flow of cutting fluid to the blade-workpiece contact point.

How to adjust:

1. Turn on the coolant pump.
2. Adjust the flow valve to keep the cut area wet.
3. Direct the nozzle at the blade-workpiece contact point.
4. Do not over-flood the cut area.

5. Vise

Holds the workpiece during cutting.

Types:

• Manual vise: Tighten with a handle.
• Quick-acting vise: Quick-release and quick-tighten mechanism.
• Hydraulic vise: Tightens automatically (on production saws).

6. Miter Adjustment

Allows the saw head or vise to swivel for angle cuts.

Types:

• Swivel head: The saw head pivots. The material stays stationary.
• Swivel vise: The vise pivots. The saw head stays stationary.

How to set the miter angle:

1. Loosen the swivel lock.
2. Set the angle using the degree scale.
3. Tighten the swivel lock.
4. Verify the angle with a protractor if precision is needed.

Adjustments

1. Blade Tension

How to check: Use a tension gauge. The correct tension depends on the blade width:

• 1/2 inch blade: 15,000 to 20,000 PSI
• 3/4 inch blade: 20,000 to 25,000 PSI
• 1 inch blade: 25,000 to 30,000 PSI

How to adjust: Turn the tension knob on the upper wheel hub.

2. Blade Tracking

How to check: Spin the wheels by hand and watch the blade. The blade should track in the center of the tire.

How to adjust: Tilt the upper wheel using the tracking adjustment knob.

3. Blade Guides

How to check: The side guides should be close to the blade without touching. The thrust bearing should be just behind the blade.

How to adjust:

1. Loosen the guide locking screws.
2. Set the side guides to the correct clearance.
3. Set the thrust bearing to the correct clearance.
4. Tighten the locking screws.

4. Vise Alignment

How to check: Cut a test piece and check that the cut is square.

How to adjust: Adjust the vise alignment screws to make the cut square.

Maintenance

Daily Maintenance

1. Clean chips: Remove chips from the vise, blade area, and chip tray.
2. Check the blade: Look for worn or broken teeth.
3. Check the coolant level: Add coolant if low.
4. Wipe down the saw: Remove coolant and chips from the saw surface.

Weekly Maintenance

1. Clean the blade guides: Remove chip buildup from the guides.
2. Check the coolant concentration: Use a refractometer to check the mix ratio.
3. Check the drive belt: Look for cracks, wear, or stretching.
4. Lubricate the swivel mechanism: Apply oil to the swivel points.

Monthly Maintenance

1. Check all bolts and fasteners: Tighten any loose bolts.
2. Check the hydraulic fluid: Check the level and condition.
3. Lubricate the hinge points: Apply oil to the saw head hinge.
4. Check the vise jaws: Look for wear and replace if needed.

Annual Maintenance

1. Check the motor: Listen for bearing noise. Check for overheating.
2. Inspect the coolant pump: Check for leaks and proper flow.
3. Replace the drive belt: Replace if worn or cracked.
4. Check the blade guides: Replace if worn.
5. Check the hydraulic cylinder: Check for leaks and smooth operation.
6. Inspect the wiring: Check for damage or deterioration.

FAQ

What is a horizontal band saw?

A metal cutting band saw where the blade runs horizontally and the saw head descends into the material held in a vise. Used for cutting metal pipe, tubing, bar stock, and structural shapes.

How do I set the blade speed on a horizontal band saw?

Set the speed based on the material: mild steel at 80 to 200 FPM, stainless steel at 60 to 100 FPM, aluminum at 200 to 400 FPM. Use the step pulley, mechanical dial, or hydraulic control to set the speed.

How do I set the feed rate on a horizontal band saw?

Start with a light feed rate and increase gradually. Stop when the saw starts to struggle or the motor loads. Reduce the feed rate slightly from that point.

References

• Practical Machinist. “Horizontal Band Saw Guide.” practicalmachinist.com.
• Modern Machine Shop. “Band Saw Cutting Speeds and Feeds.” Gardner Business Media.
• LENOX Tools. “Metal Cutting Blade Guide.” LENOX Industrial Division.
• Starrett. “Bi-Metal Blade Specifications.” L.S. Starrett Company.
• JET Tools. “Horizontal Band Saw Owner’s Manual.” jettools.com.