KAKA Industrial BS-75G User manual

METAL CUTTING BAND SAW
MODEL BS-75G
Assembly & Operating Instruction

1．INTRODUCTION
This operation instruction manual conforms to the requirements of the 98/37/EEC Machine
Directives and subsequent amendments.
In the light of this，special attention has been given to safety aspects and accident prevention in the
work-place for each stage in the machine’s “life”. Information which could be of particular
assistance to the operator has been highlighted.
The “Operating instructions” are an integral part of the machine and should be consulted
before, during and after the start up of the machine and whenever else required. The content
of these instructions should always be carefully observed.
The observance of the above is the only way to achieve the two fundamental aims of this manual:
●Optimization of machine performance
●Prevent damage to the machine and injury to the operator
The index of the chapters and the index of the drawings, diagrams and tables are contained in
chapter 3 and can be used to help the location of specific information.
CAUTION: BEFORE INSTALLING THE MACHINE, READ
THE OPERATING INSTRUCTIONS CAREFULLY
2. INFORMATION ABOUT MAINTENANCE ASSISTANCE
2.1 GUARANTEE
● The products are guaranteed against material and manufacturing defects for a period of 12
months from the date of delivery or, if the machine is installed by our employees，from the
date of machine start up.
● The buyer is only entitled to the replacement of parts which are acknowledged as faulty:
carriage and packing are at the buyer’s expense. In the event of the above, the following
information should be supplied:
1. Date and number of purchasing document
2. Machine model
3. Serial number
4. Code of any relevant drawings
● Requests for compensation for the inactivity of the machine will not be accepted.
● The guarantee does not cover uses which are not in line with these operating instructions
which are an integral part of the machine. Nor is maintenance covered if the instructions
supplied are not observed.
● The guarantee will not cover machines which have undergone unauthorized modifications.
● Modification or tampering with the safety devices is strictly forbidden.
3. INDEX
3.1 INDEX OF CHAPTERS
Chap. 1 Introduction
Chap. 2 Information about maintenance assistance
Chap. 3 Index of chapters, drawings, diagrams and tables

Chap. 4 Description of the machine
Safety standards complied with during the design and construction of the machine
Description of the machine and its components
Chap. 5 Main technical data
Chap. 6 Handling and transportation
Chap. 7 Installation
Chap. 8 Start up and operation
Devices and their location
Tools supplied
Operation
Special safety checks
General safety rules
Measures to prevent residual risks
Chap. 9 Maintenance and repairs
General safety measures
Routine checks and maintenance
Description of routine maintenance
Chap. 10 Information regarding environmental noise
Chap. 11 List of spare parts
Chap. 12 Laying off and dismantling
3.2 INDEX OF DRAWINGS，DIAGRAMS AND TABLES
ENCL.TYPE
DESCRIPTION
ENCL NO.
CHAP
Table
Cutting capacity-Selection of blade-cutting
machine
1
9.3
Drawings
Handling and transportation-Installation
plan
2
6/7/8
Drawings
Electrical details
2
Diagram
Electrical installation
3
Drawings
Block vice
4
7/8.3/9
Drawings
Blade guides
5
8.3/9.3
Drawing
Block motor pulley-Machine assembly
6
8.3
4. DESCRIPTION OF THE MACHINE
4.1 SAFETY STANDARDS COMPLIED WITH DURING THE DESIGN AND
CONSTRUSTION OF THE MACHINE
The machine produced by us is in compliance with:
• 98/37/EEC Machinery Directive (ex 89/392/EEC, as amended by the 91/368/EEC, 93/94/ECC
and 93/68/EEC Directives).
The following Standards apply:
- EN 292-1 1991 Safety of machinery- Basic concepts and general principles for design.
Basic terminology and methods.

- EN 292-2 1991 Safety of machinery. Basic concepts and general principles for design.
Specifications and technical principles.
- EN418 1994 Safety of machinery. Emergency stop devices，functional aspects-design
principles.
- EN 983 1996 Safety requirements related to systems and components for hydraulic and
pneumatic transmissions.
- EN 1037 1995 Safety of machinery. Isolation and energy dissipation 。Prevention of
unexpected start-up.
- EN 1088 1995 Safety of machinery- Interlocking devices with and without guard-
locking. General principles and provisions for design.
- EN 60204-1 1998 Safety of machinery. Electrical equipment of machines. Part 1: General
requirements Sa.
- EN 60204-2 1990 Electrical equipment of industrial machines. Part 2: Item designation
and examples of Drawings, diagrams, tables and instructions.
●89/336/EEC Directive on electromagnetic compatibility，as amended by the 92/31/EEC ，
96/68/EEC，93/97/EEC and 93/68/EEC
The following Standards apply:
-EN 50081-1 General Standard for emission levels
-EN 50082-2 General Standard for immunity
●73/23/EEC Low Voltage Directive，as amended by the 93/68/EEC Directive
4.2 DESCRIPTION OF THE MACHINE AND ITS COMPONENTS
The band sawing machine produced by us has a sturdy frame made from welded and painted
sheet-steel. The upper surface is designed to allow the complete draining away of the cutting fluid.
The band holding bow is made of cast-iron and has generous dimensions，providing the cutting
unit with the necessary strength and precision. The vice unit is also made of cast-iron and clamps
the material to be cut securely. The bar-stop device allows the length required to be preset and a
constant level of performance for repeated cuts. The blade-holding bow is firmly attached to a
reduction unit built onto the motor and to the base by means of a joint which allows 45° rotation to
the right and cutting movement with manual feed. The coolant pump is fitted to the machine base.
A changeover switch is used to start the machine and to select motor rotation speed and therefore
cutting speed. The control lever，fitted with an ergonomic hand-grip and activation button with
safety release action, reduces fatigue during operation to a minimum. The blade is protected by a
guard with interlock which covers the upper area and the hand wheels and by two adjustable lower
guards which protect the operator from ejected shavings and coolant. The machine is supplied
with a set of service spanners.
4.3 Intended and unsuitable uses of the machine
The band sawing machine has been designed and built to cut bars, structural steel and
ferrous metal pipes in accordance with the instructions contained in this manual. Therefore,
the cutting of other materials is not permitted: if the above recommendations are not
observed，the machine could be damaged and the health and safety of the operator put at

risk. Cutting is not permitted, if the bar has not been first locked in the vice.
5. MAIN TECHNICAL DATA
Under no circumstances should the following data be altered, this is in order to protect the
correct functioning of the machine and to avoid creating safety risks for the operator.
MOTOR
Motor Power
Motor revolutions (two speeds)
Electric pump
Three-phase or single-phase
KW 0.3/0.5
700-1400 rpm
KW 0.1
BLADE SIZE(length × width × thick)
Cutting thickness
2060 × 20 × 0.9
1.2 mm
Cutting speed
80-40 rpm
Cutting angle
45° right
Piece locking vice: max opening
Rapid clamping displacement
Jaws height
Jaws length
Clamping force
Bed height
215 mm
5 mm
80 mm
142 mm
350 kg – 3430 N
935 mm
Coolant tank capacity
liters 4
Machine weight
160 kg-1570 N
6. HANDLING AND TRANSPORTATION
For safe handling and transportation use a lift truck for movement indoors also indicated on the
drawing 1 Encl.1. Keep the machine in its normal position and avoid turning it upside down. If
the machine is fastened to the pedestal, stability will be greatly reduced and therefore all the
necessary measures should be taken to stop the machine from tipping over.
All handling and transportation operations should be carried out by trained staff.
7. MACHINE INSTALLATION
7.1 MACHINE CHECK
The machine should be checked to make sure that it has not been damaged during transportation
and handling. If the machine appears to have been damaged, contact us immediately. Fit all the
supplied accessories onto the machine such as the bar stop 91 (DRAW.4 ENCL.4) and the
roller arm 16 (DRAW.8 ENCL.6)
7.2 FASTENING OF THE MACHINE
The machine will be able to operate in keeping with the technical parameters supplied by us,
if it is positioned correctly and fastened securely to the bench or the factory floor so that
vibrations are minimal during operation. Consult drawing 2 machine Installation plan

Encl.2.
7.3 BAND ASSEMBLY
Remove the bow guard 47 by unscrewing the screws 125 and the hand wheels 50 (DRAW.7
ENCL.6). Fit the band by inserting it first between the bearings of the blade guide heads and then
on the two pulleys, tighten the blade slightly by means of the hand wheel 43 (DRAW.5 ENCL.5)
and replace the bow guard. Check that the band is fitted with the correct direction of teeth, as
shown in drawing 8 enclosed document 6. Make sure that the band type (dimensions 2060×20×0.9)
and its teeth pith are suited to the material to be cut.
7.4 ELECTRICAL CONNECTION TO THE MAINS
Install a differential thermomagnetic switch with characteristics suited to the mains.
Make sure that the power supply voltage corresponds to the voltage on the motor plate. Connect
the cable to the power supply line observing the color codes of the individual wires, pay particular
attention to the earth wire. Connect the machine, make sure that the rotation of the circular blade
is in the direction shown by the arrow on the guard.
7.5 CUTTING COOLANT
For the cooling of the circular blade，fill the tank with emulsible oil obtained from a mixture of
water and AGIP ULEX 260 EP oil with a percentage of 5-7%
8. MACHINE START UP AND OPERATION
8.1 DEVICES AND THEIR LOCATION
(The location of the devices described is shown on the installation plan Encl.2)
Code 203 LOCKABLE MAIN SWITCH
Code 55 START-STOP MICROSWITCH: situated inside the handle located at the end
of the control lever and has safety release action.
Code 77 ELECTRIC PUMP
Code 45 CUTTING ANGLE DEVICE: to check that cutting inclination is as required
Code 5 LOCKING VICE
Code 91 BAR STOP
Code 94 CONTROL LEVER WITH HANDLE
8.2 TOOLS SUPPLIED
1 Allen wrench size 3
1 Allen wrench size 5
1 Allen wrench size 6
1 Allen wrench size 8
1 Allen wrench size 10
8.3 OPERATION
CHECKES TO CARRY OUT BEFORE EACH CUT
A Tension the band by rotating the hand wheel 43 to the end of stroke (mechanic stop)

Remember at the end of the operation to loosen the hand wheel to avoid the slackening of the
band.
B Check that the hand indicates the required cutting angle (vice scale).
C Make sure that the bow and the vice are locked by means of the lever 74 (DRAW.3 ENCL.4)
D With the motor off, lower the bow and check that at the end of stroke, the band does not touch
the counter-vice 4. If the band does touch, adjust the screw 72 located on the bow support 3
(DRAW.8 ENCL.6). By adjusting screw 70, the width of the working stroke can also be
established.
E Make sure that the piece to be cut is properly secured in the vice.
F Make sure that the cooling liquid is circulating in the machine.
G When starting the motor, make sure that the band rotates in the direction of the arrow shown
in DRAW. 8 ENCL.6.
CUTTING OPERATION
A Before cutting, check that the inclination is the one required. In order to correct or change
the inclination, place the bench lever 74 in position 2 (DRAW.3 ENCL.4) and after
correction, move it back to position 1.
B To clamp the piece to be cut, bring the vice to about 3-4 mm from the piece by turning the
hand wheel 93 (DRAW.3 ENCL.4). Then clamp fully by lowering lever 7 to position B
(see Fig.1). Turn the speed switch 203 to the position required, take hold of the handle 67
located at the end of head lever and press the button 218.The blade will not start turning.
C Position the blade carefully on the piece to be cut. Then increase the pressure in order to
accelerate the cutting operation without using excessive force. To make a series of cuts,
position the bar stop 91 in correspondence of the size required. Fix it into position by using
the knob (DRAW.4 ENCL.4).
D To replace the band, carry out the same operations used to assemble the band (chapter 7c).
E For the choice of blade see table ENCL.1.
We strongly discourage the use of blades with ruined or insufficiently sharp cutting edges.
8.4 SPECIAL SAFETY CHECKS
A. Before using the machine, check carefully that the safety devices are in good working order,
that the mobile parts are not blocked, that no parts are damaged and that all the components
are installed correctly and are functioning properly.
B. Make sure, before operating the machine, that the screws of the guards and other protective
devices are adequately secured, especially the screws of bow guard.
C. Check that the safety microswitches and the emergency button are functioning correctly. Test
them during a loadless machine cycle.
D. Pay attention to environmental conditions. Do not expose the machine to rain; to not use it in
damp environments, position the machine on a clean dry floor that has no oil or grease stains.
E. Before using the machine, the operator should make sure that all tools and service spanners
used for maintenance or adjustment have been removed.
8.5 GENERAL SAFETY RULES

A. Wear appropriate clothing. The operator’s clothing should not be loose or dangling nor should
it have parts which could easily get caught. Sleeves should contain elastic. Belts, rings or
chains should not be worn. Long hair should be kept in a net.
B. Avoid unstable operating positions. Find a safe and evenly balanced position to operate the
machine.
C. Keep the work area tidy, untidiness increases the risk of accidents.
D. Do not use the power supply cable to disconnect the plug from the socket. Protect the cable
from high temperatures, oil or sharp edges. For outdoor use, only use extension cables that are
in line with current regulations.
8.6 MEASURES TO PREVENT RESIDUAL RISKS
A. The removal of guards and tampering with the safety devices is strictly forbidden.
B. Gloves should always be worn.
C. Standard work clothing should be used and kept closed and should not have flapping parts.
D. The machine should not be cleaned with liquids under pressure.
E. In the event of fire, extinguishers should not be used unless they are the powder type. The
electric power supply to the machine should always be disconnected in these circumstances.
F. Do not insert foreign bodies into the motor cover and to not supply the machine with voltage
by tampering with the safety microswitches or main switch.
G. Take the necessary precautions to avoid the machine being started by other people during
loading, adjustment, piece changing or cleaning.
9. MAINTENANCE AND REPAIRS
9.1GENERAL SAFETY MEASURES
A. Lockable main switch. Use the padlock in the event of machine failure or replacement of the
band. The padlock key should be entrusted to a responsible person.
B. Before carrying out any work on electrical equipment, remove the power supply plug from the
control panel (disconnect voltage).
C. Only use cables to supply power, which have a cross-section suited to the power of the
machine.
D. Opening key. The keys of the machine should be dept by authorized personnel. Do not leave
the keys for doors which provide access to the hydraulic or electrical parts or keys to lockable
switches in easy of reach of unauthorized personnel.
E. Repairs should only be carried out by authorized personnel. Only spare parts made by the
original manufacturer should be used, otherwise these could cause damage or injury.
9.2 ROUTINE CHECKS AND MAINTENANCE
FREQUENCY
(working hours)
OPERATION
100 hours
Adjustment blade guide bearings
1000
Lubrication of mobile parts in the piece locking vice (GREASE AGIP
MU 2)
50
Cleaning of the coolant tank and filter check

If necessary
Check functioning of bench lever
9.3 DESCRIPTION OF ROUTINE MAINTENANCE
A. Adjustment of the blade guide bearings
Loosen the screws 110, rotate the cams 28, so that the blade guide bushings vertically position the
blade in axis (DRAW.6 ENCL.5). Tighten the dowels 113 slightly until the blade secured. Loosen
the dowels113 slightly (about 1/10 of a turn). The front blade guides must be positioned the
nearest possible to the piece to be cut. Check every 3 months the existing tolerance between the
blade guides, making sure that it does not exceed the blade thickness of one tenth of a millimeter,
so as to avoid inexactnesses in the cut squaring. Periodically check with mounted blade that the
blade guide bearings rotate freely.
B. Lubrication of mobile parts of piece locking vice
Remove jaw 32 (draw. 4 ENCL.4), withdraw vice 5 completely by lowering the lever 93. Clean
and grease the mobile parts of the counter-vice 4 and vice 5. Lubricate the band guide devices
regularly.
C. Cleaning of the coolant tank
The coolant tank can be cleaned by simply removing the crucible 13 which supports the
motor-pump (DRAW.8 ENCL.6). Empty the coolant from the tank and collect the coolant in a
container for future disposal. Clean away the shavings and the metallic powder, taking care not to
scatter this over the machine especially around the motor and the box containing the electrical
equipment. Fill the tank with the amount and liquid stated earlier.
D. Checking of bench lever functioning
Check regularly that the rotation release-locking lever is working properly. In the event of the
lever not locking correctly, loosen grub screw 81(draw.3 Encl.4), tighten nut 79 and fasten grub
screw 81 again. Make sure that with the bench lever in position 1, arm 3 which supports the bow,
can rotate freely.
10. INFORMATION REGARDING ENVIRONMENTAL NOISE
An environmental noise test carried out on the band saw machine, identical to the machine to
which these operation instructions refer, has given the following results:
ACOUSTIC RADIATION PRESSURE
1. LAeq=71.9 dB (A)
2. LAeq=87.2 dB (the maximum acceptable value is 140dB).
3. The level of background noise has no influence = 48.5-54.2 dB (A).

11. LIST OF SPARE PARTS
POS
DESCRIPTION
CODE
Q.
POS
DESCRIPTION
CODE
Q.
1
Base
001/31
1
33
2
Tank
002/31
1
34
Bench lever hub
034/31
1
3
Rotating arm
003/31
1
35
Locking pin
014/31
1
4
Counter-vice
004/31
1
36
Antigrease ring
2036/31
1
5
Vice
005/31
1
37
Ring NILOS 32006
044/31
1
6
Bow
006/31
1
38
Blade tightener pin
038/31
1
7
Vice lever
007/31
1
39
8
Motor pulley
008/31
1
40
9
Idle pulley
009/31
1
41
Spring pin
041/31
1
10
Door
048/35
1
42
11
Reduction unit shaft
011/31
1
43
Blade tighterner
handwheel
058/35
1
12
Crucible
002-A/31
1
44
13
Waterguard
042/31
1
45
Graduated scale
045/31
1
14
Box bracket
027/31
1
46
Blade tightener guide
plate
046/32
2
15
47
Bow guard
047/31
1
16
Roller arm
016/31
1
48
Bearing 6208 2RS
073/11
1
17
49
18
moving saw blade guide
fastening washer
018/31
1
50
Handwheel D.30 M6x10
062/35
2
19
Rotating pin
019/31
1
51
Micro push plate
066/31
1
20
Vice bearing flange
021/31
1
52
21
Vice spring
020/31
1
53
Hexagon socket grub
screw M8x35 DIN914
3
22
54
Nut medium M8
3
23
Mobile blade guide rod
023/31
1
55
Handle microswitch
AH715079
028/90
1
24
Fixed blade guide rod
024/31
1
56
25
Rear blade guide
025/31
1
57
Vice gib
031/03
1
26
Front blade guide
026/31
1
58
Snap ring RS15
DIN6799
1
27
Blade guide plate
037/31
4
59
Vice screw spring spacer
085/38
1
28
Blade guide eccentric
(dx-sx)
027/35
4
60
Casing AXK30 47
060/31
1
29
Rear blade guide guard
029/31
1
61
Thrust bearing AS 30 47
061/31
2
30
Front blade guide guard
030/31
1
62
Bearing 6006 2RS
062/31
2
31
Vice screw
031/31
1
63
Return spring
063/31
1
32
Vice jaw
032/31
1
64
Roller
064/31
1

POS
DESCRIPTION
CODE
Q.
POS
DESCRIPTION
CODE
Q.
65
Idle pulley spacer bearing
065/31
1
99
Screw TPSCEI M10x20 DIN
7991
272/95
2
66
100
67
Handle
046/05
101
68
Eye tie rod M10x50
043/31
1
102
Elastic pin 8x36 DIN 1481
330/95
1
69
Blade 2060x20x0.9 Z6/10
065/75
1
103
Belleville washer 40x20,4x1.5,
DIN 2093
458/95
18
70
Screw TE M8x35 DIN 933
216/95
1
104
Blade tightener bush
041/38
1
71
Nut M8 DIN 936
013/95
1
105
72
Screw TE M8x35 DIN 933
216/95
2
106
Blade tightener screw
039/32
1
73
Nut M8 DIN 936
013/95
1
107
Casing AXK20 35
109/32
1
74
Bench lever
002/06
108
Thrust bearing AS 20 35
108/32
2
75
Screw TE M8x35 DIN 933
214/95
2
109
76
Tap
042/05
1
110
Screw TE M8x55 DIN 933
218/95
2
77
Moter pump
090/90
1
111
78
Screw TE M12x40 DIN 933
242/95
2
112
79
Bench lever nut
024/03
1
113
Hex. socket grub screw M6x10
DIN913
048/95
2
80
Screw TPSCEI M8x16 DIN
7991
251/95
2
114
Bearing 608 2RS
055/35
4
81
Hex. Socket grub screw M6x10
DIN914
081/95
1
115
Screw TCEI M6x8 DIN 912
135/95
2
82
116
83
Hex. Socket grub screw M8x10
DIN914
085/95
1
117
WasherxM8 DIN 125/A
004/95
4
84
118
85
Screw TPSCEI M8x16 DIN
7991
260/95
1
119
M12x30 spring return lever
044/09
1
86
Washer as per drawing
053/31
1
120
Reducation
190/80
1
87
121
Screw TE M8x25 DIN 933
214/95
4
88
Counter-vice pin
050/31
1
122
Screw TCEI M8x25 DIN 912
158/95
4
89
Nut M16 DIN 936
025/95
1
123
Ring-nut M30x1.5 DIN 981
304/95
1
90
Bar stopping rod
031/05
1
124
Bearing 32006
071/20
2
91
Stopping rod
004/05
1
125
Screw TBEI M6x8 ISO 7380
282/95
2
92
Handwheel D.40 M8x25
077/25
2
126
Microswitch E 100 001S51
030/90
1
93
Vice handwheel
056/35
1
127
94
Knob rod
035/32
1
128
Motor
156/80
1
95
129
96
Screw TPSCEI M8x16 DIN 912
155/95
6
130
Screw TCEI M8x25 DIN 912
158/95
4
97
Washer as per drawing
067/31
2
131
Hex. socket grub screw M6x10
DIN913
048/95
8
98

POS
DESCRIPTION
CODE
Q.
POS
DESCRIPTION
CODE
Q.
200
Box
066/90
1
210
Remote contr. Switch
CGE MC0A310AT1
032/90
1
201
Panel
069/90
1
211
Thermal relay CGE
MT03
053/90
1
202
Omega raceway
046/90
1
212
Fitting for cables PG9
213/90
1
203
Changeover switch
VEMERCSO121177IPA
012/90
1
213
Socket head screw
M4x8
2
204
Screw TCCC M4x14 DIN
7981
295/95
4
214
Screw TCCC M4x14
DIN 7981
295/95
4
205
Screw TCEI M4x6 DIN 912
120/95
3
215
Fuse blok PCH 1x38
FU2
093/90
1
206
Fuse carrier PCH 2x38 FU1
094/90
1
216
Fuse blok PCH 2x38
FU3
094/90
1
207
Contact emergency button
217
Transformer 20 VA
042/90
1
208
Emergency button
085/90
1
218
Handle button
1
209
Fitting for cables PG 13.5
215/90
2
219
Cover box
067/90
1
220
Electrical cable
016/77
1
221
Screw TCCC M4x14
DIN 7981
295/95
6
222
Screw TPSCEI M6x10
DIN 7991
249/95
2
Parts not visible on exploded
view
Tool set N°4KM 0106/4
004/73
1
Fuse 10x38 1A
202/90
4
Fuse 10x38 2A
203/90
1
12. LAYING OFF AND DISMANTLING
12.1 LAYING OFF
If the machine is to be laid off or left idle for a long period, the following operations must be
carried out:
1. Disconnect the machine from the electricity mains.
2. Empty oil from the gear box and cooling liquid from its tank.
3. Clean carefully the machine by getting rid of all traces of grease, especially on the
worked parts that must be protected with anti-oxidants.

4. Cover the machine with a sheet, preferably not plastic as it can cause rust due to the
humidity condensation.
5. Store the machine in a closed, dust-free place.
12.2 DISMANTLING
If the machine must be definitively dismantled, its components must be sub-divided for the
purpose of a possible recycle of the materials and for the environment safety. The following table
is given for your guidance:
steel
Light alloy
Cast iron
Bronze copper
plastic
various
bolts
cylinders
Structural
parts
Motor winding
springs
seals
flanges
Gear boxes
Flexible pipes
gaskets
Pins, pivots
bushings
friction items
Used oil and materials must be disposed of according to 75/439/EEC and 87/101/EEC
Directives and to country specific regulations.

BAND SAW