PowerKits™ (DB-100)
Wet/Dry Band Saw
User Guide
Thank you for buying this Inland product. Please take time to read all the instructions to understand the correct components, set up, and use of the model you purchased.
Safety
- It is extremely important to wear proper eye protection when using any saw. We highly recommend that you wear safety goggles rather than safety glasses.
- DO NOT wear loose clothing or any accessories (long necklaces, bracelets, shirts with long fringes, and similar) that might get caught by the saw during operation.
- Use only in a properly grounded and tested outlet. Under NO circumstances should you override the grounding system or modify the plug.
- Set up your machine on a sturdy, level work surface that is water tolerant and a comfortable height to work on.
Parts
The following are model specific parts for all three saws. Depending on your model, parts and the degree of assembly
will vary. Check to make sure that you have all the parts listed for your particular machine before beginning assembly.
| No. | Part Name |
No Pcs. |
Color | 91010 | 91040 | 90555 |
| 65809110 | Saw Frame | 1 | gray | yes | yes | yes |
| 10520 | Motor Unit | 1 | gray | yes | yes | (separate) |
| 65809113 | Leg Supports | 2 | gray | (installed) | (installed) | (installed) |
| 73821256 | Rubber Feet | 4 | black | (installed) | (installed) | (installed) |
| 65829122 | #10 x 1/2" Self Tapping Screws | 8 | silver | (installed) | (installed) | (installed) |
| 65909157 | Metal Work Table | 1 | gray | yes | yes | yes |
| 65809112 | Table Supports | 2 | gray | (installed) | (installed) | (installed) |
| 65829172 | 10-24 x 1/2" Phillips Screws | 4 | silver | yes | yes | yes |
| 90022 | BladeSerts™ | 2 | yellow | yes | yes | yes |
| 65809114 | Coolant Reservoir | 1 | gray | yes | yes | yes |
| 65809124 | Coolant Reservoir Cover | 1 | gray | yes | yes | yes |
| 65829184 | Sm. Diameter Plastic Coolant Hose | 1 | clear | yes | yes | yes |
| 65829114 | Coolant Flow Adjustment Screw | 1 | white | yes | yes | yes |
| 65829113 | 10-24 x 3/8" Brass Thumb Screws | 4 | gold | yes | yes | yes |
| 90016 | Blade Drip Guide | 1 | gray | yes | yes | yes |
| 78824055 | 5/64" Long Arm Allen Wrench | 1 | black | yes | yes | yes |
| 90014 | Leather Wiper | 1 | brown | yes | yes | yes |
| 65829186 | Lg. Diameter Plastic Drain Hose | 1 | clear | yes | yes | yes |
| 90007 | DiamondCut™ Blade | 1 | silver | yes | no | (separate) |
| 90001 | WoodCut™ Blade | 1 | silver | no | yes | (separate) |
Assembly Instructions
Exploded View
Depending on the model you purchased, your saw may be partially assembled .
Assembly will take from 5 to 30 minutes and requires a Phillips screwdriver. If
a part is already installed on your machine, skip to the next section. Use the
exploded drawing on the following page to reference parts during the assembly
process.
(page 1)
(page 2)
Installing the Power Unit and Lower Drive Wheel
Inserting
the PowerUnit™
The PowerKits™
PowerUnit™ comes in different voltages for different
countries. Before installation, make sure that the
PowerUnit™ you are installing is
appropriate for your electrical service. Make sure that the
PowerUnit™is NOT plugged into service at this time. The
PowerUnit™ installs from the back of the saw frame.
Starting with the toggle switch (curved side of
PowerUnit™) in the 2:00 o'clock
position, insert the motor shaft and four mounting clips into the appropriate locations on
the saw frame. Note that the openings for the clips are keyed, that is they are larger
on the left than they are on the right. The clips must align with the larger openings
on the left. Once inserted, the
PowerUnit™ turns about 20° clockwise to lock in
place. The toggle switch is now pointing to the 3:00 o'clock position.
Mounting the Lower Drive Wheel
This operation is best performed with the door removed. It simply lifts off
the (2) hinge posts. The lower drive wheel mounts onto the motor shaft by way of
a brass arbor. Locate the set screw on the brass arbor to make certain that it
is backed out clear of the inside opening. Line up the flat side of the motor
shaft and the set screw with the brass arbor so that both are in the 9:00 o’clock
position on the inside of the saw frame. Carefully press the brass arbor onto
the motor shaft so that the back of the drive wheel is 1/2" (13 mm) from
the face of the mounting clips. Using the 5/64" long arm Allen wrench
(provided), you must tighten the set screw onto the FLAT SIDE of the
motor shaft. This is most easily done by inserting the long arm through the
opening provided on the side wall of the saw frame. Make sure that the set screw
is tight. You want to make sure that you are tightening the set screw securely
to the FLAT SIDE of the motor shaft. If desired, you may add a drop of
threadlock adhesive to hold the set screw more securely. If you plan to move the
PowerUnit™ to other PowerKits™ you might want to omit the threadlock. Once
the lower drive wheel is installed, replace the front door on its hinge posts.
Installing
the Blade
1) Open the front cover of the saw. If you have a toothed blade, make sure to mount it with the teeth pointing downward, in the direction of sawing. Diamond blades are positioned with the diamond surface facing the saw front.
2) Position the blade around the lower wheel and into the right and left guide channels. DO NOT bend or twist the blade at any time during installation or use.
3) Use one hand to grasp the bottom of the upper wheel between two spokes and pull the wheel down enough to place the blade around the wheel using your other hand.
4)
Slowly release the wheel as you make sure the blade remains on both wheels and
passes through the right and left channels.
5) Tracking, the position of the blade on the wheels, is controlled by adjusting the tilt of the upper wheel. Check the tracking by rotating the lower drive wheel several revolutions by hand while watching the position of the blade on the wheels. The blade should remain centered on both wheels. If the blade isn’t centered or comes off either wheel, you will need to adjust the tracking and alignment as outlined in the next sections. If the blade rides centered on the wheels skip to installing the table on page 4.
Adjusting Blade Tracking and Alignment
The position of the blade on the wheels (tracking) is controlled by adjusting the upper wheel tilt and whether the wheels are in alignment with each other. On the back of the upper housing is the tension device with a nylon tilt adjustment screw in the middle. Be aware that any changes made to the blade position on the upper wheel will have the opposite effect on the blade's position on the lower wheel. Read through the possible problems below to find the one that best describes what is happening when you hand turned the wheel and follow the instructions for fixing it. Make all adjustments in small increments.
1) If the blade walks off the front of the upper wheel: Tilt the top of the upper wheel backward by turning the nylon tilt adjustment screw to the right (clockwise). Make 1/2 turn adjustments and test the effect on tracking by hand turning the lower wheel. Repeat as necessary until the blade remains in the correct position.
2) If the blade walks off the back of the upper
wheel: Tilt the top of the upper wheel forward by turning the nylon
tilt adjustment screw to the left (counter-clockwise). Make 1/2 turn adjustments and test the effect on tracking by hand
turning the lower wheel. Repeat as necessary until the blade remains in
the correct position.
3) If the blade walks off the lower wheel: This indicates that the upper and lower wheels are not in alignment with each other. The lower (adjustable) wheel is closer to the back of the MainFrame™ than the upper (fixed) wheel. The lower wheel should be 1/2" from the inside of the MainFrame™. You can check this with a ruler or scale. The lower wheel can be moved in or out by inserting the 5/64" long arm Allen wrench through the hole in the lower left side of the saw's MainFrame™ and loosening the set screw on the brass arbor. Move the wheel to the correct position, check with the ruler or scale and secure the set screw.
(page 3)
Blade Tension
Proper blade tension is important for ease of cutting and obtaining
maximum blade life. The tension springs lessen the stress that twists and pulls put on
the blade to maximize blade life. All Inland saws have tension springs preset for a
blade 37.7" in circumference (+ or - .005"). That is the exact dimension of Inland
brand blades. If you use an Inland blade you will never have problems with
tension. Some competitors make blades that are only 37.2". These blades will have too
much tension which could shorten blade life. We highly recommend the use of
Inland brand blades for all Inland brand saws. Because we are the only saw
manufacturer that manufactures its own diamond products, our diamond blades are
significantly less expensive anyway.
Installing the Work Table
Place the metal table on the table supports with the split facing the front of
the saw. Use a Phillips screw driver to attach the table using the (4) 10-24 x
1/2" phillips screws. Take care not to over tighten.
Our unique BladeSert™ eliminates the need for upper blade guides by providing blade support where it is most crucial: at the point of sawing. Place the BladeSert™ into the work surface making sure the blade passes through the slot and the split faces the saw front.
Installing the Coolant Hose Holder and Coolant Reservoir
The gray coolant hose holder and coolant reservoir
must be installed when using a diamond saw blade. The reservoir and hose holder feed coolant to the
blade. Using coolant with a diamond blade is imperative to maintaining the cutting
ability and life of the blade.
Install the drip blade guide by placing it against the upper back of the main frame with the blade passing through the vertical slot in the holder front. Secure using (2) 10-24 x 3/8" brass thumb screws. Attach the length of small diameter plastic tubing (about 10" long) to the stem on the back of the coolant hose holder. NOTE: Running the end of the plastic hose under warm water makes it easier to insert onto the stem.
Installing Drain Hose
When using a diamond blade, the coolant drain hose must be installed. This
is the large diameter plastic tube (about 48" long). If you are using the
WoodCut™ or MetalCut™ blade omit this step.
Straighten the hose before using by soaking it in warm water a few minutes and then pull it to remove any kinks. Slide the drain hose onto the large stem located at the bottom front of the saw. Put the opposite end of the hose into a collection container placed below the saw. Position the saw to the front edge of your work bench with th drain hose laying flat and extending straight out and then down off the work bench into the collection container.
NOTE: Periodically remove the hose and flush out any cutting residue to keep it working correctly.
(page 4)
Optional Leather Wiper
The leather wiper functions to help reduce the amount of over spray that might
be carried from the blade to the upper wheel chamber. If you run the saw with a
diamond blade, we recommend you install the wiper at this time. If you are using a
WoodCut™ or MetalCut™ blade the wiper is not needed and you may omit this step.
Installing the Wiper:
1) Use a pair of pliers to compress one end of
the leather wiper. Clamp down hard.
2) Apply a small amount of common bar soap to the crimped end.
3) Use your pliers to push the crimped end into the slot so that the edge of the leather just brushes against the blade. Make sure the wiper does not push the blade out of its normal path.
Material and Blade Use
The table below outlines a partial list of materials that can be cut wet or dry, depending on the type of blade installed on your saw.
| Material | DiamondCut™ Blade | WoodCut™ Blade | MetalCut™ Blade |
| Glass | WET | ||
| Ceramic Tile | WET | ||
| Brick and Cement Block | WET | ||
| Other Ceramics | WET | ||
| Porcelain | WET | ||
| Marble | WET | ||
| Granite | WET | ||
| Other Stone | WET | ||
| Semiprecious gem | WET | ||
| Silicon | WET | ||
| Thin Brass | WET | DRY | |
| Thin Zinc | WET | DRY | |
| Thin Aluminum | WET | DRY | |
| Hard Plastics | WET | WET/DRY | |
| Other plastics | WET | WET/DRY | WET/DRY |
| Fiberglass | WET | WET/DRY | |
| Fiberboard | WET | DRY | DRY |
| Wood | DRY | ||
| Leather | WET | DRY | DRY |
(page 5)
Using the Diamond Blade
If you have purchased a saw with a diamond blade or are installing a diamond blade for use on your saw, please follow the instructions outlined below for its proper use. Your saw must be converted for wet sawing before use. This includes installing the coolant hose holder, coolant system, drain hose, and leather wiper. (See pages 3-5)
1) Before sawing with a diamond blade, check to make sure the coolant reservoir, coolant hose holder and drain hose are installed on the saw (see page 4).
2) Make sure that the coolant flow adjustment screw on the back of the reservoir is closed shut and then fill the reservoir with water. You can fill the reservoir with water or a mixture of water and Inland Diamond Coolant (stock no. 50011).
3) Plug the saw into our grounded electrical outlet.
4) Make sure you have proper eye protection on before operating the saw.
5) Turn on the saw. The black control knob is located at the base of the motor housing. Please note the saw has a variable speed motor. You need to turn the knob slowly until you reach your desired sawing speed. It is not necessary to run your saw at full speed to achieve maximum cutting ability. In fact running the saw at full speed on a continual basis cases extra stress on the blade and does not increase its cutting ability.
6) Adjust the flow of coolant onto the blade by slowly turning the coolant flow adjustment screw. Coolant flow rate should be about one drop of coolant every 4-5 seconds. Water should not flow excessively. Increase the water flow rate ONLY if the dry powder forms on the tip of the material being sawed.
7) With the saw now running, place a scrap piece of material flat on the work table in front of the blade. Using light pressure, guide the material into the blade. It is important not to force or push material into the diamond blade . Once you have the right "feel", the blade will seem like it is pulling material into it. Pushing into the blade will not increase cutting speed and is more likely to bog it down. Use the speed control to adjust the sawing speed to the material being cut and intricacy involved. The tighter the cut, the slower the speed needed to maintain control and not twist the blade.
8) Never leave the saw running when not cutting. The blade will last longer.
9) If the blade seems limp, loose or slips on the wheels as you saw, adjust the blade tension or tracking as outlined on pages 3-4.
10) Shut off the coolant flow after use. Frequently check the reservoir level while sawing and fill as needed.
Diamond Blade Sawing Tips
Sawing effectively is an acquired skill. Just remember to let the diamond do the work. Sawing with a diamond blade is quite different than sawing with toothed blades. The diamond in the blade is actually wearing away the material being cut rather than ripping fibers like a wood blade.
1) Wear Safety eye protection while operating your saw.
2) Guide the material straight into the blade. Never push, twist or bend the
blade sharply.
3) Use lighter pressure and slower speeds when starting a cut and then increase
speed to the desired cutting level.
4) Lower speeds are recommended for intricate cuts, tight curves, and when
completing or backing out of a cut.
5) If a dry powder appears on the cutting surface or in the air, more coolant
(water) is needed. Check the reservoir level first. If there is plenty of
coolant, increase the drip rate by slowly adjusting the coolant adjustment screw
on the back of the reservoir.
6) If excess coolant (water) is spraying off the blade or coolant puddles on the
work surface when sawing, check the drip rate. You may have backed it out too
far and needs to be adjusted inward. You may also want to install the leather
wiper to help control excess water on the blade. (See page 5 for leather wipe
instructions)
7) If excess water is still spraying everywhere, turn off your saw. Over time,
turning the adjustment screw in and out will cause wear against the plastic hose
the coolant flows through. Check the hose to see if the screw has penetrated the
plastic. If this is the case, it is time to purchase a new plastic coolant hose.
Replacement hose can be purchased from any local hardware or aquarium store. Ask
for 1/8" PVC hose stock.
Using the WoodCut™ Blade
If you have purchased a saw with a WoodCut™ blade or are installing a WoodCut™ blade onto your saw, follow the instructions outlined here for proper use.
1) If your saw was set up for wet sawing using a diamond blade, make sure the flow adjustment screw that controls the water drip rate is completely turned off. Drain the water coolant reservoir. Remove the drain hose and dry out the interior of the saw.
2) Install the WoodCutv blade with the teeth pointing downward. Refer to installing the blade on page 3.
3) Plug the saw into a grounded outlet.
4) Wear safety eye protection while operating the saw.
5) Turn the saw on. The black control knob is located at the back of the motor housing. Please note that the saw has a variable speed motor. When turning the saw on, turn the speed up slowly to your desired sawing speed. It is not necessary to run the saw at full speed to cut. In fact, running the saw at full speed on a continual basis will cause extra stress on the blade and does not increase its cutting ability.
6) With the saw now running, place a scrap piece of material flat on the work table in front of the blade. Using light pressure at first, slowly guide the material into the blade. It is important not to force material into the blade. Allow the blade to do the work. As you get the right feel, the blade will seem to pull the material into it.
7) Pushing too hard will not increase cutting speed. It will actually slow it down. Use the speed control to adjust sawing speed to the material being cut and intricacy involved. For tight inside curves and intricate work, operate at a slower speed to maintain control and not twist the blade.
8) If the blade seems limp, loose or slips on the wheels as you saw, adjust the blade tension or tracking as outlined on pages 3-4.
9) Never leave the saw running when not in use. The blade will last longer.
(page 6)
WoodCut™ Blade Sawing Tips
1) Make sure the teeth point downward when installing the blade.
2) Wear Safety eye protection while operating your saw.
3) Slower speeds are recommended for intricate cuts and tight inside curves.
4) You can use the
WoodCutTM blade wet when sawing plastics and fiberglass to reduce heat and melting.
5) Never twist or bend the blade.
6) Turn off and unplug your saw when not in use.
7) Keep out of the reach of children.
Using the MetalCut™ Blade
If you have purchased a saw with a MetalCut™ blade or are installing a MetalCut™ blade onto your saw, follow the instructions outlined here for proper use.
1) If your saw was set up for wet sawing using a diamond blade, make sure the flow adjustment screw that controls the water drip rate is completely turned off. Drain the water coolant reservoir. Remove the drain hose and dry out the interior of the saw.
2) Install the MetalCut™ blade with the teeth pointing downward. Refer to installing the blade on page 3.
3) Plug the saw into a grounded outlet.
4) Wear safety eye protection while operating the saw.
5) Turn the saw on. The black control knob is located at the back of the motor housing. Please note that the saw has a variable speed motor. When turning the saw on, turn the speed up slowly to your desired sawing speed. It is not necessary to run the saw at full speed to cut. In fact, running the saw at full speed on a continual basis will cause extra stress on the blade and does not increase its cutting ability.
6) With the saw now running, place a scrap piece of material flat on the work table in front of the blade. Using light pressure at first, slowly guide the material into the blade. It is important not to force material into the blade. Allow the blade to do the work. As you get the right feel, the blade will seem to pull the material into it.
7) Pushing too hard will not increase cutting speed. It will actually slow it down. Use the speed control to adjust sawing speed to the material being cut and intricacy involved. For tight inside curves and intricate work, operate at a slower speed to maintain control and not twist the blade.
8) If the blade seems limp, loose or slips on the wheels as you saw, adjust the blade tension or tracking as outlined on pages 3-4
9) Never leave the saw running when not in use. The blade will last longer.
MetalCut™ Blade Sawing Tips
1) Make sure the teeth point downward when installing the blade.
2) Wear Safety eye protection while operating your saw.
3) Slower speeds are recommended for intricate cuts and tight inside curves.
4) You can use the
MetalCut™ blade wet when sawing plastics and fiberglass to reduce heat and melting.
5) Never twist or bend the blade.
6) Turn off and unplug your saw when not in use.
7) Keep out of the reach of children.
(page 7)
Maintenance
Maintenance to your saw is minimal but important to prolonging the life and performance of the machine.
- Saw Frame: The main components of your saw are virtually maintenance free. Periodically clean the interior of your saw. Either rinse clean with water or wood and metal cutting residues can be vacuumed out.
- PowerUnitTM: The unit is sealed and requires no internal maintenance. Make sure to keep the entire unit clean and dry.
- Upper Drive Wheel: The upper drive wheel needle bearing should be oiled about every 10 hours of running time. Do this by first emptying the coolant reservoir if need be. Tilt the saw backward at a 45° angle. Place 4 to 6 drops of general purpose oil into the bearing area.
- BladeSert™ Blade Guide: When the slot becomes worn back to the point it no longer supports the blade it is time to replace it. One extra BladeSert™ is included with your saw. First determine if you have the newer version (part no. 90022) having a short arm without screws or the older version (part no. 90012) with a longer arm and screws. For newer versions, simply remove the worn BladeSert™ from the table and insert the new one. For older versions, you need to remove the two small screws before the BladeSert™ can be removed from the table. Replace with a new one and replace the two screws.
- Leather Wiper: The wiper does wear as the blade brushes against it. As the end wears, move the wiper back up against the blade, referring to section on page 5 for proper placement.
- Work Table: The work table may be either metal or plastic, depending on the year and model you purchased. Periodically wipe down or rinse the table to remove accumulated cutting residue.
- Large Drain Hose: Periodically remove the hose and rinse it to remove
cutting residue and keep it free flowing.
Replacement Parts
Part Name Inland Part No. BladeSert™ New 90022 (no screws/short arm) Old 90012 (screw down/long arm) Work Table New 90023 (aluminum) Old 90013 (plastic) Leather Wiper 90014 Blade Drip Guide 90016
Accessories
- DiamondCut ™ Blade no. 90007: Seamless stainless steel blade with standard grit diamond coating. Suitable for wet sawing glass, tile, ceramic, stone, cement, brick and other mineral based materials. (NOTE: use this blade to replace older Inland CopperAlloy blades.)
- WoodCut™ Blade no. 90001: 1/8" (3 mm) wide toothed blade suitable for sawing all woods, wood products, other plastics, fiberboard and leather.
- MetalCut™ Blade no. 90003: 1/8" (3 mm) wide toothed blade suitable for sawing thin brass, zinc, aluminum, hard plastics and fiberglass.
- GrinderStation™ no. 50014: This washable, folding vinyl backdrop helps contain overspray, keeping your work area clean and dry.
- MagnaLight™ no. 76020: A combination magnifying glass and work light that makes all your work easier to see by providing light exactly where you need it.
- DiamondCoolant™ no. 50011: Use this water soluble coolant with diamond blades to make them last longer and cut more efficiently.
Service
If you have any questions or comments regarding the use of this or any Inland product please call Inland Customer Service at 1-800-521-8428 9 AM to 5 PM EST., email us, or write us at:
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Inland Craft Products, Co. 32052 Edward Madison Heights, MI 48071 |
Document No. 3000/QF/607 |
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