TM 9-3405-215-14&P

TECHNICAL MANUAL

OPERATOR'S, ORGANIZATIONAL, DIRECT
SUPPORT, AND GENERAL SUPPORT MAINTENANCE
MANUAL INCLUDING REPAIR PARTS LIST
FOR
SAW, BAND, METAL CUTTING
MODEL 3613-20
NSN 3405-00-351-9704
(DOALL COMPANY)

HEADQUARTERS, DEPARTMENT OF THE ARMY

JULY 1981

TM 9-3405-215-14&P

WARNINGS
1.

To Avoid Potential Hazards, Observe These Precautions When Operating Or Servicing This
Machine-Operator Must:
Wear safety glasses.
Wear gloves-when handling saw band.
Not wear gloves when operating machine.
Set saw guides as close to work as possible.
Close band wheel covers before tensioning band or starting machine.
Close doors, replace all covers and safety guards before operating machine.
Use a fixture to feed work piece and keep hands away from moving saw band.
Avoid contact with coolant. Especially guard your eyes.
Step to one side and away from welding unit before welding a saw band.
Install friction band and spark shield before friction sawing.
Use a dust collector when sawing generates dust.
Disconnect electrical supply before removing panels or drive covers.

2.

Disconnect Electric Power To The Welder Before Making Adjustments.

3.

All Adjustments Must Be Made With The Power Off, Except Where Specifically Instructed
Otherwise.

TM 9-3405-215-14&P

INSTRUCTIONS FOR REQUISITIONING PARTS
NOT IDENTIFIED BY NSN

When requisitioning parts not identified by National Stock Number, it is mandatory that the following information be
furnished to the supply officer.
1 - Manufacturer's Federal Supply Code Number - 18056
2 - Manufacturer's Part Number exactly as listed herein.
3 - Nomenclature exactly as listed herein, including dimensions, if necessary.
4 - Manufacturer's Model Number - 3613-20
5 - Manufacturer's Serial Number (End Item)
6 - Any other information such as Type, Frame Number, and Electrical Characteristics, if applicable.
7 - If DD Form 1348 is used, fill in all blocks except 4, 5, 6, and Remarks field in accordance with AR 723-50.
Complete Form as Follows:
(a)

In blocks 4, 5, 6, list manufacturer's Federal Supply Code Number - 18056 followed by a colon and
manufacturer's Part Number for the repair part.

(b)

Complete Remarks field as follows:
Noun:
(nomenclature of repair part)
For:
NSN: 3405-00-351-9704
Manufacturer: Continental Machines, Inc.
for
Model: 3613-20 DoALL Company
Serial: (of end item)
Any other pertinent information such as Frame
Number, Type, Dimensions, etc.

contact the carrier for another inspection. Repair damage in the field whenever possible. Accept the shipment. The carrier "damage inspection" report isn't final. Carriers encourage this to keep expenses down. If additional damage is found when repairs are started. c. contact the carrier for another inspection. .TM 9-3405-215-14&P DAMAGE CLAIM PROCEDURE VISIBLE DAMAGE AT TIME OF DELIVERY 1. The inspector will request a signature on the report and leave a copy. CONCEALED DAMAGE 1. b. Don't move the equipment from the receiving area and keep all shipping materials until the carrier "damage inspection" report is complete. 5. 6. b. It can be returned later if repairs aren't possible in the field. If additional damage is found when repairs are started. 7. c. b. The carrier "damage inspection" report isn't final. Carriers encourage this to keep expenses down. Request a "damage inspection" from the delivering carrier: a. 2. If possible. 2. 7. Request a "damage inspection" from the delivering carrier: a. You have 14 days after delivery to report damage not noted at time of delivery. Report damage as soon as possible. 3. 5. Again if machine isn't moved it's easier to prove your case. Photos could possibly prove a claim at a later time. Photos could possibly prove a claim at a later time. at least give them the details of the damage. 4. You have 9 months to file a claim. 4. If possible. Inspect machines carefully before moving from the receiving area. or. The carrier will send his own people or contract an independent agency to make the inspection. at least give them the details of the damage. Note damage on carrier's delivery receipt. Keep a record of all expenses and be sure they are documented. Repair damage in the field whenever possible. Don't move the equipment from the receiving area and keep all shipping materials until the carrier "damage inspection" report is complete. This makes it easier to prove that it didn't happen in consignee's plant. The inspector will request a signature on the report and leave a copy. take photographs of the damage and keep them with your file. 6. The carrier will send his own people or contract an independent agency to make the inspection. Keep a record of all expenses and be sure they are documented. take photographs of the damage and keep them with your file. 3. a. or. You have 9 months to file a claim.

ATTN: DRSAR-MAS. or DA Form 2028-2. IL 60016 Procured under Contract No.TM 9-3405-215-14&P Technical Manual HEADQUARTERS DEPARTMENT OF THE ARMY Washington. This technical manual does. Mail your letter. METAL CUTTING MODEL 3613-20 (NSN 3405-00-351-9704) REPORTING OF ERRORS You can help improve this manual. US Army Armament Materiel Readiness Command. Rock Island. IL 61299. however. DC. contain available information that is essential to the operation and maintenance of the equipment. NOTE Manufactured by: Continental Machines. please let us know. A reply will be furnished direct to you. DA Form 2028 (Recommended Changes to Publications and Blank Forms). DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS LIST FOR SAW. ORGANIZATIONAL. Military Publications. 10 July 1981 No. Minnesota 55378 for DoAll Company 254 N. located in the back of this manual direct to: Commander. i . Inc. DAAA09-79-C-4136 This technical manual is an authentication of the manufacturers' commercial literature and does not conform with the format and content specified in AR 310-3. BAND. Laurel Avenue Des Plaines. 9-3405-215-14&P OPERATOR'S. If you find any mistakes or if you know of a way to improve the procedures. Savage.

TM 9-3405-215-14&P

TABLE OF CONTENTS

INSTALLATION
Location .......................................................
OSHA Notice ................................................
Lifting ...........................................................
Uncrating ......................................................
Electrical Installation .....................................
Alignment .....................................................
Preparation For Use ......................................
Machine Dimensions .....................................

TROUBLE SHOOTING ....................................... 15
1
1
1
1
1
1-2
2
3

MACHINE CONTROLS & FEATURES .......... 4-5
OPERATION
Safety Precautions ........................................
Using The Job Selector .................................
Insert-Type Saw Guide Adjustment ................
Band Installation ...........................................
Band Removal ..............................................
Band Tensioning ...........................................
Band Tracking ..............................................
Post Adjustment ...........................................
Speed Control ...............................................
Work Table ...................................................
Table Tilt Adjustment ....................................
Chip Removal ...............................................
Welding Saw Bands ......................................
Manual Contour Sawing ................................

6
6
7
7
7
7
8
8
8
8
9
9
9
9-10

LUBRICATION
Lubrication Diagram ....................................... 12
Lubrication Chart .......................................... 13
MAINTENANCE
Head Assembly ............................................
Chip Removal ...............................................
Replacing Wheel Tires ..................................
Transmission ................................................
Drive Belts ....................................................
Saw Guides ..................................................

ii

14
14
14
14
14
15

ACCESSORIES
Variable Weight Power Feed ............................... 16
No. 1 All-Purpose Cut-Off .................................... 16
Disk Cutting ........................................................ 17
Screw Feed ........................................................ 17
Spiral Saw Band Guides ...................................... 18
Roller Saw Band Guides ..................................... 18
Insert-type Saw Guides ....................................... 18
90° Saw Band Guide Brackets ............................. 19
Rip Fence ........................................................... 19
No. 2 Cut-Off & Ripping (Side Mount) ................... 19
Universal Vise .................................................... 19
Universal Calibrated Work Fixture ........................ 20
Mist Coolant Applicator ........................................ 20
Drip Type Coolant Applicator ............................... 21
Air Pump & Chip Blower ...................................... 21
Ball Transfer Strips ............................................. 21
Heavy Work Clamps ........................................... 21
Heavy Work Slides .............................................. 22
Work Light & Magnifier ........................................ 22
Chip Pan ............................................................ 22
Spark Guard for Friction Sawing .......................... 22
Secondary (Auxiliary) Table.................................. 23
Dust Spout ......................................................... 23
Welder ............................................................... 23
Blade Shear ........................................................ 23
Etching Pencil ..................................................... 23
Work Table Option .............................................. 23
Sliding Table (Air Feed) ....................................... 23
Supply Cabinet ................................................... 23
Band Filing ................................................... 24-25
File Guides ......................................................... 25
Band Polishing .............................................. 25-26

TM 9-3405-215-14&P
INSTALLATION
LOCATION

ALIGNMENT

The machine should be located so that adequate space
is provided for your cutting needs. You will also want to
provide sufficient clearance around the machine for
maintenance and lubrication procedures, plus operation
of any accessories accompanying the machine.

Machine must be properly aligned before being bolted
into position. Follow these procedures:
(1) Release band tension. Remove band. Remove
post saw guard and table center plate, plus upper
and lower saw guides.

Floor area required for the machine itself is 40 inches
(1025 mm) by 73 inches (1850 mm). Maximum machine
height is 74 inches (1885 mm).

CAUTION
ALWAYS WEAR GLOVES
HANDLING SAW BANDS.

NOTICE!!!

WHEN

(2) Re-install band over each wheel.
maximum reading on tension indicator.

OSHA Regulation No. 1910.212 (B).
Machines
designed for a fixed location shall be securely
anchored to prevent walking or moving.

Tension to

(3) Shim between base mounting pads and floor until
machine is level and weight rests evenly on all pads.
Check by tapping with bar or hammer.

LIFTING
(4) Post front should be parallel with lower keeper
block's machined saw guide mounting recess.
Check by placing spacer block - ground to exactly
0.250-inch (6.35 mm) thickness -- in keeper block.
Place an accurate straight edge against spacer
block and post. Use a feeler gage to check post
clearance and parallelism
to straight edge.
Clearance should not exceed 0.004-inch (0.1 mm) in
4 inches (100 mm). See Fig. 1.

You will find a tapped hole in the machine head's upper
surface. Screw a forged 3/4-10 UNC eyebolt into this
hole to lift machine into position, or for later moving it to
another location.
Lifting by overhead hoist is
recommended. Machine weight is 1565 pounds (705
kg).
UNCRATING
Carefully remove all protective coverings, strappings,
hold-down brackets, and skid. Check inside rear drive
housing for other removable brackets, extra machine
parts, or supplies placed there for shipment. Unfasten
power feed weight hold-down bracket (if accessory is
supplied).
Use solvent to remove rust-preventive coating applied to
all exposed bare metal surfaces prior to shipment.
Inspect machine for broken or damaged parts.
ELECTRICAL INSTALLATION

Bring line circuit leads into electrical enclosure on
machine column. Refer to wiring diagram furnished.
Check air discharge nozzle for proper rotation of chip
blower pump.
Overload protection is provided. If machine is started
and stopped repeatedly and in rapid succession, the
overload relay may be tripped. Let relay cool a few
minutes before starting machine.

FIG. 1. ALIGN POST TO LOWER SAW GUIDE
KEEPER BLOCK.
1

TM 9-3405-215-14&P

(5) Clearance greater than 0.004-inch (0.1 mm) should
be corrected by shimming under base pad. Remove
shims to increase clearance; add shims to decrease
clearance. See Fig. 2.

PREPARATION FOR USE
(1) Check transmission oil level.
Fill with product
recommended in Lubrication Chart. Fill until oil level
is at elbow plug level. Capacity is 1 quart (0.95
liters).
(2) Check to see that all other points listed on
Lubrication Chart have been properly serviced.

FIG. 2. SHIMMING LOCATION - TOP VIEW.
(6) Square table to post side by loosening table tilt lock
nut, and making necessary adjustment. Adjust tilt
angle pointer to "zero", if necessary. Tighten lock
nut. See Fig. 3.

FIG. 3. SQUARING TABLE TO POST.
(7) Re-install post saw guard, saw guides, inserts, and
table center plate.
CAUTION
Bolt machine to floor for table loads
exceeding 100 pounds (45 kg).

2

TM 9-3405-215-14&P MACHINE DIMENSIONS 3 .

FRONT VIEW 4 .TM 9-3405-215-14&P FIG. CONTROLS AND FEATURES. 4.

TM 9-3405-215-14&P FIG. 5. CONTROLS AND FEATURES. 5 . REAR VIEW.

STEP TO ONE SIDE AND AWAY FROM WELDING UNIT BEFORE WELDING A SAW BAND. USE A DUST COLLECTOR WHEN SAWING GENERATES DUST. ALWAYS USING THE JOB SELECTOR (1) Turn dial until material to be cut is directly below cover window.TM 9-3405-215-14&P OPERATION SAFETY PRECAUTIONS WARNING TO AVOID POTENTIAL HAZARDS. REPLACE ALL COVERS AND SAFETY GUARDS BEFORE OPERATING MACHINE. (2) Locate recommended pitch and blade type listed next to work thickness. AVOID CONTACT WITH COOLANT. WEAR GLOVES-WHEN HANDLING SAW BAND. This completes blade choice and job set-up requirements. (4) Locate recommended band thickness and blade type. CLOSE DOORS. USE A FIXTURE TO FEED WORK PIECE AND KEEP HANDS AWAY FROM MOVING SAW BAND. See Fig. However. CONSULT THE OPERATOR'S MANUAL PRIOR TO SERVICING. (Your machine may be equipped with accessory spray or drip coolant applicator. or both). SET SAW GUIDES AS CLOSE TO WORK AS POSSIBLE. NOT WEAR GLOVES WHEN OPERATING MACHINE. 6. DISCONNECT ELECTRICAL SUPPLY BEFORE REMOVING PANELS OR DRIVE COVERS. pitch and tooth type. JOB SELECTOR NUMBERS REFER TO STEPS AT LEFT 6 . Refer to a saw blade specification table to determine gage and set. INSTALL FRICTION BAND AND SPARK SHIELD BEFORE FRICTION SAWING. FIG. CLOSE BAND WHEEL COVERS BEFORE TENSIONING BAND OR STARTING MACHINE. (3) Locate correct blade width on a radius chart if radius is to be cut. 4. MAKE SAFETY THE RULE AND FOLLOW SAFE SHOP PRACTICES. Determine band width. ESPECIALLY GUARD YOUR EYES. these recommendations can be adjusted to meet particular sawing requirements. (6) Note recommended coolant application method. OBSERVE THESE PRECAUTIONS OPERATING OR SERVICING THIS MACHINE-OPERATOR MUST: WHEN WEAR SAFETY GLASSES. speed for work (5) Note recommended feed force to be used with work thickness.

See Fig. 7. POSITIONING RIGHT INSERT. (3) Place left insert in slot. 7. Band tension is applied by turning handwheel located below saw head. OR UP TO 5000 FPM (1500 m/min) FOR OCCASIONAL SAWING. Adjust insert to fit exactly into gage notched end. Scale figures are recommended tensions. Place right insert in milled slot. Tighten screw. BAND TENSIONING (2) Select insert gage matching saw band. UPPER GUIDE BLOCK SHOWN. Tighten screw lightly so insert will slide in slot and hold its proper position when released. Tighten screw lightly.TM 9-3405-215-14&P INSERT-TYPE SAW GUIDE ADJUSTMENT BAND INSTALLATION (1) Select guide blocks and inserts set marked for band width. See Fig. NOTE INSERT-TYPE GUIDES ARE RECOMMENDED FOR MAXIMUM BAND SPEEDS OF 1300 FPM (390 m/min) FOR PRODUCTION SAWING. Place in slot. Relax band tension. Apply proper band tension. (4) Move table slot bar back into position and lock. 9. Tighten saw guide inserts. Loosen left saw guide insert. Remove post band guard and unlock saw slot cover. See Fig. (3) Place band carefully over wheels and between saw guide inserts. 8. They are based on most commonly used gages and pitches. See Fig. Band center should center on wheel's crown face. UPPER GUIDE BLOCK SHOWN. FIG. Increase tension when using heavier bands. (2) Loosen saw guide inserts and carefully remove band. Place gage edgewise between both inserts. 9. (1) Open band wheel doors. FIG. Release band tension. 8. (2) Unlock saw slot bar located below table front edge. Lower insert until it rests against gage. Tighten insert screw. USE ROLLER GUIDES FOR CONTINUOUS SAWING OVER 1300 FPM (390 m/min). Slip band from wheels. 7 . POSITIONING LEFT INSERT. See Fig. 8.2 mm) to 1 inch (25 mm). Move bar so that it does not cover saw slot. FIG. Tighten band to tension indicated on scale to right of handwheel. Remove post band guard. Reduce recommended tension when using bands with coarser pitch or lighter gage. Correct tensions are given for bands 1/8-inch (3. BAND TENSION AND POST CONTROLS. 7. Reinstall post band guard and close wheel doors. Move bar away from saw slot. BAND REMOVAL (1) Open band wheel doors.

(2) Always turn band speed control to "slow" before stopping machine. raise by turning counter-clockwise. Perform the following tracking procedures with drive "off" and transmission in "neutral". See Fig. See Fig. All tables are drilled and tapped on front. Always keep post and upper saw guide as close as possible to workpiece. 10. 11. (1) Before shifting gears: turn band speed control to "TRANS. (2) Change wheel tilt by loosening lock nut and adjusting tilt knob until band rides tire correctly. and for installing special-purpose center filing or polishing disks. POST ADJUSTMENT FIG. Band guards should be locked in place at all times during sawing. Band's back edge should just touch saw guide back-up bearings. WHEEL TILT ADJUSTMENT -SIDE VIEW. Manually turn wheels and observe how band tracks on tires. 10. Post elevation is adjusted manually by turning handwheel located on saw head. 11. See Fig 9. Turn wheel clockwise to lower post and upper saw guide. rear. SHIFT POINT" (this releases the solenoid interlock) and make sure band is stopped. (3) Tighten lock nut. Each can be infinitely varied within its range by the band speed control located on machine front. FIG. Adjust wheel tilt if band does not track on tire centers. Speed ranges are 50-300 fpm (15-90 m/min) and 850-5200 fpm (259-1585 m/min).TOP VIEW. Turn drive wheel by hand when shifting to engage clutch. Table center disk is removable for changing saw bands. 8 . Good practice recommends the following operator precautions: (1) Open band wheel doors. and right edges for accessory attachment.TM 9-3405-215-14&P BAND TRACKING SPEED CONTROL The upper wheel can be tilted forward and backward a maximum distance of 3 inches (75 mm) to aid band tracking. WORK TABLE Standard machine work table measures 26 inches (660 mm) by 26 inches (660 mm). (3) Do not attempt to force shift lever into place. TYPICAL WORK TABLE . A properly tracking band center should follow crowned rubber wheel tire centers. A transmission shift lever selects between two speed ranges.

to remove chips Follow these precautions when contour sawing: (1) Use Job Selector recommendations for band selection. In addition. FIG. A hole is usually drilled in the workpiece when a sharp corner is to be cut. DBW-15 WELDER. Lock table in position before sawing. 3812-2 OPTION 9 . and coolant application type. operation and maintenance for the DBW-15 butt welder with flash grinder and blade shear are provided in a separate instruction manual. band speed.3613-20 ONLY. They are described in more detail in the Accessories section. 13. CHIP REMOVAL A wheel brush above lower wheel cleans chips from wheel tire. AIR PUMP AND CHIP SLOWER . Pump is driven and delivers compressed air to chip Flexible blower nozzle can be adjusted from sawing area. 13.TM 9-3405-215-14&P TABLE TILT ADJUSTMENT WELDING SAW BANDS The table can be tilted up to 10 degrees left or 45 degrees right by loosening the lock nut with provided wrench. TABLE TILT FEATURES.FRONT VIEW. See Fig. Your machine may be equipped with pump and chip blower. feed pressure. On machines without chip pan. a vane-type air by its own motor blower on post. 12. Tilt table manually until desired angle is shown by pointer on trunnion-mounted calibrated scale. It is important that operator occasionally open lower wheel door on such machines and scoop chips out. leaving the remainder to be notched out later. FIG. See Fig. chips collect at machine base. 15. 14. Operator should remove pan and empty as necessary. MANUAL CONTOUR SAWING The standard machine can be used to manually cut contours. Lock nut is reached through a frame opening under table on machine side near lower door latch. Complete instructions covering blade welding. (2) Screw feed. Any band twisting or bowing means work is being fed too rapidly. GRINDER . 12. 14. your machine may be equipped with one or more of the following contour sawing accessories: (1) Variable weight power feed. A corner can also be by-passed with a curve cut. See Fig. See Fig. FIG. (2) Reduce initial feed force to prevent blade damage when it suddenly enters an opening. Chips are directed into a chip pan on some machines.

MINIMUM RADII CUTS. 15. Attempting to cut too small a radius with too wide a band will cause it to bind.TM 9-3405-215-14&P FIG. NOTE You will insure a better weld on band which passes through workpiece hole by insulating the band from contact with workpiece or table. Saw an internal contour by cutting band. running band through hole. Radii chart below shows minimum possible radii cuts with varying band widths. See Fig. Use a narrower saw band than recommended when sawing stock more than 1 inch (25 mm) thick. Drilled starting hole's diameter is determined by band size. 10 . then welding band. drilling starting hole. 16. Radii chart recommendations are based on sawing relatively thin stock. Widest possible band should be used for curve cutting. FIG. STARTING HOLE FOR SHARP CONTOUR CUTTING. Use Disk cutting accessory if contour is a radius. See Fig. 16. 24. It may also cause lower wheel tire grooving. Use a heavy gage blade for heavy workpiece contour sawing.

TM 9-3405-215-14&P LUBRICATION DIAGRAM AND CHART (NEXT TWO PAGES) 11 .

10 and 14 on chart not shown on diagram. 12 .TM 9-3405-215-14&P LUBRICATION DIAGRAM No's 8.

EP (extreme CHECK MONTHLY pressure) grease. Remove air intake filter. Clean and apply oil. cutting fluids and/or oils. Clean and apply oil as required. Table Trunnion. 12 Electric Motor(s). CHECK MONTHLY (For 80 degrees F and above). Oil tilt surfaces. 465. etc. 7 Miscellaneous. corrosion.TM 9-3405-215-14&P LUBRICATION CHART LUBRICATION POINT NUMBER LOCATION DESCRIPTION AND SERVICE RECOMMENDATIONS LUBRICATION INTERVAL * 1 Sand Tension Screw and Bearing. Lubricate more often when required. 13 DBW-15 Welder Lubricate as required per DBW-15 Instruction Manual. 8 9 10 RECOMMENDED LUBRICANT MONTHLY AS REQUIRED AS REQUIRED High quality. Hinges.95 liter) capacity. 13 . 14 Drip or Mist Coolant Tank (Optional). Premium quality. Clean and apply oil as required. 2 Grease Fittings and Miscellaneous applications (Optional). 315. graphite lubricant. 11 Air Pump (Optional). Drain and refill yearly or when required. MONTHLY 3 Upper Wheel Slide. Lubricate as required per manufacturer's recommendations. Clean and apply oil. AS REQUIRED NLGI Grade No. Proper oil level must be maintained. medium hydraulic and general purpose industrial oil. CHECK MONTHLY Accessory Equipment as Supplied. Post Elevation Screw and Gears. Keep air filter clean. MONTHLY 4 5 Transmission. ASTM Grade No. Proper oil level must be maintained. High quality. Air Compressor (Optional). 1 quart (0.95-liter) capacity. powdered lubricating CHECK MONTHLY graphite AS REQUIRED (natural or manufactured). lithium base. Hinge and Tilt Screw. Dry. Feed lubricant into opening while pump is in motion. medium hydraulic and general purpose industrial oil CHECK WEEKLY ASTM Grade No. Clean and apply oil. CHECK DAILY AS REQUIRED Premium quality. Pivot. rust and oxidation inhibited. multi-purpose. Keep crankcase and air intake filter clean. rust and oxidation inhibited. Keep filled. Lubrication intervals are based on an 8-hour day. saw band coolant and lubricant. 6 Transmission Shift Linkage and Interlock. etc. Drain and refill every 3 months. 1 quart (0. 40-hour week. MONTHLY 2 Post. Keep clean and apply oil as required to maintain proper function and reduce wear.

Figs. Slide motor to tension belt.38 mm). DRIVE BELTS ASSEMBLY. 14 . loosen adjusting screws and adjust brush. AIR COMPRESSOR ASSEMBLY. If your machine is equipped with a chip collecting pan. See Fig. 17. LOWER WHEEL CHIP BRUSH. See Fig. Stretch until tire can be removed. Wheel bearings are sealed and lubricated for life. and gap between brush and wheel tire is greater than 0. If worn. 18. UPPER WHEEL REMOVED TO SHOW HEAD ASSEMBLY DETAIL CHIP REMOVAL A wheel brush is mounted above lower wheel to clean chips from wheel tire.015-inch (0. FIG. Correct new transmission installation is extremely important because careful alignment is necessary. FIG. Replace as required. Then run post up and down several times through slide block. it should be emptied when necessary. 18. then tighten bolts. loud or unusual noises should be investigated immediately. It is recommended that a faulty transmission be returned to factory for repair. Check for seal leaks around shafts. Wipe oil on post occasionally. 20. 19 and 20. FIG. or other flat tool. Tighten compressor belt in a similar fashion. Upper wheel slide and band tension screw should be oiled monthly. Tighten transmission belt by loosening drive motor foot bolts. DRIVE BELTS Drive belts on the transmission and compressor pulleys may stretch slightly after initial use.TM 9-3405-215-14&P MAINTENANCE REPLACING WHEEL TIRES HEAD ASSEMBLY Replace worn tires by loosening them from wheel with a screw driver. 19. 17. TRANSMISSION Any rough operation. vibration. FIG. Scrape wheel clean and apply fresh cement before installing new tire.

(6) Coolant not being applied evenly to both band sides. (7) Upper post saw guide not close enough to workpiece. Starting and stopping machine a number of times in quick succession will cause an overload to trip starter heater. EXCESSIVE INSERT AND BLADE WEAR (1) Inserts adjusted too tightly on blade. (2) Wrong file band type being used. (7) Faulty material: heavy scale. (3) Machine base is not shimmed properly. POOR BAND FILING FINISH (1) Feed force is too high. or coolant. They are on a tag attached to motor. Machine vibration. Saw band pitch too coarse. Push reset button after locating and correcting trouble. (2) File band not correctly assembled. Re-adjust or replace. (9) Chipped tooth lodged in cut. (3) Roller guide rollers adjusted too tightly on (4) Chip brush worn or not property adjusted. New bearings are easily installed with a light press fit. (4) Improper guide block used. (2) Check band drive motor starter reset. MACHINE VIBRATION (1) Band wheels have become unbalanced. (1) Upper wheel not correctly aligned. (1) Saw band not being properly broken in on first few cuts. then pulling out bearing and shaft. hard spots. Reduce feed pressure and speed on first cuts. inclusions. Use roller saw guides. Feed is too heavy. etc. (4) Incorrect band or insert alignment. being used. if necessary. (5) Coolant not covering saw band. (2) Band speed too high. Set for same as 1/8-inch (3. FILE BAND BREAKS (1) Feed force is too high. BAND SLIPS FROM WHEELS (3) Check fuses located behind DC circuit board. Adjust cover plate. (2) Workpiece scale not removed. Saw guide insert worn. TROUBLE SHOOTING MACHINE WILL NOT START (1) Check band tension limit switch (if provided). Saw band speed too low. Listen for clicking sound during band operation. SURFACE FINISH ON WORK TOO ROUGH SAW BAND VIBRATION (1) (2) (3) (4) (5) (1) Worn blade teeth. DRIVE MOTOR PREMATURE SAW BAND DULLING Follow manufacturer's maintenance instructions for main drive motor. (3) Incorrect initial machine alignment. (2) Drive belt is unbalanced. (Inserts too wide for blade will damage set teeth). allowing them to hit set teeth.TM 9-3405-215-14&P SAW GUIDES (Insert-Type) Roller Back-Up Bearing: Bearings are sealed and packed for life with a special lubricant. This allows chips to stay on wheel. (2) Too much coolant.2 mm) wide carbon band. (5) Back-up bearing needs replacement. (11) Inserts too wide for blade width. (3) Band tension is too high. if possible. (4) Feed pressure too light. (9) Check for loose post. (2) High band speed causing friction. (10) Chip welding. (8) Incorrect saw band tension. to lubricate band. 15 . Band should track near wheel tire's center. Use Saw-Eez. (3) Saw band pitch too coarse. (8) Saw band vibration. They are replaced by removing snap ring. causing abrasion. (5) Incorrect feed force or band speed. (6) Cutting rate is too high. or slippery coolant. (3) Blade too wide for radius being cut.

1 ALL-PURPOSE CUT-OFF. Place graduation scale at "zero" marking. FIG. FIG. Where a cut has longer than 10 inch (255 mm) maximum feed distance. Weight position is set by a handwheel. (4) Change from manual to automatic feeding by disengaging feed screw with split nut lever. Slide unit along guide and square miter bar with table slot. 21 & 22. It allows operator to notch. channels. Feed force exerted against blade ranges from 0-80 pounds (0-36 kg). Use heavy feed force when sawing with wide bands and lighter feed forces for narrower bands. (3) Use handwheel for manual operation. 1 ALL-PURPOSE CUT-OFF Used with variable weight power feed for ripping. and mitering functions. or miter rods. 23. rip. THIS GUARDS AGAINST OPERATOR AND MACHINE INJURY SHOULD PEDAL BECOME ACCIDENTALLY DISLODGED. bring weight back into position at bottom of stroke by pressing pedal into notch. MITERING. NO. cuttingoff. CAUTION PEDAL SHOULD REMAIN in ITS UPPER POSITION WHEN NOT in USE. 16 . 23. Then remove work holding chain slack. RIPPING. Weight position on beam determines feed rate and pressure. (2) Lock unit in desired position with set screw. Release pressure and stop feed by removing foot from pedal. (1) Mount table guide and guide spacer. 21. The beam is raised initially by pushing foot pedal. rails. VARIABLE WEIGHT POWER FEED FEATURES. NO. Lighter feed forces are required if workpiece is significantly thicker. WORK HOLDING JAW. See Figs. tubes. See Fig. Feed force less than 10 pounds (5 kg) is achieved by partially restraining pedal. 22. Turn handwheel on side of base clockwise to reduce pressure and feed rate.TM 9-3405-215-14&P ACCESSORIES VARIABLE WEIGHT POWER FEED The variable weight power feed allows operator to use both hands for guiding work being pulled into saw band. and irregular shapes with accuracy. bars. Fasten power feed chain around miter head collar top. square. FIG.

Tighten fine adjustment clamp bolt. (5) Make final radius adjustments with fine adjustment wheel. Mount swivel in table front bracket. SCREW FEED. FIG. Move center pin to approximate distance or radius to be cut. Tighten radius arm clamp while making sure center pin is square to table. (3) Loosen fine adjustment and arm clamp bolts. FIG. (1) Place flat washers under screws and bolt bracket to post.TM 9-3405-215-14&P DISK CUTTING Used to cut internal or external true circles from 2-1/2 inches (65 mm) to 30 inches (760 mm) diameter. 25. (4) Centering pin's center must be perpendicular to the saw band cutting edge. Adjust screw to any point within its 12-inch (305 mm) movement by lifting swivel top release knob. See Fig. 25. Tighten arm clamp bolt. Loosen vertical adjustment clamp bolt. Line up centering pin with square's blade edge. CUTTING RADIUS WITH DISC CUTER. Raise or lower saw guide post to adjust unit for work thickness. Do this by placing a square against saw slot side with square blade against saw tooth tip. 24. SCREW FEED Screw feed is used for precision heavy work contour sawing. 24. 17 . (2) Lower post until saw guides are approximately 318inch (10 mm) above table. See Fig. Clamp tight.

Place one back-up roller and one side roller in each block. Pull out carbide bearing shaft and remove bearings. INSERT-TYPE SAW GUIDES FIG. FIG.6 mm) wide carbon saw band. Adjust them as follows: If bearings need replacing. insert carbide bearing and snap ring. 26. (1) Install guides on upper post and lower keeper block. Be sure inserts match band width. Set up as follows: NOTE Bearings will overheat it rollers are too tight against band. ROLLER GUIDES ALLOW CONTINUOUS HIGH-SPEED SAWING. 26. Band may wobble if rollers are loose. (1) Install saw guides and band. See Fig. These high-speed. SPIRAL SAW BAND GUIDES. ROLLER SAW BAND GUIDES Use roller guides for continuous high speed sawing. 18 . (2) Select correct rollers for band width. woods. (2) Adjust upper wheel tilt until band rides freely in roller grooves. Guides are installed and adjusted like regular insert-type saw guides. (5) Tighten roller lock screws so eccentric shaft will not turn. Band cutting edges should be facing down to table when band revolves. These bands are for sawing intricate contour patterns without turning workpiece. remove snap ring. Proper tension is same as for a 1/16-inch (1. Bearings are sealed and packed for life with a lubricant. (3) Install band and adjust tension. Required when using spiral bands having a 360 degree cutting edge. 27.TM 9-3405-215-14&P SPIRAL SAW BAND GUIDES (4) Bring rollers into contact with band by turning eccentric shaft with a screwdriver. Install new bearings with a light press fit. insert-type saw guides are designed for sawing speeds up to 5000 fpm (1500 m/min). See Fig. It can be used on such materials as plastics. Turn eccentric with a screwdriver until band rides both roller groove bottoms. Adjust eccentric by loosening guide block set screw. and light gage metals. Rollers have ball bearing mountings grooved for accurate band guidance. (3) Each guide has an eccentric shaft roller. 27.

31. NO. An adjustable cut-off gage assembly mounts in a T-slot on the table's left side to allow duplicate cut-off operations for production runs. 90° SAW SAND GUIDE BRACKETS.TM 9-3405-215-14&P 90° SAW BAND GUIDE BRACKETS NO. swing unit up. FIG. 2 CUT-OFF AND RIPPING (SIDE MOUNT). UNIVERSAL VISE. See Fig. FIG. See Fig. RIP FENCE. 30. When not in use. RIP FENCE UNIVERSAL VISE Install by squaring fixture so it is in line with table slot. Operate machine at speeds under 1500 fpm (450 m/min). Mount brackets and correct saw guides. Table T-slots allow vise to be removed quickly and easily. Be certain band is not worn on one side before attempting a long cut. 19 . to the right. Install band so it is twisted 90 degrees when passing through inserts. Make sure mitering bar is in even contact with table surface. 28. FIG. Place a combination square in table slot to check alignment and set mitering bar at various angles. 29. See Fig. 28. 2 CUT-OFF & RIPPING (Side Mount) The 90 degree saw guide brackets permit cutting material greater in length than the machine's regular throat capacity. Applies work-holding pressure needed for accurate production cut-off work between 0-45 degrees. and down on slide rod so it hangs below table. See Fig. Work is rapidly clamped and unclamped by a lever-operated eccentric. 31. This will cause work to wander relative to rip fence guide bar. 30. FIG. 29.

Loosely install T-nuts and screws. Count drops visible through sight glass. consistent mist by directing stream onto a metal surface. Bring collar snugly against bar and tighten screw. 32. Bend applicator tube to direct mist stream onto blade teeth and work. and holds the workpiece in position while it is moved into the saw band. Saw kerf into bar 1/16 to 1/8 inch (1. Make sure all joints are sealed and tight. Clogging may occur if wax-based or other coolants are used.2 mm) deep to allow cutting completely through workpiece. Set adjustable table stops to prevent deeper sawing into work bar after cut completion.TM 9-3405-215-14&P UNIVERSAL CALIBRATED WORK FIXTURE machine head back to drip applicator valve with sight glass. See Fig. MIST COOLANT APPLICATOR Coolant is delivered from a 1-quart (0. Check for a fine. Clean nozzle and coolant bottle when necessary. can be set up for straight or angle cut-off. Insert new center tube. Tighten screws. 32. Air and coolant are mixed at nozzle end to form a fine mist. Normal mist adjustment produces approximately one coolant drop per second. Coolant next enters manifold and is directed into a nylon tube which passes through flexible air tube.5 to 3. Replace nylon center tube by disassembling flexible tubing. turn fixture to desired angle. See Lubrication Chart for recommended coolant products. Square fixture to table by lining up one moveable stop edge with one table slot edge. 33. 33. place fixture on table at required distance from band. and tighten left screw. For angle sawing. Mount collar (behind bar) loosely on T-nut with socket-head screw. Regulate mist with drip applicator valve. Loosen left screw. Check all joints. UNIVERSAL CALIBRATED WORK FIXTURE.95-liter) bottle on FIG. Intermittent stream with coolant spurts generally indicates a manifold air leak. and trim excess nylon so that it is flush with nozzle end. Coil applicator tube a few times. ADJUSTING MIST COOLANT. FIG. This accessory clamps to the table. 20 . See Fig. For straight sawing. remove right T-nut and screw.

21 . and attached to table with socket head screws. Adjust flexible blower nozzle to remove chips from sawing area.TM 9-3405-215-14&P DRIP-TYPE COOLANT APPLICATOR The 1-quart (0. See Fig. 2 center strips are doweled. See Fig. 35. 34. Compressed air from pump is delivered to chip blower mounted on machine post. DRIP COOLANT APPLICATOR FEATURES. FIG. See Fig. See Fig. BALL TRANSFER STRIPS. Lubricator slide rod adjusts to blade widths. This will assure lubricant flow to both saw sides. 37. Use sparingly. A special center block is placed in table center. HEAVY WORK CLAMPS AIR PUMP & CHIP BLOWER Heavy work clamps are used for contour sawing heavy materials. 36. Adjust applicator so copper tube outlet just touches saw tooth edges. and a 4-inch (100 mm) clamping capacity. FIG.95-liter) coolant container and holding bracket mount to head side panel. Work height is reduced by 1-1/2 inches (40 mm) when ball transfer strips are attached to table. Lubricator fastens to post with a set screw. 35. Saw it to leave blade travel path or kerf. It's important to use this center block when cutting stacked parts. The other 4 strips are moveable during sawing. and stacked parts. Clamps have a ball bearing base. The vane-type air pump is belt-driven by its own motor. Adjust sight feed valve to deliver no more than 10 drops per minute. 34. 36. AIR PUMP AND CHIP BLOWER. NOTE Too much coolant will cause saw band slippage on wheels. FIG. BALL TRANSFER STRIPS Your machine may be equipped with 6 detachable ball transfer strips to make heavy workpiece moving easier.

WORK LIGHT & MAGNIFIER The operator can magnify cut area during delicate sawing procedures. FIG. SPARK GUARD FASTENED TO UPPER SAW GUIDE. SPARK GUARD FOR FRICTION SAWING HEAVY WORK SLIDES Spark guard attaches to band guard with machine bolt. See Fig. 39. HEAVY WORK SLIDES. 22 . Remove pan and clean out chips When necessary. Saw center block so a blade travel path or kerf is made. Connect power feed chain to mesh with clamp gear teeth. 40. 37. HEAVY WORK CLAMPS. Insert special center support block in table center disk. FIG. A protective lens cover which prevents scratching should be placed around magnifier when not in use. CHIP PAN Your machine may be equipped with a removable chip pan below lower wheel door. This provides solid sawing point contact between work and feed table surface. FIG. 38. See Fig. This pan catches chips removed from lower wheel by chip brush. 38. WORK LIGHT WITH MAGNIFYING LENS. Always use it when friction sawing. 39. See Fig. and a separate center block to support material at sawing point. Slide bars contain ball bearings. FIG.TM 9-3405-215-14&P Clamp material and square work with blade by using table tilting device. 40. This is done with a magnifying lens which fits over work light front portion.

Table 2 tilts 6° left. If it is used for marking on metal. 45° right.62 kg/cm ) is required. 41. Maximum table travel is 12 in. A lever controlled air feed system allows this table forward or back movement under light hand pressure. A dust-collection tube can be attached to this spout. ETCHING PENCIL Electric power for this tool is supplied by butt welder. this tool is used to cut and trim bands square preparatory to band butt welding. This table does not tilt and can be used only when the two-wheel band guard has been removed. (305 mm). As shown in Fig. It is also useful for storing component parts and removable machine accessories. safe storage for saw band coils. SUPPLY CABINET. BLADE SHEAR Mounted on machine column. WORK TABLE OPTION Your machine may be equipped with a factory-installed 30-inch (760 mm) square work table replacing the standard 26-inch (660 mm) square table. SECONDARY TABLE. 42. 23 . the table is mounted to a support unit which attaches to the machine frame behind the primary table. 41. WELDER Instructions covering the DBW-15 welder are provided by a separate instruction manual included with machine shipment. 42. See Fig. FIG. and polishing bands. DUST SPOUT A dust spout may be provided on your machine just below lower saw guide. SUPPLY CABINET (Shipped Unassembled) The supply cabinet provides orderly. Shop air at 80 psi (5. file bands. welded saw bands.TM 9-3405-215-14&P SECONDARY (AUXILIARY) TABLE SLIDING TABLE (AIR FEED) The secondary table measures 17 by 19 inches (430 by 480 mm) and is used when straight through sawing of material sections longer than 35-112 inches (905 mm) is desired. Table locks permit loading and positioning heavy work pieces. FIG.

See Figs. 47. See Fig. Depress spring steel band tip in right hand with yellow segment lock rivet in left hand. Insert one band end through table center disk. 4 inches (10 mm) for either 3/8-inch (9. and saw guides. See Fig. This should not exceed 2 inches (50 mm) for 1/4-inch (6. Slip rivot head into slotted hole. 43. Slide rivet head into slot's small end. See Fig. Hold yellow painted end in left hand. Longer guides that permit greater thickness filing are available as accessories. 47. (2) Lower upper post to proper work thickness. 43.5 mm) or 1/2-inch (12. FILE GUIDE INSTALLATION. Make sure proper file band slot width is used. 45. Tilt upper wheel. File Band Tracking and Tensioning: FIG. Band ends must be flush before operating. 44 and 45. FIG. 46. FIG. Mount file guide support to lower keeper block. Align band on wheels in same manner as for saw band tracking. FIG.5 mm) bands. to make band run on wheel crown. FILE BAND TRACKING. SPECIAL TABLE CENTER FILING PLATES File Band Joining: Place one band end in each hand. File cutting edges should face downward. table center disk. 46. 24 . Band should run freely over file guide supports when properly tracked.4 mm) band. Straighten band. 44. Allow spring steel end to snap over dowel. post band guard. JOINING THE FILE BAND. install special table center filing disk. STANDARD TABLE CENTER PLATE AND POLISHING PLATE FIG.TM 9-3405-215-14&P BAND FILING Machine Set-Up: Before internal or external filing may begin: (1) Remove saw band. (3) Install upper file guide and lock it firmly to post with knurled thumb screws. if necessary.

BAND POLISHING Keep files clean. Filing Operation: FILE GUIDES Turn Job Selector dial to "Band Filing" section. See Fig. Then reassemble.5 mm). NOTE: Excess band tightening should be avoided. Lower post to 4 inches (100 mm) from table. and 1/2-inch (12. See Fig.5 mm) guides. Mount and track polishing band on wheels in same manner as file bands. 48. Mount polishing band guide support to lower adapter. See Fig. Install special table center adapter plate.2 mm) wide carbon saw band. Run band through workpiece and join. separate band. Best filing speeds are between 80-150 fpm (24-45 m/min). 25 . 50. and run it through workpiece opening. Coil band into no more than three loops. Slide lock rivet to slot's open end and remove. release tension. Standard and long file guide sets are available for the 26-inch (660 mm) and 30-inch (760 mm) square tables. Most accurate filing can be obtained with light band tension. a coolant such applied in light mist form can be used to cool work and clean file during operation. 3/8-inch (9. Hold band at joint with both hands (yellow segment in left hand).TM 9-3405-215-14&P Tension should be same as that used for 1/8-inch (3. For internal filing. INTERNAL BAND FILING. FIG. separate band. Depress yellow band's front end with left forefinger. Do not file when teeth are loaded. Here bands are looped in a 16-inch (405 mm) radius with ends hanging in a compartment. Filing can be performed without coolant if there is difficulty in seeing layout lines. Apply tension and check alignment. Shift machine speed control to "low" gear and "start" drive motor. Store preferably in a supply cabinet. File Band Storage: Clean band with file card. plus 1/4inch (6. Correct band velocity and feed pressure are listed for many metals and materials according to work thickness. If your machine is so equipped. Use right thumb and forefinger to disengage dowel. Each set has a file guide back-up assembly. Bands are mounted over wheels in same manner as saw bands. Correct polishing band tension is that used for a 1/16-inch (1. Correct speed and pressure combination will produce curled chips. Bend joint to approximately 12-inch (305 mm) radius to expose joint slot.5 mm) wide carbon saw band. 49. (See supply cabinet sketch in this section). (1) Internal Filing: Release tension. BAND POLISHING GUIDES. Remove table center disk. 49.4 mm). FIG. Mount polishing band guide to post with two thumb screws. 48.

Application Cutting Speeds Grit Grinding 50-300 fpm (15-90 m/min) 50 Polishingcoarse 850-1000 fpm (260-305 m/min) 80 Polishingfine 850-1500 fpm (260-450 m/min) 150 FIG. 51. No. 150 (fine) for high polish and light stock removal. BAND POLISHING OPERATION. Use No. 80 (medium) for general surface finishing. 50. 50 (coarse) for heavy stock removal and soft materials. Occasionally rub graphite powder into guide fabric to lubricate and increase band life. See Fig. Use air nozzle to blow dust away. 26 .TM 9-3405-215-14&P FIG. and No. SPEED AND GRAIN RECOMMENDATIONS. POLISHING APPLICATION. Three polishing band grain sizes are available in aluminum oxide or silicon carbide. 51. Do not use coolant with polishing bands.

Insert Type Saw Guides. With Air Compressor Cutoff Attach. 399-78101 LAST SERIAL TO DWG.0 C-2-140 C-2-141 C-2-142 DESCRIPTION Final Assembly Air Compressor Air Puma Band Filer Band Filer Blade Shear Coolant Coolant. Mist. 12 Side Mount Disc Cutter Drive Electrical Assembly Etching Pencil Extra Work Height Extra Work Height(Auxiliary Post Assembly) Extra Work Height(Post Elevating Sub-Ass'y) FIRST SERIAL ALL ALL ALL ALL ALL See Buttwelder ALL ALL ALL ALL ALL ALL See Buttwelder ALL ALL ALL C-2-72 C-10-23 C-8-104 C-8-8 C-8-8 C-10-38 C-2-65 CM-10-7 C-10-6 C-10-39 C-7-18 C-7-20 C-7-19 C-10-29 C-3-41 C-3-78 C-3-79 C-3-80 C-3-38 C-4-44 CM-10-9 CM-10-1 C-9-16 C-9-17 C-9-18 C-2-28 C-3-77 C-10-16 Head Heavy Work Slides Job Selector Lamp Magnifier (Lamp Mounted) Parallel Work Clamp Post Elevating Assembly Protractor Work Stop Rip Fence Saw Eez Adapter Saw Guides.0 C-10-39 C-8-63 C-10-28 C-10-2 C-5-72 C-6-67 H1-20. Work Fixture Universal Vise Weight Feed Assembly Weight Feed Assembly Weight Feed Assembly Wheel. A-2 FICHE NO.TM 9-3405-215-14&P INDEX NO. A-47 CLASS CONTOUR MODEL 3613-20 PAGE NO. Third Work Holding Fixture Work Holding Jaws ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL 1 of 2 2 of 2 1 of 3 2 of 3 3 of 3 1 of 3 2 of 3 3 of 3 27 SERIAL NO. LIST A-4 A-6 A-8 A-10 A-10 F-10 A-12 A-14 8-2 B-4 B-6 B-8 F-12 B-10 B-12 B-14 C-3 C-5 C-7 C-9 C-9 C-1 C-13 D-1 D-3 A-11 D-5 D-7 D-9 D-11 D-13 E-1 E-3 E-5 E-7 E-9 E-11 E-13 F-1 F-3 F-5 F-7 F-9 F-11 C-4 C-6 C-8 C-10 C-10 C-12 C-14 D-2 D-4 A-12 D-6 D-8 D-10 D-12 D-14 E-2 E-4 E-6 E-7 E-10 E-12 E-14 F-2 F-4 F-6 F-8 F-10 F-12 Present FICHE NO. Insert Type Saw Guides. Air Feed Table. H-2 H-2 . Roller Type Screw Feed Table & Trunnion Table. Secondary Transmission Universal Cal. Air Feed Table. C-1-60 C-8-57 C-8-54 C-7-26 C-7-26 H1-19. Air Feed Table. A-3 A-5 A-7 A-9 A-9 F-9 A-11 A-13 B-1 B-3 B-5 B-7 F-11 B-9 B-1 B-13 P.

TM 9-3405-215-14&P FINAL ASSEMBLY C-1-60 28 .

.................... ................................................................................ Cover Plate Assembly .................................................................................................... ........................................................ .................................................... Cap 410-24NC x 1/2................................................................................... Cap 1/4-20NC x 3/8............. Door Stop Bracket ...................................................... Hex............................................................................................................... Saw Band Guard Assembly ................................................................. .... Plug Button ............................................................. ........................ Screw.............. ...................................................... Washer........................................................................................................ Rubber Grommet ............................................................................. Hd............... ............................ 48-32NC x 5/8................................ 10 Wrought ..... Frame Assembly ..................................................................................................................................................................... Drive Screw 2 x 1/4 ........................................ ....................................................................................................................... Rd........................... Wheel Tire Cement ..... DESCRIPTION Ref................... ...... ........................................................................................................ Air Hose ................ 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 37 58 59 60 61 62 63 64 UNITS PER ASS'Y Instruction Tag ................................................................................................................. 1 2 3 4 5 6 507170 091-238907 091-988972 091-993212 091-991158 090-122359 090-274077 090-166646 090-166844 091-982207 091-992586 091-187039 091-322727 091-990200 090-074360 090-168428 105-021018 091-984229 135-014918 091-988675 090-413436 090-061805 091-988386 090-060641 091-993196 090-033259 090-135526 091-056952 091-056960 091-988568 090-524356 091-408344 093-045250 090-040973 105-045207 094-061413 506959 090-382227 091-988691 090-010190 091-991117 091-201412 091-971150 134-015031 094-063963 090-410762 091-980052 091-993212 090-062910 091-086017 091-292730 093-065910 091-993972 111-024014 091-972364 095-071718 090-468174 090-234147 500372 090-070384 094-044765 090-375015 090-411018 091-980060 105-024012 091-993212 135-045250 507173 090-447988 Final Assembly ......................................... Escutcheon (Mach........ Plug Sutton ............................................................. ..... Hex..................... ................................. 1 1 2 4 4 1 1 1 8 2 A................. ................................................... Saw Band ........................................................................................................ Bracket Assembly ............................................................... Screw............................................................ Third Wheel & Hinge Assembly .............................. Screw.... .......................................... Hd....................... .......................................... .............................................................................................................................. Lock 1/4 ...................................................................................................................... CATALOG NO.................. ........................................ Thumb Screw ............. Cover Plate ..................... Lower Wheel Cover ..................................................... Lack 1/4 ........................................................................ Hd................. .................................................................................................................................. D8W-15 Butt Welder Assembly(See Welder Manual) ............................................................................... Thumb Screw ......................... ...R......................................................................... Hd................................................................ ................ Chip Baffle ................................................................................................. I/4-20NC Full . ....................................................... Lock 1/4 ............................. ... ............. Spring Lock #10 Med ............................... 010-24NC ................................See Detail) ......... 90° Street Elbow ........... ............. Truss Hd........... Flat #10 SAE .............................. Washer................ ............................................................. ................................................ .......................... Mach....................................... Gray Felt ..... Head Assembly (See Detail) ................................................................................ Cover ........................... Hd......... 1/4-20NC x 3/4 .............. Rd................... Cover Plate ... Screw.............................................................. Escutcheon (Caution) ....................................................................... 1/4-20NC x 1/2............................................................................................................... ......... Plug Button .......................................................................... Seal Strip ............ .................................................................................................................................... Chip Drawer Assembly ............ Base Door Latch ....... ................ Mach............. Table & Trunnion Assembly (See Derail) ............. Escutcheon (Bond Tension) .................... Washer................................ Upper Door Latch Assembly ................................................................ 10-24NC x 1/2 .. Plug Button .. Hex.................................................................................... Saw Bond Tog .............................................) ............................................... Hex..................... . Grommet Strip .............................................................................. ........................... ............. Hd............................................................................. ................... Mach.......... Handle Assembly ....... Washer............................................................................ ................................................................................................ ..... ........................................................ Plug Button ............................................................................ Soc.................................R................................................ .......... Screw....................................................... Hd................... Washer... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 ........................ ......................................................................................................... Rd.......... A........... Cover Assembly ......... ........................ Screw.... .................... .................................... Wheel Brush Assembly .................. Upper Sow Guide Holding Screw ........................................... Mach................................... .................... ....... #6-32NC x 1/4 .............................. ................................. Back Cover Sub-Assembly ..... .................. Plug Button . ................................................................................................................... Worklamp Assembly (See Detail) ............ Drive Assembly (See Detail) ........................................................................................................................... Mach............. ................... Cover ......................... Washer....................................... ... Soc................. ....................................................................................................... Screw..........TM 9-3405-215-14&P CODE NO........................................ ................................. ................................... Hd.. ............ ............ ................... Mach................................... Cop 1/4-20NC x 1/2.................................... ... Rd.......................... #10-24NC x 3/8.................... ........ Screw..................................................................................... ............................ 29 1 4 4 4 2 1 1 1 2 2 1 1 12 2 2 2 2 1 6 1 1 4 1 2 1 4 1 1 3 1 1 1 1 1 1 1 1 5 1 5 1 A..................... Nut..................................................... Specs................R.... Brush Holder Weldment ................................................... .. Screw......................... Rd....... Escutcheon (Patent No...................................................................... C-1-60 FINAL ASSEMBLY INDEX NO......................................... Set 1/4-20NC x 1/4 .. Seal Strip ................................................................ ... Nut........ ..... ........................................................................................ Screw.................... Clamp Strip .... .................................................... ................................... ................... ....................................................... ................... ...................................) ................................................................................................................... Wheel Brush ....... ....................................... Job Selector Assembly (See Detail) .................................... Following Items Not Shown: 094-068715 091-057018 090-185000 ......................................

PURCHASE INDIVIDUAL PART LOCALLY. NUMBERS SHOWN ARE DEVILSISS NUMBERS NOTE PURCHASE REPLACEMENT COMPRESSOR PARTS FROM LOCAL SUPPLIER 30 .TM 9-3405-215-14&P NOTE: TO REPLACE COMPLETE UNIT ORDER #400895.

....... Ref... ............ .............. .. .......................... .......TM 9-3405-215-14&P CODE NO......... Suction Valve Spring .......... Oil Pan ... ......................... Connecting Rod Assembly ................... Oil Pan Gasket .. Washer............................ 6" Pulley For X-2 Compressor ................... ...................................... ........... Oil Gauge Assembly ...... 5/16-18NC... ................................... Connecting Rod Bolt lockwasher .......................... .......................... Bearing Cone ......... Suction Valve Bumper ................ ................... .............. Breather Valve Bumper ...... ................ Bearing Carrier . ..................... ................ Lock 5/16 Std ........ 1 1 1 1 2 1 1 1 Use One 1 2 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Use One 1 4 4 4 4 1 1 1 ............. ................................................................. ........... Discharge Valve Bumper ............ ....... .............................. Bearing Plate Gasket . ............. ......... ... . . Intercooler Gasket ............................................... Bearing Carrier ..................................... Breather Assembly ..... . Discharge Valve Guide .................... Suction Valve Seat......... .................. ...... ..... Screw... Bearing Cup .............................................. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 CATALOG NO............. ............. ............ 2151-X 2149 2101 7178 2118 2117 6553 6554 6972 2115 2105 2830 2122 2123 2140 2120 2121 6551 6552 6975 6973 6489 2132 2131 2126-X 2104 2124 2130 2100 2129 2133 2134 1780 1194 2136 2137 2316-X UNITS PER ASS'Y .................. ..................................... Relief Valve .. ........................................ Flat 5/16 Std .............. ........ ......................... ......................... Washer.......... .................. Bearing Cup ....... ........... ................ Air Compressor (8" PulIey) .............. .................. ......................... ...................................................................... Cylinder Head ................................................................ .. ........................... Connecting Rod Bolt Wire ..... ................ ................ Nut.....................Discharge Valve Guide..... . .......................................... ....................... ....... ......... ................... .................................. ... . ............ Discharge Valve Spring .................... ...... C-8-57 CM-8-32 Z-7-8 AIR COMPRESSOR INDEX NO................................ ........... Hex............................. Hex................................. Breather Valve ............. ..... .............................. . Bearing Cone . .... . ......... 8" Pulley For X-2 Compressor ......... ................................. Valve ..................... ..................................... .................... ...... ...................... Piston .............. Adapter Plate Weldment .... ................. ................... 31 QUINCY CO.............. Suction Valve Bumper Gasket ....... ............... Service Tee .......... ............................. Cap 5/16-18NC x 3/4 ............................................ ........................................................................ .............. ............ .................. ........................ ... ....... . Hd....... .... ................. ............ PART NO....... Air Compressor (6" Pulley) ...................... ........... Replacement Felt ...... ............................. ............... ............................................................ . ................... Crank Shaft .... ............... ......... ....... ...... Barbed Insert .. ........... Piston Pin Assembly .......... Cylinder ..... Stud Breather .. Oil Drain Plug ....... .................... 094-008950 091-186395 091-186403 091-186015 091-186023 091-186031 091-186049 091-186056 091-186064 091-186411 091-186429 091-186072 091-186080 091-186098 091-186106 091-186114 091-186122 091-186130 091-186148 091-186155 091-186163 091-186171 091-186189 091-186197 091-209437 091-186262 091-186270 091-186239 091-186247 091-186254 091-186288 091-186304 091-T86312 091-186320 091-186338 091-186346 091-186296 091-186361 091-186379 091-186387 094-008356 094-019577 090-372525 091-980276 091-992628 091-991224 091-993238 090-021031 135-008472 090-020041 DESCRIPTION Air Compressor (Quincy) ................. Piston Compressor Ring........ Connecting Rod Bolt .................. Head Gasket ............. ....... ....................

TM 9-3405-215-14&P AIR PUMP ASSEMBLY C-8-54 CM-8-35 32 .

.... * 1 2 3 4 5 6 7 8 * 9 094-071594 090-427089 105-113161 105-114052 105-113195 091-980086 091-993741 105-111041 091-984252 135-067361 090-060732 090-040973 090-046582 135-067253 090-179029 090-000084 105-115109 135-036473 114-145287 105-115174 117-135210 090-083866 090-020041 Air Pump Assembly (Clockwise Rotation) Air Pump Assembly (Counter-Clockwise Rotation) ...... Street Elbow 1/4" Std............ Screw............... Air Hose (1612-1) .......................................................................................................................................... Set 1/4-20NC x 1/2" ............. Shakeproof Ext .............................................................................................................. ................................ Hose ...... ................................................................. Pulley ................................................ ................................................................ .................. Close Nipple (1612-U & 3012-U) ........................................TM 9-3405-215-14&P CODE NO............................................... .. Air Cleaner ......................... .............................. Hd........................................... 3613-1................ Reducer ................ Lock 1/4" I.................................................. Screw............. .................................... Ref. Bearing ............................................ .. Air Pump Rotor ..............................................R..................... ........................ 1 2 1 1 1 1 1 ........................ Hex................................................................................................. .. 3012-U.... ........................ Air Hose (1612-U........................... C-8-54 CM-8-35 AIR PUMP ASSEMBLY INDEX NO......... ....................................... .. .................... Vane .................... ....... Air Pump Body .......... .... .......... Barbed Insert .................................... *10 11 *12 *13 14 *15 *16 17 18 *19 20 UNITS PER ASS'Y *NOTE: Single Starred Items Are Not Part Of Air Pump Assembly...... 1612-0) ........ Hose Clamp ................................................................................................................................. ................ DESCRIPTION Ref..........D. Air Puma Cover .......... ..................................... ... Cap 1/4-20NC x 3/4 ................. CATALOG NO........ ............. 90° Elbow (1612-U & 3012-U) ..................... Washer............................................... Nipple (1612-U & 3012-U) ..................... Soc...................................... Wire Insert ......... 33 1 1 3 4 4 1 2 1 1 1 1 1 2 A.............................

TM 9-3405-215-14&P BAND FILING ASSEMBLY BAND POLISHING ASSEMBLY 34 .

. 1 090-340910 . 1 090-274192 ....... 1 ..... Ref...... 3612. Insert (Ass'ys #27492..... Adapter ... 1612-H...... 2013-10 2012-A.. File Guide (Ass'ys #27491...... 2612-2H. Screw Assembly .... Backup Plate (Ass’y #27414). 2013-0. 3612.... Band Polishing Sub-Ass'y (Ass'ys #106957.. #106958) .. (Ass'y #48532) 1 090-340993 .... 3612-H.. 1 .. 3613-1........ 1 ......... 2012-1A. #27489.. Guide Plates (Not Shown Ass'ys #27490.... 091-986885 091-986992 10 091-993154 091-993196 11 12 106-093073 106-093032 106-093016 106-093057 106-093099 106-093115 106-093081 106-093040 106-093024 106-092065 106-093107 106-093123 134-093137 134-09A28 13 14 090-013715 134-093129 091-109314 15 16 134-090018 090-038019 090-038027 090-106279 091-201285 Ref.. Center Plate (Not Shown) (Ass’ys #106957....... 1 ...... #132772... Mach.......... 2 INDEX NO......... File Guide (Ass'ys #27488......... 2012-A.... 2012-A. 1612-0... Small Part late ....... #27490.. 1 .. 1 .. Center Plate (Ass'ys #132773. #404994..... 6013-3) .......... #27492.... 2012-A............ #10-24NC 3/8 . 6013-3) 091-119A87 Band Filing Ass'y 1612.. Insert (Ass'ys #27491........ 1 .. 1/4" File Guide Ass'y Ass'y #40438) 1 3903-274887 ............... 1612-0... 2012-A. 2 . #440NC x 5/8 (Ass’ys #27487............. 2612-1...... #34097... #27491.... Hd.. Insert (Ass'ys #27488. #34103) ... File Guide (Ass'ys #27487.... #34099) ....... #34104) .... 3612-2.. 1 ...................... #34098) 1 ............ Bracket Ass'y #34097 ..... Hd.. Insert (Ass'ys #27489. #34103.. #34097..... #34099) . Screw . 2 ....6013-3) 090-447814 Band Filing Ass'y (2613-2............... 1 .. 1 090-147806 Band Filing Ass'y 1612.... #34097) 1 .. 3/8" File Guide Ass'y (Ass’y 401438 090-274895 . Head .. 3612-3..... 2613-3.... 2013... #10-24 NC x 5/8 (Ass’y #37488....... Bracket Ass'y #27488.......... #111948. #45597) ... 3612-3) Band Polishing Ass'y (26-2.... #44781) . C-7-26 CM-7-25 BAND FILING & POLISHING ASSEMBLIES INDEX NO. 2012-AT... File Guide (Ass'ys #27492.. 6013-2) 090-274879 . Ref. #43781) . 2612-H. 1 ........ Ref....... Fil....... 3612-3........ #34096.... Guide Backup . #10-24 NC x 3/8 .... #27492........ 1 090-340969 .......... Bracket (Ass'y #27487... 2612-2H.... 1 090-341041 ... 1612-1.. 2613-3. #45597) ..... #29023. 1 . 1 090-340977 .. 1 .. 1613-2.... 1612-0 612-H......... 2012-lAT..... #45597) . 36-3) Band Polishing Ass'y (26-3. 2013-4...... Washer Ass'ys #27488..... 2612-1........ Backup Cloth .. #34104) ....... 1/2" File Guide Ass'y (Ass'ys............. 3612-3... 1 106-093149 .. Screw. #34099) 1 .1612.. 1 090-274176 ... 60-3.... #132773.... 1 . 1 . Re. 2013. Ref.. #27489............ 2612-1. Bracket (Ass'y #34096) ... 2013..... 3613-0) 390-a85327 Band Filing Ass'y (1612-3.. File Guide (Ass'ys #27489.. 3613-2.... 1 090-120452 ..... Ref.......... #401438)...... 1611-U 1612.. 44781) .... 2013-10. 3612-3) 091-327734 Band Filing Ass’y (1612..... 1 090-27A218 . 2 090-120460 ... 2013-0............ 2012-AT.. #40994.... Washer.... File Guide Back-up (Ass'ys #44780..... 1 . Band Polishing Sub-Ass'y Ass'y #27486) 1 ......... 2013-0. 2012-AT....... Screw.. 9 CATALOG NO.. Fil.. Bracket (Ass'y #27490) .... 2013-10.. 1 .......... Screw.... 3612.. 2012-1A.. Bracket Ass'y #34103 ......... Mach..... #132773.. Canter Plat . 2012-AT.. 2013.. . Bracket ......... #34103........ 1612-3.. Lock #4 Std....... 2612-2H. #27490...#34096) 1 .. Bracket (Ass'y #34104 ... 4 5 6 7 8 CATALOG NO. #34103.. #27489..... Adapter ................... Bracket Ass'y #27489 .. #27484.. 1/4" File Guide Ass'y... Washer... 1 . #404994........ 091-069575 Ref...... #111948...2012-AT...... 2612-H..... Center Plate (Ass'ys #44780. 090-274846 Ref.... #132773......... 2012-IA... #34099 . 1 090-340936 ...... 2612-2H..... Mach.... #34098) ... 1 . 1612-1..... 2013-1. 3/8" File Guide Ass'y (Ass'ys #44780.. 1 .. 090-290230 Ref.... 3612-U....... 2012-A... 2013-0.. Bracket Ass'y #27491 ..... (Ass’ys #27488....... #34099). #27491.. 090-274853 Ref...... #111948 #48532. Screw. Screw Assembly .. #27485. 2013-0.......... Ref....... 17 091-069583 090-166869 18 090-274143 091-986968 19 20 21 22 23 24 35 090-274127 106-103013 135-099232 134-105055 134-104025 134-090018 090-038019 090-038027 090-013715 090-105701 UNITS PER DESCRIPTION ASS'Y ......... File Guide Back-up (Ass'ys #48532. Bracket Ass'y #34098 ... Bracket (Ass'y #34099) .. #27491. 1/2" File Guide Ass'y 'Ass'ys #44780...... 3612... #34104) 2 ... Insert (Ass’ys #27487.......... Head ... 2013-10.. #111948... #34099 . 1612-0........... #34097) .. 3613-1) 091-98747 .. Hd.. 2013-40........ 2013-1.......... 1 090-340944 ........ 3/8" File Guide Ass'y (Ass'y. 2012-1A.. 2013-10. 1/2" File Guide Ass'y (Ass'y #401438) . 3613-0) 094-049947 Band Filing Ass'y (1612. 2013-1...... 1612-H............. File Guide (Ass'ys #27490.. 2 ... 2013... #34098.... 1 090-340928 . Lock #10 Std. Backup Plate (Ass'y #16686) .. 2 ...... 2013-1..... 1 090-274911 ... 2013-1.. 1 . 1612-3. 6013-3) 090-455973 Band Filing Ass'y (3613-2. 60-2..... #44781. Washer Ass’ys #27487... #34104) 1 .... Band Polishing Ass'y (2612-1) ..... 1/2" File Guide Ass'y (Ass'ys..... 1612-1...... 6013-3) 094-014388 Band Filing Ass'y (1613-3.... #34097.. Screw . 1 1 2 3 Ref... 3 ... 1612-H. 36-2.... #27492 #34098.. 1612-3. #34099) ..... Insert (Ass'ys #27490. 1 090-274226 . 1 .. 2613-2........ 1612-0...... #34098.. .......... 1612-1....... 2612-H 2612-1.................. 090-274861 Ref.. #34104) ............. 2613-3.. Bracket Ass'y #27492 .... 2 106-093131 ...(1612-1...... #404994......... #401438) . 2 .... 1 .. 3613-0 3612-H... #404994) ...... 1 090-274929 ... Fil.... #3409 6.. (Ass’ys #27490... 2612-H........... Pin (Not Shown) Ass'ys #27490. #34096). 2012-lAT.......... 1 090-340985 . 1 090-340951 . 3/8” File Guide Ass'y (Ass'y #48532) 1 090-341033 .. 1 090-274200 . #45597).. Fl..... 2013...... 2012-1AT......... 1/4A File Guide Ass’y (Ass’ys #111948. Hd.. 1 090-340902 ..... #48532).. 1/4" File Guide Ass'y (Ass'ys #44780........................ 3612-H.. Mach.. 2012-1AT. 1613-2..... 090-076456 UNITS PER DESCRIPTION ASS'Y Small Parts Filing Ass'y . 3613-4.... 2013-0... Ref.. 1 ... 1 090-274903 .. 6013-2) Band Polishing Ass'y (16-2...TM 9-3405-215-14&P CODE NO.. 3612-H 3613-1) Band Polishing Ass’y . 2612-3.. 1 090-274184 ..... #106958) .... 16-3...... 3613-0.... 2012-AT. 1612-0.. #34103) 1 ... 1 Band Polishing Ass'y (1611-H...

TM 9-3405-215-14&P SAW LUBRICATOR ATTACHMENTS 36 .

.................................... .... ................................................................ ............................................. Thumb Screw ................................................................. Hex..TM 9-3405-215-14&P CODE NO...... .... 90° Male Elbow.................. #10-24NC x 11/2 ............................................. ............. Bracket .... Mach.......................... 90° Barbed Insert ..................... Hd.. Saw Eez .. 1 * 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 095-028122 135-073286 091-988931 091-369181 091-971440 105-275077 090-120643 091-988782 091-971440 134-174010 091-081166 090-160011 091-213108 105-271027 091-980268 091-993238 105-273015 091-140632 093-039568 091-993212 Saw Lubricator (2612-1) Saw Lubricator (All Other Models Listed) .................... Metal or Plastic............................... Rd.................... ... Mach...... Plastic Tubing 1/4" .................................................................................. Hd...................... 5/16-18 NC 5/8...R................... ................................................................................. Mach.. Order 090-851577 Coolant Tank Service Kit............................................... ................... Screw....................... Lock 5/16" Std....................... Ref.................................................................................... ... Pin (Bands 1/16 To 1/2”) ........... ............................................................................................................... Washer................. CATALOG NO.................................................................. 1 2 3 4 5 6 090-310442 135-081495 135-036473 135-013514 107-015104 135-004554 135-004513 Saw Eez Attachment ............ 1 1 1 1 Use One *NOTE: To Replace Other Preceding Style Coolant Tanks.......... Manifold .................... Hd............................ ....................... Elbow ..... Barbed Insert ..................... ......... Nipple ....................................................... Plastic Tubing 1/4" ................................. .............. Screw................ Screw........................ ... .................. Rd..... .......... Tube ...................... Pin (Bands 5/8" To........................... Adjustable Slide Rod................................................ 1/4-20NC x 3/8.... Bottle Assembly .................................... ................................... 2 1 A......................... Saw Lub............. .... C-10-39 SAW LUBRICATOR ATTACHMENTS INDEX NO.......... .............. .............................. Saw Lub........................................ 1 1 2 1 1 1 1 1 1 1 2 Ref......................... .............................. 37 .............................. 1”) .................... Pipe Nut ..... .......... Washer....................... DESCRIPTION UNITS PER ASS'Y Ref.................. Sight Feed Valve .................................................................................................R............................. Post Lubricator Holder ...... 1 1 2 A.......... Lock 1/4" Med ...........................................

TM 9-3405-215-14&P AIR COMPRESSOR & MIST COOLANT ATTACHMENT 38 .

........... ............................................ ................................. Use One A............... D.................. Bottle Assembly .......................................................................................................................... Ref............. Nut.......... A........... 1 2 3 4 5 6 7 8 9 CATALOG NO.................... Sight Feed Valve ..... ................................... 1/4-20NC x 3/8 ............................. Coolant Manifold Assembly ............................ ...................... Air Dome Sub-Assembly (500190) .........R........................ Lock 5/16" Std ................. Use One 1 1 1 1 1 A........ Service Tee ........................... 3612-2H................ Pipe Plug .. .................. **Double Starred Items are Used on Assemblies #500666 & 504166 Only............ Air Compressor Sub-Assembly(Ref..................................................................................................... Hex... ........ 1/4-20NC x 3/8 ........ 091-993212 .......................................................................................................................... ...................... Hex..................................................................................... ..................................3612-H) (50 Cycle) ................................................... Rd............................................................. 090-381245 .................... Bulkhead Adaptor ................. ................................................................... V-Belt (500666) ............................................................. ............................ .... Coolant Manifold Assembly (500183.......................................... .................................................. Screw............................... 093-034171 ........ Mach................................. ........... ................................................................ 091-180885 .............................. Hd............................ Air Hose (Ass'y -# 090-381245)..................... 2 A.......R.......................................... .............................................1612-0..................... ............................3612-2................. Coolant Manifold Assembly (500190) .................................................................................... Order #090-851577 Coolant Tank Service Kit................................ Lock 1/4" Med ............................................... Hex...................... Ref. ............ Coolant Tube Sub-Assembly (Ass'y #090-381245) ...................... Cap 5/16-18NC x 2 1/2 ........................ For 500666) .............................. Hd...........3613-0.................................. Manifold .......................................... 105-046122 ... ................................................................... 90° Barbed Insert......................................... Close Nipple ........ Coo 5/16-18NC x 3/4 .................................................................R..........................................................................................2612-H) Air Compressor & Mist Coolant Attachment(3612............. Air Dome Sub-Assembly(500183...........3613-0........................................................... Black Neoprene Hose 3/8" I........................ Air Hose (Ass'y #090-385121) ............R......................................504166)................... .................................................................................. Orifice .................................... . ..504166) ..................... Hex....................... 090-020041 .............................. Washer......................................................... 39 1 1 2 2 Use One A..........3613-20) 091-970947 ...... Plate Weldment (Not Shown) ............................ Spacer ................................................................ 503546 Mist Coolant Attachment (Plant Air) (1612................................................ 091-256735 ....... ........................... Safety Valve .......... 114-145287 ............................. .................................................................................................................................. 500666.................................................... Washer 5/16" Std ............................... 5/16-18NC..R... 135-008472 ................................ ................................ Screw.......................................................... Hose Clamp .... * 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ** 19 ** 20 21 22 23 24 25 26 ** ** ** ** ** ** 27 28 29 30 31 32 Ref...............................................R.......... Washer...... Mach...................500666..... Black Neoprene Hose 3/8" I......... ..................................................................... 090-179029 ....................................................................................... Screw........... 6 2 1 1 A....................................... Bracket ........................................................................ Ref...................................................... Screw............................................................................................ Close Nipple ................................................................................................................................... ............ .......................................... D.................................... Screw..R 2 1 1 1 2 2 1 1 1 1 2 2 ............. ..... Bracket .........................................3613-20) Air Compressor & Mist Coolant Attachment(2612-1............. 1 1 Use One 1 Use One 1 A............ Air Compressor ..... Coolant Tube Sub-Assembly (Ass'y #090-385121) ....3612................... ............ Hd................................................................... Rd.........................1612-0................................. Safety Valve ......................... Oil (Not Shown) ................. Barbed Insert ..... Hd.................................................. Washer...................................... Lock 1/4................................................................................................... 093-039568 .............. * NOTE: To Replace Other Preceding Style Coolant Tanks.............................................................. 3612-H.... ...TM 9-3405-215-14&P CODE NO. 1612.................................................................................... .............................................. Screw........................... Spacer ...........................................2612-1.... Ref...................................................................... V-Belt (504166) ...... 091-988931 ................... Metal or Plastic........... Plastic Tubing 1/4 ............................... ................................................ ..................................................................... Barbed Insert ................. Hose Clamp ........................................................................................................................ Bottle Assembly ......... Cop 5/16-18NC x 3/4 ........................... 500190 500183 500666 504166 091-369181 093-039568 091-988931 091-993212 090-385121 090-381245 091-971440 091-081166 105-275077 091-199778 091-199117 091-199109 090-040973 090-060732 114-145287 091-970947 090-179029 091-980250 091-993238 090-374901 090-389347 091-980276 091-991224 135-024164 135-003408 090-039546 090-389339 094-019577 135-008472 090-020041 091-180885 091-384461 091-980342 091-980276 091-992628 091-211607 091-211615 091-211631 UNITS PER ASS'Y DESCRIPTION Air Compressor & Mist Coolant Attachment(2612-H) (50 Hz) Air Compressor & Mist Coolant Attachment(1612-H..R..... 2 2 A......................................... Hd............................................................................................. Service Tee ........................................................ ............................................................................................. Following Items Not Shown: 091-369181 .......... Hex. Hd... V-Belt (500666) .......................................3612....................................................... Cap 5/16-18NC x 1/2 ........... ........ C-8-63 CM-8-40 AIR COMPRESSOR & MIST COOLANT ATTACHMENT INDEX NO............................................................. ................................................. .............

TM 9-3405-215-14&P NO. 2 STANDARD CUT-OFF & MITERING ATTACHMENT (SIDE MOUNT) 40 .

...................... ............ Hd.............. Set 1/4-20NC x 5/16" ............... Soc........ Screw............................ ........................................................ 1/4-20NC x 1/2" . ................... Roll Pin ........... ................... Miter Bar (20" Table) ...............) ................................ Screw.... ... Mach........ CATALOG NO... . ............ Slide Rod (24"Table) ......... Cap....................... 2 Std............. Cut-off & Mitering Attachment (20" x 20" Table) No....... .. Front Slide Rod Bracket (20" Table) ..... Miter Head........... Cap No.......................................... Miter Bar (26" Table) ............................................. Stop................. Screw..................................................................... ... Miter Head Pivot .......... 1 2 090-504192 090-552902 090-553058 090-505116 111-281093 091-982207 091-983783 091-984237 091-982769 091-982785 090-036823 090-295833 103-204061 104-204011 091-019356 091-019315 090-036815 090-295841 091-984237 090-507112 090-507104 090-553041 090-507120 090-036765 091-990085 090-036724 091-993998 103-203063 104-203013 091-029447 111-203014 104-203021 134-174010 090-042540 134-204072 090-051319 090-042292 090-036773 090-405986 090-209412 134-204106 134204098 091-982363 No.................. ........................ Pltd.... Cut-off & Mitering Attachment (26" x 26" Table) No............................................................................................. Hd...... Roll Pin .............................. Slide Rod (20" Table) ........................ Cut-off & Mitering Attachment (30" x 30" Table) ......................4 x 1/4 Type "U ................................................................................ Cap............................................................................. Rear Slide Rod Bracket (24"................................... Miter Attachment Sub-Assembly (24" Table) ...... ................................................. Thumb Screw ............ Screw..... .............. & 30" Table) . Cap............. Miter Bar (24" Table) ...........10-24NC x 5/16" (25" Table).............. ............ Screw...... ........... ....... Soc..... Slide Rod (30" Table) .. Cut-off & Mitering Attachment (24" x 24" Table) No.................... ....................................... ...... .............. ................. ........... 3/8-16NC x 1/2"(20" & 30" Tables)............ ............ Hd.................................................. Gauge Rod ................................... CUT-OFF & MITERING ATTACHMENT INDEX NO................... Miter Attachment Sub-Assembly (20" Table) .......................... Stud . Set.................... Screw....... ............................. ................... ........... .................. .............................. Hd.................................................. ... Pointer ........ Cap..........................................................................................8-32NC x 1/4" (Cad....... ... Screw............ ........................................ ............TM 9-3405-215-14&P CODE NO................. Pivot Washer ................................ No........................... Screw...... Slide Arm .......................................... Handwheel .................. Soc................................. 2 STD.... DESCRIPTION Ref..... ......... Front Slide Rod Bracket (24"................ Rear Slide Rod Bracket (20" Table) .. ..................... 26".... Rd........ No..................... 2 Std........... Hd...................................................... No.......................... Soc. 3/8-16NC x 3/4" (24" & 26" Tables)... ........................... Hd. Soc...................... 2 Std....................................... ................. Ref....... & 30" Tables) ... Miter Attachment Sub-Assembly (30" Table) .................. 1/4-20NC x 5/16" (30" Table)... Slide Rod (28" Table) ................................ Soc.... .......... Hd... Hd........................................................ Locking Stud Washer..... C-10-28 Z-10-6 NO.................................. .......... Miter Bar (30" Table) ..... Ref........ .......... Oven Hd.. Pk....................................................................... Soc............... Screw............... ... Miter Attachment Sub-Assembly (26" Table) ................................ 2 Std............... 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Z1 22 23 24 25 UNITS PER ASS'Y 41 1 1 1 1 4 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 .............. Ref................................... Drive..................................... ........................10-24NC x 1/2" (20" & 24" Tables) ............ ..................................... Degree Plate ........................ 26".

TM 9-3405-215-14&P DISC CUTTER ASSEMBLY 42 .

..............................................TM 9-3405-215-14&P CODE NO.......................................... Radius Arm Clamp........ ........ Bracket (Used on Ass'y #090-400441) .. Screw.......................................... .... Screw. ....... Hd... REF............................................................... Bracket (Used on Ass'y #094-020807) ........................... Center Pin Clamp............ Radius Arm ................................. Lock 5/16 Std ..................... Roll Pin (Used on Ass'y #094-020807) ..................... Cop 5/16-18NC x 7/8 (Used Only on Ass'y k094-020807 43 1 1 1 1 1 3 3 1 1 1 1 1 1 3 3 1 1 2 2 1 ....... Adjustment Housing ............... ............................ Hex.................... 6013-H3) .. Screw......................................................... Lock 3/8 Std....... Hd................ Hex............................. ....................................................... Roll Pin (Used on Ass'y #090-400441) ........................ Cap 5/16-18NC x 2(DZ-36 Only) .................... ..................... Following Items Not Shown: 134-203082 ... Center Adjustment Tube.......... Screw.. Screw........................... ... REF 1 2 3 4 5 6 7 8 9 10 094-020807 090-400441 135-033991 105-154132 105-154124 105-151096 135-034007 091-980466 091-993329 090-042615 135-034023 090-042763 090-042755 090-390196 090-200452 091-980292 091-993238 105-154157 135-034015 091-980334 091-980318 11 12 13 14 15 16 UNITS PER ASS'Y DESCRIPTION Disc Cutter Assembly (Contour & Contour-Matic Machines) Disc Cutter Assembly (Zephyr.......... 6013-3.................................... Hex... ................................................................... Cap 3/8-16NC x 1.......................... . Hd.................................................................. ...... Washer.................... Hd.................................... Hex....................................... .. Cap 5/16-18NC x 11/2 (All other Models) ............................................................... Hd...................................... C-10-2 CM-9-1 Z-9-4 DISC CUTTER ASSEMBLY INDEX NO...................... ........ Washer....... ............... Adjustment Wheel ....... ............................. ............................... Adjustment Screw............................ 091-980284 .......................................... .......... .................................... Center Pin ................................ Cap 5/16-18NC x 1 ............................................... ..... Hex................... Roll Pin .. CATALOG NO................................................................ Wrench .............................

TM 9-3405-215-14&P DRIVE ASSEMBLY 44 .

..................... ................................... 5/16-18NC ............................................. Escutcheon ..................................................................R........................ Caulking Compound (507343 Only).............................................. ..................................... Shakeproof Lock 3/4" External .................................................................... Hex............. .... Cap 5/16-18NC x 1 ...................... Hd. Washer.......................... .................. ................................................... Nut................ ................. Use 1 1 One 1 1 1 2 1 2 3 1 1 4 1 1 1 1 1 1 2 1 1 1 1 4 1 2 1 A.............. 3/8-16NC.................. Eccentric .... Pulley.. A................................................ Spacer 22 Ga ............................................. Roll Pin ..................... Key ..........................R............... V-Belt.......................................................................... Nut........... Pulley ... "O"-Ring .....R................................................................................. Ref............ Washer.................. Spacer 10 Ga............................... Cop 5/16-18NC x 1 1/4" ... .............................................................. Soc............................ .................. Hex Hd................................ Spacer 20 Ga.............................. DESCRIPTION Ref... Lower Saw Wheel Assembly(507173) ...... Screw................................ Wheel Tire .......................... Locking Pin........................................ .............. Hd........................ C-5-72 CM-5-62 DRIVE ASSEMBLY INDEX NO........................ ........................................................... Dowel Pin ................................. Shifter Lever Sleeve .................. ............................. Grommet ...................................................... Screw............................................................................................................ Shift Lever Collar ............... Soc................... ......................... Soc.......................... Wheel Assembly(507343) ........ Lower Wheel ..................... ................. 2-Speed Transmission Assembly (See Detail) ....... Jam 3/4-10NC ....... Spacer ................... ................................ Cap 1/4-20NC x 1/2 .............................................. ........... ...................................................................... ............................................................................................ Washer.... ... . ..................................................................... Hex................. Bracket ........... Drive Screw #2 x 1/4............. .. Bracket .......................................................................................... . Shift Lever Knob ................. ........ ...................................... Spring .......................................... ......................... ......... 3612-2H3) ........ A......................................... ......................................................................... Shifter Segment ................................................................................... Hex.......... Screw..... .... 3613-20) Drive Assembly (3612-2H............................. ........ ........................................... Screw............................... 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 UNITS PER ASS'Y 45 1 1 1 1 1 1 1 8 10 1 A.............................................................. .......... Set 1/4-20NC x 1/4........... .................................................................R.......... ............. Bearing ......................... Hex............................... .... Cap #6-32NC x 3/8 ........................................ ......................... ..................................... ................. ....................................... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 507173 507343 091-444950 107-013450 091-983767 091-991265 135-065639 135-065621 095-068276 091-980300 091-993238 135-066959 091-333161 091-333179 091-333187 090-294539 094-043395 135-022705 094-089737 091-991406 091-993782 090-040338 091-982363 106-044043 091-984229 090-042599 106-044159 135-024164 091-991224 091-450080 106-253057 091-136911 091-473066 091-473074 090-015124 091-473090 091-473082 090-075060 134-135086 091-493395 091-993972 094-084100 091-980292 091-992636 090-096041 Drive Assembly (3612-2............. ............. ............... Hd................................................................... ........................................................... Shift Lever ............ Nut....................................... Screw.................................................. CATALOG NO...................... Key ................................................................................................... Flat 5/16” SAE ............................................................TM 9-3405-215-14&P CODE NO...... .............................. . ........................ Lock 5/16" Med............................... ..................... .....................

TM 9-3405-215-14&P ELECTRICAL ASSEMBLY C-6-67 CM-6-57 46 .

......... ............... A.................................... 3/4" Sealtite .............. .............. Screw. End Section............ ............................................. Terminal Block ..................................... ................ .......... Screw.. Nylon Jacket ....R..... Flange Washer 1/2" ............................................................................................................................... . 48-32NC x 3/8............................................ Hd......... Pushbutton Box (507135) ................................................ Hd..................... Bond Nut 3/4" ............................... ....................... Cap 5/16-18NC x 1/2 ................ ......................R.......... 1/2" Sealtite.................................. Channel .....R........... 091-993212 ................................. 091-994749 ...................... Washer.............. ..................................... Rd................. A...........................................TM 9-3405-215-14&P CODE NO...........................R.......... Hd...................................... "O"-Ring 1/2" ............................. .................................... #14 White Nylon Jacket .... (507601) ............................ CATALOG NO. Spring Lock #8 Med ...... 1/4-20NC x 1/2 (507601) .............. Lock 1/4" Std........................................ Washer. Spring Lock #10 Med ........................................................ 3/4" Sealtite............................................... Spring Lock 5/16" Med ........ Screw... Conduit.................................... ... ... .. Wire....................... ...................................................................... Truss Hd... 2 2 2 15 1 1 A................................................................................... Gasket ..... 1 1 Following Items Not Shown: 091-971804 .............. ...................... .................... Screw... ........................................ "O"-Ring 3/4".............. Female Straight ......... Channel Clamp.............. #10 Flamenal Blue ................. Wire................................... Pushbutton Box (507601) ............. 2 2 Use One 1 12 12 8 8 2 2 2 A..... Self Tap Rd.................................. .......... Connector................... DESCRIPTION Ref............ ...... Washer......... 091-971903 ................ 1 2 3 4 5 6 7 8 9 10 507135 507601 090-156076 090-144809 135-095214 091-349688 091-349704 091-349696 091-349712 091-994657 091-993196 095-070579 095-076006 093-075034 091-990093 091-993188 091-980259 091-993238 090-145459 090-144114 090-145053 091-971580 090-146861 090-165499 Electrical Assembly Electrical Assembly (Extra Work Height) .. ............................................................................................................ Ref...................... Connector.............R.. ..... Wire................... Washer 3/4" ........................... A. Self-Tap R10-24NC x 3/8 ......................... .................. Connector.................... C-6-67 CM-6-57 ELECTRICAL ASSEMBLY INDEX NO............ 6 6 11 12 13 14 15 16 17 18 19 20 21 UNITS PER ASS'Y 47 ..................... Hex............................ Washer......................... Mach................................. #14 Red....... 091-971879 ......

TM 9-3405-215-14&P EXTRA WORK HEIGHT ASSEMBLIES 48 .

. .................. Frame Weldment Assembly(3630-2H3) ....................................... .................................................................3630-20...... Auxiliary Post Assembly (30" Work Height) ....................... Post Elevating Sub-Assembly(3618-2... Saw Band (30" Machines Only) ...................... .... 2 3 4 5 6 7 8 * 9 10 UNITS PER ASS'Y *Starred Items are Shown in Detail on Following Pages. ............ Post Elevating Sub-Assembly(3624-2. Saw Band (18" Machines Only) .............. Air Hose (30" Machines Only) ................ Air Hose (24" Machines Only) .................................3630-2H) ............ Frame Weldment Assembly(3618-2H3) .....3630-20. Auxiliary Post Assembly (18" Work Height) ....... ............... ........... Frame Weldment Assembly(3624-2H3) ...TM 9-3405-215-14&P CODE NO....................................................... ............... Electrical Assembly(See Detail) .... ... Auxiliary Post Assembly (24" Work Height) ................. . 1 095-075438 095-075446 095-075453 095-075461 095-075479 095-075487 094-077344 094-071966 094-090933 094-077336 094-072717 094-090941 095-059192 095-053799 095-075586 095-075552 095-075560 095-075578 095-075495 095-075503 095-075511 095-076014 094-082369 094-091147 094-091134 091-210252 091-210286 091-444281 091-420281 091-498568 093-063162 093-056877 093-076693 091-228361 Extra Work Height Assembly(3618-2.........3618-2H) Extra Work Height Assembly(3624-2............................... Ref.....................................3618-2H) ............... ......... ... Head Sub-Assembly(3624-2H3) .................................... .............. .. ..... Ref.................... Saw Band Guard Assembly(3630-2H3) ................. ............. ...........................................3618-20. Head Sub-Assembly(3618-2H3) ... Saw Band Guard Assembly(3618-2H3)...3624-20......................... Head Sub-Assembly(3630-2H3) ..................................3624-2H) ...................................3618-2H) .............................. ....................................... Frame Weldment Assembly(3630-2........ Saw Band (24" Machines Only) ..................3624-20........3630-20.................... Ref.. Saw Band Guard Assembly(3624-2H3) ..........................................3618-20..................... ......................... ... ..... DESCRIPTION Ref..... 49 Use One Use One Use One Use One 1 Use One Use One Use One Use One 1 .3624-20......... Post Elevating Sub-Assembly(3630-2................................... Frame Weldment Assembly(3618-2... Saw Band Guard Assembly(24" Work Height) ....................3630-2H) ...... Ref.............................3624-2H) Extra Work Height Assembly(3630-2.. Saw Band Guard Assembly(30" Work Height) .3630-2H) Extra Work Height Assembly(3618-2H3) Extra Work Height Assembly(3624-2H3) Extra Work Height Assembly(3630-2H3) .............................. Saw Band Guard Assembly(18" Work Height) ........ ...................................3624-2H) ... Ref. ...... ....................................... CATALOG NO........ Frame Weldment Assembly(3624-2..........3618-20.... Door Latch Assembly (24" & 30" Machines) (Nat Shown) ........................................... C-2-140 CM-2-89 EXTRA WORK HEIGHT ASSEMBLIES INDEX NO. ............................

TM 9-3405-215-14&P AUXILIARY POST ASSEMBLY (EXTRA WORK HEIGHT) 50 .

...... Lower Post Guide ............................... Hex..... Hex...... Hd......... .. Hex............................................................ Soc........... Hd. .................................................................. .. Screw....................................................................... Roll Pin ......... . Ref........ Upper Post Guide .................... CATALOG NO.......... Starwheel .......................... Screw... ............. ............................ Starwheel Sub-Assembly............... DESCRIPTION Ref...................... Retaining Ring ....................................................................... Hd................................................... Clamp Screw ................................ Set 5/16-18NC x 3/4 .............................. Lock 3/8" Std................... Nut....................................... ................................................................... Post Collar... 6 7 8 9 10 11 12 13 14 15 UNITS PER ASS'Y 51 1 8 1 4 4 1 Use One 1 1 1 1 1 1 1 1 1 1 1 .............................................................. ....... Auxiliary Post (24" Work Height) ........................................ Back-Up Pad Screw 1/2-13NC x 4 1/8"............................... Soc.... .......................... Screw................. Post Back-up Pad . C-2-141 CM-2-90 AUXILIARY POST ASSEMBLY (Extra Work Height) INDEX NO............................................. Post Support Arm .......................... Cap 3/8-16NC x 3 1/4”........................... Auxiliary Post (30" Work Height) ..... ...................................... ................................................... Auxiliary Post (18" Work Height) ........................................................... Screw........................................................... Cap 1/2-13NC x 1 1/2" ......... ..............TM 9-3405-215-14&P CODE NO............... ....................................... Jam 1/2-13NC ........ Cap 3/8-16NC x 1 1/2" ...... ...... ........... ........................... ... Washer....................... 1 2 3 4 095-059192 095-053799 095-075586 091-982884 091-984393 113-014237 091-980482 091-993329 090-324633 093-056836 093-056844 093-056851 090-324625 090-076290 106-011034 090-042615 113-014229 090-243379 091-980672 113-014195 091-991323 113-013098 135-096162 Auxiliary Post Assembly (18" Work Height) Auxiliary Post Assembly (24" Work Height) Auxiliary Post Assembly (30" Work Height) ................ ..................................................... .......................... Ref..................

TM 9-3405-215-14&P POST ELEVATING SUB-ASSEMBLY (EXTRA WORK HEIGHT) 52 .

............................................... Set(Nyloc) #8-32NC x 3/8 ......................... ................... ......................................005 Thk ........... Tube (18" Work Height) ............... Shim ...TM 9-3405-215-14&P CODE NO.......................................................... .............. Post (18" Work Height) ......................................................... ............... Housing..... Tube (30" Work Height)......................... ............. Soc............... 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 UNITS PER ASS'Y 53 2 1 1 1 Use One 4 Use One 1 1 A......................................................... Spring................................... Soc.. Thrust Bearing ...................... Shaft ........ DESCRIPTION Ref........ Post (30" Work Height) ........... Set 1/4-20NC x 1/4 " .............................................................................. ........................................... Soc................ Screw (18" Work Height) .............R.......) . ............................................................................ Set #10-24NC x 3/16 ..................... Soc..... ......035 Thk ...................................... Screw................. ............................................. Screw (24" Work Height) ....... Shim .... Cover........ ......... .......... Tube (24" Work Height) ................................................................................... .............................................................................................. Screw..... .... CATALOG NO......... Plug Button........................... Cop -#10-24NC x 1 ............. ............ Soc......................... ...................................................... A............................................R................................................ Friction Plug . ....... ........... .......................... Handle ................ Soc........ A....................................... ............... ....... Gear ...................R......................... Roll Pin ............ Shim .................................................. ....................................... Ref........................ ......... Screw.. Screw (30" Work Height) ................. .... Screw.................... ............... Spring.............................0149 Thk .......... ....................... Shim ......R.............. Bearing ............................ 1 1 1 Use One 1 1 4 1 1 Use One 1 2 1 1 3 1 ... Screw................... ...................................... Roll Pin ........................................................................................................................003 Thk ........................................... ............................................................................... Post (24" Work Height) .................................................... Hd.................................................................................................. ...................................................................... Block ........................... Ref........ Cap 1/4-20NC x 1/2 ......................................... ........................................... A................... ......... ............. Set #10-24NC x 1/4 (Self-Locking) ............. Screw.......................... .......................................................................... ........... ....................... ........................ Bevel Gear.................................................................................. Hd............................................. Screw......................................... C-2-142 CM-2-91 DISC CUTTER ASSEMBLY INDEX NO...................................................................... Handwheel ........................................ .............................. 1 2 3 4 5 093-063162 093-056877 093-076693 091-982256 135-028108 091-209254 105-013064 091-428169 091-428177 091-428185 091-985903 093-057511 093-057529 093-057537 090-042250 091-235812 091-333104 091-333112 091-333120 091-335138 090-386434 091-046904 094-017688 093-057545 093-057552 093-057560 091-984096 090-386442 091-982363 0971-407650 090-039710 091-984229 091-235762 090-042599 091-209221 091-209205 090-144353 091-154278 091-209239 Post Elevating Sub-Assembly (18" Work Height) Post Elevating Sub-Assembly (24" Work Height) Post Elevating Sub-Assembly (30" Work Height) . Set 1/4-20NC x 1/2 (1/2" Dog Pt. Soc..................................... ......................

TM 9-3405-215-14&P HEAD ASSEMBLY 54 .

..... Washer.................................................... Locative....................................................... 5/16-18 NC x 1-3/4" .................................................... Guard Bracket Assembly................ .................................................... Upper Wheel Tilting Locknut .. Washer #8 Std ........................................... Screw........... .......................................................... 5/16-18 NC x 1” ................... Soc........................ Roll Pin ........................................................... (Self-Locking) ................................ ...............................TM 9-3405-215-14&P CODE NO.. CATALOG NO................. ....................... Lock 3/8 Std ............................. Screw........................................ ... ............ ............... ............. Screw...... ................................. Post Saw Band Guard Assembly ................................... Lock 1/4 Std ..................... Hd..... .... .................. Dowel Pin ............................................................................. .................... ....... ............... ..................................... 1/4-20 NC x 5/8" ...................... Shim ............................ ...... Screw........................... ............... Screw................................................................... Slide Sub-Assembly .......... C-2-72 CM-2-64 HEAD ASSEMBLY INDEX NO.................................... Shim .............. Washer......................................... Screw... Washer... Soc.......................................... ................................................................................................................................................................................. 55 3 3 1 1 2 1 1 1 2 A...... ................. .................... ..................................... .. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 500372 091-982637 091-986133 091-181198 090-042599 091-992669 135-028108 091-422501 091-440610 091-991232 091-318089 135-087617 091-990226 091-993212 093-059442 090-285271 091-982819 091-993329 091-069195 091-988519 091-993188 090-390550 091-218719 094-065117 091-986984 091-398115 091-988667 105-011092 091-306761 135-004455 091-982876 090-042631 093-051357 091-988519 091-992578 091-053041 105-015069 105-015077 135-051274 135-022648 135-022705 105-015085 093-023463 094-018157 095-046215 091-206276 135-096139 091-333104 091-333112 091-333120 091-333138 39 40 41 42 43 44 45 46 47 DESCRIPTION UNITS PER ASS'Y Head Assembly ...................... ......................................................................... A............................. Washer............... ..................................... ................................................ #10-24 NC x 5/16" .............. Handle Assembly .................................... Shim ... Roll Pin ............................................... ..... Shim .................. Bearing Lockwasher ............................................................... Soc.......................................................... Truss Hd..................................... Mach..................................... ................ Set.......... #8-32 NC x 1/4" (Plated) .......... Roll Pin ............................................... Cap........ ................... ........R........ A........................................... Band Tension Pointer ........................................ ......... Jam 5/16-18 NC ................. Cap......... ......... ........ ............ Spring . ............................................................... Bearing Locknut ..... ... Angle ......................... Wheel Tire ............... Rd................... Retaining Ring ......................... Screw............................R.................. Bracket ...... .. ............ ............................... 1 4 7 1 1 2 4 1 2 2 1 4 1 2 1 2 1 1 2 2 2 1 2 2 1 1 1 1 1 1 2 1 1 1 1 2 A...... #10-24 NC x 1/2" ................ Ball Bearing ................................................................................. Set.... Screw.... Pin ................ 3/8-16 NC x 3" .................... ............................................................................... ......................... Tilting Screw Sub-Assembly .......... ........................ Head Casting ................................ ..................... Mach........... Hd................................... Bearing ..........................R.. ......................................................R.............................. Hd............................................. .............. Hex.... Upper Saw Wheel ...... ............... Tension Shaft Sub-Assembly .......... Stop .................. ........................................................................ Ref................... Cap............ Grade HV ......... Lock 08 Std ....................... Hd...... Rd........................................... Soc. Screw................................... A........................ #8-32 NC x 1/4" ............. Upper Saw Wheel Assembly ........... Wheel Hinge(See Detail) ................... Fillet Hd..................... 3/8-16 NC x 1-1/2".R................................................................ Flat 1/2" Std .. Mach............... .................................................................... Hd..... Rd........................................ ............... Hd................................ Bracket ........................................... Mach.............. Post Elevating Sub-Assembly (See Detail) .......... Soc............................................. Nut................. Screw..................... Mach.................................................................. ................................. ...................................................

TM 9-3405-215-14&P HEAVY WORK SLIDES 56 .

.................................. ...... 3613-1... 135-052470 Ref........... 3613-10... Fl Hd. CATALOG NO............... 1 2 3 4 5 094-006921 106-233190 090-279506 106-234529 091-178145 091-983205 UNITS PER ASS'Y DESCRIPTION Heavy Work Support Assembly (1612............ 57 2 1 1 1 2 ... Cap 1/4-20NC x 3/4 (Assembly #094-006921 Only) ......... Center Support (Assembly #094-006921 Only ......... Center Support (Assemblies #090-450040 & 135-052470) .... 6013-2............ 2614-1...... ....... .................TM 9-3405-215-14&P CODE NO..... 2613-2.. 2612-1...... Work Transport Bar .. Center Plate (Assembly #090-450040 Only) ........... 1612-0.... 3613-2...... 2013............... C-10-23 CM-10-33 Z-10-12 HEAVY WORK SLIDES INDEX NO. 2013-10. ZS-3620.......... Screw.. ZV-3620... 2013-0.......................... 3613-0... Ref.. 1612-1...... ZW-3620) Heavy Work Slide Assembly (2612-2H) ...... ......... 2013-1) Heavy Work Support Assembly (1613-2...... 3612-1....... 3612................. Soc. 090-450040 Ref.....

TM 9-3405-215-14&P JOB SELECTOR ASSEMBLY 58 .

........................ .... Screw........ ............. Job Selector Plate ............... Hex.... Must Be Replaced Together As A Unit............... NOTE: Job Selectors #090-468174 & #090-435603.... Outer Edge Felt .. 2613-2............................... ......................... 6013-2 2618-4.... 2012-1A.......... . 3612............. ZV-3620... 2612-1...... Bushing .... Hd.................. 3012-U......... 3613-1........... 3613-10) Job Selector (1612-1............ 3613-0.......... Mach.......... Truss Hd. 2012-A.................. C-8-104 CM-8-53 Z-6-54 JOB SELECTOR INDEX NO...... Screw............................ HS-6013........ Hex......... Jam 1/4-20 NC ............................................ . 1612-0.......... 090-435603 1 2 3 4 090-220781 106-143043 094-008380 091-990283 *091-980276 090-044496 106-144017 *090-027012 091-988907 091-993741 091-991141 090-426727 5 6 *7 *8 *9 *10 UNITS PER ASS'Y DESCRIPTION Job Selector (1612-U.. ZS-3620) .......... First Used 9/17/62............................................ ...... Bushing ..... .............................. Before This Date 4094-008380 Plate end #090-220781 Dial......................... Screw............. 5/16-18 NC x 3/4 ............. Hd........... 2012-1AT.... CATALOG NO................................ Nut......... 3612-1H.. Cap......... ......... Acorn Nut 5/16-18 NC .... ................. Job Selector Dial ........ 1612........................ 2013-10.TM 9-3405-215-14&P CODE NO......... Mach........ Job Selector Frame ........ 1/4-20 NC x 1/4 ........ 2612-1H.. 3612-1...... Rd... 2013-0......... Ref............................. 5/16-18 NC x 3/4 ................... ZW-3620.... *NOTE: Last Used On Models: MODEL 1613-2 3613-2 1612-3 2613-3 3612-3 6013-3 1612-H 2612-H 2612-2H 3612-H LAST MACH....... *NOTE: Starred Items Used Only On Assembly #090-435603. ........................ Lock Shakeproof 1/4 Internal ........ 090-468174 *Ref...... ................... 1611-H...... 2013-1......... 150-69593 151-69515 152-691017 198-69361 153-691054 199-70125 288-69204 284-69135 206-69308 272-69152 59 1 4 1 1 1 1 Use One 4 4 4 1 ................................................ Washer........... 2012-AT.................................. 2013......

NOTE: LAMP ASS’Y. LAMP & MAGNIFIER ASSEMBLIES 60 .H. REQUIREMENT WIRE WORK LAMP DIRECT TO CONTROL BOX. #406141 WILL REPLACE ALL PREVIOUS “MOFFATT” PLASTIC LAMPS.A. MOUNT LAMP SWITCH ON SIDE OF CONTROL BOX OR THE CONTROL PANEL.S.TM 9-3405-215-14&P O.

......................... Washer ........................................... 2-Position .......................................... Selector Switch.......................................................................... 61 1 1 1 1 1 1 1 1 2 2 1 1 1 ........................ Contact Block ............. Cord Grip Connector ......... ...................... Magnifier Attachment...................................................TM 9-3405-215-14&P C-8-8 CM-8-31 PS-8-103 CODE NO............................................. .................. .................. Lamp Sub-Assembly........................ ..................... .................... ............................................................. 19" Flexible Cable........................... Screw.. #10-24 NC x 1/4" ....... Washer....... DESCRIPTION Ref................................................................................. CATALOG NO...... Mach.................. Legend Plate ............................................................................. ............ ....................... .................................................. 13 091-384362 UNITS PER ASS'Y Lamp Assembly Bushing ................................. ..... Bracket ...........................................1 Z-7-61 LAMP & MAGNIFIER INDEX NO................ 1 2 3 4 5 6 7 8 9 10 11 12 094-061413 090-157454 090-152455 091-048207 091-333591 090-145459 090-144114 090-145053 090-151390 091-988659 091-993196 091-025049 091-384529 ................... "O"-Ring ...................................................... ................................... .............. Mounts to Lampshade on Lamp Part #091-384529 ............ Lock #10 Std ............... ................................... 11’-1/2" Connecting Cord ..................... Hd.. TF-4-100 F9-6.. Cord Grip ......... Rd.........

TM 9-3405-215-14&P HEAVY PARALLEL WORK CLAMP 62 .

................................ Rd................................... DESCRIPTION UNITS PER ASS'Y REF........ 10-24 NC x 1/2............................................... ... ........... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 090-450099 090-279506 106-244130 090-376294 106-244155 091-991356 106-243074 090-376286 106-245053 106-243062 091-984112 135-037976 106-245046 106-245087 105-133136 091-986893 Parallel Work Clamp Assembly ............ .................................................................... Screw................................................................................ ........................................ Ball Retainer Ring ......... Center Plate..................................... 5/8-11 NC.......... Steel Ball........................................................... Ball Cup ......................................... Nut................................. ........ Steel Ball ........... 63 1 1 4 1 1 1 1 195 3 1 3 3 1 1 4 ................. Work Holding Jaw Sprocket .. Set 10-24 NC x 3/8.......... Soc... ....................................................................................................... Clamp Stud .. .............. Screw.............................................................................................................. ..................... C-10-38 CM-10-31 Z-10-17 HEAVY PARALLEL WORK CLAMP ASSEMBLY INDEX NO..... .... ............................................................................. ................................ Hex.................................. Mach............. ......... ..................................................... ......... ............. Set Screw........ Hd............................................ ................................................... CATALOG NO.......... Parallel Work Clamp Sub-Assembly...................... Clamp Body. Parallel Arm ............... Center Support ..................TM 9-3405-215-14&P CODE NO......

TM 9-3405-215-14&P POST ELEVATING MECHANISM 64 .

Cap............................R.................................. ................... Hd.... .......................................................................................................... Bearing ....................................... Tilting Locknut .............................................................................. Set 1/4-20 NC x 5/16 .......... ................................................................. Locknut ............................... ... ....................................... .............. Block .................................R................................. Shim 003 Thk............................................................................................................................................................................... ......... ................................................... Screw................. Tube ........................................................................................................... Hd............... Soc.............. .................................................................................................. Screw......................... Soc............................ .................................... Shim 28 Ga ................ Tilting Screw ........ Washer............................ ........................ Soc...................... Spring ...................... ....... .............................. ............................................... Gear ................................. ..... ............ 4 1 1 1 1 1 1 Ref.... ................ ..................................................................... Set (Nylok) 110-24 NC x 1/4" .......................... ............ .................................. Soc......... ...................................... ...... ......................... Post.. Screw................ ................................... Shim 20 Ga ................. Screw...................................... Cap............. Set 1/4-20 NC x 1/4" ............................................................... Set 110-24 NC x 3/16" .....................R................ Set................................ A.................................. Friction Plug .................................... Soc................................................................................................................................................................................................................. Roll Pin .......................... Screw........................ Housing ........................ C-2-65 CM-2-79 POST ELEVATING MECHANISM INDEX NO.......... Soc................................... Shaft .................................... Thrust Bearing . ....... Screw...................................... .... Lock ...................R.................................................................................................................................... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 090-390550 090-391186 091-209247 090-386442 091-982363 094-017688 090-144353 090-386434 091-407650 090-039710 091-209221 091-209239 091-046904 091-209254 135-028108 091-209205 091-154278 091-982256 105-013064 091-333104 091-333112 091-333120 091-333138 091-985903 090-042250 091-235804 091-235812 091-984096 091-984229 090-042599 Post Elevating Sub-Assembly ............. Shim 005 Thk.. 1 1 1 1 1 1 1 1 65 ..................... Handwheel ........................... ................ 1/4-20 NC x 1/2".. ..............................TM 9-3405-215-14&P CODE NO........ DESCRIPTION UNITS PER ASS'Y Ref............ Roll Pin ..................................................... Plug Button ................ Screw.................. Soc............. .......................................................................... #10-24 NC x 1" ................................................... .............. ................. 1 2 3 4 5 6 7 8 105-011084 091-206268 105-011092 105-015069 105-015077 105-014245 091-984237 091-206243 Wheel Hinge Assembly ............................................. Spring ........................... .......... Screw............. ................................................................................ Tilting Screw Knob .............. .... Gear ....... Cover ..... Handle .............................. 1/4-20 NC x 1/2" (Half Dog) ............................. .. Block .............. Hd................ ................ Stud ...... ........................ CATALOG NO................................................ A................... A... 1 1 1 4 1 1 1 1 1 2 1 1 1 1 1 3 2 1 A..................................

TM 9-3405-215-14&P PROTACTOR WORK STOP AND ALIGNMENT GAGE ASSEMBLY CM-10-7 D-1 66 .

........................................ Stud ........... Knob ...............................................A............................................................................................................................................... ......................................................... .... Dowel Pin ...................................... Gage Rod .. ........................................... Tee Nut ................................................ ................ REF... CATALOG NO.................................. .................. Washer................................................................. ..................... Knob ........................................... Tee Nut .......................... Plain 7/16 S.. .................................................................. CM-10-7 PROTRACTOR WORK STOP & ALIGNMENT ASSEMBLY INDEX NO........................... Std ......................E..... ............................................. DESCRIPTION REF......... Shaft ......................................... ........................... Screw....................... Thumb Screw ..................... 4 5 6 7 8 9 10 11 12 *NOTE: UNITS PER ASS'Y Starred Items Are Pert Of Assembly /090-547589 67 5 1 2 2 1 1 1 1 1 1 1 1 1 1 1 ........... Stud ..................................................................................... Mitre Head ..............TM 9-3405-215-14&P CODE NO..................................... Protractor Plate ................................................. ............................. Hd......... Pointer ..... ........................................... ....... ......... 1 2 3 090-514951 090-547589 091-988675 114-004732 091-339713 *114-115183 090-116344 090-116336 090-253022 *090-291329 090-116351 *091-011189 091-992651 135-016145 134-174010 135-019768 090-514969 Protractor Work Stop & Alignment Assembly Protractor Work Stop & Alignment Assembly ........................................................ Rd...................... Mach #10-24 NC x 3/8 ................................ .........................................................

TM 9-3405-215-14&P RIP FENCE ASSEMBLY C-10-6 Z-9-5 68 .

............. ................................................. DESCRIPTION Ref........... Soc................... Hd...................................... Soc.......................... Clamp Bar Screw............ St 1/4-20 NC x 1/2.. .... Rip Fence Sub-Assembly (090-477795 & 135-005429) .......................... Ref............. 2 3 4 5 6 7 8 9 10 11 UNITS PER ASS'Y 69 1 1 2 1 1 2 1 2 2 1 2 1 1 1 ....................... Spring Clip ..... ....... ........ Sec. Cap 3/8-16 NC x 3/4 .. Screw.. ... ..................................................... ............................... Hd................ Work Guide (135-052512) ..... .................................... ................................................... Cap 3/8-16 NC x 3/4 ............................................................. Clamp Guide (135-005429)... Handwheel Assembly. ....................... Screw............................................... Clamp (135-052512) ............................ Work Guide (135-05178) ........................................ Screw........................... ................ . Clamp Bar ......................... Clamp (135-051787) .... 1 090-477795 135-005429 135-005437 105-163026 111-163028 091-982785 135-051787 135-052512 134-065044 105-163034 105-164032 091-982785 135-005460 135-005486 091-984252 105-160048 135-005445 135-005452 Rip Fence Assembly (26" Table) Rip Fence Assembly (30" Table) Rip Fence Assembly (24" Table) ................................................. .... CATALOG NO............................. ..... C-10-6 Z-9-5 RIP FENCE ASSEMBLY INDEX NO....... Ref..................................TM 9-3405-215-14&P CODE NO.. Clamp Guide (090-477795 & 135-005437 ..................................................................................... ................. Rip Fence Sub-Assembly (135-005437) ................................. .................... ..............

TM 9-3405-215-14&P C-7-18 CM-7-23 70 .

TM 9-3405-215-14&P
CODE NO.
C-7-18
CM-7-23
#121230
SAW GUIDE SELECTION
INDEX CATALOG
NO.
NO.
DESCRIPTION
HEAVY DUTY GUIDES STEEL BACKUP)
Ref.
1
2

091-201434
090-380767
091-982447

3
4
5
6
Ref.
7

134-085026
090-115403
090-115411
090-115296
091-201426
091-982447

8
9
10
11
12
Ref.
Ref.
1

134-085026
090-377383
090-115403
090-115411
090-115296
090-115288
090-115304
091-984450

2
3

091-203695
091-982421
091-982447

4
5
6
7
8

090-115403
090-115411
090-115296
134-085026
090-252529

Ref.

090-252537
090-115437

Ref.
9

090-115429
091-982421
091-982447

10
11
12
13
14

090-115403
090-115411
090-115296
134-085026
090-252586

090-252578
HEAVY DUTY GUIDES
Ref.
091-199182
1
090-380767
2
091-982389
3
8
9
10
Ref.
11
12

134-085026
090-172180
090-115411
090-115296
091-190017
090-377383
091-982389

13
14

134-085026
090-172180
**NOTE:

UNITS PER
ASS'Y

Upper Saw Guide Ass’y. (1/18” to 1/2”)
. Upper Saw Guide Block ..................
. Screw, Soc. Hd. Cap 1/4-20 NC
x 1-1/4 .........................................
. Washer ........................................
. Bearing Cap...................................
. Retaining Ring ...............................
. Bearing ........................................
Lower Saw Guide Ass'y. (1/16” to 1/2")
. Screw, Soc. Hd. Cap 1/4-20NC
x 1-1/4 .........................................
. Washer .........................................
. Lower Saw Guide Block ..................
. Bearing Cap...................................
. Retaining Ring ..............................
. Bearing ........................................
Upper Saw Guide Ass'y (5/8” to 3/4”)
Upper Saw Guide Ass’y (1")
. Screw, Sac. Hd. Set 5/16-24 NF
x 1/2 ............................................
. Sac. Hd. Pipe Plug .......................
. Screw, Sac. Hd. Cap 1/4-20NC
x 1 (5/8" to 3/4”) .............................
. Screw Sac. Hd. Cap 1/4-20N C
x 1-1/4” (1 “) ..................................
. Bearing Cap...................................
. Retaining Ring ..............................
. Bearing ........................................
. Washer .........................................
. Upper Saw Guide Mack (5/8' to
3/4") ............................................
. Upper Saw Guide Block (1”) ............
Lower Saw Guide Ass'y. (5/8" to
3/4)
Lower Saw Guide Assy. (1”)
. Screw, Sac. Hd. Cap 1/4.-20NC
x 1 (5/8" to 3/4”) ............................
Screw, Sac. Hd. Cap 1/4-20NC
x 1-1/4” (1”) .......................................
. Bearing Cap ..................................
. Retaining Ring ..............................
. Bearing ........................................
. Washer ........................................
. Lower Saw Guide block (5/8” to
3/4”) ............................................
. Lower Saw Guide Block (1”) ............
(CARBIDE BACKUP)
Upper Saw Guide .Ass'y. (1/16” to 1/2”)
. Upper Saw Guide Block ..................
. Screw, Soc. Hd. Cap 1/4-20NC
x 5/8.............................................
. Washer .........................................
. Bearing Cap ..................................
. Retaining Ring ..............................
. Bearing ........................................
Lower Saw Guide Ass'y. (1/16" to 1/2”)
. Lower Saw Guide Block ..................
. Screw, Soc. Hd. Cap 1/4-20NC
x 5/8 ............................................
. Washer ........................................
. Bearing Cap ..................................

INDEX
NO.

CATALOG
NO.

15
16
Ref.
1
2
3
4
5
6
7
8
9
10
Ref.
11
12
13
14
15
16
Ref.
1
2
3
4
5
6
7
8
9
10
Ref.
1
2
3
4
5
6
7
8
9
10
Ref.
11
12

090-115411
090-115296
090-178617
091-984450
091-332023
091-354415
090-252529
091-982421
134-085026
090-183377
090-172180
090-115411
090-115296
090-181686
090-252586
091-982421
134-085026
090-172190
090-115411
090-115296
093-030112
091-984460
091-351445
091-332023
090-252537
134-085026
091-982421
090-183377
090-172180
090-115411
090-115296
091-201194
090-335092
090-336314
091-081166
091-982447
134-085026
091-354415
090-188837
090-172180
090-115411
090-115296
090-177320
090-252578
091-982447

13
14
15
16
Ref.

134-085026
090-172180
090-115411
090-115296
093-048437

2
2
1
1
2

1
2
3

091-212100
094-064300
091-982447

1

4
5
Ref.

134-085026
091-102040
093-048445

6
7
8

091-212100
091-102040
091-982447

9
10

134-085026
094-067683

1
2
2
1
1
2

2
2
1
1
1
2

1
1

2
1
1
2
2
USE
ONE

2
2
1
1
2
2
USE
ONE

1

2
2
1

If Your Machine Was Equipped With Two
Coolant Lines to the Upper Saw Guide, Order

Additional Parts 091-094524 Swivel Joint, Qty.
1,090-160011 Barbed Insert Qty. 2 and Delete
091-081166 90°- Barbed Insert, Qty. 1.

71

DESCRIPTION

UNITS PER
ASS'Y

. Retaining Ring ..............................
. Bearing ........................................
Upper Saw Guide Ass'y. (5/8” to 3/4”)
. Screw, Soc. Hd. Set 5/16-24 NF x 1/2
. Pipe Plug ......................................
. Lockout ........................................
. Upper Saw Guide Block ..................
. Screw, Soc. Hd. Cap 1/4-20NC x 1..
. Washer .........................................
. Guide Guard .................................
. Bearing Cap...................................
. Retaining Ring ...............................
. Bearing ........................................
Lower Saw Guide Ass'y. (5/8” to 3/4”)
. Lower Saw Guide Block ..................
. Screw, Soc. Hd. Cap 1/4-20NC x 1.
. Washer ........................................
. Bearing Cap...................................
. Retaining Ring ..............................
. Bearing ........................................
Upper Saw Guide Ass’y. (1”)
. Screw, Soc. Set 5/16-24 NF x 1/2" ...
. Locknut ........................................
. Pipe Plug ......................................
. Upper Saw Guide Block ..................
. Washer .........................................
. Screw, Soc. Hd. Cap 1/4-20NC x 1..
. Guide Guard .................................
. Bearing Cap...................................
. Retaining Ring ...............................
. Bearing ........................................
Upper Saw Guide Assy. (1”)
. Coolant Nozzle ...............................
Upper Saw Guide Block ..................
. 90° Barbed Insert ...........................
. Screw, Soc. Hd. Cap 1/4-20NC x 1-1/4
. Washer .........................................
. Locknut ........................................
. Guide Guard ..................................
. Bearing Cap ..................................
. Retaining Ring ..............................
. Bearing ........................................
Lower Saw Guide Block (1”)
. Lower Saw Guide Block ..................
. Screw, Soc. Hd. Cap 1/4-20NC
x 1-1/4 .........................................
. Washer ........................................
. Bearing Cap ..................................
. Retaining Ring ..............................
. Bearing ........................................
. 1 Inch Upper Saw Guide Stack
Sub-Assembly
. Back-Up Insert ..............................
. Upper Saw Guide Block ..................
. Scr. Soc. Hd. Cap 1/4-20NC x
1-1/4.............................................
. Washer .........................................
. Pivot Bolt .....................................
. 1 Inch Lower Saw Guide Block
Sub Assembly
. Back-Up Insert...............................
Pivot Bolt .....................................
. Scr. Soc. Hd. Cap 1/4-20NC x
1-1/4 ............................................
. Washer ........................................
. Lower Saw Guide Block ..................

1
2
1
1
1
1
2
2
1
1
1
2
1
2
2
1
1
2
1
1
1
1
2
2
1
1
1
2
1
1
1
2
2
1
1
1
1
2
1
2
2
1
1
2

1
1
2
2
1

1
1
2
2
1

TM 9-3405-215-14&P

C-7-20 CM-7-29
72

TM 9-3405-215-14&P
CODE NO.

C-7-20
CM-7-29

#121230
SAW GUIDE SELECTION
INDEX
NO.

CATALOG
NO.

PRECISION GUIDES
Ref.
090-115197
1
091-984450
2
091-203695
3
091-982389
4
134-085026
5
090-252495
6
134-080092
7
091-985010
Ref.
090-115072
8
091-985010
9
134-080092
10
091-982389
11
134-085026
12
090-252479
Ref.
134-080092
1
134-084185
2
134-090439
3
134-083096
4
134-083120
SPIRAL GUIDES
1
090-268723
2
135-069532
3
NA Alone
4
NA Alone
5
090-268715
6
135-069524
7
NA Alone
8
NA Alone
HIGH SPED GUIDES
Ref.
090-280819
1
090-279811
2
091-982389
3
134-085026
4
091-37339
5
090-115411
6
135-022804
7
090-184151
Ref.
090-282827
8
091-982389
9
134-085026
10
090-279837
11
091-373399
12
090-184151
13
135-022804
14 090-115411
Retaining Ring
90° SAW GUIDE BRACKETS
Ref.
090-448044
1
135-036473
2
090-275975
3
091-982421
4
090-116583
5
091-982397
6
090-275966
090-292616
093-021780
STEEL AND CARBIDE INSERT SELECTION
Ref.
090-044991
090-044983
090-044975
090-044967
090-044959
090-039603
090-039595
090-039587
090-039579
090-039561

UNITS PER
ASS'Y

DESCRIPTION

Upper Saw Guide Assembly, (1/16" to 1/4”)
. Screw, Soc. Set 5/16-24 NF x 1/2 .....................................................................................................
. Soc. Hd. Pipe Plug.........................................................................................................................
. Screw, Soc. Hd. Cap 1/4-20NC x 5/8...............................................................................................
. Washer ........................................................................................................................................
. Upper Saw Guide Block...................................................................................................................
. Bearing Sub-Assembly (See Detail)...................................................................................................
. Screw, Soc. Set #8-32 NC x 1/4”).....................................................................................................
Lower Saw Guide Assembly (1/16" to 1/4”)¶
. Screw, Soc. Set #8-32 NC x 1/4.......................................................................................................
. Bearing Sub - Assembly (See Detail) .................................................................................................
. Screw, Soc. Hd. Cap 1/4-20NC x 5/8...............................................................................................
. Washer ........................................................................................................................................
. Lower, Saw Guide Block .................................................................................................................
Bearing Sub-Assembly
. Shaft ...........................................................................................................................................
. Bearing ........................................................................................................................................
. Roller Seal ....................................................................................................................................
. Washer ........................................................................................................................................
Spiral Saw Guide Assembly (Upper)
. Eccentric Guide .............................................................................................................................
. Tire Only ......................................................................................................................................
. Rim Only .......................................................................................................................................
Spiral Saw Guide Assembly (Lower)
. Plain Guide ...................................................................................................................................
. Tire Only .......................................................................................................................................
. Rim Only .......................................................................................................................................
Upper Saw Guide Assembly (1/16" to 1/2")
Upper Saw Guide Block.......................................................................................................................
. Screw, Soc. .Hd. Cap 1/4-20NC x 5/8...............................................................................................
. Washer .........................................................................................................................................
. Plug..............................................................................................................................................
. Retaining Ring ..............................................................................................................................
. Bearing ........................................................................................................................................
. Bearing Cap...................................................................................................................................
Lower Saw Guide Assembly (1/16" to 1/2")
. Screw, Soc. Hd. Cap 1/4-20NC x 5/8...............................................................................................
. Washer ........................................................................................................................................
. Lower Saw Guide Bock ...................................................................................................................
. Plug .............................................................................................................................................
. Bearing Cap...................................................................................................................................
. Ball Bearing ...................................................................................................................................
1
90° Saw Guide Assembly
. 90 Elbow ......................................................................................................................................
. Upper Angle Block .........................................................................................................................
. Screw, Soc. Hd. Cap 1/4-20NC x 1 .................................................................................................
. Nipple ..........................................................................................................................................
. Screw, Soc. Hd. Cap 1/4-20NC x 3/4 ..............................................................................................
. Lower Angle Block .........................................................................................................................
. Center Plate 24 x 24 Table (Nor Shown).............................................................................................
. Center Plate 30 x 30 Table (Not Shown).............................................................................................
Steel Insert * Req'd)
1/16”
3/32"
1/8"
3/16"
1/4"
3/8"
1/2"
5/8"
3/4"
1"

Ref.
090-161688
090-161704
090-132911
091-058941
090-132929
090-089822

73

Carbide Insert (4 Req'd)
1/4"
3/8"
1/2"
5/8"
3/4
1"

1
1
2
2
1
1
1
1
1
2
2
1
1
1
1
1

1
1
1
1
1
1

1
2
2
1
1
1
1
2
2
1
1
1
1

1
1
2
1
2
1
USE
ONE

TM 9-3405-215-14&P C-7-19 CM-7-27 74 .

........................... Scr.. Internal Ring ......... Bearing (N..... 090-29257A Lower Roller Saw Guide Ass'y 1/4'” REF.... Select flanged backup roller subass'y from type 1 detail and parts list. 6 7 8 9 10 Ref............... 2 091-993212 ........... Use 090-135401 ....................... Washer. Retaining Ring . Retaining Ring ..... 090-289679 Side Roller Guide Assembly 1 091-007583 .......... Cloth Bag (Not Shown) ....... 1 INDEX NO.... Backup Roller 3/4" ......... Ref... 1 091-982363 ............... Guide Roller 3/4" . 1 2 3 4 5 Ref....................... 2 091-984492 .......... One 090-147799 ... Z99500XRIE) ..... Snap Ring ............................ Upper Guide Block .....ROLLER SAW GUIDES WITH ROLLERS REF....................... 1 2 090-289851 .. Guide Roller 1/2" ........... Upper Saw Guide Block.......... 2 5 090-115411 .......................... 090-135427 ..... One 090-017799 ...... (Not Shown) ............ Internal Ring ... 2 090-015686 ......... 1 5 090-135302 . 1 10 090-182965 . Hd................. Soc............... 1 090-172156 Lower Guide Sub-Assembly 090-277435 ........................... 090-289786 Flanged Roller Sub-Assembly 3/8" Backup REF.. Guide Roller 3/8" .......... Retaining Ring .............. 2 TYPE II ....... 090-289828 Flanged Roller Sub-Assembly 1/4" Backup REF......... 1 090-135302 ......... Soc........ Select flanged backup roller sub-ass'y From type 1 detail and parts list............. 1 091-000463 .... Soc. 2 090-017A19 ...... 2 090-239604 .ROLLER AND SPINDLE ASSEMBLY REF................. Guide Roller 1"..... Flanged Roller 3/8" ........... 1 090-013038 .................. Backup Roller 5/8 " .. Lower Saw Guide Block . Retaining Ring ........ Cap 1/4-20NC x 3/4 (Not Shown) ............... 1 090-021403 ... DESCRIPTION ASS'Y 090-289687 Backup Roller Guide Assembly 091-007583 ...... 1 091-982355 .... DESCRIPTION ASS'Y TYPE I ......................... REF. 6 7 8 9 10 Ref........ Retaining Ring .. 090-289802 Roller Sub-Assembly 3/8" Side REF. Guide Roller 5/8" ... 5 090-289612 ............... 1 091-000463 ....... Backup Roller 3/8" ........ Lock 1/4 Std ...... 1 090-013038 . Backup Roller 1/2" ..... Bearing .... Scr..... Scr............ 1 090-207986 Backup Roller Guide Ass'y 1/4" 090-208083 Backup Roller Guide Ass'y 3/8" 090-202953 Backup Roller Guide Ass’y 1/2" 090-210717 Backup Roller Guide Ass'y 5/8" 090-202961 Backup Roller Guide Ass'y 3/4" 090-135328 Backup Roller 1/4. 090-289745 Roller Sub-Assembly 1/2" Side 1 090-182965 ......... Close Nipple ...... 1 090-015686 ........ Bearing (N.... 1 107-0151045 .. 2 090-015686 .. Ref......... Lock 1/4 Std........ Washer..................ROLLER AND SPINDLE ASSEMBLY REF... 090-292582 Upper Roller Saw Guide Assembly 3/8" REF 090-295064 Upper Roller Saw Guide Assembly 1/2" 1 Ref..................... Bearing ........... Hd... 1 114-145287 ............ Bearing ........................................... NO.......... Ref............. 1 6 Ref... 1 ....................... Scr....... Soc......... Plug ................................ Soc..... Use 090-289794 .. Scr.............. Roller 1/2" ......... 090-289844 Roller Sub-Assembly 1/4" Side REF...... Spindle .................. Snap Ring . Roller 1/4” .............. Hex..... Z99500XRIE) ............. Ref....... 090-289773 .... Lock 1/4 Std ........ Hd.......... 090-292566 Upper Roller Saw Guide Assembly 1/4" REF....... Pipe Nipple .................... 090-289760 Flanged Roller Sub-Assembly 1/2" Backup 6 090-289836 ..... Hd............ 1 TYPE IA ................ 1 2 090-013038 ............. 1 090-335092 ...... 1 090-207994 Guide Roller Ass’y 1/4" Side 090-208075 Guide Roller Ass'y 3/8" Side 090-202920 Guide Roller Ass'y 1/2" Side 090-210725 Guide Roller Ass'y 5/8" Side 090-202938 Guide Roller Ass'y 3/4" Side 090-135302 ..... Cap 1/4 20NC x 1/2 .......... Coolant Guard ... Cap 1/4-20NC x 3/4 (Not Shown) ... 090-135344 .D................................................... Washer..... Bearing Shaft .. C-7-19 CM-7-27 SAW GUIDE SELECTION INDEX CATALOG UNITS PER NO.......... Flanged Roller 1/4" ....... Use 090-289810 ........ 2 091-993212 .... Flanged Roller 1/2" ...... 090-135369 .......... Cap 1/4-20NC x 3/8 ............... Lower Guide Block ........ Spindle ......TM 9-3405-215-14&P CODE NO........ Scr.......... 091-982397 ... Retaining Ring . Retaining Ring .................................... Hd............. 2 3 090-017799 ................... Hd.. Guide Roller 1" ..................................... Select side roller sub-ass'y from type 1 detail and parts list............................. Bearing Shaft .................. Ref.............. 1 090-135310 .............. Set 3/8-16 NC x 3/8 .... Guide Roller 1/4" ... Spindle ............................ 1 3 Ref......... Soc............................................................ Roller 3/8” ... 2 090-326363 .. Select side roller sub-ass'y from type 1 detail and part list.............. Bearing .......... One 7 090-115411 ... 090-135351 .......... 1 091-984484 .D............... 1 4 090-315686 ... Set 3/8-16 NC x 1/2 . 090-295056 Lower Roller Saw Guide Ass'y 1/2'” 4 Ref............. 1 090-135302 .. Plug . Coolant Nozzle............................ One 3 090-415296 ... 10 11 12 13 14 75 CATALOG UNITS PER NO.... 091-982397 ................... 2 090-017799 .......... 1 REF......................... 1 Roller Guide Block Assembly 091-095174 Upper Guide Sub-Assembly 090-335175 . Spindle ... Chip Deflector ....... Ref...................... 1 090-013038 .......... 1 2 3 4 5 6 7 8 9 Ref.... 2 9 090-115296 ... Use 090-435419 ............................ 090-135336 . Ref..... Ref.................... 090-292590 Lower Roller Saw Guide Ass'y 3/8" REF.. Retaining Ring .......... 2 ...... 2 REF................... 091-993212 ........... 2 090-017419 ............. 090-289752 ... 090-135435 ...........

TM 9-3405-215-14&P SCREW FEED ASSEMBLY C-10-29 CM-10-17 76 .

. Screw Feed Screw........ 2612-1 3612...... Roll Pin ............... CATALOG NO....................... 77 1 2 1 1 1 1 1 1 1 1 1 2 1 1 .... Hd............. 2013-0.............................. C-10-29 CM-10-17 SCREW FEED ASSEMBLY INDEX NO......... ............................ .......................................................... 1/4-20 NC x 1/2 ................ .. .... 2012-1AT........ 3613-1) Screw Feed Assembly (1613-2........... Screw Feed Swivel Sub-Assembly ...................................................... 6013-2) ...... ..... 2012-1A... 3613-2.. ........................... 1612-0.................. Rd....................................................... Screw........ Collar .........................TM 9-3405-215-14&P CODE NO......................................... ..................... Soc... 135-062123 REF..................... Mach. 1612-1............. Screw Feed Key ............................. Screw.. ...................... Detent Spring ................ 2613-2............................... ....................................... .. 2013........ Screw Feed Handle & Screw Sub-Assembly ........... .................. Screw Feed Handle .................................................... Steel Ball......................................................... 2013-10........................ REF... NOTE: Starred Items Used Only On Assembly #090-454679........................ Screw Feed Swivel . 2013-1....... Set #10-24 NC x 1/4 ................................................... #6-32 NC x 1/4................................................................. Hd......... Screw........ Feed Screw Bracket ................... Mach..... ...... ....................... Rd..... 1 2 3 4 5 6 7 8 *9 10 11 12 13 14 090-454679 135-062115 091-988956 091-984104 111-284188 111-030078 111-034013 090-042557 134-031061 135-052249 091-988386 105-034029 105-035026 105-035018 105-034011 UNITS PER ASS'Y DESCRIPTION Screw Feed Assembly (1612...............

TM 9-3405-215-14&P C-3-41 78 .

....................... Hex................. Hd....................... 1 090-10A902 ............ Hex.... USE 090-553033 . 2 090-120452 .................... Cap 3/4-16 NC x4 3/4 . 1 091-987487 ........................ 1 091-988378 .... Lock 1/2" Shakeproof Ext .............. 5 091-980458 .. Center Plate (Used on Band Polishing Assembly) .......................................... 1 090-076456 ........................ 2 090-038613 ............ 1 134-134071 ............................................ 4 091-993774 ...... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 *16 *17 *18 *19 *20 *21 22 23 24 25 26 *27 28 29 30 31 32 33 34 35 1...................................... Rd.................. Hd... Cap 1/2-13 NC x 1 ......... 1 091-980466 ....................................................... Shim (090-524356 Only) ..................................................... 090-524356 Only) ............... 1 091-991414 .............. Mach............ Before Ser.......... A........................................................... 3612-U................................ Pointer ...........R.... Soc..... **Note: Before Ser...................... 79 ................................R.............................. 090-598269 ........ 1 090-406455 ......... Shim (090-549353... Washer. Screw. ONE 091-980656 ............... #6-32 NC x 3/16 ................................... 1 135-005163 .............. 091-333138 ............................ Cap #10-24 NC x 3/8................................ Spacer ................................................. REF............................................. Center Plate (Used on Band Filing Assembly) ............................... Hex....... Screw................ Screw........ 091-333120 ..................................................................... Screw................... Rd................................................ #148-701464 on 1612And Before Ser........................................................................ Hd............... 1 090-045998 ........................................................ 090-553066....... 2 091-982918 ..................... Hd........................................ 1612-U...... 3012-U....... Lock 3/8 Std ........................ Hex............... 1 090-394644 ..... 1612... Cap 3/8-16 NC x 1 .................................................. 3613-10........................... Washer.... Hd....................................................R....................................................................... A............................................... ONE 090-105016 ................ CATALOG NO................. 1 090-106279 ......... Shim (090-598624...... 2 091-993329 .........................................................TM 9-3405-215-14&P CODE NO..........................0................................ Shim (090-598624 Only) .......... 2 091-985788 .............. Nut....... 3613-0......................... 090-394644 Head Was 090-107566............ Lower Post Block .................... Hd..... Wrench(Not Shown) (090-524356 Only) ............................... 114-004732 .......................................................... Ca 1/2-13 NC x 3/4.......... 3613-20) 090-549353 Table And Trunnion Assembly (1612-1) 090-553066 Table And Trunnion Assembly (2612-1........................................................................................................................................... Table (24" x 24" Specify Size)............................. Clamp ...................... 1 090-105701 ... Cap 3/8-16 NC x 11/4 t090-549353... 3613-1) 090-541855 ............................................................ Screw................................................................................................. Hd....................................................... A.............................. Set 3/8-16 NC x 3/4 Flat Point (090-524356 Only) ...................................... Screw........ 5 091-991273 ..................R.................................................................. Cap 3/8-16 NC x 7/8 /090-524356 Only)..... Shim (090-524356 Only) ............................................... UNITS PER ASS'Y DESCRIPTION Table And Trunnion Assembly (16M & 30M................................. 091-333112 ............................................. 090-524356 Only) ............. Dowel Pin ......................................................................................... 3613-1) 090-598624 Table And Trunnion Assembly (2612-1......................................................R................... Trunnion ....................................................... Hex..................... Screw.. REF....R........ Center Plate ............................................................... Flat 3/8 Std ........... Head ........... A.. 2 091-980474 ......................... A.................................................... A................................R..... 1611-U............ Screw.................................................................. 3/4-16 NF ........ Screw........................................................................................... 1 090-120460 ..... Drive PK #6 x 3/8 Type "U”................. *Note: Items #16 thru #21 Are Not Port of Assemblies 090-524356..................... USE 091-981233 ....................... Nut................................. Soc.. Cradle .......................................... 090-524356 Only) ................... Shim (090-598624.. Shim (090-598624................... 090-524356 REF......................... 1 090-042094 ..................................................................... 090-598624 Only) .......... REF.... 090-406497 ... Hex...... Small Parts Filing Assembly ......... Shim (090-598624. 090-553066 Only) ................................................................... 135-009934 ........ 4278-70253 on 3613-0.............. A........................................................... Plate .......... A................... Screw........... 1 091-333146 ......................................... #287-70259 on 1612... C-3-41 TABLE AND TRUNNION ASSEMBLY INDEX NO................................ 2 091-992644 ... 3612-1................................ 1 091-333203 ..........................R................R. Center Plate ........................ 090-108531 ..... 3612. 4 091-333104 ..................................................................................................... Dowel Pin .. A................................ Washer.......................................... 090-598624... 091-333211 ................. Hd.................................................................... Screw............ Jam 3/8-16 NF (090-524356 Only) . Escutcheon .................. 1 090-242447 .................................. Cap 3/4-16 NC x 5 ....................... Table (30" x 30" Specify Size) .................... 3612-2....... Roll Pin ...... Dowel Pin ............... Hd......................... #277-70778 on 1612-0................................ 090-549353.......... 1 134-033158 ...................... 2 091-981068 .................... 1612-..... Hex................................................... 090-524356 Only) ........... Fiat Hd.......... Before Ser........ Table (26" x 26" Specify Size)............................................................................ 4 091-994012 ......

TM 9-3405-215-14&P C-3-78 80 .

.................... Screw............................................. Washer......................................... Rd........ .........................TM 9-3405-215-14&P CODE NO......... Cap 1/4-28 NF x 1-1/4 ... Screw. Trunnion ............................ ................................E..... ............ Mach................ Guard Assembly (#503826) .............. Chip Guard Assembly (#501532) ........................................................................................... 2614-1........................... Locknut ........................ Hex.. ............ .................................. Handle Sub-Assembly .......... .. Flat 3/8 Std........................... Hex.. ............................. ...... DESCRIPTION UNITS PER ASS'Y Ref............ 2012-AT.............. #8-32 NC x 1/4 ............................................................................................................A...... 06-32 NC x 1/4" ....................... 1612................ Washer.......... Lube Fitting 90° ........................ Hex................... Screw Assembly .......... Handle Assembly . 1/4-20 NC x 3/8........................................ 3612-1...... Rd.... Pan Hd..................... 1/4-20 NC x 3/8 (#503826) ............................... Lock 1/4 Shakeproof Int ................................................ Chain....................... Pointer ............................... Keeper Block ................... ............................................... ..... Center Plate ................................ Mach.................................................................... Screw.. ................................ Screw..................... Ball Bushing .................................................. .................. .... Head .................................................................................. ................................................ Pipe Plug (#503826) .......... Spacer . 2012-1AT....... Cap 3/8-16 NC x 1-1/4...... Rd............................ ................................. S........ Soc................................ .............................. .................. Screw................. ........ .................... Screw. CATALOG NO...... #10-24 NC x 3/8 .. ................................. .......................................................... ...... Washer............................................... Belleville Washer .............. 090-285271 .. Dowel Pin.... Mach..................................... Trunnion Plate ...... Hd...... Mach.................................................. Roll Pin ....................... 3/4-16 NF .......... ..................................................................... 111-055091 ............................. .............................................. 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 501532 503826 090-042094 090-104902 095-013801 091-253617 091-988519 091-295907 091-253930 091-990192 095-030458 091-988675 135-065803 090-507914 090-036476 090-051806 090-394644 090-410937 090-450800 090-216219 090-409038 090-105016 091-981068 091-991414 091-980474 091-993329 135-003283 090-242413 091-988386 134-033158 091-988931 091-988220 091-993568 Sliding Table Assembly (1612-0.............. ................. .......................... Hd............. Lock 3/8 Std................................. Mach.................................................. 1 1 1 1 2 1 1 6 1 16 1 1 4 2 1 1 1 1 1 1 1 1 4 10 2 1 1 1 2 2 8 33 34 35 36 37 38 39 40 090-087909 106-335185 090-042441 091-046326 091-982520 091-156604 091-310110 091-992644 ........ ............................. ................................. 1/4-20 NC x 3/8 (#501532) ................... Spacer .............. ... Ref............. Hd......................... 2012-1A....... Chip Cover Assembly (#501532) ...... Cradle .............................. Screw................... Square Weldment ................................................. 2 1 1 6 1 1 1 2 Following Items Not Shown: 091-319483 ......... Nut...................................... ................ ...... Rd................................................................................... 3612............................. Roll Pin .......................................................... .................................................... 3613-10) Sliding Table Assembly (2012-A................................... .............. Truss Hd......................... Hd................ ......... ............................................................................. .............. C-3-78 SLIDING TABLE ASSEMBLY (AIR FEED) INDEX NO..... Mach................................................... 1 1 1 1 81 . Hd........................ 091-294470 .................. 2012-2A) .......... Hd...................................................................................................................................... Pan .... Plug ......... Screw....................................................................................................... Screw....................... Pipe Plug ............................ Pipe Plug .................................... Table........................ Hd...................................................... .... Cap 3/4-16 NF x 5.......................................................

TM 9-3405-215-14&P SLIDING TABLE ASS Y AIR FEED 82 .

..................................... Soc......................................... Cylinder Bracket ..... ................. ................ 2614-1............................................................................................................................................... Cap 3/8-16 NC x 3/4 ............................................................. 2012-2A) ................................................................... ......................... Washer.......................................................................... ................. Mach...... 3612.................... 1/4-20 NC x 1/2 .. .................... ................................................ ................................ ................ .. Hd.............................................................. Hd................. Bracket Weidment ................................................................................................................... #12-24 NC x 3/4 ..........................R.......................................................................... Plunger .......................... Barbed Insert ........................................ Hex......................... 1612............. Mounting Plate (#503826) ................. ................ Bearing ........................................................... Mach................................. Hd............. 1 1 1 A... T-Bolt ................................ A............................... Slide Bar ........... Seal Disc .. 1 1 1 1 1 1 1 2 1 2 2 1 .................... Lock #10 Std .......................................................................................... ............. ... Hd..................... Knob .................................... ........................................... Soc.......... Shaft .......... Screw....... Jam 3/8-16 NC...................... Guide Rod ........................................................................................................... .................. Regulating Valve...................R................. Mach..... .............................................................................. A..................................................................................................................................... Screw................................................................................................ .......................................................... Screw............. Hex... #10-24 NC x 5/8..... Cap #10-24 NC x 1/4 ........................ A............................................................................................... 2 4 1 1 2 1 4 2 4 2 2 16 2 4 4 4 2 A............................ .................... ......................... ................... 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 UNITS PER ASS'Y 83 1 2 1 2 2 2 1 5 2 10 1 1 1 1 1 1 1 1 A................................... Screw................................ Hd.......................................................... Rd........... ........................................................................................................ Mach............................ .. ......... Screw.................................. Dowel Pin (#503826) ..................................................................... Hd................................ Fil......................... Shim .......... Hd...................................................... Hex............................................... ...... Screw......................................... Shim .R...... ..................................................... Cap 3/8-16 NC x 1 .................................... Plug Button ............. Shim ......................... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 501532 503826 091-256743 091-987107 091-253864 090-093923 090-149097 090-095043 090-095035 091-988956 090-239674 091-982215 091-253872 091-991273 091-253880 091-253898 090-042557 091-253922 091-181164 090-042425 091-333104 091-333112 091-333120 091-333138 090-216128 090-051772 094-045465 091-193649 091-991349 094-033206 091-980441 091-980276 091-982918 134-134071 090-163510 091-993196 091-988659 090-051764 091-980698 091-993279 091-980466 091-992644 090-045998 093-013712 091-282319 134-015031 090-017906 090-042151 091-282152 114-065535 093-013720 090-160011 091-282160 091-980094 091-227488 091-982181 091-991224 090-062910 Sliding Table Assembly (1612-0............................... ... Tapered Handle................................................................................. ........................................... Hd............ Screw.. 2012-AT................................................................................... Roll Pin......... ........................................ ............ Screw................... Screw. Hex..................... Retainer .................... ........................ ................................TM 9-3405-215-14&P CODE NO... ................................................................................................... .................... 3613-10) Sliding Table Assembly (2012-A...................... CATALOG NO............. ............ .................................................. .............................................................................................................. C-3-79 SLIDING TABLE ASSEMBLY(AIR FEED) INDEX NO.................................... Hex................................... ........... ....................................... ..... Hex................................. ....................................................................................... .................... Cap 5/16-18 NC x 3/4 ........................... Dowel Pin (#501532) ...... 1/4-20 NC x 7/8 ............................... Lock 1/2 Std .........................R......... Screw.................. . Clamp....................................................... Hd..... Hex............... ........................................................................................................ Valve Body .......... Soc................................................................................................ Actuator Rod ....................... Pipe Plug ........................................... .................................R......................... Nut.......... Screw.................................................................................................................................... Hd.... ............................ Rd.............. Jam 1/2-20 NC (#503826) .......................................... ............. Cap 1/2-13 NC x 3/4 ............................. ...... 2012-1AT............................................................. Spring ...........................................R. Ref.. ............ Dog ................................. Washer 3/8 Std ................................................. 5/16-18 NC.............................. Release Valve Assembly (2012-A Only) ................................ Nut.................... Roll Pin .................................... #10-24 NC x 1/4 ........................... Adhesive .. Mach.............. Shim ........................................................... ........................................................... .................................................................................... Washer........................................... Roll Pin ............................................... Nut............... ...... Stop ................................................................................... ................................................................. .................................................................................................................................................................................................................................... Hd........................... DESCRIPTION Ref....................................... Grip Ring (#501532) ..... 2012-1A............................................................................................................................................................. 3612-1..... Actuator Rod ... Cap 1/2-13 NC x 2 ......................................................................... Table Cylinder Assembly (See Detail) ................ Scraper Ring ............... ...................... Shaft ........ ....... ........................................ Hex........................................................................................................................................

TM 9-3405-215-14&P C-3-80 84 .

....................................................................... 1 091-982421 .......................................... 2 114-145287 .......... 1 090-042615 ........................................... Roll Pin ..................................................................................................................... Washer.......................................................................................... Solenoid Valve 380V 60 Hz ..................... Solenoid Valve 240V 60 Hz .................................. 2 090-038183 ................................. 1 091-278218 ... 091-194019 ................................. 4 091-256859 ..... Hose Clamp (#501532) .......................................... 1 135-004661 .... 6 090-000035 ........................... 90° Street Elbow ... One 091-256735 .................................... Solenoid Valve 120V 60 Hz ........................ (#503826) ............................ 2012-AT 2012-1AT............. 1 090-127762 ............ 6 135-068880 ............................................... Seal Ring ...........................................................................D........................................... 1 091-454991 ........ Swivel Pin ... Bulkhead Adapter ............................... Cylinder Collar ............................................... Bearing ... A..................................................... Soc..... Shim ........................................... 2012-1A.... End Cap....................................................................................................................................................... Hd.................................................................................................................... 2012-2A) 094-033206 .......... 4 090-020041 ................ 091-194076 ...... 85 .......................... Reducing Coupling ............................................ 091-970962 .......... 3 093-004687 ............ Orifice ............................................................... 2 135-004653 .......................................... Hose 3/8 O.............................................. 3612........ Solenoid Valve 480V 60 Hz ............. Snap Ring ............................................................. Swivel ....... 1 091-277749 .......... 1 090-256553 ......TM 9-3405-215-14&P CODE NO................. Piston ........................................ Locknut .. Lock 1/4-Hi-Collar ......................... Cap 1/4-20NC x 1 ........................................................... 1 091-203695 .......D................. Escutcheon ......... 1 090-215948 ................................................... 2 090-051301 ........................................ 1 117-135210 ............ Cylinder Gasket ........................................ 1612.............................................. 1 091-059964 .................... 1 *NOTE: Starred Items Used Only On Assembly #501532...................................................................... 1 093-023273 ....................R................................... Hose 5/8 O. Set Self-Locking.................. 1 135-008910 ............................ 1 091-044784 ............................................................... Manifold ........ Ref................................ Soc............ Screw............................ 1 135-004638 . 1 093-034171 .................. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 * 23 * * * * * * * * * 24 25 26 27 28 29 30 31 32 CATALOG NO.......................... 1 091-128066 ............................................................................... Close Nipple ........................ Table Cylinder Assembly ................. Use 091-194043 ..................................................................................................................................... Hose Clamp (#503826) ............. 3 091-281485 ...................................... C-3-80 SLIDING TABLE ASSEMBLY (AIR FEED) INDEX NO.........R..... Cylinder . Barbed Insert . 4 090-035593 ................ Reducer Bushing .... Screw................................................... Ref....................................................... Ref...................................................... 1 114-035074 ............................................................ 091-194084 ............... Piston Rod............. "O"-Ring ...... 3613-10) 503826 Sliding Table Assembly (2012-A.................................................................................................................. A................. (#501532) ....... Close Nipple .......................................................................................... Oil Lubricator (Not Shown) ................... 1 091-458836 ..................... 2614-1 3612-1............................................. 1 090-051236 ........... 501532 UNITS PER DESCRIPTION ASS'Y Sliding Table Assembly (1612-0........... Pipe Plug ........................ 1 091-154278 ................................................ Rear Cylinder Cap ............

..................... 4 ............... 4 ................. ONE ...... Screw............... Cap 1/2-13NC x 1-1/2........................................ Ref.................................. Hex............................................................. 1 86 (87 blank) ........... Secondary Table ..... 503691 ........................................ Hex........... Support (Use on Ass'y.......................... Washer....... Washer................................. Washer......... Cover Plate Assembly (Not Shown) (Ass'y................. 50369 48046 503536 111-031068 090-208273 090-480450 091-991364 111-034047 091-995589 091-980532 091-980672 091-993048 091-991315 091-993279 090-086885 UNITS PER DESCRIPTION ASS'Y Secondary Table Assembly Secondary Table Assembly (3612-31 Secondary Table Assembly (3612-1H3) ................................ USE ............. Hex.... Secondary Tool......... Cap 3/8-16NC x 2-3/4...TM 9-3405-215-14&P C-3-38 CM-3-26 SECONDARY TABLE ASSEMBLY INDEX NO................................................................................. 148046 & 503536) ...... Secondary Table Support (Use on Ass'y................... 4 ...... Lock 3/8" Shakeproof Int ............ Wrought 1/2" Std....................... #503536) ...................... Lack 1/2" Std.. 1 .... Nut.............. Hd... 4 ......... 4 ............. Screw............. Secondary Table Support Stud ...... 1/2-13NC ............. Ref.......... Jam s 5/8-11 NC ........... Ref............ Nut.... 1 2 3 4 5 6 7 8 9 10 CATALOG NO......... Hd.............. 4 . 4 ......... 4 .

TM 9-3405-215-14&P MODEL 2012-2A 2013-20 2013-2 2012-2H 2012-2H3 3612-2 3613-20 3612-2H 3612-2H3 TRANSMISSION ASSEMBLY C-4-44 CM-4-19 88 FIRST MACH 389-77101 377-77101 396-78101 383-78101 397-78101 398-78101 399-78101 400-78101 401-78101 LAST MACH .

........ Spacer ............................................................... Ball Bearing ............ Woodruff Key......................................................... Shim ...................................................................................... 1 ........... Cap 1/4-20NC x 3/4 .... 1 . Drive Screw #2 x 3/16" . 1 ........... 1 .................... Seal Ring ....... 1 .............................................. 90° Elbow ... Cap 1/4-20NC x 3/8 ........... 1 ..................... 4 ................ Gasket ..................................... 1 ...TM 9-3405-215-14&P CODE NO........ 5/16-18NC x 1............................................................................................ Mach............ Retaining Ring.............................................................................................................................. 1 .......................................................................................................................................... 2 .................................................................................................................................................... Clutch Gear .............................................. Spacer .................. Dowel Pin ......... Retaining Ring......................................................... 2 ................................................................... C-4-44 CM-4-19 TRANSMISSION ASSEMBLY INDEX NO......................................... Nipple ....................... 1 ........................................... 1 ... ...................... 1 .......... 1 ..................... Escutcheon .. Transmission Case ................................................................. 1 . Inner Race ........................................... Woodruff Key................................................................................................... Soc................................................. 1 ....... Ref.. 1 . 1 ........................................ 2 ........................................................................................................... Pipe Nipple ................................................................................................................................................................................... Gasket .................... Pipe Plug............................................. 1 ............................................ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 CATALOG NO....... Transmission Cover................................................... 1 ...................... 1 .......................................................... Ball Bearing .............................. 1 .... 1 ................. Counter Shaft ......................... Screw. 1 ................... Hex......................................... 1 89 ....... Retaining Ring ............... 90° Street Elbow................ Output Shaft ................. Gasket ................................................................................. 1 ............. Spacer ................................................... Bearing ................... 1 ................ 1 ............ Oil Seal ...................................................................... 2 .......................... Input Shaft Assembly .............. Hd....... 8 .............................. Counter Shaft Bering Cover .................................... Gear ...................................................... Oil (ASTM 315) ........ Dowel Pin ....................... .. Retaining Ring.......... A......................................................... 1 ......... 2 ....... 1 ................................................................................................................................. Bearing .................................................................. 2 ............ 1 ........................R..................................... 1 ........................ Gasket ................................................... 1 .............. Square Hd.......... 1 ........... 1 ....................................................................................................................................................................... 1 ......................................................................................................................................... Bearing Cover Plate ........ 1 ................................... 095-068276 117-135210 091-601492 091-993964 091-001875 105-046171 090-059056 090-110693 091-384453 091-980052 091-987701 091-982389 094-086378 105-046049 091-475244 094-086410 093-073419 091-475236 091-475228 106-044217 135-004430 091-114512 091-476200 091-476218 091-114496 090-022732 135-075380 135-081891 091-001222 135-086643 093-073435 135-086882 091-056887 091-056895 105-043038 105-043095 105-046023 091-032359 105-044242 090-548710 091-027268 105-046122 105-043111 090-131228 095-068284 090-292699 091-057000 091-085571 091-476226 135-071926 091-475210 UNITS PER DESCRIPTION ASS'Y 2-Speed Transmission Assembly ..... 1 ...................................... Needle Bearing................................... Woodruff Key................................................................ Shifter Fork Assembly ......................... 1 ....................... 1 ............................................... Bearing Spacer ....................................................... Cover Plate .................. Screw............................................................................. 1 ..... Flat Hd...................... 1 ..................005 Thk................................... Shifter Clutch Sub-Assembly .............................................................................................................. Hd................................................................................................................ Pipe Cap ........................................................................ Screw................................................................................ 5 ...............................

WORK FIXTURE (USE WITH T-SLOT TABLE ONLY) FITS ALL CONTOURMATIC MACHINES 90 .TM 9-3405-215-14&P UNIVERSAL CAL.

..........A................................... Flat 3/8 S.......................................... Wear Strip ..... REF..... Pin . ............. ............................................... Hd........................ 6013-1-1H3 Universal Calibrated Work Fixture (English) 16-2........ . Ball ....... 2613-3................ 2612-H........ .............................. 2012-1AT.......................................... Can Assembly .. Screw......... 090-450842 REF............................................................. ....... .......................................... ................................. Mach........................... Scale (Used on Ass'y #090-450842) ....... Screw........ ........ 3612-1................ 2618-4......................... ............................. Truss Hd.................. Cap 3/8-16NC x 13/4 .......... ........................................ 1 2 3 4 094-048170 090-183906 090-450859 091-982363 090-450875 090-A50867 090-450891 090-450883 090-475005 090-474990 091-988337 091-982819 091-982827 091-992644 090-038555 090-183922 091-990051 090-183914 091-984179 090-288929 134-135086 090-025792 091-007021 091-011171 5 6 7 8 9 10 11 12 13 14 15 16 17 18 UNITS PER ASS'Y DESCRIPTION Universal Calibrated Work Fixture (English) 26-3............................... ............. ....................................... #5-40NC x 1/8................ Soc.......... Mach................E .... 2012-1AT....... CATALOG NO..... Screw......... ..... . Rd...... ..... Set #10-32NF x 1/4 ........... Hd............................................................... CM-10-9 UNIVERSAL CALIBRATED WORK FIXTURE INDEX NO....................... 6013-3.......................................................................... Soc.......... Hd... 1612-3..................3612-1H................................. Collar .............................................................. ........... 3613-10 Universal Calibrated Work Fixture (Metric) 2612-H ................... Screw...... ................ Washer... . Scale (Used on Ass'y #094-049079) . ... .............................................. T-Nut ........... 2012-A.............. 36-3..................................................... Soc... Hd............................ Head ................. Cap 1/4-20NC x 1/2 ...................... Cam ........................................ 3612-H......................................... Screw................. 2012-1A............ 3613-10 Universal Calibrated Work Fixture (Metric) 2012-A........... Screw................ 2012-AT... 3612-1................................................... 60-3................... Handle .............. Scale (Used on Ass'y #090-450834) . ..................... Pointer ....TM 9-3405-215-14&P CODE NO............ 91 2 1 4 1 1 USE ONE 10 USE TWO 2 2 2 4 1 2 1 1 1 1 1 ............................ 094-049079 REF..... Bar (Used an Ass'y #094-048170 & 090-450842) ........... 3612-3...... 3612-1H... Soc. #6-32NC x 1/4 Plated............ Scale (Used on Ass'y -#094-048170) ........... . 090-450834 REF.................. Cap 3/8-16NC x 11/2 ........................ 1612-H............ 2012-AT........... Bar (Used on Ass'y 0094-049079 & 090-450834) ...

TM 9-3405-215-14&P UNIVERSAL VISE ASSEMBLY 92 .

............................................................................ ... Cap 1/2-13NC x 11/4..................................... 26 27 28 29 30 31 32 33 090-403650 090-205592 091-980664 091-992669 090-025768 091-988386 090-205584 090-093675 090-03367/1 Rear Vise Assembly ............. Nut........ Head ........ Pivot Pin ............................... 090-403635 090-403650 090-204538 090-403643 090-025818 UNITS PER DESCRIPTION ASS'Y Universal Vise Assembly ............ Knob .......... Std..................... Rd...................................................... 1 . ...................................................... Body ................................................... 1 ............................................. 12 13 14 15 16 17 18 19 20 21 22 23 24 25 090-403643 090-205618 090-205634 090-033671 134-135086 090-205600 090-025842 091-984229 090-025834 090-205626 090-023227 090-025826 090-023201 091-980664 091-992669 Front Vise Assembly ................ Hd........................................................................................................ Hd...... Nut.................................... 1/2-13NC...................................................... ..................E...................................................... Washer 1/2 S......... 1 ....... Pin .. Offset Socket Wrench (Not Shown)............................. .............................. Hex....... Cap 1/2-13NC x 1-1/4........................................................................ Screw.......................E.. Hd............... 4 5 6 7 8 9 10 11 090-204538 135-005544 090-204544 090-023359 090-023342 090-023367 090-025800 090-033671 091-992669 Cutoff Gauge Assembly ........................... 1 1 1 1 1 1 1 1 REF... Screw......................................................................... Hex....... 1 REF................................. ................... Std .............................. Cut Off Gauge Assembly (See Below).................................. ....... Mach........... Nut............ ..... Std ..A......................... Screw........ .............. Soc................................................ Spring..................................... ............ ................................... ................................................. ....................................................... ...........TM 9-3405-215-14&P CODE NO........................ Cam Assembly . .................................................................................................. ....................................................... Hex............................A........... Hex..................................................... 1 1 1 1 1 1 1 1 1 1 1 2 2 3 REF........ Escutcheon .... Jaw Support ..................A.......... Gauge Bar Assembly .... ............................... .......................................... ........................................................................................................................................... Front Vise Assembly (See Below) ... .... .................. ................................. Washer 1/2 S.. .............. Thumb Nut .................................................................................. 1 2 3 1 2 1 1 1 93 ........................................................................................................ Rear Vise Assembly (See Below) ........................ 1/2-13NC... #6-32NC x 1/4...................... Spring Stud ................................................................. REF.. ........................................................................ T-Slot Bolt ........................................ T-Slot Bolt ..............E....... .............. T-Slot Bolt ...................... Jaw.......... Hd... Washer 1/2 S........................... Jaw and Body ............ Hex......... Set 1/4-20NC x 1/4 Cup Pt..................................... Adjusting Screw... ...................... Screw........... ..................... Jaw ................................................................................ CM-10-1 UNIVERSAL VISE ASSEMBLY INDEX NO....................................................................... ......... 1/2-13NC............................ Body . 1 2 3 CATALOG NO............

TM 9-3405-215-14&P MODEL 2013-20 2013-2 3812-2 3613-20 WEIGHT FEED ASSEMBLY 94 FIRST MACH 377-771011 396-78101 398-78101 399-78101 LAST MACH .

... Washer........................................ Mach.................... 6 .................... Washer.............. Lock Spring 3/8" Med ....................... Cap 5/16-18NC x 1/2 .............. Screw... Nut...................................... 1 ............................... Rivet.......... C-9-16 WEIGHT FEED ASSEMBLY INDEX NO................................................... 1 ..................... Cap 3/8-16NC x 3/4 .... 2 .... Hex........ Pin .. 2 .. ......... 6 ............. 1 ........... Catch Bracket ........................................................................... Screw................................................ Foot Pedal ... Hd....... Cap 1/4-20NC x 1 1/2.............. Hex............................................ 1 ..... Bracket ............................................................................................... Hex........................................ Hex..................................... Screw............... Release Lever Weldment Assembly ............... Release Lever Chain Assembly ......................................................... Anchor .................... ........................................................ 095-073474 095-072112 091-980441 091-993329 135-053221 105-134118 090-447962 090-042599 105-131130 090-139965 093-028520 093-028512 091-306662 091-980128 091-991158 091-993212 094-010352 091-980292 091-992628 091-993238 093-013423 091-980250 105-133169 091-990325 091-991273 091-980466 091-991265 135-050128 105-135107 105-133144 091-995472 UNITS PER DESCRIPTION ASS'Y Weight Feed Assembly (2013-2.......... Spring Lock 5/16" Med... Jam 3/8-16NC........... 1 ........................... Cap 3/8-16NC x 1 .................................. 2 ...... 2 ....................................................... Roll Pin .................. Truss Hd. 3/8-16NC x 1 1/4..................................... 1 95 .................. 2 .. Hex............................................3613-20) .......... Hd...................................................................... Hex. Washer................... 1 ............. Ref............. Carrier and Cable Assembly (See Detail) .......................................................... Chain ............................................................. 1 ..... Flat 5/16" SAE......... Screw............................ Anchor ........ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 CATALOG NO......................... 1/4-20NC ............................................................. Nut....... 1 .... Dowel Pin .......... Screw........................... Hd................... Ref................... Hd.................................... 5 .... Rd..... Hd..........................2013-20) Weight Feed Assembly(Power) (3612-2............... Release Lever ....................................................................... 1 ..... 3/8-16NC .................. 1 .... Hd...... 3/16 x 5/8 ............................... Hex............. 1 .... Cap 5/16-18NC x 1 ............................................................... Screw....................TM 9-3405-215-14&P CODE NO. 1 .................................. 1 .. 1 .................................................. Lock 1/4 .......... Hex...... 2 .................................................... Power Feed Hinge Assembly (See Detail) ........... Nut.................. Washer...................................... 4 ........ Block ..... 1 .............. 1 .......................... 1 ............ 1 .....................................

TM 9-3405-215-14&P C-9-17 96 .

.... 2 . Hd................... Weight ........................... 1 .. Chain Roller ... 1 ... 1 ........... C-9-17 WEIGHT FEED ASSEMBLY (continued) INDEX NO.... Bearing Block .......... Screw Stop Nut 1/2-13NC x 3/8 .................................. Weight Bracket ................. Hex............................... 1/2-13NC ............. 1 ................ 2 ...... 1 .......................................................................... 1 . Hex..................... Mach................................. 1 ............ Flat 3/8" SAE... Screw..................................................................... 095-073474 095-072112 091-186957 091-980276 091-987677 091-993238 091-306555 091-993048 091-995183 105-134100 091-980748 091-993279 091-991315 105-131122 105-133086 091-980425 091-475707 093-077089 091-992644 091-306563 091-306571 UNITS PER DESCRIPTION ASS'Y Weight Feed Assembly (2013-2..... Washer............... 4 ............................. Shaft .... ...................... Bracket Weldment ............................................... Nut.................... Washer....... 3613-20) .................................................. Ref............... Screw....... Washer................. 1 ... Lock Spring 5/16" Med...... Cap 3/8-16NC x 1/2 .............................. Flat Wrought 1/2" ........................... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CATALOG NO.............................................. Flat Hd............. 1 . 6 ............................................................................................... Cap 5/16-18NC x 3/4 ............................................................. Lock Spring 1/2" Med.. 5/16-18NC x 1/2... Screw...... 2013-20) Weight Feed Assembly(Power) (3612-2.... Washer............................... Release Arm....................................TM 9-3405-215-14&P CODE NO..................................................... 1 .......... 6 .................................................................................................. Hex.................. 2 ............................................................................................... Cotter Pin 1/8 x 1/2 .......... 2 . Ref................................................. 6 ................................ 1 97 ............... Screw.................................. Hd.... Bracket ............ Hex........... Cap 1/2-13NC x 3 1/2 ............. Hd............... .........

TM 9-3405-215-14&P WEIGHT FEED SUB-ASSEMBLIES 98 .

................... ..... Pulley .. Screw Assembly ....................................................... ..................... ............................................................................. Washer................................ Power Feed Chain Assembly ...................................... Washer ............... Hinge Bracket ..... ..... Pulley Screw.................................................................................................... Cable Clamp Eye ............... ............................................................. Screw............................................................................................................................................................................................................ Hd........ Cap ...................................................................................... ........................................................ Flat 1/2" SAE .............................. Washer................................................................ 1 2 3 4 5 6 7 8 9 10 UNITS PER ASS'Y DESCRIPTION 99 ......................................................................... Cable Carrier................................................................................................................................................... ........................................... Pulley ................... Handle ........................ Md..... Handwheel Assembly .. 1 2 3 4 5 6 7 8 135-063956 135-063980 134-134188 105-133094 134-054147 091-993741 091-980052 134-133016 134-135045 Horizontal Pulley Assembly ........... Cap I/4-20NC x 3/8 ................................................................. ........................................................................... Washer................... ....... Roll Pin .. Shakeproof Lock 1/4” Ext................... .......................................................................... Nut...................................................... Screw............. C-9-18 WEIGHT FEED SUB-ASSEMBLY INDEX NO....................................................................... ....................... Hex.......................................................................... 1 2 3 090-447962 105-134100 090-167966 090-213448 105-134019 105-131056 090-168717 091-980458 091-993329 090-099714 090-042.................... .. ....................................................... Ref....................... Spring Lock 3/8" Med ...... .... ... ...... Stop Nut .................. Horizontal Pulley Assembly(See Detail .......................................... ........................ ......... .......... Rd........... ........ .................... ............... 1 1 1 1 1 1 1 1 Ref........ ..................................... Pulley Spacer ................................................................. ......................... ............... ....... .................................................................................... Soc......................... 1 2 3 4 5 135-063964 091-980052 091-9937A1 134-135045 135-063998 134-133016 Vertical Pulley Assembly ............... .................. ................. Clevis ................. Cap .................................... ................... ....... Thumb Nut ...................................... Hex................................................................................................ Screw................ .. Power Feed Chain ......................................... ................................................... Feed Hinge ....................................... Collar ................................................................................................................................................... Set #10-24NC x 1/4 ............................................................................................................. .................................................................................................... Gear ..... Cap 3/8-16NC x 7/8 ........ Hex......................................................................................................................................... ............. ............. Pulley Axis .... Pulley Stud ................................ ............................... Weight Adjusting Screw 1/2 x 14" ........................................ 1 2 3 4 5 135-074979 134-133115 134-135045 090-032756 090-032749 090-032764 Equalizer Pulley Assembly ................................................................................................................ Handwheel .......................................................................... 1 1 1 1 1 Ref.............................. Washer............................... Soc... ........................................................................................................................................................... Pulley ..................................... Cable Beam ............. Vertical Pulley Assembly (See Detail)............. .. .......................................... ..........................................................TM 9-3405-215-14&P CODE NO................................................................................... ............................................................................ Pulley Spacer ................................................................................................. Shaft ...................................... Cable Clamp Housing................................... ................................................................................................................................................................ ..... .................. ................... Cap ............................... Washer ... .... Hd.......... .......... ......................................................... Weight Beam ...................................................................... Handwheel .................................................................................... Hd........ Equalizer Pulley Assembly (See Detail) ........................................................................................... Screw.... ............................................... ....... ............ ..................................................................................... ..................... ........................... CATALOG NO................................................................................ Cap 1/4-20NC x 3/8......................... Jam 3/8-16NC ............. 3/16 x 7/16 .................... .......................................... ......................... Spring Lock 3/8" Med..................................................................................... Shakeproof Lock 1/4" Ext..................................................................... Weight Grace ....... Washer..................... Roll Pin ....... .......... Screw.. 1 1 2 1 4 4 5 6 7 8 9 10 11 12 13 14 15 Ref..... Pin .............................................................. .................................................. Rivet...... Cable Clamp Hack............... ............................................................................. ........... .... .......... ........ ....................................................................... Hex............. .... ......................... . ............................................................. ...................... Set 1/4-20NC x 1/4....................... Hinge Bushing...................................................... Power Feed Cord.............. .................................................................................................................................................................................... 1 2 2 2 2 2 2 2 2 1 1 1 1 1 1 2 1 Ref............................ Retaining Ring ... 2 1 1 1 1 1 6 6 2 1 2 1 1 1 2 2 1 1 1 1 1 1 11 12 13 14 135-053221 135-074979 135-063964 134-054147 105-133094 091-992669 134-131069 091-993329 091:-991273 105-134175 135-050110 106-135015 105-134191 091-995464 135-063972 105-134183 135-063956 105-135099 Carrier & Cable Assembly ................................................................................................................................................................................................................................... ....................................................................599 091-984104 090-275256 090-16872 090-540998 134-054105 091-984229 090-275272 090-425489 090-042599 090-167958 091-181164 091-181172 Power Feed Hinge Assembly .....................................................

TM 9-3405-215-14&P C-2-28 CM-2-66 100 .

........ Set 1/4-20NC x 1/2.....................................R......... ... Hd............................. Hd......... ....................... ............... Screw........ Jam 3/4-16NF................... Nut........................ ....... Hinge Pin . Screw........................... Tilting Screw Knob ........... Upper Wheel Axis Stud ..... REF.............. Screw............ Upper Wheel Hinge Assembly (CS-36 Only) ............................. 101 1 1 1 1 A................... ............................................. Screw.......... ..................................... .......................................................... ............. Soc.. ................ ........ Hinge Bracket Spacers (Not Shown) .. Cap 3/8-16NC x 1-1/2....................................... Third Wheel Bracket ................................................. Upper Wheel Tilting Locknut .... .............. Locknut ............. .. ......................................... Hd...................................................................... ....................... Saw Wheel........................ ................ Screw...TM 9-3405-215-14&P CODE NO................................... ... Wheel Bearing ...................................... Soc.................... Cap 3/8-16NC x 2-3/4.......................... Nut.................................. Hex................... Set Screw Dog Pt............... ................................. ................................... .. .................... ...... Third Wheel Bracket ........... Wheel Assembly (36-2 Only) ... ....... ..................... Adjustable Screw ............................... ............................ Wheel Hinge .............. .......................................................... Wheel Tire (36-2 Only) ..... DoAII Tire Cement ............. ................................................................. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 -18 19 20 21 22 23 24 CATALOG NO......... .. ..... ................. Upper Wheel Hinge Assembly . ....................................... ....................................... Wheel Assembly ... ...................... Set 1/4-20NC x 1" ..................................... ........................... ....................................................................................... ... Hinge Pin ............................ ........................... Upper Wheel Tilt Screw........ Set 3/8-16NC x 3/4...... . Screw............ .................................................. Hex.............................. Washer................................ Jam 1/4-20NC ........................ *NOTE: Items With One Star Are Parts of Assembly #135-071124........................................ ......... ......... ................ ............ ................................................. ........................................................ Set 3/8-16NC x 1/2................................. 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 3 3 2 2 A.... ............ Hd............................... Hd........................................................ .......................... Hd................................................................ Wheel Tire................................... .R...... .................................................................................... Lock Washer ................................................................. Wheel Hinge ............................................................ 135-071124 090-413436 135-051258 135-051274 105-015028 135-022705 134-015031 135-022648 105-015085 *135-051894 **090-215476 105-011092 105-011084 105-015077 105-015069 *091-984492 **091-984518 105-014252 105-014245 *135-093516 **090-215468 091-991141 090-038621 *090-012394 **090-412644 *090-012782 **135-086106 091-991422 090-059569 **091-980532 *091-980482 091-993329 **091-984286 *091-984252 *111-013082 UNITS PER ASS'Y DESCRIPTION Third Wheel Assembly (CS-36 Only) Third Wheel Assembly .. ........ Soc... **NOTE: Items With Two Stars Are Parts of Assembly #090-413436............. Lock 3/8 S td.. REF......... C-2-28 CM-2-66 THIRD WHEEL ASSEMBLY INDEX NO.......................................................................... . Soc..... .........

TM 9-3405-215-14&P C-3-77 CM-3-75 102 .

. Handle .............. ................................. Chain Assembly (Not Shown) ................................................................ .... ......... ....................... ........................... ............................................... ...TM 9-3405-215-14&P CODE NO.................................................. .......................................... Hd....................................................... .. Chain Connector .......................... Hex.............................................. Cap #10-24NC x 11/2........ Soc.......................... ........................................................... DESCRIPTION UNITS PER ASS'Y Ref.......................................................................... Dowel .............................. 103 1 1 2 1 2 2 2 1 1 1 1 1 1 1 1 1 ...... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 094-033107 095-015160 091-253328 091-339705 090-130428 091-991117 091-982272 135-003291 091-253351 090-042557 091-253377 091-253385 091-052639 090-042516 091-253344 091-253336 091-253401 Contour Feed Work Holding Fixture ..... #10-24NC...... Roll Pin ................. CATALOG NO........... .............................................................................................................................................. Clamping Ring .................................... Chain............................... Clamp Screw ......... .... Belleville Washer .................... Clamp................................... ........................ Screw......................... Roll Pin .................................................... .................................................................. Jaw ................................................................................................................ Screw ........................... .. C-3-80 CONTOUR FEED WORK HOLDING FIXTURE INDEX NO..................................... Nut................................................................................................. Screw Feed Sub-Assembly.........................................

TM 9-3405-215-14&P C-10-16 CM-9-5 Z-9-9 104 .

...................................... Specify Pitch Of Chain When Ordering.... ........ .................... Left Arm ........ #10-24NC x 1/2............................................................................ Truss Hd............ Mach..................... ............................... Hd.............................. Work Holding Jaw ........ Screw...... Rd......... Soc..... Sprocket ............... Hd.. Screw............... ..... ......... Screw. Handle .... C-10-16 CM-9-5 Z-9-9 WORK HOLDING JAW INDEX NO................................. ..................... Work Holding Jaw Sub-Assembly ..................TM 9-3405-215-14&P CODE NO. 1 2 3 4 *5 6 7 105-130074 105-135123 105-133185 090-406786 105-131106 105-133136 091-988923 091-990150 Work Holding Jaw Assembly .... #10-24NC x 3/8 ......... Set #10-24NC x 1/4....................................... Soc...... ........... .................. Sprocket............................. ........................ Knurled Screw....................... REF............................. ...................... ........................ CATALOG NO. Mach... 134-031079 DESCRIPTION Work Jaw UNITS PER ASS'Y REF.................. Cap 1/4-20NC x 3/8......... 2 4 1 1 1 2 1 REF..................................... Hd. 105 .......... *1 2 3 4 5 6 7 090-402629 105-133136 091-986984 090-203860 091-982355 090-021627 091-984104 090-203852 Work Holder Assembly ........... ........................................ Mach........... ...................... Hd.................... Screw...... Right Arm .............. 1/4-20NC x 5/16 ....................................................................................... ...... 2 2 1 1 2 6 4 *NOTE: Before 2/12/44 On Hydraulic Machines Use #106-233372 Sprocket With 3/16" Pitch........... ............... Screw........ ......................... Handle Bracket .............. Fil..........................................................................................

TM 9-3405-215-14&P 43033 SUPPLY CABINET ASS'Y. CM-10-41. F9-7. Z-10-18. G6-10.0. C-10-40.0 106 ALL MACHINES . PS-10-17 TF-5-110.

TM 9-3405-215-14&P INSTRUCTION AND PARTS MANUAL Model DBW-15 BUTT WELDER 107 .

ELECTRICAL CONNECTIONS (PORTABLE ONLY) The welder must be connected to an electrical power line of sufficient capacity to provide for the instantaneous load specified on the data plate. Correct band length for the machine is stamped on a data plate attached to the rear of the machine column. The welder should be fused according to the amperage on the data plate. The welder should also be located so that the welding sparks will not ignite flammable material.TM 9-3405-215-14&P CHAPTER 1 INSTALLATION LOCATION Locate the welder so that the operator will have sufficient room for handling and welding saw bands. The welder may be installed on sawing machines. 108 . Refer to the wiring diagram supplied with the welder. Space should be allowed so that the coiled band will not injure persons passing nearby. The welder will not operate on direct current. The location is convenient for welding bands to fit over two or three band wheels of saw.

109 . the weld should pass freely through this gage. Pressing the welding lever also releases a spring which causes the jaws to force the band ends together. an electric current is induced through the butted band ends. This returns the band to an approximation of its original condition. After grinding. The electrical current is shut off before the movable jaw completes its movement. WELD GRINDER The grinding wheel is used to prepare the blade for welding and to remove flash from the weld. A greater upset force produces the same unit pressure in welding a wider or thicker band. The gage at the top of the wheel guard is used to check for complete removal of the flash. JAW GAP AND UPSET FORCE CONTROLS The initial gap between the welder jaws and the spring upset force must both be adjusted in proportion to the crosssectional area of the band being welded. When the welding switch lever is pressed.TM 9-3405-215-14&P CHAPTER 2 OPERATING FEATURES GENERAL DESCRIPTION The Model DBW#15 is a '"resistance -type" butt welder. depending upon the width of the saw blade. The annealing push button is used to "anneal" the weld by reheating it. creating enough heat to soften and join them. the steel at the point of weld "air-hardens" and becomes brittle. a pilot light is provided as a safety feature. ANNEALING When the band is heated in the butt welding process. but is no longer being heated by its electrical energy source. Flash on both sides of the weld must be ground off to blade's thickness. Since it may be difficult to see if the grinding wheel is rotating. This light is "on" when the grinding motor is running. A selector switch is provided for choosing the correct annealing heat. A jaw upset force selector is used to provide a variable control of upsetting force. A greater jaw gap will allow a wider or thicker band to reach its proper welding temperature. Final upset or "forging" occurs when the band is still hot. Initial jaw gap is set by adjusting the position of the weld lever before making the weld. The two clamping jaws of the welder hold the butted band ends together.

15 Welder controls and features. 110 .TM 9-3405-215-14&P Model DBW . front view.

TM 9-3405-215-14&P

NOTE: 1968 DESIGN
WELDERS ARE EQUIPPED
WITH SLIGHTLY DIFFERENT
JAWS AND INSERTS, AS SHOWN HERE.

111

TM 9-3405-215-14&P

CHAPTER 3
OPERATION

PREPARING THE BLADE
(1)

Cutting the Blade: Cut the saw blade to length. Use the blade shear if it is available. Using the blade shear will
insure that the blade ends are flat, square and smooth.

(2)

Tooth Spacing: In fine pitched bands, one or more teeth on each side of the cut must be removed by grinding, so
that the cross section of the weld area of the band is uniform. This will also insure proper tooth spacing at the weld
area and that the set pattern of the teeth will be retained.

Using the Blade Shear.

If snips are used to cut blade,
grind ends square as shown.

NOTE
If the Blade Shear has not been used to cut the blade, square the ends of the blade
before welding. Grind both ends of the saw blade in one operation as shown in the
sketch. Hold the ends so that the teeth point in opposite directions. Regardless of
the angle of grinding, the two ends will match perfectly when turned over.

(3)

Clean the band: Use No. 120 grit emery cloth or equivalent for this operation. Care must be taken so that the teeth
are not touched with the emery cloth, because the set or sharpness of the teeth could be damaged. The part of
each end of the band that comes into contact with the inserts must be sanded. Any dirt, oil, oxide or scale that is
not removed will prevent good electrical contact. The oxide on Dart Blade must be removed.

112

TM 9-3405-215-14&P

Points to remember in preparing the blade for welding.

PREPARING THE WELDER
(1) Clean the welder jaws.
(2) Remove and clean the lower jaw inserts.
(3) The jaw upset force selector control should be set to the correct position for the width of saw blade
being welded.
(4) Set the "initial jaw gap" by adjusting the position of the weld lever, according to the blade width.

NOTE
The jaw upset force and initial gap between the welder jaws must both be
increased in proportion to the increase in cross-sectional area of the blade being
welded. In other words, the upset force and initial jaw gap must be increased for a
thicker blade as well as a wider blade. A greater jaw gap and upset force will allow
a wider or thicker blade to reach its proper welding temperature.
Because there are so many variables involved (such as the different widths, types
and gages of blades, as well as variations between welders), it is difficult to
establish recommended jaw gap and upset force settings. The settings that
provide the best welds for each width, gage and type of blade should be
determined by experience and noted for future use.

113

this will insure a better weld. see sketch.TM 9-3405-215-14&P SAW BLADE ALIGNMENT BEFORE WELDING (1) For internal sawing. NOTE: Blades which are 1/8 inch or less in width are too narrow to be clamped correctly when they are placed against the line-up plates. Move these narrow blades back slightly from the line-up plates and align them by eye. A misaligned joint will cause an incomplete weld. (3) The jaws are clamped by moving the handles upward. When rewelding a used band cut out the old weld . then clamp them in place. (4) Check to be sure that the band ends meet in the center of the jaw gap without any offset either in thickness or across the width. If the contact across the width is not complete.it is recommended that the saw band contain only one weld. NOTE: When welding band which passes through hole in workpiece be sure to insulate band from contact with workpiece or table. the blade is inserted through the starting hole in the work. 114 . (2) Place the band ends between the jaws with the teeth against the line-up guides which are attached to the front edge of the jaws. The ends of the saw blade are then brought together to be clamped into the jaws. remove one end and recut it.

automatically recocked. (3) Preventing shorts or poor electrical contact. (3) Release the weld lever. When the lever is released. The lever should be held down until the weld has cooled. 115 . (2) Preventing flash from becoming embedded in the band. it is recommended that the weld be annealed before it is removed for grinding. the welder mechanism and electrical switches are Special note only for IMPERIAL BI-METAL Saw Band or very narrow carbon band: In order to protect the weld from accidental breakage. Inspect the weld as described on the next page. see the Trouble Shooting Chapter for possible causes. CLEAN-UP WELDER JAWS AFTER WELDING It is important that the welder jaws be kept clean at all times. (4) Remove the welded saw band. This will prevent scoring the welder jaw surface. as well as after grinding. The jaws and inserts must be wiped or scraped clean after every weld.TM 9-3405-215-14&P MAKING THE WELD STEP TO ONE SIDE TO AVOID WELDING SPARKS. Follow the annealing instructions given on a following page. Doing this will insure better welds by: (1) Holding proper alignment. If weld is poor. (1) Press (using a smooth and steady motion not too fast or slow) and hold down the weld lever to make the weld. (2) Release the stationary jaw clamping handle before releasing the weld lever.

See the Trouble Shooting Chapter if the weld is imperfect. Hold a straight edge to the back edge of the band to check for misalignment. The spacing of the teeth should be uniform and the weld should be located in the center of the gullet. Some of the characteristics of good and bad welds.TM 9-3405-215-14&P INSPECTION OF THE WELD When the band is removed from the welder it should be inspected carefully. Major jaw misalignment is easily noted at this time from the weld appearance. 116 .

117 . Grinding the weld. or burn or overheat the weld area. the band must be dressed to remove excess metal or flash from the weld. Because it may be difficult to see if the wheel is rotating. Move the lever up before running the grinder. Be sure to remove flash from the back edge of the band. Any flash or "stub" teeth which project beyond the normal set or height of the other teeth must be ground off. SPECIAL NOTE FOR EARLY MODELS OF THE DBW-15 Early models of this welder had a different wiring arrangement for the grinder motor. This light is “on” when the grinder motor is running. With the teeth facing out. Check the weld thickness by passing it through the correct gage for the thickness of the band. Handle the band carefully the weld will be brittle because it has not been annealed. These welders can be recognized easily because they were equipped with a grinder motor pushbutton and did not have a pilot light. Grind Carefully: do not hit the teeth. After welding. grind the weld as shown in the drawing. a pilot light is provided. or grind deeper than the thickness of the band. On these early models only: the grinder motor will not operate if the weld lever is in its lowest position. Grind the welded area down to the same thickness as the rest of the band.TM 9-3405-215-14&P GRINDING THE WELDED BAND WARNING Keep hands away from rotating grinding wheel.

Cool quickly by releasing the anneal button. 118 . (4) Anneal the band as explained below. (b) For Dart Blade: Heat the blade slowly until the weld becomes a deep blue color. Correct annealing of Dart Blade. it is too hot. The lever will be held in place by the bend in the drag spring. (2) Clamp the band just as in welding. (a) For Carbon Blade: Press and jog the annealing switch button until the weld is a "dull cherry" to "cherry red" color. The desired color may not be visible in normal room light. Cool the weld quickly by releasing the annealing button. NOTE: This procedure should be followed both before and after grinding IMPERIAL BI-METAL Blades. Do not overheat or the temper of the band will be damaged. CAUTION . CAUTION: Follow these instructions carefully. Continue to heat by jogging the anneal button until the width of the blue color is one-half the length of the band exposed between the jaws. Allow the blade to cool slowly by decreasing the jogging frequency. (c) For IMPERIAL BI-METAL Blade: Heat the band slowly by jogging the annealing switch button until the weld just begins to emit light (this would be the dullest red color).Do not heat beyond the "blue" stage if the band begins to show any red color.TM 9-3405-215-14&P ANNEALING THE WELDED BAND (1) Swing the weld lever up all the way to the "anneal" position which is marked by the letter "A". Always shade the weld area with your hand. (3) Set the "anneal heat" selector switch for the width of the band.

TM 9-3405-215-14&P

CHAPTER 4
MAINTENANCE

LUBRICATION
The slide rod, upset force selector cam, and all miscellaneous pivot points should be lubricated every six months. The
interval between lubrication may be shortened or lengthened, depending upon how much dust and dirt are in the area. If
the slide rod sticks, then the rod should be cleaned and greased more often. The grinder motor will not normally require
lubrication for several years. Use ASTM Grade 215 Union 76 UNAX RX 215, or equivalent oil on all lubrication points
except the slide rod.
SLIDE ROD MAINTENANCE
The slide rod should be kept clean and greased. Rust or dirt may cause rod to stick and "burn out" the weld.
Check movable jaw for freedom of movement. If it binds, apply a drop of oil to slide rod and work it in by repeatedly
pressing the lever. If this does not free the jaw movement, remove slide rod and clean and grease it. Before removing
slide rod, clamp a piece of saw band securely between welder jaws to maintain correct spacing. Use UNION 76 UNOBA
EP2 grease, or equivalent on slide rod.
The slide rod stop screw should not bind slide rod. Turn screw in, then back off 3/4 turn.
WELDER JAWS MAINTENANCE
To secure consistent results, the welder jaws must be kept clean. During the welding cycle, excess metal in the form of
incandescent particles is blown out of the weld, causing a scale or flash to build up on the welder jaws. The welder will
not weld properly unless the jaws are wiped clean after every weld.
Misalignment of the weld is usually caused by worn or dirty jaws. However, if the welder jaws are clean and not worn and
the welds are out of line, then the jaws are not aligned properly. This misalignment can be determined by inspection of
the weld after the flash has been removed. After determining which jaw is not in alignment, the jaws can be adjusted as
desired. Jaw alignment instructions are given in a separate "Engineering Adjustment Summary". Replace lower jaw
inserts that are worn excessively.
CUT-OFF SWITCH AND WELD SWITCH CONTACT POINTS
If the cut-off and weld switch contact points are welded together, pitted, corroded. or covered by oxide, they must be
replaced. If the points are only dirty, clean them with a commercial point cleaner and clean, lintless cloth (such as linen
tape).

119

TM 9-3405-215-14&P

Maintenance and adjustment locations.
120

TM 9-3405-215-14&P
JAW ALIGNMENT
The importance of accurate jaw alignment cannot be overemphasized. The jaws have been carefully aligned during
assembly at the factory; however, it may be necessary to align the jaws if they are bumped or damaged. The easiest and
most effective way to see if misalignment exists is to actually inspect the weld joint. A misaligned weld is usually caused
by worn or dirty welder jaws.
(1)

Check with a straight edge to see if the jaws are in alignment with each other with respect to elevation, inclination,
and twist.

(2)

The stationary jaw can be moved slightly on its mounting screws by loosening the screws and tapping the jaw.

(3)

The movable jaw tilt is adjusted with two set screws as shown in drawing.

Detailed alignment instructions are given in a separate "Engineering Adjustment Summary".
ADJUSTMENTS (Jaw Gap, Electrical Cut-off, Upset Force)
"Incomplete" and "burned out" welds are a result of incorrect adjustments. If the weld cycle is cut off too soon, the weld
will be incomplete (low heat produces a weak weld which may be only partly joined). Too long a weld cycle will produce
excessive heat which will result in a "burned out" weld (excess molten metal around a discontinuous joint).
For adjusting the cut-off point, a hole in the outside leaf of the cut-off switch permits insertion of an Allen wrench into the
end-knob of the slide rod (see drawing).
For all adjustments, follow the procedures given in the "Engineering Adjustment Summary".

WARNING
DISCONNECT ELECTRIC
ADJUSTMENTS.

POWER

TO

121

THE

WELDER

BEFORE

MAKING

WELD BREAKS WHEN USED (1) Weld not annealed correctly. (2) Weld has been ground too thin. 122 . (2) Blade ends not cut off square. MISALIGNED WELD-BLADE ENDS ARE OVERLAPPED (1) Jaw upset force control set for wider blade than used.TM 9-3405-215-14&P CHAPTER 5 TROUBLE SHOOTING MISALIGNED WELD (1) Dirt or scale on jaws or blade. (4) Worn jaws or inserts. (3) Blade ends not correctly aligned when clamped in jaws. adjust correctly. (5) Jaws are not aligned correctly. (2) Blade ends or jaws not aligned correctly. (3) Weak "Incomplete" weld.

123 . INCOMPLETE WELD (joint is not complete. (5) Points of cut-off switch welded together. Bring weld up to correct color as described under "Annealing" in Operation Chapter. (2) Improper clamping procedures. Incorrect annealing heat. b. Clean and oil rod see Maintenance. BRITTLE WELDS (1) Weld has not been annealed correctly.TM 9-3405-215-14&P Incomplete weld. see "Annealing" in Operation Chapter. “Blown-out” weld. (8) Jaw movement obstructed by kinked jaw cable or tangled wires. (3) Defective cut-off switch may not break the circuit at end of welding operation. Scale or oil on weld can cause poor annealing. (b) Upset force control not set correctly. Poor annealing can be caused by: a. Bend cable and untangle wires. (6) Slide rod sticking because of rust or dirt. "blow holes" in joint) (1) Incorrect Initial Set-Up: (a) Initial jaw gap (weld lever position) not set correctly. (9) Movable jaw binding on jaw bearings because of tilt adjustment screw turned in too far. (4) Cut-off switch not adjusted correctly. (7) Slide rod movement obstructed because stop screw too tight on rod.

The copper point should be kept sharp to secure best results. Using the Etching Pencil. 124 . templates. Move weld lever up to "anneal" position. Since the machine is "grounded" there is no second lead required to the work. To use the etching pencil: (1) Clamp cable end of etching pencil in welder stationary jaw. fixtures.TM 9-3405-215-14&P CHAPTER 6 ACCESSORIES ETCHING PENCIL The Etching Pencil is used with the butt welder to mark tools. (4) Etch with sufficient pressure to prevent the point from arcing. (2) Press the anneal and etching pushbutton and clamp the button down with the etching pencil clamp. etc. jigs. (3) Place the work to be marked on the table of the machine. This closes the circuit through the welder and also grounds the etching current through the machine. but not great enough to destroy the copper point.

The Blade Shear Assembly. 125 . Then remove the retaining screws on the bottom blades. Disassemble by removing the snap rings from the pivot pin and eccentric disk.TM 9-3405-215-14&P BLADE SHEAR The cutter blades can be easily replaced.

TM 9-3405-215-14&P REPLACEMENT PARTS CATALOG FOR BUTT WELDER You can avoid unnecessary delay and inconvenience by specifying correct model and serial numbers on all parts orders. 126 .

TM 9-3405-215-14&P 127 .

........... DESCRIPTION 401436 199019 199356 131807 59788 116552 199396 132814 132815 6-06342 50528 1927 10132821 16180 408838 198895 199321 199115 7506 198897 199321 133848 133861 104770 133160 199396 UNITS PER ASS'Y...... Washer.......................... Drive #2 x 3/16 Type "U" ................ ........................................ Ref.. ........................... H1-13.... 1/4-20NC x 1/2 (#132815 Only)................. ...................... Screw................................................. Ground Tag .................................... ........). ..... Wire..... ........................................... ........ Rd.. Following Items Not Shown: STK #714 STK #724 Wire........................ Nut................ Washer..................... A........... Hd................ 240 Vac...........R..................................................................... Buttwelder Box ................... Drive #2 x 3/16 Type "U" ....................................................... Lock 1/4 Std......................................... .. Screw............ .......... ................................................................. Hd.TM 9-3405-215-14&P CODE NO.... Rd.......... DBW# 15 Portable Assembly ... .......... #12 AWG Black .................... Hd... Safety Switch 3-Pole ............ Spacer (Sq.............................................................................. . Screw............. #10 AWG Green................... Mach................ Blade Shear Assembly (See Detail). (#132815 Only)... Transformer (#132815 Only)..................................... Mach....... ..... ... 1/4-20NC x 3/8........................................... Lock 1/4 Std.... Hd..................................) .................. Rd......... .......................................... ........ .................................... ......... Buttwelder Box .................................. Truss Hd..................................... 4 4 1 1 1 4 USE ONE USE ONE 4 USE ONE 1 4 4 4 1 4 4 2 2 1 1 4 .... Buttwelder Assembly (See Detail).......... 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 PART NO........ Washer........................................ Escutcheon ("Warning ---“) ... Grommet . Lock 1/4 Shakeproof Int .......................... ........... 1/4-20NC x 3/4................................. ........ Fuse 10A-250 V........................................................ A....... Rd............................................................0 DBW #15 BUTTWELDER ASSEMBLY INDEX NO............ Data Plate .. 128 ..................................... D Switch Only) (#132815 Only) ................ Buttwelder Box Assembly (Std......R............. Screw................ Hex 1/4-20NC (#132815 Only)............................... ........................................................... ... Screw.. Buttwelder Box Assembly (Above 240 Vac................................................................................................................... ..... Safety Switch 3-Pole .......... ................ Fuse 5A-600 V........... Mach.............. ................

TM 9-3405-215-14&P 129 .

........................................................... Handle .............................................................................................................................. Hd.. 1 59788 136185 136186 198840 114591 119906 121067 121066 198346 199023 34-06518 107171 108450 114568 119861 199397 199015 119880 198866 120268 119883 119564 119879 4231 119862 38660 35-778 34-06503 35-2010 199538 303886 59767 2761 3172 2748 35-9614 119863 401871 121477 401872 Following Items Not Shown: 133826 103848 133827 Stk #731 111123 2 3 4 ** 5 ** 6 ** 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ** 21 22 23 24 25 26 27 28 29 30 31 32 ** 33 34 * 35 UNITS PER ASS'Y...................................................................... On-Off Plate (International) .......................... order Item no's 5.............. .. Escutcheon (International) ............................................................................... Lock ............... * 43 ........... Hd........................... ...................... ......................................... 33...... DBW #15 Buttwelder Assembly ... Mach.... ........... ..................... Hd..................................... 39..................................................................................................... Hex....................D...................... x 1/2................................. Circuit Breaker 1.............................. Wire Connector ....... Screw............................. Glo-Lite 240-V ......................................... Stationary Welder Jaw................................................................................. ................. ..................................................................................................................................... DESCRIPTION Ref.......................................... Truss Hd.......................................................................................................... Pushbutton Clamp................ Escutcheon (English) . Mach.............................. Panel ..................................... Rd.. Washer.. Jaw Insert ...... ............ NOTE: The Following Items Are For Machines After Serial #290-68182 and Before Serial #290-745446.................... 1 107171 ....................... ...R.................................................................................................... Anneal Switch.................................................................................................................. ......................... ................. Screw.......................... Rd................... Stranded #14 Black ................................. NOTE: For Canadian Welders....................... Shim.. Insulator................................. 21.......... Soc.............................................................................................................. ......... ......... Escutcheon (English) ... ................................................................................................................................................................... Insulator Bushing.......................... Wire........................ .......... .............. Drive Pk #2 x 1/4 Type “U” ............ .....................................................................................................................H...................................................................... Screw......................................................................................... ..................... 2 114591 ...... #10-24NC x 3/8........................... A.............. ................................... H1-13..................... Switch S.................................... 37................ Screw...............................TM 9-3405-215-14&P CODE NO. 38...... Screw.... ONE 111123 .......................... Escutcheon ..................... Cap #8-32NC x 3/8 (Button)................................................ Mach..................................................................... Knob.......... 1 121410 ........................... 3 10 1 A.......... ........................................................................... Hd.......................... Lock ........................................................................... Handle Assembly ..........................................................................................1 DBW #15 Buttwelder Assembly INDEX NO........................................................................................................................................................................................................... .............................. Escutcheon .............................. Hd.............. 6.................... 1/8 Dia..................... USE 131203 ........... .... 1 113262 ........................................................... USE ONE 2 1 2 2 2 8 2 1 1 1 1 1 5 3 1 2 3 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 2 1 1 1 1 .................................................... and 35 Inclusive................ 43 and Replace With 100888 ...................... Insulator.............. Pin ............................... Cap ... Rd............................................................... 4 Wire Connector ......... Grinder Wheel Guard Assembly (See Detail) .................. Shaft................. Escutcheon (International) ............. Washer................. Screw........... PART NO......................................................... Line Up Guide .... Mach.... ...................... 2 **NOTE: When Replacing any one part of the Double Starred Items for Machines Before Serial # 290-69396............ .............................................. ................................................................................................................. ..................................... #10-24NC x 5/16....................................................................................................... Hex................... Rd......................... On-Off Plate (English) ....................................................... Movable Welder Jaw ....................................................... ........................................................ Insert Bearing ......P..................... ............................................................ Escutcheon .............................................. ........... Hd...........................................R....................................................................................... 2 121411 ................................................ Screw......................................................... ............................................................ ................................................... Rivet................................................. Roll Pin ...............................................5A E-T-A ............................................ Connector . 7...................... . Cam Sub-Assembly ........................................................................................................................................... L............................ ...................................................................... Toggle Switch ............................................................................................................... ....................................................................................................................................................... 1/4-20NC x 3/4................................. Wire Terminal.............................. Nut................ ............................................................................................... * 36 10776 131202 * 37 * 38 * 39 40 41 42 110953 . Wire Terminal... ............................. Hd.................. Truss................... Wire Terminal....... #16-32NC x 3/8 ............................................. .. Drag Spring ....................................................... ................. Glo-Lite 250-V ............................................................. . 130 USE ONE ............................................T................................................................... Plug Button.................... 15/32-32 NC ..... ................................. ....... ....................... Wire Terminal........... Omit Items 36............ .................

TM 9-3405-215-14&P 131 .

............................................. .................................... Screw........ Screw....................... .................... .. Set 1/4-20NC x 1/4................................. Rear Adapter ........................................................... ............. Cam Sub-Assembly............ ......... 132 1 1 2 1 1 1 8 12 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 ..................... PART NO. 1 PH........... Nut................. ......... ......................................................... Nut............... Lock 1/4 Shakeproof Int ....... Grommet ....... .............. . Mach..................................................................................................................... Lock 5/16 Std................................................................................. Switch Bracket..................... Roll Pin ......................................... Soc..............................TM 9-3405-215-14&P CODE NO......... ...... Hex...................................................... Hex.... ............... Pin............ L.......... Bearing ......... Hardened Washer........................ ..................... 3/32 Across Flats .............. 1/4-20NC.... Cam Lever Sub-Assembly ................................... DBW #15 Buttwelder Assembly .................... Washer .............. Washer.. Knob ............... Screw............................................. ......................... R.............................................................. H1-13............ Truss Hd..................................... Hd................ Stop............................................ ................................................................. Screw....P.................... ............... ................................ .... Screw. Cam Lever & Pin Assembly .. .... .......................................... Hex...H............ Set 1/4-20NC x 5/16........................... 1/4-20NC x 3/4....... Transformer Assembly 240-V ..... ................................................................................................ Hex.................. ........ Buttwelder-Tag ................................ Cap 5/16-18NC x 3/4 .............. ........ ................................................................................. Cap 5/16-18NC x 1/2 ........................................H........................................................... Bearing Stud. .................................................................................................... .......... *NOTE: Before Serial #290-745446......................... ............................ DESCRIPTION Ref...................... 1/4-20NC............................... Hd....... Hex.......... Motor 1/6 H.... .. Key... ..H....................................... Cam Lever & Pin Assembly .............................................................................................. R....... Soc....................................................................................... ..... Jaw Bearing......................... 1 2 3 4 5 6 7 8 9 10 11 12 * 13 14 15 16 17 18 59788 35-9545 198039 12736 6-06502 199563 405422 198025 199323 35-9617 7677 12442 135510 303815 198422 199115 1006 6-06417 119859 120738 199023 133971 199356 199115 119858 4229 119857 103947 198423 121478 105116 19 20 21 22 23 24 25 26 27 28 29 UNITS PER ASS'Y.................. ................................. Item 13 #303815 was 35-614................................................... Conduit Anchor.........2 DBW #15 BUTTWELDER ASSEMBLY INDEX NO............................. Washer..

TM 9-3405-215-14&P 133 .

.......................... ................ ......... .................................................... Screw...................................... L............................ Cam........ ............ ....................................... Spring.............................................. .................................................................................................. ... ............ Slide Rod Assembly (See Detail) ......................................................................... Screw........ Set 1/4-20NC x 5/8 Dog Pt.............................................................................................................. ... Hex.................................. Bracket Assembly.................................. Screw................................................................... .................................. ........ DBW #15 Buttwelder Assembly ....................... Nut............... ..................... ............................. Set 5/16-24NF x 1-1/4 .. Hd....................................... . Truss Hd................................................................ Soc........ .... R... ....................... ........................... 134 1 4 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 ....................... ........ Soc........................ ........... Nut....................................... Screw.................. Lever............ Washer................... Soc.................... ......... ... 5/16-18NC x 5/8 ........................... #8-32NC x 1-1/2................... .................... ..... Hex...................... Rd......... Set #10-24NC x 1/4.......................... Hd............... Jam 5/16-24NF . Mach............................ Screw... .................. ...................... ..................... Rd.................. Mach............................... Buttwelder Frame................ .......... ..................... Screw.................... Nut........................................... Hex....... Jam 1/4-20NC ............ DESCRIPTION 59788 28091 199033 198446 103147 198591 199114 35-9549 198447 199125 35-9557 119884 4227 35-5078 198861 199318 104030 35-9592 35-9548 6-06324 198410 1005 35-9550 198887 20017 6-06313 6-06339 198026 199122 135944 28090 UNITS PER ASS'Y. 5/16-18NC x 5/8. Screw............. Cutoff Switch Assembly.... Hd............... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PART NO..................... Welder Switch Sub-Assembly ............. Spring Stud .. Shaft ............................ Soc.......................... Bracket Assembly ......TM 9-3405-215-14&P CODE NO...........H............................................. Screw...............................H.... Spring.................................... 5/16-18NC... H1-13....................................... Mach....... Lock #8 Std...........................................3 DBW #15 BUTTWELDER ASSEMBLY INDEX NO..... #10-32NF x 1 ................................................................................................................................................................ Roll Pin .................................................................................................. Spring Stud .............................. Circuit Breaker..... ... Mach................... Ref.. Hex.................................. Pivot .................. Lever Weldment............................................................................... Insulator ... Set 5/16-24NF x 3/4....................

1 FIG. 2 FIG.TM 9-3405-215-14&P FIG. 3 135 .

.......... ...... .015).... Abrasive Wheel....... Screw......... 1 2 3 4 5 6 7 59788 103147 6-06418 199113 6-06336 6-06337 6-06338 198420 16541 Buttwelder Assembly ............................... ...................................... DESCRIPTION UNITS PER ASS'Y...... Mach......... Collar......................................................................................... Spring...... ........ 1/4-20NC x 1/4.. Soc............................. ............ Nut........................................................................................... ........ 1 2 1 *NOTE: Before Ser........ .............. Rd.............................................................................. Front Adaptor ............... Guard Sub-Assembly FIG ......................... Block ........ ...................1.................................................................................................................. ............ 59788 ASS'Y.... Hd...................................................... 15 BUTTWELDER DETAIL REF.............................. .............................................. Spacer (....................0359)...... ........ H1-13....................... ..... Screw...... . Set 10-32NF x 1-1/4............ Screw.... Spacer (...... Escutcheon ................................................ ................ Slide Rod Assembly FIG .................. Hex....... ........... Block ......................... INDEX NO............... Ref.. Slide Rod ................... ................ 1 2 3 4 5 6 7 8 9 10 11 12 * 13 14 303886 198888 133798 133799 13-06304 13-06307 405735 6-06306 13-06306 199113 199319 113447 13-06501 303816 198890 ...................................... Soc................................................ Pedestal Top Weldment............... 136 ...................... #10-32 NF x 1 ...................... Spacer (.......................... . Screw........................ #10-32NF (Plated)......................... Rd.................... PART NO........................ Front Adaptor #303816 was replaced with #34-12402 washer and #6-06429 screw................................................. ....................040).................. Spacer (....................... Pedestal Base ................... 1 2 1 1 1 1 1 2 3 2 1 1 1 1 2 Ref.................................................................................... 1 1 1 1 1 1 1 1 Ref................................................................................................................. Mach...................TM 9-3405-215-14&P CODE NO....................... .....................................................................................................................................4 DBW No..................................... ................ Lock #10 Std....................................... Ref....................................3 ......................... Hd..... Key . .............. ...................... Knob ............................................................ ........................................................ Grinder Wheel Guard....... Set 1/4-20NC x 3/8........012).... 1 2 3 402520 39653 198424 503117 Buttwelder Pedestal FIG .... Nut........ 10-32NF Std.......... #290-745446........... Washer......... .....2.................

0 137 .TM 9-3405-215-14&P H1-19.

............................................... ............................ Hex........................ Side Plate R......... Blade ...................... 1/4-20NC............................................. Screw...................... Knife .... Hd................................................................... .... H.............................................. Lock 1/4 S................ Ref....................... Hex.......................................... Cap 1/4-20NC x 1-1/2 ............................. .............. Spacer ...................... ............................................. ...... Hex................................ Retaining Ring................ Retaining Ring. . ........... Rd............................. Std........ Hd............ Blade Shear Assembly . #10-24NC x 1/4.....H.......................................... Cap 1/4-20NC x 1-1/4 ... ........................................................H.... Mach............ Hd........................... ............... ............... ................... Square L................ Spacer .............................................................. Pin....................... ....................... .. Screw......................... ... Nut........... Washer...................... ......................................................................... Screw............................................................... Ball ......................... Square R............... Eccentric...........................H........ ...... Side Plate L................................................................ ............................0 BLADE SHEAR ASSEMBLY INDEX NO........TM 9-3405-215-14&P CODE NO.. Handle ............... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO..................................................................................................................................................................... ..........A................ DESCRIPTION 35-8440 35-8438 34-13508 35-8447 35-8448 35-7558 35-8441 35-8437 35-8582 35-8451 100015 198865 198011 35-8445 198012 100016 35-8585 199115 199321 35-8446 UNITS PER ASS'Y................ ....................... ............................... ......................... H1-19............E......................................................... 138 1 1 1 1 2 1 1 2 1 2 4 2 1 1 3 1 3 3 1 .........

0 ETCHING PENCIL ASSEMBLY 139 .TM 9-3405-215-14&P H1-20.

.................................................... ................................................................ ........................................................................................... Stem........................ Terminal Lug ................................................. Insulator ..... Plug ............................... ................. Fin .................................................................. ...................................... ........................................ Fin .......................... 140 1 1 2 A............. Connector ............................ Ferrule ......................... Fin ... Etching Pencil Assembly ......... H1-20...................................... Etching Pencil Assembly ......................................... Cable.......................................................................... Terminal Strip ...................................................................................................................... Nut............ Cable........ Brass #8 Std............... ......................... Fin ............. ... ............................................................. PART NO.................................... ...........R...................... ................... ................................................. ...... DESCRIPTION * Ref 1 2......... .....................................................................TM 9-3405-215-14&P CODE NO....................... Hex......... ....................... *NOTE: For welders shipped before 6-23-44 with ground bushing in panel.................. Screw.................. #8-32NC x 5/16 ........................................... ..................... ................................................................................................. Short End Assembly. Mach #8-32NC x 5/16 .................................................. ........................................................... Rd............................................................ ... **NOTE: For welders shipped after 6-23-44.......... .............................................................. Washer.................................................... Stem Assembly ............... ................... Hex #8-32NC...........................................................0 ETCHING PENCIL ASSEMBLY INDEX NO.......................................................................................................................................................................................................... Washer ...................... Washer............... 1 12 2 1 1 1 1 1 1 ..... ............. ........ ............................ .......................R................................ Solder Lug......................................... Terminal Strip ............................................... Rd............ ................................ Pin.................................. ................. ................. Point .................... .................. Tube ................ File Rivet .................. #8-32NC............ Hd........................ . ...................................... Nut............ ........... Tube ................................................. 3 4 5 6 7 8 9 10 11 ** 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 13-07003 35-5109 6-07420 2154 19546 19545 198852 199109 199292 13-07302 13-07303 34-18407 13-07004 2154 19545 198852 199109 199292 13-07304 6-07424 6-07310 6-07309 135994 6-07423 6-07307 6-07311 35-5077 6-07425 6-07421 6-07201 6-07503 6-07308 UNITS PER ASS'Y.......................................................................... Brass #8-Std............................................................... 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 A................................................... Ferrule ........................ Hd....... ....... Mach................ Screw.....

TM 9-3405-215-14&P ELECTRICAL SCHEMATICS FOR ALL DBW 15 BUTTWELDERS 141 FIRST USED APRIL 1974 LAST USED FEB. 1977 .

1977 .TM 9-3405-215-14&P ELECTRICAL SCHEMATICS FOR ALL DBW 15 BUTTWELDERS 142 FIRST USED FEB.

the weld lever return spring. The blade alignment guides shall insure that the tooth edge of the band be straight within . "Inclination" and "Twist". In order to make the initial adjustment with the straight edge. They are all dependent on one another. 10 OF 11 WELD LEVER PAR. They are "Elevation'. 025" up to 1" x . Prepared by: Roger Harris Approved: Date: 7-31-69 2 120789-2 REVISED & REDRAWN FOR CLARIFICATION SMUTKA 8-1-69 2 REVISIONS MAX. the insert bearings. The welder jaws shall be aligned to result in a finish weld which is within 4% of the band gage. 8 OF 11 SMUTKA 2-24-70 143 . WAS ON SHT. WAS ON SHT. It is advisable to remove the transformer straps from the jaws.085" Imperial band will meet the above specifications.004" per 4". The final adjustment is made so that the weld produced in a 1" x . the jaw upset spring. except where specifically instructed otherwise. JAW GAP PAR. WARNING: All adjustments must be made with the power-off. WELDER JAW ALIGNMENT: There are three basic adjustments for the alignment of the welder jaws.035” Carbon. The initial line up of the welder jaws is accomplished with a straight edge. measured 2" on either side of the weld. Any adjustment of one may require a re-adjustment of one or both of the others. Dart and Imperial band. it is necessary to remove the lower jaw inserts.TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 1 OF 1434 11 NUMBER 120789-2 This welder is a "resistance type" buttwelder capable of welding 1/16” x. and space the jaws approximately 1/8" apart. and the blade alignment guides.

The fixed jaw must be moved to correct this problem. 1 1. Fig. 1 is an example of jaw elevation misalignment.TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 2 OF 1434 11 NUMBER 120789-2 FIG. Loosen the mounting screws and move the jaw as required. It is checked with a straight edge. The mounting screws are located inside the welder case and behind the fixed jaw Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 144 .

Loosen the mounting screws and move the jaw as required. 2 2.TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 3 OF 1434 11 NUMBER 120789-2 FIG. Fig 2 is an example of inclination misalignment as checked with a straight edge. The mounting screws are located inside the welder case . Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 REVISIONS 145 . The fixed jaw must be moved to correct this problem.behind the fixed jaw.

Fig. Care must be taken to prevent any binding on the slide rod. It is adjusted to maintain 1/4 turn clearance between the end of the stop screw and the milled flat on the slide rod. 3 3.continued FIG.TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 4 OF 1434 11 NUMBER 120789-2 Welder Jaw Alignment . Two adjustment screws are provided. Fig. 4. Verify the proper setting of the slide rod stop screw (Item 2. Both of them must be used when making a correction. Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 146 .. The movable jaw must move freely with both tilt adjustments bearing on the jaw. The movable jaw must be adjusted to correct this problem. 3 is an example of twist misalignment. 4).

Slide rod stop screw 3.TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 5 OF 1434 11 NUMBER 120789-2 FIG. Upset force adjustment screw 7. Weld lever return spring 6. Jaw gap adjustment screw 4. 4 1. Jaw upset spring 8. Movable jaw lock screw 2. Cut-off adjustment screw 5. Cut-off switch Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 REVISIONS 147 .

4) as required to just break the circuit with . Turn the adjustment screw (Item 4. Adjust the electrical cut-off in the following manner. Fig.con't.) Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 148 .140" gap. 2. (CW reduces the gap. FINAL JAW GAP The final jaw gap shall be . Connect a continuity meter to the wires on the cut-off switch. Fig. 4) and lock the jam nut on it. The jaws must hold the gage in place. with the power :'OFF": 1.075" gage between the jaws. 5. It is set in the following manner: 1. Place a . JAW GAP AT ELECTRICAL CUT-OFF The jaw gap at the electrical cut-off shall be . Push the slide rod toward the fixed jaw until the shoulder of its milled flat contacts the slide rod stop screw (Item 2. Place a . Fig. Fig. The jaws must hold the gage in place.TM 9-3405-215-14&P NAME ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 PROJECT SHEET 6 OF NUMBER 1434 11 120789-2 Welder Jaw Alignment -. The final jaw alignment cannot be finished until all of the steps in this Adjustment Summary have been completed.140" gage between the jaws. Loosen the lockscrew (Item 1. 4).140". 4. 5. 3.075" with the weld lever fully depressed. Tighten the lockscrew (Item 1. 3. Only then can a weld be made that is suitable for alignment purposes. CCW increases the gap. Re-check the final jaw gap dimension. 4) that holds the movable jaw to the slide rod. 2.

manually pull the jaw to its maximum open position. Disconnect the jaw upset spring. 5. Fig. Replace the jaw upset spring and re-check as in steps 5 and 6.) 2. If the spring scale reading at this point does not fall in the required range (10 to 12 lbs. To re-set the screw. 4) and turn the screw. disconnect the jaw upset spring (Item 7. Replace the weld lever return spring. as required. Fig. 4. The final adjustment is made in the following manner: 1. Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 149 . Bend the transformer lead that attaches to the movable jaw so that when it is connected it will just urge the jaw to its final jaw gap position. 4. 10. Reconnect the jaw upset spring. 4.) the upset force adjustment screw must be reset. Gradually release the pull on the scale. 3. 4) is with the back end of the screw flush with the cast jaw surface. (Item 6. Disconnect the weld lever return spring (Item 5. 6. 7. Attach a spring scale to the movable jaw and with it.) 8. (approximately 15/32"). when measured at the movable jaw with the upset force selector set for the narrowest width band. Fig. Fig. 9. The approximate locations of the upset force adjustment screw (Item 6. Note the reading when the jaw just starts to move.TM 9-3405-215-14&P NAME ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 PROJECT SHEET 7 OF 1434 11 NUMBER 120789-2 WELD UPSET FORCE: The upset force shall be from 10 to 12 lbs.

turn the jaw gap adjustment screw (item 3. (item 2. 5) usually is used to establish detent. and the bottom shim (item 4. Lock the adjustment in place. the top shim (item 3. Shims under either top or bottom screws will affect function. however. This allows the operator to clamp a blade in the welder or adjust the upset force selector without disturbing jaw gap setting. the force exerted by the spring against the weld lever provides the frictional drag to hold the lever at any of the several required initial jaw gap settings for welding. Fig. Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 150 . Fig. Shim as required to obtain both objectives. (as located by the detent of the drag spring) and the upset force selector in its widest position. 5). MAXIMUM JAW GAP With the weld lever in the anneal position. 4) to obtain 15/32" jaw gap. (Both are secured by two screws. 5) to establish frictional drag. 5) serves two functions: First.) It is adjusted by shimming between the escutcheon and the spring. Fig. the upper corner acts as a detent to locate the movable jaw for annealing band. Fig. and second. The spring is mounted on the band width escutcheon.TM 9-3405-215-14&P NAME ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 PROJECT SHEET 8 OF 1434 11 NUMBER 120789-2 WELD LEVER DRAG SPRING The weld lever drag spring (item 1. Fig.

Weld lever Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 151 . 5 1. Escutcheon 3. Drag spring 2. Bottom shim 5. Top shim 4.TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 9 OF 1434 11 NUMBER 120789-2 FIG.

035 ga. check their mounting surfaces on the welder jaws. shims and escutcheon. A file may be used to bring the surfaces in line. Move the escutcheon (note elongated holes Fig.025" (Fig. Adjust the "Band Guides" so they touch the side of the 1" x .note Fig.004".035 band and lock in place. 4.025" shim on top of the band. Loosen the screws holding the "Band Guides" to the jaws. 6. so the jaws just touch the gage. The weld lever drag spring must be properly shimmed as described above. 6). band into the welder jaws. but within the jaw clamping area. Insert a section of 1" x . The guides are aligned to protrude below the band clamping surface of the welder jaws by . BLADE ALIGNMENT GUIDES The blade alignment guides are used to maintain tooth edge alignment of the ends of the band being welded. Place a . 2. 5) so the weld lever pointer indicates the narrowest position (the bottom line on the escutcheon that also corresponds with 1/16" band . Loosen but do not remove the two screws that secure the spring. Before installing the band guides. 4.150" gage between the jaws and bring the weld lever down. 5) and then tighten the two screws. 2. 5. These surfaces must be in line within . 3. Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 152 .TM 9-3405-215-14&P NAME ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 PROJECT SHEET 10 OF 1434 11 NUMBER 120789-2 WELD LEVER must be calibrated in the following manner: 1. 3. Adjust in the following manner: 1. Clamp the jaws. The band must be out of the jaws (teeth extend in front of alignment guides by at least 3/16") as shown in Fig. Place a . when checked with a straight edge.

Prepared by: Roger Harris Approved: Date: 7-31-69 120789-2 NUMBER REVISIONS 153 (154 blank) .004" in 4" measured 2" on either side of the weld. Imperial band in order to check the final alignment. Set the jaw upset force knob to its maximum wide position. The finished weld must be within 4% of the band gage. To make this weld: 1. 2. It must be set to the line indicating the widest width. 6 FINAL JAW ALIGNMENT A weld must be made in 1" x .TM 9-3405-215-14&P NAME PROJECT ENGINEERING ADJUSTMENT SUMMARY MODEL DBW-15 SHEET 11 OF 1434 11 NUMBER 120789-2 FIG. Set the initial jaw gap by adjusting the position of the weld lever. The tooth edge of the band must be straight within .035 ga. 3. Make the final jaw alignment adjustment as required to result in the tolerances listed.

United States Army The Adjutant General Distribution: To be distributed in accordance with Special List. S. MEYER General. GOVERNMENT PRINTING OFFICE: 1989-242-451/06119 . United States Army Chief of Staff Official: ROBERT M. C.TM 9-3405-215-14&P By Order of the Secretary of the Army: E. JOYCE Brigadier General. KU.

TM 9-3405-215-14&P .

TM 9-3405-215-14&P .

TM 9-3405-215-14&P .

TM 9-3405-215-14&P .

METAL CUTTING .TM 9-3405-215-14&P TM 9-3405-215-14&P SAW. BAND.1981 PIN: 049455-000 .