ZIBAS205 - Saw Zipper - Free user manual and instructions

USER MANUAL ZIBAS205 Zipper

CE-Conformal! - This product complies with the EC-directives.

Follow the instructions!

Switch off the machine before maintenance and breaks and pull out the mains plug.

Wear personal protective equipment!

Warning of pointed (sharp) tool.

Keep safety distance.

Caution risk of injury!

Push the door to close to the machine with one hand, and rotat the knob counter clockwise with the other hand

• (EN) Notice noise emission: The values given are emission values and therefore do not have to represent safe workplace values at the same time. Although there is a correlation between emission and immission levels, it cannot be reliably deduced whether additional precautions are necessary or not. Factors influencing the actual immission level at the workplace include the nature of the workspace and other noise sources, i.e. the number of machines and other adjacent operations. The permissible workplace values may also vary from country to country. However, this information should enable the user to make a better assessment of hazard and risk

Anweisungen in der Bedienungsanleitung einstellenPREFACE (EN) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 35 ZI-BAS205 / ZI-BAS25035 12 PREFACE (EN) Dear Customer! This user manual contains information and important notes for safe start-up and handling of the wood band saw model ZI-BAS250, ZI-BAS205 for simplification purposes hereinafter referred to as "machine". The manual is part of the machine and must not be removed. Keep it for later use in a suitable place, easily accessible to users (operators), protected from dust and moisture, and enclose it with the machine if it is passed on to third parties!

Pay special attention to the chapter Safety! Due to the constant further development of our products, illustrations and contents may differ slightly. If you notice any errors, please inform us. Technical changes reserved! Check the goods immediately after receipt and note any complaints on the consignment note when taking over the goods from the deliverer! Transport damage must be reported separately to us within 24 hours. ZIPPER-MASCHINEN cannot accept any liability for unnoticed transport damage.

Copyright © 2020 This documentation is protected by copyright. All rights reserved! Especially the reprint, the translation and the extraction of photos and illustrations will be prosecuted. The place of jurisdiction shall be the Regional Court of Linz or the court responsible for 4707 Schlüsselberg.

Customer service contact

ZIPPER MASCHINEN GmbH Gewerbepark 8, A-4707 Schlüsslberg AUSTRIA Tel.: [phone] Fax: [phone] Mail: [e-mail] ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 36 ZI-BAS205 / ZI-BAS25036 13 SAFETY This section contains information and important notes on safe commissioning and handling of the machine. For your own safety, read these operating instructions carefully before putting the machine into operation. This will enable you to handle the machine safely and prevent misunderstandings as well as personal injury and damage to property. In addition, observe the symbols and pictograms used on the machine as well as the safety and hazard information! Intended use of the machine The machinery is intended exclusively for the following operations: For longitudinal and cross cuts of wood and materials with similar physical properties as wood within the given technical limits. ZIPPER-MASCHINEN assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.

13.1.1 Technical Restrictions

The machine is intended for use under the following ambient conditions: Relative humidity: max. 65 % Temperature (for operation) +5° C bis +40° C Temperature (for storage and/or transport) -20° C bis +55° C

13.1.2 Prohibited Use / Forseeable Misuse

• Operating the machine without adequate physical and mental aptitude.

• Operating the machine without knowledge of the operating instructions

• Operating the machine outside the technical limits specified in this manual.

• Changes in the design of the machine.

• Modify, circumvent or disable the safety devices of the machine.

• Remove the safety markings attached to the machine.

• Operating the machine in wet and rainy conditions.

• Operating the machine in a potentially explosive environment (machine can generate ignition sparks during operation) The improper use or disregard of the versions and instructions described in this manual will result in the voiding of all warranty and compensation claims against Zipper Maschinen GmbH. User Requirements The machine is designed for operation by one person. The physical and mental aptitude as well as knowledge and understanding of the operating instructions are prerequisites for operating the machine. Persons who, because of their physical, sensory or mental abilities or their inexperience or ignorance, are unable to operate the machinery safely must not use it without supervision or instruction from a responsible person. Please note that local laws and regulations may determine the minimum age of the operator and restrict the use of this machine! Put on your personal protective equipment before working on the machine. Work on electrical components or equipment may only be carried out by a qualified electrician or under the instruction and supervision of a qualified electrician.SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 37 ZI-BAS205 / ZI-BAS25037 Safety Devices The machine is equipped with the following safety devices:

• The saw blade guard protects against accidental contact with the saw blade and from flying chips.

In order to provide adequate protection, the upper saw blade cover must always be placed as close as possible to the workpiece (max. distance 3 mm).

• Door safety switch: one safety switch each on the inside of the covering of the upper and lower wood band saw roll. Push stick

• Use a push stick to prevent the hands from being too close to the saw blade when working! General safety instructions To avoid malfunctions, damage and health hazards when working with the machine, the following points must be observed in addition to the general rules for safe working:

• Before start-up, check the machine for completeness and function. Only use the machine if the guards and other non-parting guards required for machining have been fitted, are in good operating condition and have been properly maintained.

• Choose a level, vibration-free, non-slip surface for the installation location.

• Ensure sufficient space around the machine!

• Ensure sufficient lighting conditions at the workplace to avoid stroboscopic effects.

• Ensure a clean working environment.

• Only use perfect tools that are free of cracks and other defects (e.g. deformations).

• Remove tool keys and other adjustment tools before switching on the machine.

• Keep the area around the machine free of obstacles (e.g. dust, chips, cut parts, etc.).

• Check the strength of the machine connections before each use.

• Never leave the running machine unattended. Switch off the machine before leaving the working area and secure it against unintentional or unauthorised recommissioning.

• The machine may only be operated, serviced or repaired by persons who are familiar with it and who have been informed of the hazards arising from this work.

• Ensure that unauthorised persons maintain a safe distance from the machine and keep children away from the machine.

• When working on the machine, never wear loose jewellery, loose clothing, ties or long, open hair.

• Hide long hair under hair protection.

• Wear close-fitting protective clothing and suitable protective equipment (eye protection, dust mask, ear protection; gloves only when handling tools).

• Work on the machine should only be carried out in well-ventilated rooms. If necessary, use dust protection.

• If there are connections for dust extraction, make sure that they are properly connected and in working order.

• Always work with care and the necessary caution and never use excessive force.

• Do not overload the machine!

• Shut down the machine and disconnect it from the power supply before carrying out any adjustment, conversion, cleaning, maintenance or repair work. Before starting any work on the machine, wait until all tools or machine parts have come to a complete standstill and secure the machine against unintentional restarting.

• Do not remove any sections or other parts of the workpiece from the cutting area while the machine is running!

• Do not remove splinters and chips by hand! Use a sliding stick for this purpose!

• Use a push stick for cutting operations!

• Do not work on the machine if it is tired, not concentrated or under the influence of medication, alcohol or drugs!

• Do not use the machine in areas where vapours from paints, solvents or flammable liquids represent a potential danger (danger of fire or explosion!).

• Do not smoke in the immediate vicinity of the machine (fire hazard)!SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 38 ZI-BAS205 / ZI-BAS25038 Electrical Safety

• Make sure that the ON/OFF switch is in the "OFF" position before connecting the machine to the power source.

• Do not use the power tool if it cannot be switched on and off with the ON/OFF switch.

• Proper plugs and matching sockets reduce the risk of electric shock.

• Ensure that the unit is earthed.

• There is an increased risk of electric shock if your body is in ground contact. Avoid physical contact with earthed objects, such as pipes, radiators, etc.

• Water that penetrates power tools increases the risk of electric shock. Do not expose the power tools to rain or moisture.

• Only use suitable extension cords.

• A damaged or tangled cable increases the risk of electric shock. Handle the cable carefully. Never use the cable to carry, pull or disconnect the power tool. Keep the cable away from heat, oil, sharp edges or moving parts.

• Use of the power tool in a humid environment is only permitted if the power source is protected by a residual current circuit breaker.

• Always shut down the machine before carrying out any conversion, adjustment, measuring, cleaning, maintenance or repair work and always disconnect it from the power supply for maintenance or repair work. Before starting any work on the machine, wait until all tools or machine parts have come to a complete standstill and secure the machine against unintentional restarting. Safety instructions for wood band saws

• Work with gloves on rotating parts is not permitted!

• Replace torn and deformed saw blades immediately, they cannot be repaired.

• Never clean the band saw blade or the wood band saw rollers of the machine while running with a brush or scraper held in the hand.

• Only use sharpened tools.

• Never remove parts of the workpiece from the cutting area while the machine is running.

• Do not use the machine to cut fire wood.

• When cutting boards in upright position, use aids to prevent kick-back.

• When cutting round or irregularly shaped wood, use a device to stop the workpiece from twisting.

• Risk of injury to hands/fingers from the saw blade during operation.

• Risk of injury/cutting hazard due to deburred cutting edges.

• Risk of injury due to contact with live components.

• Risk of injury due to breakage or ejection of the saw blade or parts thereof, especially in the event of overloading or incorrect running direction of the saw blade.

• Excessive noise can cause hearing damage and temporary or permanent hearing loss. Wear hearing protection certified to health and safety regulations to limit noise exposure.

• Risk to the respiratory tract from harmful emissions of wood dust.

• Risk of injury to the eye from flying parts, also with protective goggles.

• During operation of the machine wood dust is generated. Therefore, connect the machine to a suitable dust collection system during installation!

• Always switch on the dust collection system before you start machining the workpiece! Hazard warnings Despite their intended use, certain residual risks remain. Due to the design and construction of the machine, hazardous situations may occur when handling the machines, which are identified as follows in these operating instructions: DANGER

A safety instruction designed in this way indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING

A safety instruction designed in this way indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE

A safety notice designed in this way indicates a potentially hazardous situation which, if not avoided, may result in property damage. Irrespective of all safety regulations, your common sense and appropriate technical suitability/training are and will remain the most important safety factor for error-free operation of the machine. Safe working depends primarily on you! 14 TRANSPORT WARNING

When handling the machine, ensure the correct posture or respectively use suitable means of transport (such as forklift trucks, pallet trucks, etc.). Observe any instructions and information on the transport packaging with regard to centre of gravity, attachment points, weight, means of transport to be used and prescribed transport position, etc. Two persons are recommended for transport and installation. If you transport the machine with a vehicle, ensure that it is protected against slipping, shocks and vibration. Never lift the machine by the worktable or by the hand wheels, but only by the frame or by the base where the holes for fixing the machine to the ground are located. Make sure, that the blade guard is in lower position when the machine is being transported. When lifting, carrying and depositing the load, make sure that you are in the correct posture:

• Lifting, Depositing: Ensure stability when lifting / setting down (legs hip width). Lift / lower load with bent knees and straight back (like weightlifter). Do not lift / lower the load jerkily.

• Carrying: Carry load with both hands as close to body as possible. Carry load with straight back. 15 ASSEMBLY Preparatory activities

15.1.1 Delivery content

Please check the product contents immediately after receipt for any eventual transport damage or missing parts. Claims from transport damage or missing parts must be placed immediately after initial machine receipt and unpacking before putting the machine into operation. Please understand that later claims cannot be accepted anymore.

15.1.2 Workplace requirements

The workplace has to fulfill the requirements. Please consider the safety requirements. The worktop has to be even, in level and vibration-resistant. It must be suitable at least to weight it with double weight per square meter than the machines net weight. The chosen workplace must have access to a suitable electric supply net hat complies with the machines requirements. A distance of at least 0.8 m round the machine must be guaranteed.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 40 ZI-BAS205 / ZI-BAS25040 An adequate distance must be provided for the feeding of long workpieces in front of and behind the machine. Secure the bandsaw to the floor Assembly The machine is delivered almost ready for operation. Prior to operation, the machine must only be secured against tipping over and the following components must be attached or mounted:

1. Assembly of the worktable

• Dismantle the two screws M6x20 (S), the two nuts (N) and the clamp (C) from the worktable.

• Lift the work table (WT) to the mounting position on the bench angle gauge (B). Thread the saw blade into the work table (WT).

• Position the table inlay (TI) on the work table properly.

Check that the table inlay is at the same height as the machine table.

• Fasten the worktable to the bench angle gauge (B) using three screws (M6x16), three washers and three nuts (M6).

Secure the wood band saw to the floor at the place of installation using screws to prevent the machine from tipping over during operation. The machine base has a total of four through holes (B) for this purpose - see illustration on the left.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 41 ZI-BAS205 / ZI-BAS25041

2. Assembly of the clamp

• Mount the clamp (C) using two screws (M6x20) and two nuts (N).

3. Assembly of the push stick

• Fix the screw (M6x35) with the nut (M6) onto the machine.

• Only tighten the screw with the nut on the machine to a point where a secure hold is guaranteed and the push stick (PS) can be hung on it.

4. Assembly of the rip fence

• Position the rip fence (RF) on the worktable.

• The rip fence is fixed by turning the locking lever (LL) downwards.

• To release the fixation, the locking device has to be turned upwards.

• The rip fence can be applied to both sides of the saw blade.

5. Machine assembly completed

Power Supply WARNING

Dangerous electrical voltage! Connection of the machine as well as electrical inspections, maintenance and repair may only be carried out by qualified personnel or under the supervision and supervision of a qualified electrician!

When working with non-grounded machines: Severe injury or even death may arise though electrocution! Therefore: The machine must be operated at a grounded power socket.ADJUSTMENTS ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 42 ZI-BAS205 / ZI-BAS25042 The connection of the machine to the electric power supply and the following checks have to be carried out by a respectively trained electrician only.

• The electronic connection of the machine is designated for operation with a grounded power socket (Mains voltage 230 V)!

• The connector plug may not be manipulated.

• The grounding wire should be held in green-yellow.

• The mains supply must be secured with 20A.

• Check that the mains voltage complies with the requirements of the machine.

• In case of repair or replacement, the grounding conductor must not be connected to a live box!

• Make sure that a possible extension cord is in good condition and suitable for the transmission of power. An undersized cord reduces the transmission of power and heats up.

• A damaged cable must be replaced immediately NOTICE

Operation is only allowed with safety switch against stray current (RCD max. stray current of 30mA). NOTICE

Use only permitted extension cable with cross- section the one in the following table declared.

Connecting to a dust collection system NOTE

The machine must be connected to dust collection system. The system must start up at the same time as the motor of the wood band saw starts. For materials with a humidity <12 %, the air velocity at the dust collector port and in the hoses must be at least 20 m/s (for moist chips with a humidity >12 %, at least 28 m/s). The suction hoses used must be flame-retardant (DIN4102 B1), permanently antistatic (or grounded on both sides) and comply with the relevant safety regulations.

Dangerous electrical voltage! Always disconnect the machine from the power source before carrying out any adjustment work and secure it against unintentional restarting!

In order to ensure the desired precision of the machine, certain basic settings must be made before commissioning, which are described below.ADJUSTMENTS ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 43 ZI-BAS205 / ZI-BAS25043 Open and close the front doors

• ZI-BAS205: Rotate the hand wheel counterclockwise to open the front door.

• ZI-BAS250: Rotate the hand wheel clockwise to open the front door.

Close the front door:

• ZI-BAS205: Push the front door with one hand to the wheel housing, and rotate the hand wheel clockwise with the other hand.

• ZI-BAS250: Push the front door with one hand to the wheel housing, and rotate the hand wheel counterclockwise with the other hand.

Selection of saw bands CAUTION

Always wear gloves when handling wood band saw blades. Handle the wood band saw blades carefully to prevent damage. Unused, untensioned band saw blades should be folded and stored securely in a (child-) safe, dry place. Always check saw blades for damaged teeth and cracks before use! Select the band saw blade according to the material to be cut. Narrow band saw blades are suitable for curved and circular cuts, wide band saw blades for straight cuts. For hard wood you need finer toothed band saw blades, for soft wood you should use coarser toothed band saw blades.

Correct winding of saw bands Band saw blade transport device

Dimensions of the saw bands Refer to technical dataADJUSTMENTS ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 44 ZI-BAS205 / ZI-BAS25044 Tensioning/changing the saw blade Procedure for exchanging the saw blade:

• Disconnect machine from the power supply.

Loosen the two screws M6x20 (S) and nuts (N). Remove the u-shaped clamp (C) from the worktable.

• Open the upper and lower front door (F).

• Release the saw blade tension with the hand wheel (H). - Turn the hand wheel counter-clockwise: the band saw blade tension is reduced. - Turn hand wheel clockwise: the band saw blade tension is increased.

• Unthread the old band saw blade through the work table and the table insert. ATTENTION: For this purpose use cut-proof gloves!

• Thread the new saw blade (SB) into the work table and into the table insert.

• In the next step, place new saw band (SB) in the bearings (B) of the saw band guide, then place it in the middle of the rubber tracks of the two band saw wheels (W). ATTENTION: note the cutting direction! The teeth of the band saw blade must point downwards in the cutting direction and towards the front of the machine.

• Tension the band saw blade with the hand wheel (H).

• Close the upper and lower front door (F).

• Mount the clamp (K) back on the worktable using two M6x20 screws (S) and two nuts (M).

• To check whether the band saw blade is correctly positioned in the rubber bands of the two band saw wheels (W), let the machine run for at least one minute; stop the machine, open the upper and lower front doors and check the settings and, if necessary,

adjust the band saw blade run using the hand wheel for band saw blade tracking adjustment (see paragraph 16.4).

• Adjust the saw band guide. NOTICE

The saw band tension must be adjusted according to the saw band width.ADJUSTMENTS ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 45 ZI-BAS205 / ZI-BAS25045 CAUTION

If the tension is too high, the saw band may tear - risk of injury! If the tension is too low, the driven band saw roller may spin and the band saw blade may stop. Therefore check the saw band tension before each start-up! A correct saw blade tension is essential for a long service life of the saw blade and to ensure the quality of sawing. Adjusting band saw blade tracking If the band saw blade tracking does not run properly (centred), the band saw blade tracking must be readjusted.

• Clamping screw (CS) must be loosened.

• The hand wheel (HW) must be tilted either forwards or backwards. - Turn the hand wheel clockwise: the upper wheel is tilted towards the front door.

Turn hand wheel counter clockwise: the upper wheel is tilted backwards.

• Tighten the clamping screw (CS).

• Check the saw blade tracking again. This procedure may have to be repeated several times to ensure correct running. Adjusting the saw band guide NOTE

Adjust the saw band guide only after the blade tension and the running of the saw band have been adjusted and checked. Correct adjustment of the saw blade guide is important. The saw band becomes unusable if the teeth touch the guides while the saw band is running.

16.5.1 Adjusting upper saw band guide

The upper saw band guide consists of the following components:

• Lateral guide discs Rear thrust bearing

The thrust bearing (TB) prevents the saw blade from being pushed back strongly during the cut. Procedure:

• To adjust, loosen the clamping screw (CS) and position the rear thrust bearing (TB) at a

stance of about 0.5 mm from the saw band back.

The lateral guide pins should slightly strip the saw band to obtain a vibration-free and straight cut.

• To a djust, loosen the clamping nuts (CN) and press the lateral guide discs (GD) up to 0.5 mm to the saw band.

• Then retighten the clamping nuts (CN).

16.5.2 Adjusting lower saw band guide

The upper saw band guide consists of the following components:

• Lateral guide discs Rear thrust bearing

• Loosen the two screws (M6x20) and nuts (N). Remove the u- shaped clamp (C) from the worktable.

• To disassemble the worktable from the bench angle gauge (AG), loosen the three screws (M6x16), washers and nuts (N).

• Raise the upper blade guide fully (see 16.6).

• Loosen the two locking screws (LS) and remove the bench angle gauge (AG).

• To adjust, loosen the clamping screw (CS) and position the rear thrust bearing (TB) at a distance of about 0.5 mm from the saw band back.

• Then tighten the clamping screw (SC) again. Lateral guide discs

• Mount the bench angle gauge (AG) with the two locking screws (LS).

• Close the lower front door (F).

• Fix the worktable with three screws M6x16, three washers and three nuts (M6) to the bench angle gauge (AG).

• Fix the u- shaped clamp (K) with two screws (M6x20) and two nuts (M). Height-adjustment of the blade guard

The blade guard protects against unintentional contact with the saw blade and against flying chips.

• ZI-BAS205: loosen the locking screw (LS) by turning it counter clockwise.

• To adjust the height between blade guard and workpiece, turn the hand wheel (H) until the desired height is reached. ATTENTION: Always lower the upper saw band guide as close as possible (max. 3 mm) to the workpiece.

• ZI-BAS205: retighten the locking screw (LS) by turning it clockwise. Adjusting the tilt of the worktable The following steps are necessary to adjust the cutting angle:

• After loosening both locking screws (LS), the work table tilts steplessly through 45° to the blade.

By means of the angle scale (AS) the inclination angle can be read off the indicator (I).

Retighten the locking screws (LS) after adjusting the inclination of the worktable.ADJUSTMENTS ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 48 ZI-BAS205 / ZI-BAS25048 Adjusting the work table at right angles to the saw blade

Loosen the two locking screws (LS) on bench angle gauge.

• Using a try square (TS), set the table at right angle to the blade and tighten the locking screws (LS) again.

• Loosen locking nut (LN) and adjust the limit stop screw (SS) until it touches the work table (WT).

• Tighten locking nut (LN) again. Adjusting the saw table lateral alignment

• To disassemble the worktable from the bench angle gauge, loosen the three screws (M6x16), washers and nuts.

Align the work table in a position where the saw band runs through the middle of the table insert (T).

• Tighten the three screws (M6x16) again. Adjusting the rip fence The rip fence is clamped to the front and can be used on both sides of the blade.OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 49 ZI-BAS205 / ZI-BAS25049 17 OPERATION Important operating instructions Device to be operated in a perfect state only. Inspect the device visually every time it is to be used. Check in particular the safety equipment, electrical controls, electric cables, operating components and screwed connection for damage and if tightened properly. Replace any damaged parts before operating the device.

17.1.1 Before you start working

• Check the workpiece for foreign objects, cracks and loose knots.

• General technical condition of the machine.

• Safety equipment available and in working order.

• All the components for correct fit and function.

• Moving parts are not blocked.

• If all tools have been removed from the machine for service / maintenance.

• Use only sharp, crack-free and sufficiently set saw blades.

• Check that the saw blade on the band saw wheel is correctly tensioned and aligned.

• Check the saw blade guide for correct adjustment.

• Have any necessary aids (e.g.: rip fence, push stick, etc.) ready.

• If gloves are required for workpiece handling, they must be finger-free.

17.1.2 Before each work step

• Wait until the sawband has reached full speed – then performing the cut!

• Never switch the machine on while pressing the blade against the material!

• Move the adjustable guard for the band saw blade as close as possible to the workpiece.

• When feeding the workpiece, do not place your hands on the workpiece in the area of the cutting plane.

• Feed the workpiece at a constant speed and constant pressure.

• Use aids for safe workpiece guidance: - When cutting workpieces standing on edge, secure them against tilting (e.g. by means of rip fence). - Secure round workpieces against twisting with a wedge support. - For long or wide workpieces, ensure good workpiece support (e.g. by widening or lengthening the table).

• Never remove splinters or chips by hand while the saw blade is running.

• Switch machine off, wait for standstill.

• Remove wood chips and splinters from cutting area and table insert.

• Lower the saw blade cover onto the work table.

• To protect the running surfaces of the wheels, detension the band saw blade and attach a warning sign to the machine reminding you that the saw blade tension must be reset before the next use. Switching On and Off

ON-switch (I): starting the machine

When cross-cutting a round or irregularly shaped workpiece, it is necessary to secure the workpiece with a suitable template or holding device and to use a suitable band saw blade (for cross section)!

17.3.1 Longitudinal cutting of narrow (thin) workpieces

Longitudinal cutting is sawing parallel to the wood fibre. For rectangular cuts (table at right angles to the saw blade), place the rip fence to the left of the saw blade to guide the workpiece safely along the fence with your right hand. For longitudinal mitre cuts with an inclined table, attach the parallel stop to the right of the saw band on the downward side (if the width of the workpiece permits this) in order to secure the workpiece against slipping. Use a sliding stick to prevent the hands from being too close to the band saw blade!

For diagonal cuts, use auxiliary devices as shown in the illustrations above.

17.3.5 Cutting Curves

When cutting curves, pay particular attention to the width of the saw blade. Choose a narrow band saw blade with which you can cut even the smallest radii in your workpiece. Work at a low feed rate so that you do not push the workpiece sideways out of the cutting line.

17.3.6 Cutting with a template, handling shaped work

Working with a template Correct handling of moulded parts

To cut round slices, use a circular cutting device as shown in the illustrations on the left and below!

Handling the machine with the power supply on, may lead to serious injuries or even death. Always disconnect the machine from the p ower supply before cleaning, servicing or maintenance work and secure it against unintentional reconnection! Cleaning CAUTION

Never clean the band saw blade or the band saw rollers with a brush held in the hand or with a scraper while the machine is running. Always wait until the machine has come to a complete standstill!

Wrong cleaning agents can attack the varnish of the machine. Do not use solvents, nitro thinners, or other cleaning agents that could damage the machine's paint. Observe the information and instructions of the cleaning agent manufacturer! Prepare the surfaces and lubricate the bare machine parts with an acid-free lubricating oil. Subsequently, regular cleaning is a prerequisite for the safe operation of the machine and its long service life. Therefore, clean the device after each use of chips and dirt particles. Maintenance WARNING

Danger due to electrical voltage! Handling the machine with the power supply up may result in serious injury or death. Always disconnect the machine from the power supply before servicing or maintenance work and secure it against unintentional restart!

The machine is low-maintenance and only a few parts have to be serviced. Nevertheless, malfunctions or defects which could impair the safety of the user must be rectified immediately! Intervall Component Measure Before operating the machine Safety devices Check the condition Nuts, Bolts Check if securely tightened Drive belt Check the condition. If necessary tension it. Saw band Check the condition. If necessary replace it. After every use of the machine Machine Clean the machine from chips and sawdust. Wheel housings Vacuum off chips and sawdust Saw band guide Lubricate the saw blade guide slightly with acid- free lubricating oil Thrust bearing Guide discs Keep guide discs and the thrust bearing free from deposits Saw band Slacken the saw blade Monthly Drive belt Check the condition. If necessary replace it. Security stickers Check the condition. If necessary replace them. Table insert Check the condition. If necessary replace it. Thrust bearing Guide discs Check the condition and replace them replace if they are worn out.DISPOSAL ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 53 ZI-BAS205 / ZI-BAS25053

18.2.1 Replacement of the V-belt (only for ZI-BAS250)

Always keep the V-belt correctly tensioned. A belt that is too loose weakens the power transmission (drive and braking effect), too much tension leads to excessive stress on the belt (heating).

• Disconnect the machine from the power supply.

• Remove the saw b lade. Proceed as described in

• Loosen the screw (S) which fixes the motor (M) to the exterior of the housing.

• Reduce the tension of the V-belt (AR) by pushing the motor (M) upwards.

• To remove the drive belt (DB), push the saw wheel (SW) with the motor pulley (MP) off the shaft.

• Replace the old drive belt with a new one.

• Reinstall lower saw wheel (SW) with the motor pulley (MP) by sliding it back onto the shaft.

• Secure with the shaft circlip (SC).

Place the new drive belt (DB) partially around the motor pulley (MP), then turn the wheel by hand until the drive belt (DB) is completely seated on the motor pulley (MP).

• Tension the driv e belt by moving the motor (M) downwards. To check the drive belt tension, press inwards in the middle of the belt with a force of three to four kilograms. The tension is correct if the drive belt does not yield more than 1.2 cm.

• When the tension of the belt is at the desired level, retighten the screw (S) that was previously loosened.

• To reattach the saw blade, proceed as described in

The table insert needs to be replaced when its slot has become enlarged or damaged. Procedure:

• Remove the table insert from the work table by pushing up from underneath.

• Fit a new table insert. 19 DISPOSAL Observe the national waste disposal regulations. Never dispose of the machine, machine components or equipment in residual waste. If necessary, contact your local authorities for information on the disposal options available. If you buy a new machine or an equivalent device from your specialist dealer, he is obliged in certain countries to dispose of your old machine properly.TROUBLESHOOTING ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 54 ZI-BAS205 / ZI-BAS25054 20 TROUBLESHOOTING WARNING

Danger due to electrical voltage! Handling the machine with the power supply up can lead to serious injuries or even death. Always disconnect the machine from the power supply before servicing or maintenance work and secure it against unintentional or unauthorised reconnection! Many possible sources of error can be excluded in advance if the machine is properly connected to the mains. If you are unable to carry out necessary repairs properly and/or do not have the required training, always consult a specialist to solve the problem. Trouble Possible cause Solution Motor does not work

1. Front doors open (limit switch)

2. Motor, cable or plug defective

1. Close front doors exactly

2. Contact an electrician

3. Contact an electrician

The motor starts up slowly and does not reach operating speed

1. Contact an electrician

2. Contact an electrician

3. Replacement of the capacitor by

a qualified electrician Motor makes excessive noise Motor defect Replacement of the motor by a qualified electrician Motor does not reach its full power Circuits in the network are overloaded (other motors, etc.) Do not use any other equipment or motors on the same circuit Motor overheats easily

1. Overloading of the motor

2. Insufficient cooling of the

2. Remove dust from the motor in

order to ensure optimal cooling of the motor Saw cut is rough or wavy

1. Saw blade is dull

2. Tooth shape is not appropriate

for the material thickness

1. Resharpen the saw blade

2. Use a suitable saw blade

Workpiece pulls away and/or splinters Excessive cutting pressure and/or the saw blade is not suitable for use Insert a suitable saw blade Saw blade is not running straight

1. Saw band guide has been

according to the operating instructions

2. Select a saw blade according to

the operating instructions Burn marks appear on the wood during the cutting work

1. Change the saw blade

2. Select a saw blade according to

the operating instructions Saw blade jams during cutting work

2. Deposits on the saw blade

3. Saw band guide has been set

1. Change the saw blade

2. Clean the saw blade

Circlip for Shaft 10

Setting Knob for Blade Tension

Setting Knob for Blade Tracking Adjustment

Setting Knob for Blade Guard

Motor Connecting Plate

Top cover plate for Upper Blade Guard

Adjusting Knob Cover

Fixing Seat of Door Locker