Maggi BIG 800 User manual

Cod.00008254 REV.02 / 06-2012
JUNIOR 640
BIG 800
BEST 960
BEST 1250
88
tel. [phone]
fax [phone]

1
GENERAL INFORMATION - MACHINE IDENTIFICATION
INFORMATIONS GENERALES - IDENTIFICATION DE LA MACHINE
INFORMAZIONI GENERALI PER L'IDENTIFICAZIONE DELLA MACCHINA
INFORMACIONES GENERALES - L'IDENTIFICACION DE LA MAQUINA
ALGEMENE INFORMATIES VOOR DE IDENTIFICATIE VAN DE MACHINE
Manufacturer
Fabricant
Fabbricante
Constructor
Fabrikant
Manufacturer's address
Adresse fabricant
Indirizzo fabbricante
Dirección del constructor
Adres van de Fabrikant
Machine name
Nom appareil
Nome apparecchio
Nombre del aparato
Naam van het toestel
MAGGI ENGINEERING s.r.l.
Via delle Regioni, 299
50052 CERTALDO - (FI)
ITALIA
Power supply - Absorption
Alimentation - Absorption
Alimentazione assorbimento
Alimentación - Absorción
Absorptievoeding
Year of manufacture
Année de construction
Anno di costruzione
Año de fabricación
Bouwjaar See rating plate on machine
Voir instructions sur la machine
Vedi targhetta dati sulla macchina
Ver chapa datos sobre la máquina
Zie het naamplaatje op de machine
❏JUNIOR 640 ❏BIG 800
❏BEST 960 ❏BEST 1250

2
JUNIOR 640 / BIG 800 / BEST 960 / BEST 1250
English............................................................................................................................................................page 3
Français..........................................................................................................................................................page 29
Italiano............................................................................................................................................................pag. 55
Español ..........................................................................................................................................................pág. 81
Nederlands .....................................................................................................................................................pag. 107

3
UK
JUNIOR 640
BIG 800
BEST 960
BEST 1250
RADIAL ARM SAWSRADIAL ARM SAWS
RADIAL ARM SAWSRADIAL ARM SAWS
RADIAL ARM SAWS
engineering

5
UK
CONTENTS
CHAPTER 1
- GENERAL INFORMATION ..............6
1-1 OPERATING REMARKS .................. 6
1-2 DESCRIPTION OF THE MACHINE .. 6
1-2.1 USABLE TOOLS............................... 6
1-3 SAFETY PROTECTIONS ................. 7
1-4 INDIVIDUAL PROTECTION AIDS .... 7
1-5 TECHNICAL SPECIFICATIONS ....... 8
1-6 INTENDED USE ............................... 8
1-7 HANDLING AND HAULAGE ............. 9
1-8 CONTENTS AND PACKAGE ............ 9
1-9 DIMENSIONS ................................. 10
1-10 DIRECTIONS FOR INSTALLATION 11
1-11 DISCONNECTING PROCEDURE ...11
CHAPTER 2
- INSTALLATION ..............................12
2-1 ASSEMBLING NOTES ................... 12
2-2 SPARE CLEARANCES AROUND
THE MACHINE ............................... 12
2-3 SETTING UP THE BENCH ............. 12
2-4 FITTING THE TOOL-HOLDING ARM
AND THE RELATED CONTROLS .. 13
2-5 FITTING THE TOOL-HOLDING
HEAD .............................................. 13
2-6 SETTING UP THE WORKTABLE ... 14
2-7 FITTING THE BLADE GUARD ....... 15
2-8 FITTING OR REPLACING THE
BLADE ............................................ 15
2-9 FITTING THE QUICK ARM POSITION-
ING LEVER "A" ............................... 16
2-10 CONNECTING THE SQUARING
MACHINE TO THE MAINS ............. 16
CHAPTER 3
- USE AND ADJUSTMENTS ............17
3-1 PERPENDICULARITY OF THE TOOL
TO THE WORKTABLE.................... 17
3-2 SQUARING THE ARM WITH THE
ABUTTING STRAIGHTEDGE......... 17
3-3 PARALLELISM OF THE BLADE WITH
REFERENCE TO THE CARRIAGE
TRAVEL .......................................... 19
3-4 RADIALADJUSTMENT OF THE
TOOLS ACCORDING TO THE
CUTTING ANGLES......................... 19
3-5 TOOL TILT ADJUSTMENT WITH
REFERENCE TO THE WORKTABLE19
3-6 WORKTABLE PREPARATION........ 20
CHAPTER 4
- MAINTENANCE .............................21
4-1 ADJUSTING THE SELF-BRAKING
MOTOR BRAKING EFFECT........... 21
4-2 PERIODICAL LUBRICATION AND
CLEANING OF THE MACHINE ...... 21
4-3 REDUCING THE PLAYS ................ 22
4-3.1CARRIAGE-SLIDEWAYS PLAY...... 22
4-3.2PILLAR-BASE PLAY ....................... 22
4-3.3ARM-PILLAR PLAY......................... 22
4-4 NOISE EMISSION .......................... 23
4-5 OUT OF COMMISSION OF THE
MACHINE........................................ 23
CHAPTER 5
- ELECTRICAL DIAGRAM ...............24
5-1 MONOPHASIC MOTOR - MOTOR
SAFE-BOX ...................................... 24
5-2 WIRING CONNECTION TO TERMI-
NAL BOARD ................................... 25
5-3 THREE-PHASE MOTOR - MOTOR
SAFE-BOX ...................................... 26
5-4 WIRING CONNECTION TO TERMI-
NAL BOARD ................................... 27

6
CHAPTER 1 - GENERAL INFORMATION
1-1 OPERATING REMARKS
WOOD PROCESSING MACHINES CAN BE
DANGEROUS.
1) Careful and accurate compliance with the
directions provided by this instruction book
will allow the user to use the machine in a
safe and proper way.
2) The machine must only be used by skilled
andadultstaff. The Safetymanagershould
make sure that the person in charge of
using the machine has read and under-
stood the directions provided by this in-
struction book.
3) The staff in charge of the scheduled and
unscheduled maintenance of the machine
must have a good mechanic and electronic
background.
4) Stay away from any moving part of the
machine.
Never touch the blade while the machine is
running.
5) Never place the pieces to be processed on
top of each other. Always saw one piece at
atimeafterproperlyadjustingthemachine.
THE HANDLING OR REMOVAL OF THE
SAFETY DEVICES CAN CAUSE SERIOUS
ACCIDENTS. DO NOT REMOVE, SWITCH
OFF OR ALTER SUCH SAFETY DEVICES.
IN ADDITION, MAKE SURE THAT THE
SAFETY DEVICES ARE IN WORKING OR-
DERAT ALL TIMES, BYINSPECTING THEM
AT REGULAR INTERVALS.
IMMEDIATELY CORRECT ANY FAULT OF
FAILURE.
1-2 DESCRIPTIONOFTHEMACHINE
Radial squaring machines are used for cutting
wood or wood-like boards so as to obtain
squaredor45°-cutpieces.Thecuttingcapabili-
ties of the machines can be drawn from the
table contained in paragraph 1-5.
Working is carried out as follows:
- lay the piece down and keep it pressed
against the square abutting end;
- setthemachineforthedesiredcuttingdepth,
and the required direction and blade-to-
piece angle;
- move the blade away for a further check,
thenstartthemotorwhilekeepingahandon
the grip; use the other hand to exert suffi-
cient pressure on the piece to be worked;
keep your hand at a safe distance from the
cutting line;
- pull the carriage, exercising extreme cau-
tionwhenthebladecomesintocontactwith
the piece, so as to avoid possible cutting
reactions;
- After the cutting, stop the machine moving
the blade to its home position and remove
the cut pieces.
1-2.1 USABLE TOOLS
As regards the USABLE tools, Maggi Engi-
neeringrecommendtheuseofbladesfitforthe
type of process to be carried out, and THAT
such blades should be highly reliable, should
not recoil and should pose a low risk of acci-
dents.
Maggi Engineering’s technicians, according to
their studies and tests, recommend the use of
universal disk blades for longitudinal cuts and
cross-cuts with alternating teeth (fit for radial
saws).
In any case, the blade diameter to be used is
Dia.350/400mm.
Fig.Ashowsauniversaldisk saw for longitudi-
nal cuts and cross-cuts with alternating teeth.
Fig.A
WARNING
WARNING
Disk saw
withalternatingteeth

8
1-5 TECHNICAL SPECIFICATIONS
Blade diameter (mm)
Hole diameter (mm)
Size of driving shaft (mm)
Three-phase motor power (Kw)
Single-phase motor power (Kw)
Motor revs (r.p.m.)
Intake opening on blade guard (mm)
Intake opening on back hood (mm)
Table size (mm)
Max cutting length (mm) [Ø350]
Max cutting length max (mm) [Ø400]
Max height cutting width (mm) [Ø350]
Max height cutting width (mm) [Ø400]
Max cutting height (mm) [Ø350]
Max cutting height (mm) [Ø400]
Max blade height from plane (mm) [Ø350]
Max blade height from plane (mm) [Ø400]
Max blade cutting height at 45°(mm) [Ø350]
Max blade cutting height at 45°(mm) [Ø400]
Max cut with arm at 45°(right) (mm)
Max cut with arm at 45°(left) (mm)
Net weight (Kg)
Gross weight (Kg)
Size of package (mm)
Ø350/400
Ø30
Ø25x80
3
2,2
2800
Ø60
Ø100
975x1580
20x550
20x545
100x480
125x450
100
125
70
45
60
80
20x380>100x330
20x190>100x140
180
220
1400x850x590
Ø 350/400
Ø 30
Ø 25x80
3
2,2
2800
Ø 60
Ø 100
1145x1860
20x710
20x705
100x640
125x610
100
125
70
45
60
80
20x500>100x450
20x310>100x260
198
246
1400x850x590
Ø 350/400
Ø 30
Ø 25x80
3
2,2
2800
Ø 60
Ø 100
1290x2000
20x870
20x865
100x800
125x770
100
125
110
85
60
80
20x615>100x565
20x425>100x375
269
331
1500x1000x550
Ø 350/400
Ø 30
Ø 25x80
3
2,2
2800
Ø 60
Ø 100
1580x2400
20x1160
20x1155
100x1090
125x1060
100
125
110
85
60
80
20x800>100x770
20x610>100x580
285
347
1800x1000x630
Junior 640 Big 800 Best 960 Best 1250
DESCRIPTION
1-6 INTENDED USE
It is recommended for the radial arm saws
machinestobeexclusivelyusedfortheopera-
tions described in this manual, including nor-
mal maintenance operations.
Themachinesaredesignedinparticularfor
perpendicular and 45°cutting with refer-
ence to the abutting square.
It is therefore advisable to look the instruc-
tion manual over before assembling the
machine. Any modification, use or inter-
vention other than those provided for rep-
resents an anomalous condition which,
besides damaging the machine, can be ex-
tremely dangerous for the operator.
WARNING
WARNING

9
UK
1-7 HANDLING AND HAULAGE
Theradialarmsawsmachinesaredeliveredin
a single package. The package dimensions
and weight are shown in the table.
Handling is possible by lifting and moving de-
vices such as:
- fork-lift trucks, bridge cranes, cranes
When handling the packages, make sure that
the area is clear of obstacles.
Store the packages in a dry place, sheltered
from the rain, snow and humidity.
During all handling phases, we recommend
excercising extreme caution so as to avoid
hurting people or damaging things or the ma-
chine itself.
Itisadvisabletokeepthe package for possible
subsequent transport purposes.
1-8 CONTENTS AND PACKAGE
Fig.1
WARNING
Model A) Machine packing Weight
Junior 640 1400 x 850 x 590 mm 220 kg
Big 800 1400 x 850 x 590 mm 246 kg
Best 960 1500 x 1000 x 550 mm 331 kg
Best 1250 1800 x 1000 x 630 mm 347 kg
Model B) Wooden plane packing Weight
Junior 640 1580 x 530 x 70 mm 30 kg
Big 800 1860 x 700 x 70 mm 38 kg
Best 960 2000 x 780 x 80 mm 46 kg
Best 1250 2400 x 1100 x 100 mm 75 kg
The package contains 2 boxes, the machine
and the wooden plane boxes.
When you open box A), machine, you find:
1) Handbook
2) Carriage
3) Tool kit
4) Bench screws and nuts
5) Self-centring lever for bench positioning
6) Bench locking handle
7) Lift handle knob
8) Cable holder spring
9) Carriage locking group and measuring in-
dexes
10) Blade guard assembly
11) Motor protector
12) Leg box containing the 4 bench legs
13) One right-hand square
14) One left-hand square
15) One centre square
16) Two locking wing-nuts
17) Bench
18) Arm with slides for tool carriage
19) Envelope with locking handle on pillar and
spacers
In package B) wooden table you will find:
1) The wooden worktable.
Beforestartingtheassembly,itisadvisable
to read the handbook thoroughly, as it pro-
vides all the information and directions re-
quired to safety operate the machine.

10
1-9 DIMENSIONS
Fig.2a Fig.2b
Fig.2c
See figures 2a, 2b, 2c.
Mod.
1550 800 630 1400 1200 975 1580 1100
1550 800 630 1570 1365 1145 1860 1300
1680 800 600 1740 1470 1290 2000 1450
1680 800 600 1940 1670 1290 2400 1650
AB CD E F GH
Junior
640
Big
800
Best
960
Dimensions (mm)
Best
1250

11
UK
1-10 DIRECTIONS FOR INSTALLA-
TION
To keep the machine in perfect working condi-
tion and to ensure precise and safe operation
for a long time, scrupolously follow the direc-
tions for installation given below.
- The machine must be installed in a closed,
dry place, with a temperature of +10°C to
+40°C.
- Sufficientspacemustbeleftcleararoundthe
machine, so as to prevent the operator from
being jammed between the moving parts of
the machine and any surrounding object.
- The feeder cable must be laid in such a way
thatitdoesnotcausetheoperatortostumble.
- Mains voltage variations must not exceed
±10%.
- The earth wire of the machine must be con-
nected to the earth wire of the plant.
1-11 DISCONNECTING PROCEDURE
Before carrying out any operation on the
machine, the following two-step disconnecting
procedure is to be followed:
A: Disconnect the machine from the mains.
B: Make sure that no power is being supplied
and that no residual energy is present.
A single person is to be responsible for the
carrying out of both operations.
Whenever the machine fails to operate, per-
form the above-mentioned disconnecting pro-
cedureandpointoutthesituationwithaclearly
visible inscription.
Fig.3

12
CHAPTER 2 - INSTALLATION
2-1 ASSEMBLING NOTES
This chapter contains all the directions re-
quired to properly assemble the machine.
Before assembling the squaring machine, it is
advisable to choose a suitable place for the
installation, making allowance for the overall
dimensions of the equipment (see figure at
paragraph 1-9).
For safety distances refer to paragraph 2-2.
Place the machine in a closed room, in a
positionsuitableforwork and foreasyconnec-
tion to the mains.
The area where the machine will be located
must be lit enough for both work and mainte-
nance activities.
Do not use bolts, nuts and screws other
than those indicated. Carefully follow the
assembling procedure described in the fol-
lowingchapters.Impropermachineassem-
bly can result in extremely dangerous situ-
ations.
2-2 SPARE CLEARANCES AROUND
THE MACHINE
Ifthemachineisto beproperlyusedandeasily
maintained under safe conditions, the area
aroundtheinstallationsiteshouldbekeptclear
as shown in the figure 4.
2-3 SETTING UP THE BENCH
Fasten the four legs to the bench as shown in
the figure. Use three screws (1), three nuts (2)
and six washers (3) for each leg.
The next step consists in making the machine
level.
WARNING
Fig.4 Fig.5
Use a spring level and turn screws (4) until the
machineislevel.Tightenlocknuts(5),figure5.
To ensure maximum safety and efficiency of
the machine, the floor is to be made of well-
levelled concrete. If the floor does not meet
such requirement, a concrete slab will have to
be prepared.
N.B.: Dimensions in mm

13
UK
2-4 FITTING THE TOOL-HOLDING
ARM AND THE RELATED CON-
TROLS
The fitting of the arm can be dangerous, on
account of the considerable weight of the
object (about 60-90 kg).
Carry out the operation with the aid of a
liftingtool,oratleastwiththeassistanceof
somebody.
Fasten the base of the BASE-PILLAR-ARM
assembly to the bench (6) (see figure 6) by
means of the 4 screws (7) and the related
nuts (8) and washers (9).
WARNING
Fig.6
With regard to the figure detail, insert the arm
lifting handle (10), then hammer in the related
lockpin (11).
Take jacquard (12) with spacer (13), supplied
inaseparateenvelope,andfitthemtothestud
screwed into the arm.
2-5 FITTING THE TOOL-HOLDING
HEAD
Remove lid (12) from the arm end (see fig. 7).
- Drive locking knob (13) home as shown in
fig. 8.
- SlidetheCarriage-Fork-Motorassemblyinto
theslideways,tryingtoavoidshocksorjolts
capable of affecting the adjustment of the
bearings (fig. 8). The assembly was tested
by our Quality Dept.
- Screw the lid back into place.
- Now fasten spring (14) to the arm by using
the screw screwed in the arm itself. Slide
motor electrical cable (15) through the eye
of the spring as shown in fig. 9.
Make sure that the carriage can slide freely
without pulling the cable.
Fig.7
Fig.8
Fig.9

14
2-6 SETTING UP THE WORKTABLE
Fit the worktable supporting brackets to the
bench as shown in fig. 10. Do not tighten the
screws until the brackets have been adjusted.
Proceedasfollowstocheckthe levelling of the
bracketsandtheperpendicularityoftheirplane
to the tool plane:
1) Take a spirit level
2) The brackets must be both levelled and at
thesamedistance from the arm.Todothis,
take advantage of the movability of the arm
as shown in figures 11 and 12. Take the
measurements while the arm is over the
brackets. If necessary, loosen screws (16)
Fig.11Fig.10 Fig.12
Fig.13
of brackets (17) and correct the position
while checking the levelling of the brackets
with the spirit level.

17
UK
CHAPTER 3 - USE AND ADJUSTMENTS
NEVER CARRY OUT THE ADJUSTMENTS
DESCRIBEDBELOWWHILETHEMACHINE
IS CONNECTED TO THE MAINS.
3-1 PERPENDICULARITY OF THE
TOOL TO THE WORKTABLE
- Openthecasingasdescribedinparagraph2-
7 removing the front part of the lower casing
unscrewing the 4 fastening screws.
- Fit the blade while the casing is open.
- Check, with a square, that the blade is per-
fectlyperpendiculartotheplane(seefig.19).
Ifnot,turnthenut (A)withanopenmouthkey
of 13 and the dowel (B) with a socket head
screw. Loosen the upper dowel, tighten the
loweroneorviceversa,onceyouhavesetthe
perpendicularity,y,workingbecomesdanger-
ous and this should be absolutely avoided.
- Once the perpendicularity to the worktable
has been obtained, check and if necessary
adjustindex(29)bylooseningscrew(30)until
theblacklineis aligned with thezeroposition
(see figure 20).
WARNING
Fig.19
Fig.20
3-2 SQUARING THE ARM WITH THE
ABUTTING STRAIGHTEDGE
- Turn the arm to the 0°position as shown in
figure21,thenstop thearmrotationbyinsert-
ing lever (31) in the specially-designed slot.
- Restaboardontheabuttingstraightedgeand
cutitforthe whole carriage travel;thencheck
if the cut is squared (see figure 21).
Fig.21

18
Fig.22
If the squaring is defective, follow these steps:
- Raisethearmlockinghandle(31)(seefigure
22).
- Turn adjusting grub screws (32) so as to
move the lever and eliminate the defect.
- Lowerthewedgeleveragainandtightenlock
nuts (33).
If the defect cannot be eliminated with the
adjusting screws, loosen screws (34) (see
figure 23) of base (35) and turn it slightly.
Once the perpendicularity of the arm to the
abutting straightedge is obtained, proceed to
thefinalsettingofthearmindex(seefigure24).
Loosen screw (36) and move index (37) until it
is aligned with the 0 position on the graduated
nonius.
Fig.23 Fig.24