ITALMAC JS 40 User manual

INSTRUCTIONS AND SPARE
PARTS HANDBOOK
1 EDITION 20/06/2008
BAND SAW
JS 40 - JS 47
UK

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BAND SAW JS 40 - JS 47
1. GENERALINFORMATION ................................................................................................................. 5
1.1 INTRODUCTION ON HOW TO USE THE INSTRUCTION BOOK ..................................................... 5
1.2 GUARANTEE...................................................................................................................................... 6
1.3 USE AND MAINTENANCE OF THE INSTRUCTION BOOK............................................................... 6
1.4 INFORMATION SENDING .................................................................................................................. 7
2. SAFETY .............................................................................................................................................. 9
2.1 FORESEEN USE OF THE MACHINEAND CONTRA-INDICATIONS FOR USE................................ 9
2.2 GENERALSAFETY RECOMMENDATIONS....................................................................................... 9
2.2.1 Safety of the person operating the machine ........................................................................................ 9
2.2.2 Individual protection gear..................................................................................................................... 9
2.2.3 Working environment safety................................................................................................................ 9
2.2.4 Prevention measures on behalf of the user ........................................................................................ 9
2.2.5 Safety instructions for the user .......................................................................................................... 10
2.2.6 Safety on the machine....................................................................................................................... 10
2.2.7 Procedure for isolating the machine ..................................................................................................11
2.2.8 During maintenance ...........................................................................................................................11
2.3 SYMBOLS: MEANINGAND USE...................................................................................................... 12
2.4 SAFETYDEVICES........................................................................................................................... 12
2.4.1. Main switch ON/OFF and emergency button.................................................................................... 12
2.4.2. Warning and safety stickers ............................................................................................................. 13
2.4.3. Safety devices and blade guards...................................................................................................... 15
2.5. DISPOSING OF HARMFUL WASTE................................................................................................ 15
2.6. MACHINE DISMANTLEMENT ......................................................................................................... 15
3. MACHINE DESCRIPTION ................................................................................................................ 17
3.1 OVERALL DIMENSIONS OF THE MACHINE ................................................................................... 17
3.2 TECHNICAL FEATURES .................................................................................................................. 17
3.3 EQUIPMENT..................................................................................................................................... 18
3.3.1 Standard equipment .......................................................................................................................... 18
3.3.2 Accessory equipment ....................................................................................................................... 18
3.4. BLADE SELECTIONAND MAINTENANCE ..................................................................................... 18
3.5. SOUND EMISSION........................................................................................................................... 18
3.6. ELECTROMAGNETIC COMPATIBILITY........................................................................................... 18
3.7 MAIN PARTS OF THE MACHINE ....................................................................................................19
4. INSTRUCTIONS FOR THE INSTALLATION .................................................................................... 21
4.1 WHAT THE CUSTOMER SHOULD PREPARE................................................................................. 21
4.2 HANDLING AND TRANSPORT ........................................................................................................ 21
4.2.1 necessary tools and equipment ......................................................................................................... 21
4.2.2 Unpacking ......................................................................................................................................... 21
4.3 INSTALLATION ................................................................................................................................. 22
4.3.1 Required space ................................................................................................................................ 22
4.3.2. Cleaning ........................................................................................................................................... 22
4.3.3. Dust extraction connection ............................................................................................................... 23
4.3.4. Electric connection ........................................................................................................................... 23
4.4. MACHINE PARTSASSEMBLING .................................................................................................... 24
4.4.1. Blade guide handwheel lever assembling......................................................................................... 24
4.4.2. Belt tensioning handwheel lever assembling .................................................................................... 24
4.4.3. Dust port assembling........................................................................................................................ 24
4.4.4. Table assembling.............................................................................................................................. 25
4.4.5. Support fence for straight cuts fixation ............................................................................................. 25
4.5. COMMISSIONINGAND PREVENTIVE CHECKS............................................................................ 25
4.6. PRELIMINARYCHECKS ................................................................................................................. 25
INDEX

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BAND SAW JS 40 - JS 47
4.7. DISMANTLEMENTAND TRANSPORT ........................................................................................... 26
4.7.1. Transport .......................................................................................................................................... 26
4.8. INSTALLATION OF FIRE EXTINGUISHING SYSTEMS .................................................................. 26
5. ADJUSTMENTS .............................................................................................................................. 27
5.1. TABLE ADJUSTMENT ..................................................................................................................... 27
5.2. BLADE LIGNING UPAND TENSIONING ADJUSTMENT................................................................ 27
5.3. BLADEALIGNEMENT...................................................................................................................... 27
5.4. BLADE GUIDEADJUSTMENT ........................................................................................................ 28
6. USE OF THE MACHINE .................................................................................................................. 29
6.1. MACHINE START ............................................................................................................................ 29
6.2. USE OF THE ANGULAR CUTS SYSTEM ....................................................................................... 30
6.3. TABLE TILTING ............................................................................................................................... 30
6.4. EXECUTION OF ROUND PIECES.................................................................................................. 30
6.5. MACHINE STOP .............................................................................................................................. 31
6.5.1. Machine stop .................................................................................................................................... 31
6.5.2. Machine stop at the end of the job.................................................................................................... 31
6.6. MACHINE RESTARTAFTER AN ACCIDENTAL STOP.................................................................... 31
7. MAINTENANCE ............................................................................................................................... 33
7.1. MACHINE CLEANING ..................................................................................................................... 33
7.2. LUBRICATION ................................................................................................................................. 34
7.3. BLADE CHANGE ............................................................................................................................. 34
7.4. BELT CHANGE ................................................................................................................................ 34
7.5. BLADE ROTATION SPEED CHANGE ............................................................................................. 35
8. TROUBLE SHOOTING GUIDE ....................................................................................................... 37
9. ELECTRIC DIAGRAMS ................................................................................................................... 39
10. SPARE PARTS ................................................................................................................................ 39

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BAND SAW JS 40 - JS 47
1 GENERALINFORMATION
1.1 INTRODUCTION ON HOW TO USE THE INSTRUCTION BOOK
In drawing up this manual, all the operations pertaining to normal use and regular maintenance of the machine
have been taken into consideration.
Therefore, to use the machine correctly and optimally it is necessary to read the instructions contained herein
carefully and to follow them meticulously.
It is advised to use original spare parts, please consult the pages concerning SPARE PARTS.
This document has been written in compliance with the following regulations:
- Directive EEC 89/392 enclosure I p. 1.1.2.b, 1.1.2.c and 1.7.4.
- Standard EN 292-2 p5
- Various applicable standards and directives.
The copyrights of this manual are owned by ITALMAC, its reproduction, even partial, is absolutely for-
bidden without authorisation on behalf of the owner.
The user shall make sure that the place of installation is suitable for the machine, in compliance with national
and local laws and regulations. A specialised technician or an inspector from the specific association shall be
called out to check the situation.
The client will be informed in advance on the requirements of the place of installation, the overall size and
weights of the packs and the dimensions of the machine once installed, before the machine is consigned. The
handbook shall be kept until the machine is dismantled. If you should loose the handbook or it should deteriora-
te, you can request another copy from the manufacturer or the importer.
It is advised to keep this manual in good condition, in an easily accessible place close to the machine.
It shall be handled with care to avoid damaging it; it is forbidden to remove, re-write or modify any of the pages
or their contents.
The handbook reflects the state of the art at the time of commercialisation of the machine and cannot be
considered to be inadequate merely because it has been up-dated at a later date due to knew knowledge and
experience.Themanufacturerreserves theright to up-dateproduction andrelativehandbooks withouthaving to
up-date previous production and handbooks, except in exceptional cases.
FOR CLARITY RESONS SOME OF THE
ILLUSTRATIONS IN THIS MANUAL
SHOW THE MACHINE WITHOUT ITS
GUARDS.
NEVER USE THE MACHINE WITHOUT
THE GUARDS UNLESS YOU ARE SPECI-
FICALLY TOLD TO DO SO FOR SERVI-
CING PURPOSES.
OPERATORSAND SERVICE TECHNICIANS
SHALL CAREFULLY READ THIS HAN-
DBOOK BEFORE STARTING TO USE THE
MACHINE OR CARRYING OUT MAINTE-
NANCE. THIS HANDBOOK MUST BE KEPT
NEAR THE MACHINE SO THAT IT MAY BE
READILYCONSULTED AND MUSTALWAYS
ACCOMPANY THE MACHINE EVEN IF
SOLD ON AT A LATER DATE.
CAUTIONCAUTION

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BAND SAW JS 40 - JS 47
1.2 GUARANTEE
The manufacturer guarantees the machine for 12 months as of the date of billing, at the following terms and
conditions, unless other agreements are made when stipulating the contract:
1. During the guarantee period, the manufacturer shall replace, free of charge, any mechanical parts that
should prove to be faulty in terms of the material utilised or in terms of poor manufacture. Faulty pieces shall
be forwarded to the manufacturer, at the customer’s expense, so that the nature of the fault may be verified.
The manufacturer shall return the replacement part carriage free.The manufacturer is not liable for assem-
bling and disassembling such pieces.
2. The guarantee does not cover pieces that may possibly be damaged during unsafe transport, incorrect or
bad installation, negligence or incapacity to use the machine, tampering, repairs or modifications made to
the machine without written authorisation on behalf of the manufacturer and in any event anything that has
nothing to do with the manufacturer.
3.Ifthe partsare repairedand replacedwherethe machine isactually installed, thepurchasershall payfor call-
out charges according to current regulations in force in the country of the manufacturer.
4. The manufacturer is not liable for the reimbursement of any form of damages to persons or property, caused
by the machine or due to delays in carrying out the jobs under guarantee. Complaints concerning the con-
tract or the operation of the machine do not provide grounds to suspend or delay the agreed payments:
Suspended or delayed payments do however provide grounds to resolve the rights of the contract.
5. Electric components and technical equipment that are not purchased directly from the manufacturer are not
covered by the guarantee.
6. All consumables and/or materials needed for periodic maintenance such as brushes, heating elements,
components subject to normal wear and parts damaged by bad maintenance and/or improper use are not
covered by the guarantee.
7.At the end of the guarantee period, the technical assistance service may still be carried out upon request of
the customer, who will be charged for the costs of any parts replaced and for all labour, travelling, board &
lodging expenses of personnel and transport of materials, based on current rates.
8. Assistance for normal adjustment and commissioning jobs is not covered by guarantee.
9. Whatever the jobs carried out (assistance, repairs, replacement of parts), you will be requested to show the
technician your use and maintenance handbook, which must prove to be in perfect conditions of use and
care.
10. The manufacturer reserves the right to charge the customer for all the costs involved in the job if the
technicians should fail to find the operating defects stated by the customer, or if such defects are actually
due to obvious neglect or incapacity of the personnel in charge of operating or servicing the machine.
1.3 USE AND MAINTENANCE OF THE INSTRUCTION BOOK
IMPORTANCE OF THE INSTRUCTION BOOK
- It is integral part of the machine supply.
- It is an indispensable tool for using, operating and servicing the machine.
- It must be kept with care throughout the life of the machine and can only be eliminated after the machine has
been scrapped.
- It must be up-dated whenever new up-dated documents are received accordingly.
- It must be handed over to the new owner of the machine if the machine is sold on at a later date.
- The wiring diagram is enclosed.
THE INSTRUCTION BOOK HAS BEEN WRITTEN FOR:
- Personnel in charge of transport.
- Personnel in charge of assembling the machine.
- Personnel in charge of installing and connecting the machine to the auxiliary utilities (air, electricity etc.).
- Personnel in charge of functional testing and operator training.
- Operators.
- Service technicians.
- Personnel in charge of final dismantlement

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BAND SAW JS 40 - JS 47
1.4 INFORMATION SENDING
For every need for written correspondence or telephone communication with the Dealer or with ITALMAC
concerning the machine, it is necessary to provide the following information
(points 1-2-3 can be found on the machine’s rating plate on the base, see fig. 1-1)
1 – machine model
2 – serial number
3 – machine voltage and frequency
4 – date of purchase
5 – name of the Dealer where purchased
6 – description of defect found, if any
7 – description of type of work being carried out
8 – hours of daily use
Send it to: ITALMAC
Via Zuccardi 28/a - Z.I. Ponte Vettigano
42012 CAMPAGNOLAEMILIA(RE) ITALY
Tel. [phone] Fax [phone]
Fig. 1-1

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BAND SAW JS 40 - JS 47
2 SAFETY
2.1. FORESEEN USE OF THE MACHINE AND CONTRA-INDICATIONS FOR USE
The machine has been designed and made to cut wooden or similar materials panels within the size limits
indicated in the technical data and in compliance with the safety, use and maintenance instructions contai-
ned in this manual.
The machine must be used by one only person staying in front of the machine itself, to be able to run the
START and STOP buttons and handle the pieces to be used. The pieces feeding is manual.
The assigned personnel will need to have carried out a sufficient training period on the use and mainte-
nance of the machine and have the minimum age required by the law in force in the relative country. Use
the individual protection gear and take the precautions given in this handbook. Use any other means that
may become necessary depending on the conditions of the working environment. The safety measures
have been adopted in relation to the above so it is forbidden to use the machine for any other work and/or
to make modifications without the manufacturer’s prior consent.
Particularly it is forbidden to use the machine to apply the edge to materials different
than wood and/or similar materials or to exceed the technical features and the dimen-
sions indicated in this handbook.
2.2. GENERAL SAFETY RECOMMENDATIONS
The woodworking machinery, due to the high blades speed rotation and the execution speed, are conside-
red very dangerous, so be careful to the risks and stay concentrate during the job.
Therefore, work in an optimum state of mind and body.
All the safety and protection devices must be kept in a state of perfect efficiency. The rating plates giving
various indications and safety recommendations must always be perfectly readable.
It is absolutely forbidden to remove them or modify the particulars they contain.
It is absolutely forbidden to carry out adjustments, cleaning, maintenance or otherwise while the machine
is running.
2.2.1. Safety of the person operating the machine
Wear close-fitting clothes suited to the working requirements. Take off any objects or clothing (scarves,
watches, bracelets, etc.) that may get caught up.
Avoid using the machine if your state of body and mind is not up to par, i.e. that may reduce the speed of
your reflexes or your level of attention.
2.2.2. Individual protection gear
It is recommended to use the following individual protection gear:
- Strong gloves for the handling of pieces.
- Goggles to protect against any splinters and/or dust getting thrown up.
- Ear defenders.
- Crush-proof footwear when handling pieces of a certain size and weight.
- Protection mask complete with interchangeable filters.
2.2.3. Working environment safety
Keep the working environment tidy and sufficiently well lighted.Arrange for spaces to store untreated and pro-
cessed materials and for moving around the machine. Likewise, keep the floor clean from dust and sawdust.
Untidiness is a synonym for accident risk.
2.2.4 PREVENTION MEASURES ON BEHALF OF THE USER
- Operators shall respect Health & Safety regulations currently in force (in Italy : D.P.R. 626/94).
- It is absolutely forbidden to run the machine in automatic mode while any of the fixed and/or mobile safety
guards are not in place.

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BAND SAW JS 40 - JS 47
- It is strictly forbidden to eliminate the safety systems installed on the machine.
- No part of the machine shall be modified to adapt it to additional devices; in the case of malfunctioning
caused indeed by the failed observance of this recommendation, ITALMAC is relieved from all forms of
consequent liabilities. Modifications must be requested and authorised on behalf of ITALMAC.
- Make sure that you remove tools, process waste or bits that could cause personal injuries or material dama-
ges from the machine before starting it.
- Wear close-fitting clothes, tie long hair back and do not wear jewellery, which could all get caught up in
moving parts of the machine.
- Keep the work area clean and tidy at all times.
- Follow all the safety and caution warnings.
- Always wear and use personal protection equipment (according to CEE 89/686 and CEE 89/656).
- Make sure that all safety devices are enabled and efficient before you start to work.
- Safety guards must always be fitted perfectly in place while working.
- Disconnect the electric and pneumatic supplies at the end of each work cycle.
- Maintenance and repairs shall be carried out by qualified personnel.
- Adjustments, which need to be carried out with the safety guards removed, shall be carried out by just one
person. Access to the machine on behalf of unauthorised personnel must be prevented while carrying out
such jobs and, if possible, only one guard shall be opened at a time.
- When repairing or servicing the machine, you must always disconnect it from the electric mains by turning
the main ON/OFF switch OFF (pos. 0) ; you must also shut-off the pneumatic supply via the stop valve by the
compressedairinlet fitting;This mustbedone to preventthe machine frombeingstarted accidentally oreven
its pneumatic parts, which could cause personal injuries.
- Safety guards removed during adjustments and maintenance must be put back in place as soon as possible,
restoring the original conditions of the machine.
- The quality of the job carried out is guaranteed exclusively by having it done by a qualified electrician using
suitable tools and testers.
- Always remember that electricity can cause fatal accidents.
- The operator shall not carry out any jobs for which he is not trained or authorised.
- The machine shall be kept clean at all times.
- Operators must advise their superior of any deficiencies and/or potentially hazardous situations possibly
noticed.
- The customer must immediately inform Italmac of any defects and/or anomalies noticed in Health and
Safety systems, together with any other situations of supposed danger that he may become aware of.
2.2.5 Safety instructions for the user
Machineoperatorsshall keep tothejobs forwhichthey are trainedandauthorised andnothingelse, as already
mentioned.
All machine operators must have read this instructions handbook and must have fully comprehended all the
instructions and warnings given.
In case of malfunctions or seizures, stop the machine using the emergency button and request the assistance
of a service technician.
Alwaysbearthe warnings givenhereinclearly in mindatall times.Whenloading pieces tobeprocessed, make
sure you do not knock against safety guards and be very careful not to get your hands, clothing, hair and other
personal objects on moving parts.
2.2.6. Machine safety
The band saw must always be correctly and steadily fixed to its base and if possible to the floor.
When you decide where positioning the band saw consider the dimensions of the pieces to be worked and by
consequence the required space around the machine.
The voltage and frequency to be used are 220 - 380 Volts +/- 10%; 50 Hz with total harmonic distortion = 5%
In case of troubles, never work with the machine running: stop the machine first and wait for its complete
stopping.
Never cut any materials that can cause sparks or overheat the shavings, thereby causing fire or explosion as
they pass through the extraction pipes.
Never try to cut wet material to avoid any risk of electric shock. The machine must be used only for cutting dry
material.
Don’t lay any object on the working table.