Lumag BSW 76EPRO Operating Manual
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Lumag BSW 76EPRO Operating Manual

Bandsaw mill
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Bandsaw mill
BSW 76EPRO with electric motor
BSW 76GLPRO with petrol engine
BSW 76GLPRO
BSW 76EPRO
Operating manual
(Translation of the original operation manual)
Both the model number and serial number can be found on the nameplate on the machine. You should keep both
numbers safe so that you can refer to them in the future. This manual explains the function and application of the
machine.
FOR YOUR SAFETY
Read the user manual before commissioning. Safety and warning instructions must be observed!
Version BSW76EPRO / BSW76GLPRO (07.24 en)

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  • Page 1 Bandsaw mill BSW 76EPRO with electric motor BSW 76GLPRO with petrol engine BSW 76GLPRO BSW 76EPRO Operating manual (Translation of the original operation manual) Both the model number and serial number can be found on the nameplate on the machine. You should keep both numbers safe so that you can refer to them in the future.
  • Page 2 Project ID: BSW 76EPRO I BSW 76GLPRO Rev.: 2024-07-30 © LUMAG GMBH Rudolf-Diesel-Str. 1a 84375 Kirchdorf a.Inn Tel.: +49 8571 92556-0 Fax: +49 8571 92556-19 Email: info@lumag-maschinen.de Internet: www.lumag-maschinen.de...

  • Page 3: Table Of Contents

    10.3.11 Assembly: Push handle assembly with electric box, EC Declaration of conformity switch box for height adjustment and limit switch APPENDIX A - Electrical circuit diagram BSW 76EPRO (BSW 76EPRO) APPENDIX B - Electrical circuit diagram BSW 76GLPRO 10.4 Placing the saw carriage on the rail track...

  • Page 4: Preface

    Thank you for choosing the mobile bandsaw mill from LUMAG. Your new bandsaw mill has been manufactured to the highest standards of reliability, ease of operation and safety. Please enter the date of purchase here for reference purposes: ________________________________________ Keep the receipt.

  • Page 5: Machine Designation

    MACHINE DESIGNATION The designation "Machine" replaces the trade name of the object to which this user manual – see cover sheet – refers. COPYRIGHT All documents are protected by copyright. A passing on and duplication of documents, also in extracts, as well as communications of the contents to third parties are not permitted, as far as not expressly agreed.

  • Page 6: Product Description

    PRODUCT DESCRIPTION INTENDED USE This bandsaw mill is designed exclusively for sawing soft, hard or dry logs or prismatic workpieces without branches. Their length depends on the design of the machine. The rails and log supports are reinforced by a steel frame that is specially designed for sawing directly on the ground.

  • Page 7: Residual Risks

    RESIDUAL RISKS Even if the machine is used correctly, there is always a certain residual risk that cannot be ruled out. The following potential hazards can be derived from the type and design of the machine, depending on its use: Touching the bandsaw blade in the uncovered areas –...

  • Page 8: Machine Overview

    MACHINE OVERVIEW...
  • Page 9 Adjustment lever of movable blade guide T-handle band tension Locking lever (right/left) for saw head Push handle Electric box (BSW 76EPRO) or throttle lever (BSW 76GLPRO) W Locking brake (parking lock) Safety switch on push handle (BSW 76EPRO) 1 Bandsaw blade, mounted (not shown)

  • Page 10: Safety Instructions

    SAFETY INSTRUCTIONS For your own safety and the safety of others, do not work with the bandsaw mill or bandsaw blade before you have read and understood the entire manual. WARNING! This symbol indicates that failure to follow the instructions may result in serious injury or, in the worst case, death.

  • Page 11: Operator

    OPERATOR WARNING! Suitable personal protective equipment (PPE) must always be worn whenever the machine is in use. Suitable personal protective equipment does not prevent the risk of injury, but it does reduce the impact of an injury in the event of an accident. Persons under the age of 18 and untrained persons are prohibited from using the bandsaw mill and handling bandsaw blades.

  • Page 12: Safety Equipment

    SAFETY EQUIPMENT Do not use the machine if the safety equipment is defective. 4.4.1 End stop Mechanical stops prevent the saw carriage from rolling off at the end of the track. 4.4.2 Locking brake The machine is equipped with a mechanical brake on the saw carriage, which quickly brings the saw carriage to a standstill when in the active position.
  • Page 13 WARNING! Adjust the movable blade guide as close as possible to the log. Do not work alone! Always make sure that another adult is within hearing distance in case you need to call for help. Do not stand between a wood stack and the bandsaw mill. Always stand to the side of the wood stack when handling logs.
  • Page 14 WARNING! Risk of crushing between the bandsaw mill and the log during loading. Do not climb onto the guide rails or the log supports (cross struts). When the machine is not in use, for example at the end of a cut, always release the band tension with the saw head locked.
  • Page 15 – The rail track is free of waste, dirt and other debris. – When using the BSW 76EPRO: DANGER! Dangerous voltage, risk of short circuit. Work on the electrical system may only be carried out by an authorised electrician. The machine with electric motor must be connected via a residual current circuit breaker (RCD).

  • Page 16: Storage

    Before the next use, the bandsaw blade must be checked for damaged teeth and cracks. When storing the BSW 76EPRO bandsaw mill for longer periods, the following must be observed: Lower the saw head to the lowest position and lock it in place –...

  • Page 17: Maintenance

    MAINTENANCE WARNING! Risk of serious injury. Before all repair, set-up, maintenance and cleaning work on the machine: Shut down the drive and secure it against restarting and unauthorised commissioning. – Wait for the bandsaw blade to come to a standstill. –...

  • Page 18: Transport Of The Bandsaw Mill

    TRANSPORT OF THE BANDSAW MILL Warning! Risk of crushing. Keep people and animals away from the danger area of 5 m around the machine when lifting and transporting machine parts. Secure the load during transport. The saw carriage and the rail track must not be lifted or transported as long as they are mounted together. The parts must be transported separately.

  • Page 19: Scope Of Delivery

    The machine is equipped with a bandsaw blade (not shown), which is inserted in the machine, with an electric motor (mod. BSW 76EPRO) or with the oil filling of the engine and without fuel (mod. BSW 76GL). The transport box also includes 18 levelling feet (O), three short log stops (I), three long log stops (J), two short clamping fixtures (M), two long clamping fixtures (N), a coolant tank (D) and a movable blade guide (R).
  • Page 20 Fig.: Scope of delivery BSW 76GLPRO...

  • Page 21: Installation

    The machine does not require any special foundation. For safe operation of the machine, we recommend installing the machine on a level concrete slab or on concrete slabs in a hall or under a roof. The selected location must ensure access to the electrical connection (BSW 76EPRO) and convenient handling of workpieces (log stacks/sawed timber).

  • Page 22: Assembly

    ASSEMBLY 10.1 RAIL TRACK Assemble the rail system loosely using the provided screws, washers and nuts. It is important that the screws are not yet fully tightened at this point. This is only done after the saw carriage has been mounted and the rails have been connected.
  • Page 23 Fig.: Rail track dimensions  Attach the log supports to the left and right rail using the screws, washers and nuts.  Attach the rail segments to each other. Attach the flat bar under the two rails using the screws, washers and nuts.
  • Page 24  Attach the feet hand-tight to the left and right rail using the nuts. After set-up, the rail track must be levelled using the feet and a spirit level. To do this, loosen the lock nut (k) and adjust the height using the adjusting nut (s).

  • Page 25: Log Stops And Clamping Fixtures

    10.2 LOG STOPS AND CLAMPING FIXTURES The following figure provides an overview of possible positioning of the stops (I+J) and clamping fixtures (M+N) on the rail track. Stops and clamping fixtures are accessories that can be attached at various points along the rail. They provide support for clamping and prevent the risk of being run over by a tree log.

  • Page 26: Clamping Fixtures

    10.2.2 Clamping fixture Please observe that the clamping fixtures can be attached at various points along the rail track. Depending on how many rail segments are used, select a position for the clamping fixture in which the log is pressed firmly against the stop (I or J) of the rail guide.

  • Page 27: Saw Carriage

    (BSW 76EPRO) (BSW . Assembly steps that are exclusively intended for the electrical machine are marked accordingly. 76GLPRO) Fig.: Complete saw carriage BSW 76EPRO Fig.: Complete saw carriage BSW 76GLPRO 10.3.1 Assembly: Chassis  Using two people, position the square guide rail (a) on the chassis, with rollers at the bottom on the guide rail.

  • Page 28: Assembly: Saw Carriage Frame

    ATTENTION! The saw head is very heavy (approx. 220 kg). The correct technique must be applied to avoid any injury or damage Fig.: Saw head BSW 76EPRO Fig.: Saw head BSW 76GLPRO...
  • Page 29 Position the saw head on the corresponding guide rail receptacles (a+b) on the left and right of the chassis. Then lower the saw head onto the chassis. NOTICE: It must be possible to insert the saw head without friction. Fig.: Assembly: Saw head BSW 76GLPRO (BSW 76EPRO not shown)
  • Page 30 Ensure that the clamping jaws close securely around the guide rails when the locking levers are actuated. Locking the saw head: Press the locking lever down (a) Releasing the saw head: Press the locking lever up (b) Fig.: Locking the saw head BSW 76GLPRO (BSW 76EPRO not shown)

  • Page 31: Assembly: Carrier With Lifting Eyes And Cable Guide

    (M12x70) and the spacer plate. The carrier is now secured in place. NOTICE: In the next step 13.3.5, the cutting height indicator and the carrier are screwed to the guide rail (b). Fig.: Assembly: Carrier with lifting eyes with cable guide BSW 76GLPRO (BSW 76EPRO not shown)

  • Page 32: Assembly: Cutting Height Indicator

    NOTICE: The measuring tape (d), measuring rod (e) and measuring pointer (f) can also be fitted at a later time – e.g. after the saw carriage has been placed on the rail track. Fig.: Assembly: Cutting height indicator BSW 76GLPRO (BSW 76EPRO not shown)

  • Page 33: Assembly: Winch With Electric Drive

    The figure below shows an electric drive with mounted switch box (BSW 76GLPRO) NOTICE: With the BSW 76EPRO, the switch box for the electric drive is fixed at a later stage. Using two people, position the winch with electric drive (1.) and the holder for the coolant tank (2.) on the ...
  • Page 34 Fig.: Assembly: Winch with electric drive and coolant tank holder BSW 76EPRO...

  • Page 35: Assembly: Steel Cables

    10.3.7 Assembly: Steel cables Preparation 1. Move the saw head to the lowest position. 2. The saw head should be levelled before you continue. 3. Make sure that the locking levers on both sides are actuated before attempting to connect the cables. 4.
  • Page 36 Fig.: Assembly: Steel cables BSW 76GLPRO (BSW 76EPRO not shown)

  • Page 37: Assembly: Coolant Tank

    (d). Use a 16 mm wrench. Notice: Do not overtighten the screw (d) to prevent the copper end from being crushed. Fig.: Assembly: Coolant tank BSW 76GLPRO (BSW 76EPRO not shown) ATTENTION! If the temperature falls below freezing, empty the tank and the hoses if there is water in them.

  • Page 38: Assembly: Push Handle Assembly

    10.3.9 Assembly: Push handle assembly (BSW 76GLPRO) Fit the push handle assembly to the saw carriage frame as shown below. Fig.: Assembly: Push handle assembly BSW 76GLPRO...
  • Page 39  Insert the holder (a). To do this, push the holder (as far as it will go) into the saw carriage frame on the right (as seen from the operator position) and connect the two parts with the hexagon screw (M10x40). Firmly tighten the screw.

  • Page 40: Assembly: Electric Connection Of Battery And Height

    10.3.10 Assembly: Electric connection of battery and height adjustment and limit switch (BSW 76GLPRO) Connect the 12V starter battery (1.) and the electric height adjustment (2.) as shown below. WARNING! Before connecting the battery, the key on the E-starter must be turned to OFF position and removed. ...

  • Page 41: Assembly: Push Handle Assembly With Electric Box

    10.3.11 Assembly: Push handle assembly with electric box, switch box for height adjustment and limit switch (BSW 76EPRO) Fig.: Assembly: Push handle assembly with electric box, switch box for height adjustment and limit switch BSW 76EPRO...
  • Page 42 Fig.: Bowden cable on locking brake handle Fig.: Locking brake on chassis, right  Slide the handles (e) all the way onto the handle bar (b). Fig.: Push handle with electric box BSW 76EPRO...
  • Page 43 Now attach the switch box (2.) to the bracket of the electric height adjustment drive using the provided 4 Phillips screws (M4x16) and nuts.  Screw the cover back on after fitting and connect the switch box and the electric drive of the height adjustment with the connector (3.) Fig.: Switch box for height adjustment BSW 76EPRO...
  • Page 44 Screw the limit switch (5.) into the pre-drilled holes on the right-hand side of the chassis (as seen from the operator position) using the 2 hexagon head screws (M4x35) supplied. NOTICE: Adjust the limit switch so that the band guard does not get into contact with the log supports. Fig.: Limit switch BSW 76EPRO...
  • Page 45 Lift the saw carriage using a forklift truck or crane that is suitable for picking up the load and slowly place the component on the installed rail track. Fig.: Placing the saw carriage on the rail track BSW 76EPRO (BSW 76GLPRO not shown)
  • Page 46 ATTENTION! Do not press too hard or tilt when fitting the rollers. The V-groove on the rollers must be in contact with the rail.

  • Page 47: Kw Electric Motor Bsw 76Glpro

    5.5 KW ELECTRIC MOTOR BSW 76EPRO 11.1 POWER CONNECTION WARNING! Work on the electrical installation and electrical equipment may only be carried out by qualified electricians. Three-phase motors must be checked for their direction of rotation when newly connected or relocated.

  • Page 48: Bandsaw Blade Drive

    11.3 BANDSAW BLADE DRIVE The bandsaw blade is driven by an electric motor via a drive wheel and a belt drive. The band stops within 10 seconds of the drive being switched off. Main switch (a) – Used to switch the power supply to the machine on and off. Operated by turning: Position "I" ON;...

  • Page 49: Kw Petrol Engine Bsw 76Epro

    6.7 KW PETROL ENGINE BSW 76GLPRO The bandsaw blade is driven by a petrol engine via a drive wheel and a belt drive. The band stops within 10 seconds of the drive being switched off. Before the machine is started for the first time, it must be filled with oil and fuel. Lower the saw carriage to the lowest position to make work easier.

  • Page 50: Electrical Connection

    12.1 ELECTRICAL CONNECTION WARNING! Work on the electrical installation and electrical equipment may only be carried out by qualified electricians. 12.1.1 Electric start The 12V starter battery is located on the right-hand side of petrol engine. When viewing, assume that you are standing at the workplace while sawing.

  • Page 51: Starting Process

    12.2 STARTING PROCESS 1. Set fuel switch (5) to ON position. 2. When the engine is cold, set the choke (4) to the left to CLOSE (=CHOKE). When the engine is hot, leave the choke (4) on the right in the OPEN position (= RUN), no choke. 3.

  • Page 52: Switching Off The Machine

    12.3 SWITCHING OFF THE MACHINE 1. Push the throttle lever (8) to the right to the idle position LOW (=TURTLE). 2. Turn the ignition key on E-start (1) to the OFF position and remove. 3. Then turn the fuel switch (5) to the left to the OFF position to close it. When leaving the machine, remove the spark plug connector (9) = protection against unauthorised use! ATTENTION! Never set the choke to CLOSE to stop the engine.

  • Page 53: Before Commissioning

    Make sure that the guide rollers with V-shaped groove are positioned at right angles on the rails. If the saw carriage does not move smoothly, adjust the width of the track accordingly. Fig.: Rail track alignment BSW 76EPRO (BSW 76GLPRO not shown)
  • Page 54 If the saw carriage continues to stall, the rails must be placed further apart or closer together in order to achieve a constant width over the entire rail path. If the desired width has been reached, all bolts and nuts of the log supports (cross struts) (K) can be tightened, as shown below.

  • Page 55: Bandsaw Blade Horizontal Alignment

    The lifting cable B controls the height of the right-hand side of the saw head (as seen from the operator side). Correct the measurement difference using the eyebolt and the lock nuts. See also... ASSEMBLY: Steel cables (10.3.7) Fig.: Bandsaw blade horizontal alignment BSW 76EPRO (BSW 76GLPRO not shown)

  • Page 56: Raising And Lowering The Saw Head

    13.4 RAISING AND LOWERING THE SAW HEAD Electric height adjustment enables smooth raising and lowering of the saw head.  The saw head can be raised and lowered using the rocker switch. Fine adjustment of the cutting depth is set using the indicator scale.

  • Page 57: Checking The Band Tension

    13.8 CHECKING THE BAND TENSION A bandsaw blade is correctly tensioned if the band cannot be bent more than 3-6 mm in the centre by hand. To tension the bandsaw blade, turn the T-handle to the right. Use the 24 mm insert of a torque wrench to tighten the T- handle to 32 - 34 Nm.

  • Page 58: Sawing

    Fig.: Sawing direction BSW 76EPRO (BSW 76GLPRO not shown) Please follow the steps in the next section "MACHINE SETUP". Otherwise, poor sawing results, injuries or damage...

  • Page 59: Machine Setup

    14 MACHINE SETUP DANGER! Before all adjustment and installation work on the machine:  Position the machine in the stop zone. Saw head is locked.  Shut down the drive and secure it against restarting and unauthorised commissioning.  Wait for the bandsaw blade to come to a standstill. ...
  • Page 60 However, if the drive belt is too tight, the nut can be turned anti-clockwise. Over-tightening can cause the machine carrier to twist, resulting in belt misalignment and excessive wear. Fig.: Tensioning the drive belt (toothed belt) BSW 76EPRO (BSW 76GLPRO not shown)

  • Page 61: Adjusting The Bandsaw Blade

    14.2 ADJUSTING THE BANDSAW BLADE DANGER! The bandsaw blade is not covered in the cutting area. Risk of injury! The bandsaw blade runs on two band wheels (tensioning wheel 1 and drive wheel 2), which are cast from aluminium and balanced so that they run evenly. Two band guides (one movable blade guide and one fixed band support) ensure that the bandsaw blade remains in the correct position during sawing.

  • Page 62: Adjusting The Band Run

    WARNING! Wear protective gloves and safety goggles when working on the bandsaw blade! 14.2.1 Adjusting the band run The base of the tooth of the bandsaw blade must be flush with the outer edge of the tensioning wheel (± 2 mm). Fig.
  • Page 63 14.2.2 Adjusting the blade guides The fixed blade support and the movable blade guide must be adjusted so that the bandsaw blade runs without recoil. The saw blade should glide quietly and effortlessly through the guides when the band wheels are turned. If this is not the case, the band wheels are probably tilted.
  • Page 64 Fig: Adjusting the upper and lower blade guide Adjusting the blade guard and band stopper  Loosen the two T-handles or star knob screws to release the movable blade guide (c). Then slide the guide to the left or right to adjust the blade guard (a) for sawing. Fig.

  • Page 65: Adjusting The Cutting Thickness

    14.3 ADJUSTING THE CUTTING THICKNESS The machine has two scales: A millimetre scale showing the distance between the log support and the bandsaw blade. – A scale that takes the cutting kerf into account and indicates different board thicknesses in inches. –...

  • Page 66: Cooling The Bandsaw Blade

    14.4 COOLING THE BANDSAW BLADE The bandsaw blade must be rinsed with water or a slightly aqueous cooling lubricant solution. When processing wood with a high resin content, the concentration of the cooling lubricant must be increased. Suitable cooling lubricant concentrate is available from qualified specialist dealers. Fill the water tank (D) only before operation.

  • Page 67: Operation

    15 OPERATION DANGER! Before commissioning the machine, ensure that all protective devices and covers are in place and properly secured. Non-compliance can result in serious injuries. When working with the machine, ensure that there are no persons or animals in the work area. Non- compliance can result in serious injuries.

  • Page 68: Sawing Process

    (BSW 76GLPRO). – Press and hold the safety switch and press the black START button (BSW 76EPRO). – 11. This brings the machine up to its operating speed and the bandsaw blade begins to rotate.

  • Page 69: Releasing Jammed Bandsaw Blade

    15.4 RELEASING JAMMED BANDSAW BLADE DANGER! Before all work on the machine:  Position the machine in the stop zone. Saw head is locked.  Shut down the drive and secure it against restarting and unauthorised commissioning.  Wait for the bandsaw blade to come to a standstill. ...

  • Page 70: Maintenance

    16 MAINTENANCE DANGER! Before all maintenance and repair work on the machine:  Position the machine in the stop zone. Saw head is locked.  Shut down the drive and secure it against restarting and unauthorised commissioning.  Wait for the bandsaw blade to come to a standstill ...
  • Page 71 ATTENTION! New bandsaw blades are supplied rolled up and are under great mechanical tension. Unpack carefully to prevent the band from snapping out and causing cuts! It is important to change the bandsaw blade regularly to ensure maximum performance. The use of blunt bands leads to wavy or imprecise cuts, reduces the service life of the bands and increases the risk of band breakage.
  • Page 72 7. Insert the new band into the guides first. 8. Then place the band on the band wheels and tension the bandsaw blade by turning the T-handle (S) clockwise. Pay attention to the sawing direction! The teeth must always point towards the chip ejection chute (G). Make sure that the band is correctly aligned on the band wheels and in the guides.

  • Page 73: Replacing The Drive Belt

    16.2 REPLACING THE DRIVE BELT Regularly check the condition of the drive belt (c). Replace any worn and damaged parts. Also regularly check the tension of the drive belt and adjust it if necessary. To remove the drive belt, first remove the bandsaw blade. See also...

  • Page 74: Replacing The Drive V-Belt

    16.3 REPLACING THE DRIVE V-BELT The drive V-belt (a) is replaced by simply pulling off and inserting a new belt by hand. The belt sits loosely enough on the band to make this possible. There is no need to remove the band wheel (1) from the shaft.

  • Page 75: Troubleshooting

    17 TROUBLESHOOTING WARNING Any faults on the machine or motor requiring major intervention must always be repaired by your LUMAG workshop or authorised specialist workshops. The warranty becomes void in the event of improper intervention. DANGER! Before you start with troubleshooting: ...
  • Page 76 Fault/issue Possible cause Remedy/solution Blade slows down or Incorrect blade tension Tension the blade – – stops when sawing. Incorrect drive belt tension Belts are worn or loose, replace – – Saw pressed too fast Reduce feed rate – – Saw does not cut / Blunt blade Install new blade...

  • Page 77: Warranty / Guarantee / Customer Service

    LUMAG guarantees perfect quality and, without prejudice to the statutory warranty, provides a warranty in the event of material or manufacturing defects. The guarantee for LUMAG products is 24 months in the case of exclusively private use, and 12 months from the date of delivery in the case of commercial and / or professional use and / or leasing.
  • Page 78 Guarantee work is carried out exclusively by our LUMAG service workshop. Defects occurring within the guarantee period due to material or manufacturing defects shall be rectified by means of a repair, provided that they occurred despite proper operation and care of the machine. We reserve the right to rectify the defect twice in the case of the same defect.

  • Page 79: Technical Data

    Weight of roller track extension 63 kg Packaging dimensions (LxWxH) 214 x 16 x 18 cm Noise emission explanation Model BSW 76EPRO: = 103.7 dB(A), L = 85.1 dB(A); Model BSW 76GLPRO: L = 109.3 dB(A), L = 92.2 dB(A);...

  • Page 80: Dimensions

    19.1 DIMENSIONS The following figures provide an overview of the dimensions of the machines and the optional roller track extension. BSW 76EPRO – without roller track extension...
  • Page 81 BSW 76GLPRO – without roller track extension BSW 76PRO series – roller track extension (optional) Art. no. 5BSWR2000PRO...

  • Page 82: Ec Declaration Of Conformity

    In accordance with the provisions of the EC Directives Machinery Directive 2006/42/EC EMC Directive 2014/30/EU the company: LUMAG GmbH, Rudolf-Diesel-Straße 1a, D-84375 Kirchdorf am Inn Phone: +49 8571 92556-0, Fax: +49 8571 92 556-19 declares that the product Designation: Bandsaw mill (Saw mill)
  • Page 83 APPENDIX A...
  • Page 84 APPENDIX B...
  • Page 85 NOTES...
  • Page 86 NOTES...
  • Page 87 NOTES...
  • Page 88 Subject to change without notice! Version BSW76EPRO/BSW76GLPRO (07.24 en) LUMAG dealer can be found at www.lumag-maschinen.de LUMAG GmbH Rudolf-Diesel-Str. 1a D-84375 Kirchdorf a. Inn Germany Internet: www.lumag-maschinen.de...

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Bsw 76glpro

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