Ellis 1600 Mitre Band Saw Instruction Manual

PARTS CATALOG 2 H-1
Mitre Band Saw
Installation and Operating Instructions

1600 Mitre Band Saw

Note: Not all saw parts are shown in this booklet. Product changes are made and improved overtime and therefore not all images displayed may reflect the actual product shipped.

B LADE G UIDE

Blade Guide Assembly

Part Number For Models

**Item No.| ****90H
1100| 900
1000
1200| ****1440
1500| 1600
1800
2000
3000| ****4000| ****Description
---|---|---|---|---|---|---
Complete Assy.| 9016DC| 5370| 5539| 5720| 5732| Blade Guide Assembly, Drive End
Complete Assy.**| 9016IC| 5371| 5519| 5721| 5733| Blade Guide Assembly, Idler End
1| 5391| 5391| 5588| 5588| 5981| Housing Assembly, Idler
2| 4181| 4181| 4181| 4181| 4137| Adjustment Stud, Bearing Plate
3| 4260| 4260| 4260| 4260| 4260| 1/4-20 Hex. Nut
4| 6066| 6066| 6066| 6066| 5999| Spindle, Pressure Bearing
5| 4499| 4499| 4499| 4499| 4522| Ball Bearing, Pressure
6| 4260| 4260| 4266| 4266| 4279| Nut, Hex.
7| 4336| 4336| 4337| 4337| 4343| Lock Washer, Spring
8| 4310| 4310| 4310| 4310| 4311| Flat Washer, SAE
9| 4271| 4271| 4271| 4271| | Wing Nut or Stop Nut
10| 5389| 5389| 5587| 6074| 6073| Spindle, Guide Bearing
11| 4522| 4522| 4502| 4502| 4515| Ball Bearing, Guide
12| 4140| 4140| 4140| 4140| | 8-32 x 3/8 Set Screw
13| 4258| 4258| 4258| 4258| 4260| Hex. Nut
14| 4155| 4155| 4155| 4155| 4137| Socket Head Cap Screw
15| | 4304| | | | Flat Washer, 3/16 or 1/4 Std.
16| 4355| 4355| 4356| 4356| 4343| Lock Washer
17| 5374| 5374| 5542| 5542| 6056| Guide Clamping Bolt
18| 5390| 5390| 5540| 5540| 5982| Housing Assembly, Drive
19| 9012| 9012| 9012| 9012| 5996| Pressure Bearing Assembly
20| 5406| 5406| 6730| 6742| 6747| Stationary Guide Bearing Kit
21| 5407| 5407| 6732| 6743| 6747| Adjustable Guide Bearing Kit

*On all saws, except for the Model 4000, the stationary and adjustable kits are the same except for items 6, 16, and 15 which are included with the adjustable kits. On the Model 4000 there is no adjustable kit. Therefore, use part number 6747 for both bearing kits on the Model 4000.
For Replacing Bearings in Blade Guides, Order 2 Each of Parts 19, 20, 21

Pressure Bearing Assembly

Stationary and Adjustable Guide Bearing Assemblies

HYDRAULIC FEED CONTROL

Hydraulic Feed Control Assembly
Part Number For Models

**Item No.| 90H
900
1000
1100
1200| ****1500
1600
1800| ****1440
2000| ****3000
4000|
---|---|---|---|---|---
Assy.| 5355| 5506| 5708| 5777| Hydraulic Feed Control Assy.**
1| 5529| 5529| 5529| 5529| Cap
2| 4950| 4950| 4950| 4950| O-Ring-Shaft
3| 5532| 5532| 5532| 5532| Sealing Washer, Top
4| 4951| 4951| 4951| 4951| O-Ring-Cylinder
5| 5361| 5530| 5530| 5766| Shaft
6| 4305| 4305| 4305| 4305| Flat Washer, 5/16
7| 5531| 5531| 5531| 5531| Sealing Washer, Bottom
8| 5533| 5533| 5533| 5533| Leather Cup
9| 5534| 5534| 5534| 5534| Washer-Special
10| 4266| 4266| 4266| 4266| Nut, Hex. Jam, 5/16-24
11| 5362| 5528| 5528| 5767| Cylinder
12| 4743| 4743| 4743| 4743| Plug, Oil Fill
13| 4730| 4730| 4730| 4730| Male Elbow – Tube Fitting
14| 4732| 4732| 4732| 4732| Sleeve
15| 4729| 4729| 4729| 4729| Nut
16| 5363| 5590| 5711| 5706| Tube, 1/4 Dia. Plastic
17| 4727| | | | Needle Valve-Tube Fitting
18| 4728| 4728| 4728| 4728| Male Elbow Assembly
19| 4727| | | | Needle Valve Assembly
20| 5356| 5749| 5749| 5748| Travel Stop Tube
21| 6702| 6702| 6702| 6702| Rebuilding Kit (2,4,8,16)
22| | | 4798| 4798| Remote Needle Valve Assembly
23| | 4808| | | Flow Needle Valve Assembly
24| | 4735| | | Elbow, Male to Male
25| | 4734| | | Flow Needle Valve
26| | 4736| | | Straight Fitting

Chip Brush & Pivot Arm Assy.
Part No. 5484

Mitre Head Locking Handle ALL MODEL SAWS

Press center button and pull back to reset ratchet in Handle.

Bearing Carrier Assembly
Part Number For Models

Item No.| 90H
1000| 1100
1200
1500
1600| 1800
2000
3000
4000| Description
---|---|---|---|---
1| 4500| 4510| 4514| Carrier Guide, 4 Reqd.
2| 4499| 4522| 4522| Thrust Ball Bearing, 2 Reqd.

Note: Serial No. required when ordering Idler Wheel and Bearing Assy.
With Vulcanized Rubber
Part Number For Models

Drive Wheel With Vulcanized Rubber
Part Number For Models

90H
900
1000
1100
1200| 1440
1500
1600
1800
2000| 3000
4000| Description
---|---|---|---
5367| 5740| 5775| Drive Wheel With Rubber

Vertical Table and Blade Guards
Order by Saw Model Number.
Table sold with blade guard.
Part Number For Models

Description/Item| 90H
900
1100
1200| **1500| ****1600| ****1800*
---|---|---|---|---
Vertical Table #9374| ✔| ✔| ✔|
Vertical Table #6040| | | | ✔
Blade Guard #6041| ✔| ✔| ✔| ✔
T-Nut #6021| | | | ✔
Vertical Support Bar #6022| | | | ✔

• Replace Head Weight Adjustment Handwheel with 6021 T-Nut

INSTALLATION & OPERATION

CAUTION: Disconnect power supply cord from power source before changing the blade or making any other repair or adjustment to the saw.
Installation Instructions

1. Visually inspect machine for hidden shipping damage.
2. As part of the receiving inspection, check for broken ball bearings on the bearing carrier assembly. This is the assembly that the saw swivels on for miter cuts. CHECK ALL SIX BEARINGS. Two are located in the groove under the degree plate. See illustration on page 4.

IMPORTANT Model 2000, 3000 and 4000 owners note: The shut off rail was removed for shipping. You must mount the rail on the machine table before using the saw.
Vertical Sawing Position
NOTE: Model 1800 only – before raising the head on the Model 1800, remove the head weight adjustment handwheel and install the 6021 T-Nut. Attach the threaded vertical support bar (6022) tightly to the rear of the drive housing. See the chart on page 4. Adjust, if needed, to square blade with the vertical table.

1. Pull hydraulic pin at bottom of hydraulic. Disengage compensating spring assembly. Head is now free to raise to vertical position. Raise head up and over center. Hold head and gently let it move up to vertical position. DON’T LET THE HEAD DROP! See illustration on page 4.
2. Slide the vertical saw table into the blade and against the back of the horizontal table. Secure with the screwless vise or C-clamps. Adjust the drive end of the blade guide assembly, if necessary, to provide support for that end of the vertical table.
3. Attach the vertical blade guard on the moveable guide arm and secure with wing nut supplied.
4. Position moveable arm as close to work as possible.

Removing and Replacing Blade

Call 1-800-383-5547 for experienced help in selecting the proper saw blades for your application.

1. Disconnect power supply cord from power source.

2. Raise saw head assembly until blade clears the back of the table. Close hydraulic valve to lock in position.

3. Open the covers of the idler and drive wheels.

4. Pivot the chip brush to horizontal position and lock in place.

5. Loosen blade tension T-handle sufficient to release the blade around the wheels. Pull blade out of the blade guide bearings.

6. Brush chips from blade guide bearings and housings. Wipe bearing surfaces clean. Check that all bearings are running free.

7. Check that the guide bearings are set correctly for the new blade thickness. Use a feeler gauge that is one thousandth of an inch thicker than the blade. This is the best method because it does not rely on judgement.
   A saw blade can also be used as a gauge, but it must be new.
   After the blade has been installed and under proper tension, check for proper spacing. Twist the blade at the idler and drive wheel side of the respective guide bearing housings. There should not be any noticeable motion of the blade on the other side of the guide bearings. Reset the gap to correct fit.

8. Place the new blade over the idler and drive wheels with the teeth facing toward you. The blade should run under the guides. The teeth should point out toward you and the tips of the teeth should point toward the motor end of the saw.
   A fast check is to compare the blade (as you place it over the idler wheel) with the decal on the top of the saw head. Check to make sure the blade is on both orange wheels.

9. By turning the T-Handle, apply tension to the blade until all slack is removed from the blade or the blade is pulled in a straight line across the top of the saw from wheel to wheel. Grasp the blade on each side of the guides and twist the blade. Push down on the teeth with your thumbs and roll the back of the blade between the guide bearings. Proper tension is 1-1/2 to 2 full turns (360) of the T-Handle.

10. Proper blade tension is reached by grasping the T-Handle and applying one full turn (360) on the tension handle. You can  use the casting number on the handle as a reference point.Reconnect the power supply. Turn the saw on for a couple of revolutions to square the blade on the wheels. Turn the saw off. Now put the second full turn of tension on the T-Handle. Turn the saw on again for a few revolutions. Turn the saw off. Check the tracking of the blade on the wheels. On saws with a 9″ wheel the blade runs centered on the wheels. On saws with 12″ and 14″ wheels the teeth of the blade should be sticking out past the edge of the wheel. The teeth should not be on the rubber of the idler or drive wheels. If the blade is not tracking properly then the idle wheel needs to be adjusted. If you think the idle wheel needs to be adjusted, call the factory at 1-800-383-5547 for assistance.

11. Check the blade tension by setting the guide housings about 8″ apart then grasp the blade between the fingers and thumb halfway between the guide housings. With a rotating or twisting motion of the hand the blade should deflect no more than 1/8″.

See our website at www.EllisSaw.com and explore our videos and links for additional troubleshooting and maintenance information.
Troubleshooting Crooked Cuts

1. Check blade for worn or broken teeth and replace if needed.

2. Check to make sure that the number of teeth per inch on the blade fit the application. As a rule, only 6 to 12 teeth should be in contact with the workpiece.

3. Check the head pressure on the saw. The compensating spring tension should be 8 pounds with the blade 1″ above the table, coming down with the hydraulic valve open.

4. Check the blade tension. Review the proper blade tension procedure under “Removing and Replacing Blade” on page 5, item 10.

5. Check the space between bearings of both guide bearing assemblies. It should be only .001″ over the thickness of a new blade. As an example, a .033″ feeler gauge would be used to set the guides for a .032″ thick blade.

6. Check the blade tracking on the idler and drive wheels.
   9″ solid wheels: blade in center of wheels 12″ spoked wheels: 3/4″ wide blade should have teeth protruding from the side of the wheel about 1/8″, and the 1″ wide blade about 1/4″. 14″ spoked wheels: 1″ and 1-1/4″ wide blades should have teeth protruding 1/4″ to 5/16″ from side of wheel.

7. Check to make sure that the blade guide assemblies are not too far apart. Set the idler blade guide closer to the work to provide greater support for the blade.

Saw Adjustments
(If above steps did not eliminate crooked cuts)

1. Squaring blade with back of saw table.
   Raise the head up 1/8″ and hold in place with the hydraulic valve. Place a 6″ square against the table back and move the head until the blade is exactly 90 degrees from the table back. Lock the head in position. Check that the POINTER points to zero (0 degrees) on the degree plate. If the pointer does not point to zero, bend the pointer so that it lines up to 0 degrees. The saw is now adjusted to cut from front to back accurately at 90 degrees and at all angles.

2. Square blade with top of saw table.
   Use a blade aligning tool of the “clip on” or magnetic type to attach to the blade. Set a 6″ square on the table top with the blade vertical and touching the aligning tool. These test measurements should be made with the tools kept as close as possible to the guide bodies. If the blade is not square with the table, the guide bearing plate needs to be adjusted to bring the blade into alignment. See illustration of Blade Guide Assembly on page 2.
   First the wing nut, Item 9 in the illustration, must be loosened. Next, loosen nut, Item 13. The adjustment to the bearing plate is set using the cap screw, Item 14. If the adjustment requires that the cap screw be backed out, the adjustment stud, Item 2, must be manually pushed so it is in contact with the cap screw. When the blade is aligned parallel with the square, tighten the wing nut to lock the bearing plate in position. Hold the cap screw from turning and lock nut, Item 13, against the guide clamping bolt.

Blade Speeds

The V-belt must be changed on the pulleys to change speeds.
For HIGH speed, place the belt in the largest pulley on the motor shaft and the smallest on the reducer shaft.
For MEDIUM speed, the middle pulley is used on both shafts.
For LOW speed, the smallest pulley on the motor shaft is used with the largest on the reducer.
Replacement of Hydraulic Oil

The hydraulic cylinder can be filled on the saw or in a benchvise.
THE SHAFT MUST BE FULLY PUSHED IN BEFORE STARTING TO FILL.

1. Remove pipe plug from near top of cylinder.
2. Fill with light weight hydraulic oil until oil flows back out of hole. Replace pipe plug.

Maintenance

A good clean machine is easy to operate and promotes safety.

1. Keep areas clean by brushing chips from table grooves, guide bodies, idler and drive wheels, pivot shaft hinge area and turntable grooves.
2. Oilite bushings in pivot shaft should be oiled annually.
3. Check oil level in hydraulic. Proper level is at pipe plug hole.
4. Oil in wormgear should be checked every 90 days. FILL TO PROPER LEVEL AT PLUG, BELOW THE BREATHER VENT, using 80 to 140 weight gear oil.

AIR COOLING

Air Cooling System

Part Number For Voltage Rating

Item No.
Sys.| 120V
5922| 230V
5932| Description
Air Cooling System-Complete
---|---|---|---
1| 5925| 5925| Valve and Nozzle Assembly
2| 4728| 4728| Elbow Fitting
3| 4734| 4734| Flow Needle Valve
4| 4744| 4744| Nipple
5| 5923| 5923| Mounting Bar*
6| 5924| 5924| Nozzle Cap
7| 4970| 4970| Blow Gun
8| 4969| 4969| Air Hose Assembly
9| 5903| 5912| Solenoid Valve Assembly-Complete
10| 5001| 5002| Solenoid and Cord Assembly Only
11| 5926| 5926| Tubing, .25 OD, 5 Feet
12| 4015| 4015| Bolt, Hex. Head 5/16-18 x 1-1/4

• For saw Model 4000 use mounting bar 5928

ACCESSORIES

For Saw Models  2000, 3000 & 4000

Adjustable Gauge Pipe & Micro-Adjuster Assy. – Only –| 5750

Heavy Duty Stock Stands (4 Rollers)

Saw Model| Part No.| Roller & Shaft| Length| Width| Roller Dia.| Height
---|---|---|---|---|---|---
3000 – 4000| 6227| 6198| 5ft| 20″| 2.38″| 24″
1600 – 2000| 6228| 6198| 5ft.| 20″| 2.38″| 22.5″
1600 – 2000| 6229| 6193| 5ft.| 12″| 2.38″| 22.5″

2 Roller Stock Stand Assy.
Part No. 6252
Includes: Stock Stand with 2 Rollers, Adjustable Gauge Pipe & Micro-Adjuster Assy. (+ W-Clamps, Hardware and Handwheel)

For Saw Models 1800, 1600 and Smaller

6252 – Sub-Assemblies – Options
Description| Part #’s
Stock Stand – 1 Roller Assy. Includes: Everything except Second Roller Assy.
(6240) (+ W-Clamps and Bolts)| 6200
Adjustable Gauge Pipe & Micro-Adjuster Assy. Sold with 6252| 6216
Stock Gauge Assy. Includes: 6216, 2 Pipes, 2 W-Clamps with Bolts and Handwheel| 6222
Micro-Adjuster Screw Assy. T-Rod, Nut and Knob Sold with (6216) 6252| 6210
End Stock Stand Assy.
End Stand with Roller (+ W-Clamp + Bolt)| 6250
Second Roller Assy. (4. W-Clamp + Bolt)| 6240
W-Clamp
(Under Saw Table)
2 Req., includes J-Bolts Used with Part No’s: 6252, 6200, 6222

Single Stock Stand

1 – 8 0 0 – 3 8 3 – 5 5 4 7
107 W. Railroad Street • P.O. Box 930219 • Verona, WI 53593-0219
Phone:608-845-6472 • Fax: 608-845-5199 • www.EllisSaw.com
www.EllisSaw.com
Revised: 2022

Documents / Resources

| Ellis 1600 Mitre Band Saw [pdf] Instruction Manual
1600 Mitre Band Saw, 1600, Mitre Band Saw, Band Saw, Saw
---|---

References

• Ellis Band Saws, Saw Blades, Drill Press and Beltgrinder

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