Epple Maschinen BS 125 GS User manual

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User manual
Metal bandsaw
BS 125 GS
Keep for future reference!

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Table of contents
1SAFETY.............................................................................................................. 5
1.1 Safety notes (warning notes)............................................................................ 6
1.1.1 Classification of hazards........................................................................... 6
1.1.2 More, used pictograms.............................................................................. 7
1.2 Proper use.......................................................................................................... 7
1.3 Danger, which can emanate from the bandsaw............................................... 9
1.4 Qualification of personnel................................................................................10
1.4.1 Target group..............................................................................................10
1.4.2 Authorised personnel...............................................................................10
1.4.3 The operator must.....................................................................................11
1.4.4 The user must ...........................................................................................11
1.4.5 Special claims to the qualification...........................................................12
1.5 Operator position..............................................................................................12
1.6 Safety equipment..............................................................................................12
1.6.1 Main switch................................................................................................13
1.6.2 Saw band protection.................................................................................13
1.6.3 Handle grip................................................................................................13
1.6.4 Prohibition, instruction and warning signs.............................................13
1.7 Safety check of the machine............................................................................13
1.8 Personal protective equipment for special work............................................14
1.9 Safety during the use of the machine .............................................................15
1.10 Safety during general maintenance work....................................................15
1.10.1 Breaking and assuring the machine........................................................16
1.10.2 Use of hoisting devices for attendance work..........................................16
1.10.3 Mechanic attendance work at the machine.............................................16
1.11 Accident report..............................................................................................17
1.12 Electricity.......................................................................................................17
2TECHNICAL DATA .......................................................................................... 18
2.1 Electrical connection data................................................................................18
2.2 Machine data.....................................................................................................18
2.3 Machine dimensions.........................................................................................18
2.4 Necessary working room .................................................................................18
2.5 Environmental conditions................................................................................18
2.6 Emissions..........................................................................................................18
3ASSEMBLY...................................................................................................... 19
3.1Delivery volume................................................................................................19
3.2 Transport...........................................................................................................19
3.3 Storage..............................................................................................................19
3.4 Positioning and assembly................................................................................20
3.4.1 Claims to installation location..................................................................20
3.4.2 Load rope stops........................................................................................20

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3.4.3 Positioning plan........................................................................................20
3.4.4 Positioning ................................................................................................20
3.4.5 Anchor –free assembly............................................................................20
3.4.6 Anchored assembly..................................................................................20
3.5 First initiation....................................................................................................21
3.5.1 Cleaning.....................................................................................................21
3.5.2 Sight check / manual function check.......................................................21
3.5.3 Electrical connection................................................................................21
3.5.4 Function check..........................................................................................21
4HANDLING....................................................................................................... 22
4.1 Safety.................................................................................................................22
4.2 Control and indicator elements .......................................................................22
4.3 Activating the machine.....................................................................................23
4.4 Deactivating the machine.................................................................................23
4.5 Hand drive.........................................................................................................23
4.6 Cutting speed....................................................................................................23
4.7 Adjust saw band protection.............................................................................23
4.8 Lift and sag saw arm ........................................................................................23
4.9 Clamp saw band ...............................................................................................24
4.10 Activating and deactivating saw band.........................................................24
4.11 Clamp and declamp vice...............................................................................24
4.12 Adjust mitre square.......................................................................................24
4.13 Insert saw table and saw perpendicular......................................................25
4.14 Working notes...............................................................................................25
4.14.1 General notes............................................................................................25
4.14.2 Fixing the work part in the vice................................................................25
5SAW BANDS.................................................................................................... 26
5.1 Assortment of saw bands ................................................................................26
5.2 Levelling of saw bands.....................................................................................27
5.2.1 Saw band types without limit...................................................................28
5.2.2 Saw band types with limit.........................................................................29
6CHANGE SAW BAND...................................................................................... 30
6.1 Preparative work Arbeiten ...............................................................................30
6.2 Cycle: Dismantle saw band..............................................................................30
6.3 Cycle: Assemble new saw band......................................................................30
6.4 Running –in of the new saw band ..................................................................31
7MAINTENANCE ............................................................................................... 32
7.1 Safety.................................................................................................................33
7.1.1 Preparation................................................................................................33
7.1.2 Recommissioning.....................................................................................33
7.2 Inspection and attendance...............................................................................34
7.2.1 Daily work..................................................................................................34

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7.2.2 Weekly work..............................................................................................34
7.2.3 Monthly work.............................................................................................34
7.2.4 Semi –yearly work....................................................................................34
7.3 Maintenance......................................................................................................35
8CHANGE OF EXPENDABLE PARTS.............................................................. 36
8.1 Change saw band guides.................................................................................36
8.2 Change saw band guide bearings...................................................................36
9FAILURES........................................................................................................ 37
10 SPARE PARTS ................................................................................................ 39
11 APPENDIX........................................................................................................ 43
11.1 Copyright.......................................................................................................43
11.2 Product follow - up........................................................................................43
11.3 EG –declaration of conformity ....................................................................44

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1 Safety
Glossary of symbols
Symbol
account

Reference to another page

Calls on you to get in action

Gives additional indications

Forbidden
⚫
enumerations
This first part of the operating manual:
•Explains the meaning and use of the warning references contained in the
operating manual
•Highlights the dangers that might arise for you and others if these instructions are
not followed
•Explains how to use the machine properly
•Tells you how to avoid dangers
In addition to this operating manual please observe:
•Legal regulations for accident prevention
•Applicable laws and regulations
•The prohibition, warning and mandatory labels as well as the warning notes
You are liable to follow the european norms by installation, operation, maintenance and
reparation of the machine.
If european norms still are outstanding you are liable to use the country –specific
effectual norms.
If necessary you have to take some in –company actions before the use of the machine
to follow the country –specific instructions.
Always keep this document close to the machine.
Support / Information
If you are unable to solve a problem using this manual, please contact us for advice:
Epple Maschinen GmbH
Service und Support
Auf der Breite 2-14
D-73349 Wiesensteig

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1.1 Safety notes (warning notes)
1.1.1 Classification of hazards
We classify the safety warnings into various levels. The table below
gives an overview of the classification on symbols (pictograms) and
warning labels for the specific danger and its (possible) consequences.
Symbol
Warning
alert
Definition/ Consequences
Danger!
Imminent danger that will cause
serious injury or death to
personnel.
Warning!
Risk: a danger that might cause
serious injury of death to
personnel.
Caution!
Risk: a danger that might cause
serious injury of death to
personnel.
Attention!
Situation that could cause
damage to the machine or
products and other types of
damage. No risk of injury
personnel.
Information!
Application tips and other
important or useful information
and notes. No dangerous or
harmful consequences for
personal or objects.
In case of specific dangers, we replace the pictogram by
General
danger
Injuries to hand
Dangerous,
electrical
tension

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1.1.2 More, used pictograms
Engaging
forbidden
Draft mains
plug
Wear
protection
gloves
Wear protection
glasses
Wear ear
protection

Wear
protective
suit
Wear safety
shoes
Mind the
environment
Your contact
person
1.2 Proper use
Warning!
In the event of improper use, the machine
•Will endanger employees,
•Will endanger the machine and other material property of the operator,
•may affect proper operation of the machine
The machine may not be in an explosive environment.
The machine was built and construed for the following utilisations:
This saw only is for sawing of steel, non –ferrous heavy metal, cast iron,
not rusting steel and plastic. Working with flammable material is forbidden.
Any other use is improper.
The use and positioning of the machine only is allowed in dry and well aired
rooms
If the machine is used in any way other than as described above, modified
without authorisation of Epple Maschinen GmbH or operated with different
process data, then it is being used improperly.
We do not take any liabilities for damage caused by improper use. We would like
to point out that any modifications to the construction, or technical or
technological modifications that have not been authorised by Epple Maschinen
GmbH will also render the guarantee null and void.
It is also part of proper use that

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•The maximum values of the machine are complied with,
•The operating manual is observed
•Maintenance and inspection commands are followed
For an optimal efficiency, you have to observe the following:
•The correct choice of the saw band, accordant to the material
•The correct clamping of the saw band
•The correct abrasiveness of the saw band
•The correct cutting pressure and cutting speed
•The adequate coolant lubrication
Warning!
An improper use can lead to heaviest injuries.
The rebuilding or the change of the performance data is forbidden and endanger
personnel and machine.

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1.3 Danger, which can emanate from the bandsaw
Construction and building of the machine equate to level of technique. The
machine was checked of operating safety.
However there exist risks and dangers by the use:
•Improper use and non –observance of safety instructions can cause
extensive injuries like bruises, crops, fractures or separation of members
•Danger of cuts also by stopped saw band
•Risk of injury by kickback of work parts
•Danger of electric shock by damaged and electric units
•Eventually damage or irritation of the respiratory system and eyes by
cutter dust
•Risk of stumbling by about lying work parts or work part rests
•A cant of work parts can break the band saw and cause heavy injuries
•Danger for ears by loud noise (from 85 dB(A))
•The running saw band can catch and contract your working wear
•Danger of cuts by chips and sharp edged construction parts
•Danger of accident through damaged saw bands (f. e. stump, demolished)
•During use of coolant lubricant exists the danger of skin diseases
By the maintenance and use of the machine dangers because of false use or
improper maintenance may encounter you.
Information
To avoid errors and dangers, all users who are assigned with the
assembly, the use and maintenance have to be qualified and read plus
understand the operating manual.
By improper use of the machine may:
•Danger for body and life exist
•The machine and other property can be endangered
•The safe function of the machine can be affected
It is very important that you disconnect the machine for cleaning and maintenance
work.
Warning!
The machine only can be used with functioning safety equipment. The machine
must be disconnected directly if you notice damaged or failure safety equipment.
All special units that are mounted from the operator have to include the
accordant safety units. You are not allowed to derogate or avoid the safety units
of machine. The responsibility therefore is the operators.

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1.4 Qualification of personnel
1.4.1 Target group
This manual is addressed to the operators, users and maintenance staff.
The warning notes therefore refer to both operation and maintenance of
the machine.
Determine clearly and irrevocably who will be responsible for the
different activities on the machine (operation, maintenance and repair).
1.4.2 Authorised personnel
Warning!
Incorrect use and maintenance of the machine constitutes a danger for
personnel, objects and the environment.
Only authorized persons may operate the machine.
Authorised personnel for the use and maintenance are:
•Trained and instructed operators
•Trained and instructed experts of the retaile

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1.4.3 The operator must
The operator is bound to instruct the personnel in regular intervals (at
least once a year) on
•Monitoring all safety standards that apply to the machine
•Maintaining the operation
•Obtaining accredited technical guide lines
Furthermore the operator is bound to:
•Document training/ instructions
•Require the staff to confirm participation in training/ instruction by
means of a signature
•Control whether the personnel observes the operation manual
and whether it is close to the machine
•Check that the staff is aware of safety and dangers in the
workplace and that they observe the operating manual
1.4.4 The user must
•Observe commands of superiors and sentinels
•Do not remove safety equipment during work
•Avoid a cant of the work part during work part feeding
•Cover band saw until the area that is needed for cutting
•Avoid contact with band saw
•Use personal protective equipment (incl. skin protection)
•Wear close working wear
•Remove chips with adequate equipment and not by hand
•Do not use damaged saw bands
•Work parts have to be clamped safe and feast
•Assure order and cleanness at the work place
•Never work with damaged machine parts
•Announce defects directly to your superior
•Read and understood the user manual
•To be familiar with all safety regulations and safety arrangements
•Use the machine

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1.4.5 Special claims to the qualification
For the work with electric units or operating materials more claims to the
qualification are efficient.
Only electronic experts are allowed to do work at electric units. If the
instruct and oversee you, you are allowed, too.
Before you accomplish work at electric units or operating material you
have to keep the following instructions in this order:
•Disconnection
•Assure against resetting
•The unit must be de - energized
Please observe the effective regulations of the insurance association
and the accident prevention.
1.5 Operator position
The operator position is straight standing in front of the machine. Every other
position can lead to danger of personnel.
1.6 Safety equipment
The use of the machine is only allowed with correct functioning safety devices.
The machine is to decommission directly if a safety device is deficient of
effectless. Therefore you are responsible as an operator/ user. After response,
defect or falling out of a safety device, the profile roll may not be in use until:
•The failure/ cause of the failure is abolished
•You have checked the machine and fell confident that there is no danger
for personnel or property values
Warning!
If you remove the destined safety devices or abrogate them by bridging you
endanger yourself and other personnel working at the machine.
Consequences can be heavy injuries until death.
The band saw includes the following safety equipment:
•Main switch with end stop
•Saw band protection cover
•Handle grip

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1.6.1 Main switch
The main switch is at the same time the
deactivating end limit.
1.6.2 Saw band protection
Protect the saw band until the area
that you need for sawing.
1.6.3 Handle grip
Only move the saw bow at the handle grip.
1.6.4 Prohibition, instruction and warning signs
Observe additionally to the user manual the safety and warning notes at
the machine. Warning notes that only are at the user manual and not at
the machine have additionally unlimited validation and are to follow
absolutely.
1.7 Safety check of the machine
You are bound to check the machine at least once pro shift. Announce scarcities
and defects directly. You have to check all arrangements
•Before every shift
•By disconnected use before every use
•After every maintenance
Assure and check that all warning notes and signs at the machine are complete
and good readable.
Document your security check in an adequate way.
Checking in general
Safety equipment
Operation
OK
Saw band
protection
Feast, and is easy moveable after declamping.
Safety notes
All safety notes are located and undamaged at
the machine
Function check of the safety elements
Element
Operation
OK
Deactivating end
stop
You have to deactivate the machine directly
after the saw bow was moved to the lower
arrester.

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1.8 Personal protective equipment for special work
Use for your work always the necessary personal protective.
Protect your face and your ears: Wear a safety helmet with a face guard for
every work, especially for any kind of work where your face and eyes are
exposed to hazards.
Use protective gloves when lifting or handling pieces with sharp edges.
Wear safety shoes when fitting, dismanteling or transporting heavy components.
Use ear protection over 80dB
Wear closely safety suit.
Do not wear long hair open, wear hairnet or cap
Check before start of work whether the required protective is complete and intact.
Broken protective has to be modernized. Always announce missing protective
and only begin to work if the protective is complete.
Caution!
Contaminated, defiled protectives can release indispositions. Clear them up after
every use and at least once a week.

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1.9 Safety during the use of the machine
Warning!
Assure before activating the machine that no person or property value is
endangered.
Do not accomplish work at the machine that is dangerous:
•Assure that other people are not endangered by you
•Observe the maximum cutting capacity of the machine
•Clamp the work parts before connection correct and feast
•Always disconnect the band saw for control measurements at the work part
•Wear adequate personal protective for protection equipment
•Do not remove chips with hands, use adequate means of work
•Never work at the machine if your concentration is limited (f. e. by
medicaments)
•Follow the using, assembly, attendance and maintenance instructions in this
user manual
•Observe the accident prevention regulations that are effective for your business
•Announce damages directly to your superior
•Only leave the machine after deactivating i fit stopped completely
1.10 Safety during general maintenance work
Before you begin with maintenance work at the machine you are bound to inform
the operating personnel.
Announce and document changes which are safety relevant. Do not execute
changes without consultation with the manufacturer. Refresh the operation
manual only in consultation with the manufacturer. Only instruct the operation
personnel if all changes are approved.
Document the instruction in an adequate way.

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1.10.1 Breaking and assuring the machine
Deactivate the machine before the beginning of attendance and
maintenance work with the main switch.
Mark the machine clearly against resetting.
After breaking with the main switch all dangers of tensions are broken.
Warning!
Moves of machine parts and electric machine parts can hurt you and
others heavy. Act very careful if it is not necessary to unplug the
machine because of working. Inform personnel around you about your
cycle and the possible dangers.
1.10.2 Use of hoisting devices for attendance work
Warning!
If the lifting tool is not stable enough it can burst what may cause heavy
or deadly injuries.
Check before working with lifting tool whether it is admitted for the load
and undamaged. Assure that the load is fixed correctly. Never step
under lifted loads. Please observe the effective accident prevention
regulations for your business.
1.10.3 Mechanic attendance work at the machine
Before or after attendance work:
Replace all protection and safety units that are especially for attendance
work and activate the machine with the machine –own protection and
safety units. Check the protection and safety units after every
attendance or maintenance work about completeness and correct
function.

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1.11 Accident report
Inform your superior directly about accidents or “nearly accidents”.
So –called „nearly accidents“ can have different causes and need a detailed
analysis.
1.12 Electricity
You are bound to let the electrical equipment of the machine check regularly.
We advise you at least a checking every 6 months. Deficiencies like damaged
cables or not fixed connections you have to correct always immediately
underneath observance of the safety measures. During work at live parts a
second person always has to be attendant who can switch –off the machine in
an emergency.
The machine must be out off gear immediately by failure in the electrical supply.
 You will find more information in chapter maintenance.

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2 Technical data
2.1 Electrical connection data
Connection
230V / 50Hz
Main motor
1,2 kW
2.2 Machine data
Saw band
1.440 x 13 x 0,65 mm
Cutting speed
35-80 m/min stepless
Mitres
45°/60°
Cutting capacity
0°
45°
Round
120 mm
70 mm
Square
130 x 125 mm
70 x 100 mm
2.3 Machine dimensions
Total height
700 mm
Depth
315 mm
Width
740 mm
Weight
ca. 20 kg
2.4 Necessary working room
Width
1.500 mm
Depth
1.500 mm
2.5 Environmental conditions
Temperature range
5 –35°C
Air humidity
25 up to 75%
2.6 Emissions
The noise emission of the machine is ca. 60db(A).
If you use more machines at one time it is possible that the acoustic emissions
cross the allowed extreme value.
Therefore we advise to wear always ear protection.
Bethink that the constancy of the sound emission, type and character of the work
place plus more machines influence the noise level.

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3 Assembly
The band saw is pre –mounted, apart from the stand and the transport rolls.
3.1 Delivery volume
After receipt of the delivery you have to check directly of shortfalls. Compare the
scope of delivery with the information at the packing slip.
Check whether the machine has damages in transit.
3.2 Transport
Warning!
Through tilting over or falling down of machines and/ or machine parts of the
transport vehicles or fork trucks it can come to heaviest or even deadly injuries.
Observe the transport box or palette with respect to:
•Rope stops
•Weight
•Balance point
•Prescribed means of transport
Warning!
It can come to heaviest or even deadly injuries by cracking of damaged or not
effectual load –bearing hoisting devices and lifting fixation devices.
Assure and check that the hoisting devices and lifting fixation devices are
adequate load –bearing and in blameless condition.
Observe therefor implicitly the accident prevention regulations that are effective
for your business.
Never Step under lifted loads for your own safety.
Make sure that the loads are fixed correctly.
3.3 Storage
By an improper storage the machine or machine parts can be damaged. Never
store the machine under other environmental conditions than in the operation
manual denoted. The warranty claim declines by improper storage.

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3.4 Positioning and assembly
3.4.1 Claims to installation location
The machine may not be in an explosive area. The machine is therefore
not construed. The acceptable environmental conditions have to be
followed at the installation location. Organise the installation location
according to the safety regulations for the use of this machine. See that
the installation location is not limited for the use, attendance and
maintenance.
Guarantee a boundless and free amenability of the mains plug and all
operation units of the machine.
3.4.2 Load rope stops
The machine needs no load rope Stops because it has transport rolls
and grips.
3.4.3 Positioning plan
Observe during positioning of the machine that the design of the working
place is ergonomic. Observe during positioning of the machine the
accident prevention regulations that are effective for your business.
The room for handling, attendance and maintenance may not be limited.
Bethink, a cramped work place recovers accident risks.
3.4.4 Positioning
Observe that the bottom/ ceiling are stable enough. If the rigidity is not
enough, it can come to oscillations between machine and bottom. This
can lead to failures at the machine and adjoining devices.
3.4.5 Anchor –free assembly
Machines of this construction form and size can be used transportable
with the provided stand and do not have to connect with the bottom.
3.4.6 Anchored assembly
If you apply the machine at another stand than the provided one, the
machine has to be screwed. Assure during the anchorage that you follow
your internal safety regulations.
Anchor the complete mounted unit accordant to the condition of the
bottom with the adequate anchor fuses or dowel and screw
combinations.