Bomar Extend 900.720 User manual

Operating Instructions for Band Saw
Extend 900.720
Before transporting and using the machine, please read
the instructions thoroughly!
Serial number:

Version 1.05 / June 2008
BOMAR, spol. s r.o. Extend 900.720
Těžební 1236/1
62700 Brno
CZECH REPUBLIC
Service and Information
In case of technical difficulties or spare parts order, please contact your dealer:
Or contact Bomar, spol. s r.o. directly:
BOMAR, spol. s r.o.
Těžební 1236/1
62700 Brno
CZECH REPUBLIC
Telephone: [phone]
Fax: [phone]
e-mail: [e-mail]
WWW: http://www.bomar.cz
We are available Mondays to Fridays from 700 to 1600.
Version 1.05 / June 2008
BOMAR, spol. s r.o. ©- Subject to modifications and amendments

Version 1.05 / June 2008
BOMAR, spol. s r.o. Extend 900.720
Těžební1236/1
62700 Brno
CZECH REPUBLIC
3
Content
1. INTRODUCTION..................................................................................................................6
2. BAND SAW USING .............................................................................................................6
3. TECHNICAL DATA..............................................................................................................7
4. SAFETY NOTES..................................................................................................................8
4.1. GENERAL .....................................................................................................................8
4.2. PROTECTIVE SUIT AND PERSONAL SAFETY ........................................................................8
4.3. SAFETY NOTES FOR MACHINE OPERATOR..........................................................................9
4.4. SAFETY NOTES FOR THE SERVICING AND REPAIRS............................................................10
4.5. SAFETY MACHINE ACCESSORIES ....................................................................................11
5. SEZNAM BEZPEČNOSTNÍCH ZNAČEK / LISTE DER SICHERHEITSZEICHEN / LIST OF
SAFETY SYMBOLS...........................................................................................................13
6. TRANSPORTATION AND STOCKING ...............................................................................15
6.1. CONDITIONS FOR TRANSPORTATION AND STOCKING .........................................................15
6.2. SAFETY NOTES ...........................................................................................................15
6.3. TRANSPORT AND STOCKING PREPARATIONS ....................................................................16
6.4. TRANSPORT AND STOCKING ..........................................................................................16
7. ACTIVATION.....................................................................................................................17
7.1. MACHINE WORKING CONDITIONS....................................................................................17
7.2. MACHINE INSTALLING AND LEVELLING.............................................................................17
7.3. ELECTRICAL CONNECTION ............................................................................................18
7.4. FILLING OF THE COOLING SYSTEM..................................................................................19
7.5. CHECK MACHINE FUNCTIONS.........................................................................................20
8. CONTROL PANEL –DESCRIPTION..................................................................................21
9. STARTING THE BAND SAW .............................................................................................24
10. PREPARATIVE MODE ......................................................................................................25
10.1. ENTRANCE TO MENU ....................................................................................................25
10.2. CUTTING PARAMETERS.................................................................................................25
10.3. INTERRUPTING THE CYCLE SELECTION............................................................................25
10.4. VICE PARAMETERS (VICE OPENING) ...............................................................................25
10.5. STOP TIME OF THE HYDRAULICS ....................................................................................25
10.6. SWARF CONVEYOR ......................................................................................................25
10.7. LANGUAGE VERSION SELECTION ....................................................................................25
11. SEMI-AUTOMATIC CYCLE................................................................................................26
11.1. CYCLE BREAKING ........................................................................................................27
11.1.1. STOP button ................................................................................................................... 27
11.1.2. TOTAL STOP button ....................................................................................................... 27
12. MATERIAL INSERTION.....................................................................................................28
12.1. SAFETY NOTES ...........................................................................................................28
12.2. HANDLING AGENT SELECTION........................................................................................28
12.3. MATERIAL INSERTION...................................................................................................28
12.4. BUNDLE MATERIAL CUTTING ..........................................................................................29
13. BAND SAW ADJUSTING...................................................................................................30

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13.1. SAFETY NOTES ...........................................................................................................30
13.2. SAW FRAME LIFT STOP SETTING ....................................................................................30
13.3. ADJUSTING BAND GUIDES .............................................................................................31
13.4. CUTTING SPEED ADJUSTING ..........................................................................................31
13.5. ADJUSTMENT OF PRESSURE IN THE CUT..........................................................................31
14. BLANKS REMOVING FROM THE BAND SAW...................................................................32
14.1. SAFETY NOTES ...........................................................................................................32
14.2. HANDLING AGENT SELECTION........................................................................................32
14.3. BLANKS REMOVING ......................................................................................................32
15. SELECTION AND REPLACEMENT OF THE SAW BAND ...................................................33
15.1. SAFETY NOTES ...........................................................................................................33
15.2. SAW BAND SIZE...........................................................................................................33
15.3. SELECTION OF THE SAW BAND TOOTH SYSTEM:................................................................33
15.4. SAW BAND RUNNING -IN...............................................................................................35
15.5. SAW BAND DISMANTLING ..............................................................................................36
15.6. SAW BAND INSTALLATION .............................................................................................36
15.7. SAW BAND STRETCHING AND INSPECTION .......................................................................38
15.7.1. Saw band stretching........................................................................................................ 38
15.7.2. Saw band inspection ....................................................................................................... 38
16. COOLING AGENTS AND CHIPS DISPOSAL .....................................................................39
16.1. SAFETY NOTES ...........................................................................................................39
16.2. COOLING LIQUID PREPARATION .....................................................................................39
16.3. COOLANT DEVICE INSPECTION.......................................................................................40
16.4. CHIPS DISPOSAL .........................................................................................................41
17. GREASES AND OILS........................................................................................................42
17.1. GEARBOX OILS............................................................................................................42
17.2. HYDRAULIC OILS .........................................................................................................43
17.3. LUBRICANT GREASES ...................................................................................................43
18. SERVICE ..........................................................................................................................44
18.1. MACHINE CLEANING .....................................................................................................44
18.2. LUBRICATION ..............................................................................................................44
18.3. COOLING LIQUID INSPECTION ........................................................................................44
18.4. HYDRAULIC OIL LEVEL CHECK........................................................................................44
19. ADJUSTMENT ..................................................................................................................46
19.1. HARD METAL GUIDES ADJUSTMENT ................................................................................46
19.2. SAW BAND RUN ADJUSTMENT ON THE STRETCHING WHEEL ................................................46
19.3. BRUSH ADJUSTMENT....................................................................................................46
19.4. ADJUSTING OF THE LIMIT SWITCH OF THE SAW BAND STRETCHING ......................................47
19.5. SAW ARM LOWER POSITION STOP ADJUSTMENT................................................................47
19.6. LIMIT SWITCH ADJUSTMENT OF THE SAW FRAME LOWER POSITION ......................................47
19.7. ADJUSTMENT OF THE CUTTING PRESSURE REGULATION ....................................................49
20. WORN PIECES REPLACEMENT .......................................................................................51
20.1. PUSHING BEARING REPLACEMENT..................................................................................51
20.2. SAW BAND GUIDING PULLEYS REPLACEMENT ...................................................................52
20.3. HARD METAL GUIDES REPLACEMENT ..............................................................................54
20.4. ROUND BRUSH REPLACEMENT .......................................................................................56

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21. ROZMĚROVÉ SCHÉMA / AUFSTELLZEICHNUNG / INSTALLATION DIAGRAM ................57
22. ELEKTRICKÁ SCHÉMATA / ELEKTROSCHEMAS / WIRING DIAGRAMS ..........................59
23. KUSOVNÍK ELEKTROSOUČÁSTÍ / STÜCKLISTE DER ELEKTROTEILEN / PIECE LIST OF
ELEKTROPARTS ..............................................................................................................71
24. HYDRAULICKÉ SCHÉMA / HYDRAULIKSCHEMA / HYDRAULIC DIAGRAM .....................73
25. VÝKRESY SESTAV PRO OBJEDNÁNÍ NÁHRADNÍCH DÍLŮ / ZEICHNUNGEN FÜR
BESTELLUNG DER ERSATZTEILE / DRAWING ASSEMBLIES FOR SPARE PARTS ORDER
.........................................................................................................................................77
25.1. PÁSOVÁ PILA /BANDSÄGE /BAND SAW...........................................................................78
25.2. PODSTAVEC /UNTERGESTELL /PEDESTAL......................................................................80
25.3. RAMENO /ARM /ARM ..................................................................................................82
25.4. SVĚRÁK /SCHRAUBSTOCK /VICE ..................................................................................84
25.5. POHON /ANTRIEB /DRIVE ............................................................................................86
25.6. VÁLEC ZVEDACÍ /HEBEZYLINDER /LIFTING CYLINDER.......................................................88
25.7. NAPÍNÁNÍ PILOVÉHO PÁSU /SÄGEBANDSPANNUNG /SAW BAND STRETCHING .......................90
25.8. VEDENÍ PÁSU /SÄGEBANDFÜHRUNG /SAW BAND GUIDING ................................................92
25.9. KARTÁČEK /BÜRSTE /BRUSH .......................................................................................96
25.10. LEVÁ VODÍCÍ KOSTKA /LINKER FÜHRUNGSKLOTZ /LEFT GUIDING CUBE...............................97
25.11. PRAVÁ VODÍCÍ KOSTKA /RECHTER FÜHRUNGSKLOTZ /RIGHT GUIDING CUBE .......................99
25.12. TŘÍSKOVÝ VYNAŠEČ /SPÄNEFÖRDERER /SWARF CONVEYOR ..........................................102
25.13. POHON TŘÍSKOVÉHO VYNAŠEČE /ANTRIEB VON SPÄNEFÖRDERER /DRIVE........................104
25.14. REGULACE TLAKU SVĚRÁKU /SPANDRUCKREGULIERUNG/VICE PRESSURE REGULATION .......106
25.15. KOSTKA /KLOTZ /CUBE.............................................................................................108
26. UMÍSTĚNÍ BEZPEČNOSTNÍCH ZNAČEK / VERTEILUNG DER SICHERHEITSZEICHEN /
POSITION OF SAFETY SYMBOLS ..................................................................................110
26.1. PILA /BANDSÄGE /BAND SAW.....................................................................................110
26.2. NAPÍNACÍ A HNACÍ KOLO /UMLENKRAD UND ANTRIEBSRAD /TIGHTENING WHEEL AND DRIVING
WHEEL .....................................................................................................................111
27. TROUBLESHOOTING TABLE .........................................................................................113
27.1. MECHANICAL PROBLEMS.............................................................................................113
27.2. ELECTRIC AND HYDRAULIC PROBLEMS ..........................................................................115
28. SPECIAL ACCESSORY...................................................................................................117
28.1. VICE PRESSURE REGULATION......................................................................................117
28.2. MICRONISER.............................................................................................................117
28.3. TENZOMAT ...............................................................................................................117
DECLARATION OF CONFORMITY .........................................................................................119

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Do not touch the cooling liquid with bare hands!
Do not set the nozzle of the cooling liquid, when the machine
is started on!
Do not remove the chips from the working area of the
machine, when the machine is started on!
Do not use the compressed air for the machine cleaning or
for the chips removing!
Use the protective instruments for chips removal!
4.4. Safety notes for the servicing and repairs
The machine is equipped with safety accessories. It protects
the operator from injuries and the machine before damage.
The safety accessories are blocking accessories, emergency
switches and covers. Check once in a week the function of
the safety accessories. If the safety accessories are
functionless, you must stop work and repair or change the
safety accessories.
TOTAL STOP button
TOTAL STOP button is used for emergency switching –off
the machine in case defect or health hazard. By pressing
TOTAL STOP button is interrupted the supply of the
electrical power.
If any damages or fault appears, immediately press
TOTAL STOP button!
Release the pressing button is possible by twisting of the
upper part of the button.
Enhanced risk!
Do not come into or intervene in the cutting area. Otherwise,
there is possibility of heavy injury.
Saw band stretching and rupturing inspection
This device checks the saw band stretching and causes
immediate machine shut –down in the event the band
ruptures.
The device contains limit switch. Check the stretching
carefully and periodically –eventually adjust.
Left saw band cover

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It covers the visible area of the saw band from left guiding
cube to the frame.
Never switch on the saw band driver if this cover is not
mounted!
Left cover
It covers tightening wheel. If the cover is opened during
operation, the limit switch is opened and the band saw is
stopped. The band saw is not possible start in set mode.
The band saw is stated to the operation, when the cover is
closed!
Right cover
It covers driving wheel. If the cover is opened during
operation, the limit switch is opened and the band saw is
stopped. The band saw is not possible start in set mode.
The band saw is stated to the operation, when the cover is
closed!
4.5. Safety machine accessories
The machine is equipped with safety accessories. It protects
the operator from injuries and the machine before damage.
The safety accessories are blocking accessories, emergency
switches and covers. Check once in a week the function of
the safety accessories. If the safety accessories are
functionless, you must stop work and repair or change the
safety accessories.
Enhanced risk!
Do not come into or intervene in the cutting area. Otherwise,
there is possibility of heavy injury.

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TOTAL STOP button
TOTAL STOP button is used for emergency switching –off
the machine in case defect or health hazard. By pressing
TOTAL STOP button is interrupted the supply of the
electrical power.
If any damages or fault appears, immediately press
TOTAL STOP button!
Release the pressing button is possible by twisting of the
upper part of the button.
Saw band stretching and rupturing inspection
This device checks the saw band stretching and causes
immediate machine shut –down in the event the band
ruptures.
The device contains limit switch. Its setting is described in
chapter “Service and Adjusting”. Check the stretching
carefully and periodically –eventually adjust. To stretch the
saw band press the left button (left arrow). To release the
saw band press the right button (right arrow). Stretching
value is set by the producer.
Left cover
It covers tightening wheel. If the cover is opened during
operation, the limit switch is opened and the band saw is
stopped. The band saw is not possible start in set mode.
The band saw is stated to the operation, when the cover is
closed!
Right cover
It covers driving wheel. If the cover is opened during
operation, the limit switch is opened and the band saw is
stopped. The band saw is not possible start in set mode.
The band saw is stated to the operation, when the cover is
closed!

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5. Seznam bezpečnostních značek / Liste der Sicherheitszeichen / List of
safety symbols
Značka / Zeichen / Symbol
Význam / Bedeutung / Signification
Objednací číslo / Bestell - Nr. / Reference No.
NS-Nebezpečí stlačení / Pressunggefahr / Crushing hazard
NR-Nebezpečí říznutí / Schnittgefahr / Cutting or severing
hazard
NN-Nebezpečí nárazu / Stoßgefahr / Impact hazard
NV-Nebezpečí vtažení / Einzuggefahr / Drawing – in hazard
NZ- Nebezpečí zachycení / Erfassunggefahr / Tramping
hazard
NT-Nebezpečí střihu / Schnittgefahr / Shearing hazard
NE-Nebezpečí úrazu elektrickým proudem / Verletzunggefahr
vom elektrischen Strom / Electrical hazard

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HV-Hlavní vypínač / Hauptschalter / Main switch
SOL-Směr otáčení doleva / Drehrichtung nach links /
direction of rotation left
SOP-Směr otáčení doprava / Drehrichtung nach fechte /
direction of rotation right
SOO-Směr otáčení oboustranně / Drehrichtung doppelseitig /
direction of rotation double-sided
OBS-Noste ochranné brýle a sluchátka / Tragen Sie eine
Schutzbrille und Gehörschutz / Wear protective googles and
headphones
PO-Noste pevnou pracovní obuv / Tragen Sie
Sicherheitsschuhe / Wear fixed protective shoes
CZ-Přečíst návod k použití / Bedienungsanleitung lesen /
Read the operating instructions

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6. Transportation and stocking
6.1. Conditions for transportation and stocking
Keep recommendations for the manufacturers for
transportation and stocking! If the recommendations are not
kept, damage can occur to the machine.
Conditions for transportation and stocking:
•Temperature of the air from –25°C to +55°C, for a short
term (max. 24 hours) temperature of the air until +70°C.
•Do not expose the machine to radiation (for example
microwave radiation, ultra-violet radiation, laser radiation,
X –ray radiation). Radiation can cause problems with the
machine function and deteriorating condition of the
isolation.
•Take measures, to prevent damage by dampness, by
vibrations and by shakes.
6.2. Safety notes
Keep safety notes for the transport!
Always wear protective hardhat to avoid hard injuries during
loading and transportation!
Wear protective gloves!
Sharp edges of the machine, pallets and means of transport
can injure your hands.
Wear safety boots!
Loose parts and packing materials can cause serious
injuries.
Do not use a forklift truck for handling the machine, if you do
not have licence for it!
Do not move under suspended loads! Fault in lifting device
may cause serious injury.
Keep a safe distance from the machine during the transport.

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6.3. Transport and stocking preparations
Close the vice and thoroughly oil all blank surfaces.
Lower the saw frame to the lowest position.
Make sure to empty the machine of all traces of the cooling
agent.
Fasten all loose parts securely to the machine.
Pack and wrap the control desk securely to avoid damage
during transport.
Fix the stickers stating the minimum approximate machine
weight to at least five well visible places.
The machine has to be screwed to a pallet for the transport!
6.4. Transport and stocking
Handle the machine only with suspension cables and the
crane. The pedestal is equipped with slots =70 mm. Insert
the appropriate steel bars to all of these slots (see arrows on
the picture). It is possible use two long or four short bars. Fix
the suspension cables to the steel bars.
Make sure that the suspension cables and the crane had
sufficient capacity.
Make sure that the van or the trailer had sufficient capacity.
The machine must be secured during transportation.
Screw on the palette to the floor of the van or the trailer.
Be careful that the machine is not damaged during
transportation.
It is forbidden to handle the machine any other way (for
example by, lifting by the saw frame of the band saw), than it
is written in this operating instructions, the machine can be
damaged!

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7. Activation
7.1. Machine working conditions
Keep the conditions of the manufacturer for machine
operating! If recommendations are not kept, damage can
occur to the machine.
The manufacturer warrants the correct function of the
machine for these conditions:
At temperature air from +5°C to +40°C, the temperature
average during 24 hours must not exceed over +35°C.
At relative dampness of the air in the extend from 30% to
95% (not concentrate).
Altitude higher than 1000 metres.
Do not expose the machine to the radiation (for example
microwave radiation, ultra-violet radiation, laser radiation, X
–ray radiation). Radiation can cause problems with the
machine function and deteriorating condition of the isolation.
7.2. Machine installing and levelling
Check the floor supporting capacity before machine
installing. If the floor capacity does not agree with
requirements, you must prepare the necessary base for the
machine.
Minimal requirement:
machine weight (chapter Technical data)
+ weight of accessories
+ maximum weight of material
The machine must be levelled at the horizontal position. All
feet of the machine must touch with the floor after levelling.
The machine must be levelled by means of the calibrated
spirit level. Spirit level is put on the vice area. Set the roller
conveyors according to the spirit level.
For machine levelling, take care that there is sufficient
available space for operation, repair work, servicing of the
machine and handling the material.
The machine including appended parts and accessories must
be visible from the place of operation.

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7.3. Electrical connection
ATTENTION! Only a qualified professional must carry out the
servicing and repairs of the electric equipment! Take special
care during work with electrical equipment. High voltage
shock can have fatal consequences! Always keep notes
about work safety!
Electrical parameters of the machine:
Service voltage: ~ 3 x 400 V, 50 Hz, TN-C-S
Total input: see Technical data
Max. fuse: 16 A
Before connecting switch off the main switch of the power
supply circuit for the machine and ensure dry place when
doing connecting works!
Service voltage must agree with the line voltage!
Crosscut of the supply line must respond with rated current
for max. machine load. Note: The values of the crosscut of
the conductor and the rated current are in the norms.
Connect the service cable of the machine on the clamps of
the electric distribution. Note: The socket with the fork can
be used only at the machines with the rated current less than
16A and total input less than 3 kW.
In case the machine is connected with a direct connection,
an extra main switch must be added which can be locked in
zero position.
Attention! In this case the extra main switch becomes
primary and the main switch on the machine has only
secondary function.
Check the direction of the saw band!
After the machine has been successfully connected, briefly
switch on the machine and put the driving engine of the band
in the running position. The direction must be in accordance
with the arrow direction on the saw band cover. In case the
direction of the saw band does not match, two phases at the
terminal strip must be switched.

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7.4. Filling of the cooling system
If handling cooling liquid, keep the notes about work
safety and instructions of the cooling liquid
manufacturer!
Wear protective gloves when working with cooling liquids!
Wear protective goggles!
The cooling liquid can get into your eyes and cause serious
injury.
Prepare the mixture of the water and the cooling liquid. Keep
the concentration specified by manufacturer.
Fill the mixture of the water and the cooling liquid to the tank
of the cooling system. Area of the tank for the cooling liquid
is discovered from the chapter „Technical data“.
Filling the tank with the cooling liquid, take care that the
liquid does not drip out of the tank and the tank does not
overflowed.
Keep by manufacturer specified recommendation for adding
the anticorrosive agents, the antifreezes or other agents! For
mixture of two different mixes can produce toxic and
aggressive mixes, which can threaten your health or damage
cooling system of the machine!
Note: If the machine is equipped with Microniser (see.
Special accessory), fill the tank of the Microniser by
specified cooling liquid. Microniser is ready for operation.

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7.5. Check machine functions
Before starting the check machine functions, you must read
the chapter „Machine operation“. Do not carry out check
machine functions, if you do not comprehend meaning of all
buttons and all machine functions.
Check, if the machine or some parts of the machine were not
damaged during transport.
Check, if covers are installed and functional.
Check by means of the Tenzomat (see Special accessory),
if the saw band is correctly stretched. If it is necessary, you
can stretch the saw band according to chapter „ Selection
and replacement of the saw band“. Values of the saw band
stretching are on the Tenzomat.
Switch on the main switch and check the motors and systems
(saw band drive, hydraulic pump, cooling pump, chips
conveyor).
Open and close the main vice and the feeding vice. Drive the
front feeder from the front position to the rear position. Turn
the saw frame of the band saw from one outer position to
other outer position. Raise the saw frame to the top position
and drop the saw frame to the lowest position.
Start the machine with the cooling pump and let it run without
load until the cooling system will be filled with cooling liquid.
As soon as the cooling liquid starts to escape from the
nozzles of the cooling system, the cooling system is ready
for the operation.
Carry one cycle of cutting without material. Check, if the
machine runs with no irregularities. If all machine functions
are right, the machine is ready for operation.

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8. Control panel –description

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1
Display
There are described all processes on display.
2
Safety circuit switching on
Switch on the safety circuit by pressing button.
3
Cooling system selection
You can select from three possibilities:
Cooling with Microniser
0
Without cooling
Cooling with water
4
START - Switch on the semi-automatic cycle
By pressing 6and button 4 is starting only the band saw drive. It is stopped with button
5.
5
STOP - Switch off the engine of the band saw
It stops the engine of the machine. With holding button STOP during the time 2 second
is stopped hydraulic engine ( if it running). The hydraulic engine is started automatic on
switch whatever motion.(Open vice, close, Lift the saw arm, lower) or the cycle is
starting with button Start.
6
Close the vice
When this button is pressed, the vice is opened.
This button may be used in semi-automatic cycle.
7
Open vice
Vice is opened after pressing this button.
8
Lift the saw arm
9
Lower the saw arm
If this button is pressed with 8 button together, the saw arm is starting chute on the
cutting material with accelerated shift. ATTENTION! If you will be running with
accelerated shift until the cut, the saw band may be damaged.
10
TOTAL –STOP button
In emergency causes the machine must be immediately switched off.
11
LED-control lamp blink by cycle.
12
Frequency convertor
Turn to change the speed of the saw band.
13
Cutting pressure manometer

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14
Cutting pressure regulation
Adjust the arm pressure to the cut.
15
Governing valve
Adjust the speed of the arm sinking to the cut by governing valve.
Notice: If you keep closing the throttle valve too tightly, the valve seat may wear off
which causes its leakage. Therefore, close the valve always gently.
16
Deblock
Use the deblock to replace the saw band.
Position 0 –operating mode. During the running of the machine, the
switch must be in position 0.
Position 1 –saw band replacement. In this position it is possible to
run the hydraulics and strain and release the saw band despite of the
open covers. The functions activate only by buttons on the arm. Other
functions are blocked.

Version 1.05 / June 2008
BOMAR, spol. s r.o. Extend 900.720
Těžební 1236/1
62700 Brno
CZECH REPUBLIC
24
9. Starting the band saw
1) Switch on the main switch of the band saw. The main
switch is situated on the side of the switchboard.
2) Switch on the safety circuit of the band saw (button 2–
control panel of the band saw).