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N2-38 / N3800 / N4400 Band saw Keep this manual to hand and in good condition for future reference. Read this operating manual carefully before using the machine. Translation of the original operating instructions Operating instructions 500033-901A, 1, en_GB...
Information about the manual Information about the manual Explanation of symbols safety instructions Safety instructions in this manual are indicated with symbols. The safety instructions are introduced by key words which state in words the extent of the hazard. Comply with safety instructions under all circumstances, and act with care in order to avoid accidents, personal injury, or material damage.
N2-38 / N3800 / N4400 Information about the manual Safety instructions symbol The following symbols may appear in the operating instructions. Icon Object description General warnings Warning of electrical voltage Warning of dangers due to charging batteries Warning of obstacles in the head area...
Information about the manual ● The operating manual is an integral part of the machine. It must therefore be kept in the direct vicinity of the machine and be accessible at all times. ● The operating manual must always accompany the machine. Liability and warranty ●...
N2-38 / N3800 / N4400 Safety instructions Safety instructions Intended use ● The machine described in this manual is intended solely for the processing of wood, synthetic materials, and similar machinable materials. Operational safety is only guaranteed when the machine is used for the intended pur- poses.
Safety instructions ● In addition to the safety advice and instructions specified in this operating manual, any local accident prevention regulations and general safety regula- tions applicable to the machine's area of use, as well as any applicable environmental protection regulations, must be observed and complied with. ●...
N2-38 / N3800 / N4400 Safety instructions Please note Protective footwear: To protect feet from heavy falling objects and prevent from slipping on slippery floors. Ear protection: To protect against loss of hearing. Safety goggles: Protection to prevent damage to eyes.
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Safety instructions Incorrect work on the electrical units Work on the electrical equipment may only be carried out by qualified personnel. People could be seriously injured or killed. ● Work on electrical equipment may only be carried out by qualified personnel and in strict observance of the safety instructions.
N2-38 / N3800 / N4400 Safety instructions Standing on the machine The covers or projecting components of the machine are not suitable for standing on them. Falling off the machine can result in serious injury. ● It is forbidden to climb onto the machine.
Safety instructions Damage to electrical components or their insulation Damaged electrical components or damage to their insulation cause deadly electric shocks. ● Work on electrical fittings may only be carried out by qualified personnel and in strict observance of the safety instructions. ●...
N2-38 / N3800 / N4400 Safety instructions ● Do not lean over the working area. ● Only remove chips when the machine is at a standstill. Foreign objects in the workpiece Serious injuries ● Carefully inspect workpieces for foreign matter (nails, screws) which might impair processing.
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Safety instructions Exceeding the lifespan of protective devices that carry out a safety function Serious injuries The safety devices have a lifespan of 20 years. If safety devices are used exceeding their lifespan, the proper function of the safety devices can not be guaranteed. Deficiently maintained safety devices can cause severe injury.
N2-38 / N3800 / N4400 Declaration of Conformity Declaration of Conformity EU-Declaration of Conformity EU-Declaration of Conformity according to Machine Guidelines 2006/42/EC Note on the serial number: The serial number is printed on the cover sheet of the operating manual.
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6060 Hall in Tirol, AUSTRIA Product designation Band saw Brand Hammer Model type N2-38 / N3800 / N4400 The following UK guidelines were applied S.I. 2008/1597 - Supply of Machinery (Safety) Regula- tions 2008 S.I. 2016/1091 - Electromagnetic Compatibility Regu- lations 2016...
800 x 650 mm Total height H 1865 mm Working height G 886 mm Net weight 170 kg Machine table and cutting width N2-38 / N3800 Data Value Unit Table length C 400 mm Table width D 510 mm Table tilt -5 to +45 °...
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575 mm Table tilt -10 to +45 ° Cut width max. F 420 mm Rip capacity with parallel cutting fence 377 mm Packaging dimensions (incl. pallet) N2-38 Fig. 2: Packaging dimensions Data Value Unit Length L 1200 mm Width W...
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N2-38 / N3800 / N4400 Technical information Packaging dimensions (incl. pallet) N3800 Fig. 3: Packaging dimensions Data Value Unit Length L 1200 mm Width W 800 mm Height H 2010 mm Gross weight *) 170 kg Packaging dimensions (incl. pallet) N4400 Fig.
Frequency 50 / 60 Hz Protection class IP 55 Drive motor The actual values of the components can be found on the data plate. Drive motor N2-38 Data Value Unit Motor voltage (standard) 3 x 400 V Motor frequency...
N2-38 / N3800 / N4400 Technical information Drive motor N 4400 Data Value Unit Motor voltage (standard) 3 x 400 V Motor voltage (option) 3 x 230 V Motor frequency 50 / 60 Hz Motor power 2.5 kW Operating mode S6-40 % *) ...
84.7 sound pressure level, L in dB at workplace A All data in dB(A) and with a measurement uncertainty factor of 4 dB(A) Tools Bandsaw unit N2-38 / N3800 Data Value Unit Min. bandsaw blade length 3531 mm Max. bandsaw blade length 3581 mm Min.
Machine overview Fig. 6: Pictograms overview On / Off switch Saw blade guard operation Blade direction Saw blade tensioning operation Warning sticker - Start button release Warning sticker - Do not lift the machine by crane Scale - blade tension (depending on machine var- using the eyelet iant) Danger, electric current...
N2-38 / N3800 / N4400 Machine overview Fig. 8: Safety limit switch Safety limit switch Lock Flywheel cover 5.4.2 Automatic braking system CAUTION Electric brake will not work in the event of a power failure Failure of the electric brake can cause serious cuts. In the event of a power failure, the tool does not stop within 10 seconds and continues to run.
Machine overview The brake shoes of the brake are wearing parts and must therefore be checked regularly and replaced if necessary in order to comply with the braking time speci- fied in the regulations. ⮫ Chapter 10.7 ‘Check safety devices (emergency stop)’ on page 76 In the event of any problems or malfunctions, contact Felder-Group service centre.
N2-38 / N3800 / N4400 Transporting, packing, storing Transporting, packing, storing Transport inspection Upon arrival, inspect the shipment to ensure that it is complete and has not suffered any damage. If any transport damage is visible from the outside, do not accept the delivery or only accept it with reservation.
Transporting, packing, storing Transport bracket Fig. 12: Transport bracket Machine screws Fig. 13: Packaging N2-38 Pallet screws Machine screws The machine is delivered partially assembled on a pallet. The machine is attached to the pallet with screws. Only remove the screws when the machine is lifted off the pallet.
N2-38 / N3800 / N4400 Transporting, packing, storing Means of transportation 6.7.1 Unloading with a pallet truck Fig. 14: Transport with a pallet truck Pallet recesses WARNING Tipping over of the machine Serious injury due to the high machine weight.
Transporting, packing, storing Tip the machine off the wooden board onto the floor. The machine is unloaded. 6.7.1.2 Unload N2-38 Personnel: ● Trained machine operator ● 2 additional assistants Tool: ● Hexagon socket screwdriver WARNING Tipping over of the machine Serious injury due to the high machine weight.
N2-38 / N3800 / N4400 Transporting, packing, storing Remove the transport screws from a mounting board. Remove the fixing board and tilt and hold the machine. Remove the transport screws from the second mounting board and move the machine off.
Transporting, packing, storing Personnel: ● Forklift driver:in Fig. 15: Transporting with a forklift Recesses in the pallet The transport locks can be removed, once the machine has been unloaded at the installation site. Move the forks of the forklift truck so they fit into the machine frame or pallet recesses.
N2-38 / N3800 / N4400 Setup and installation Setup and installation Requirements of the location, where the machine is to be installed W + 500 mm Fig. 17: Space requirement at the installation site In order to be able to operate the machine trouble-free, efficient and ergonomically, the following conditions must be met: ●...
Setup and installation Fig. 18: Machine table Fixing pin Washers Screws Table insert Table holder Lift the machine table onto the table holder. Screw the machine table to the table holder using screws and serrated washers. Reinsert the table insert and fixing pin. ...
N2-38 / N3800 / N4400 Setup and installation There is no visible gap between the precision hair angle and the saw blade running surface. A gap is visible between the precision hair angle and the saw blade running surface. Loosen locking nut.
Setup and installation Install 7.4.1 Install the dust extraction CAUTION Electrostatic charging Burns or electric shock caused by unearthed, or poor quality extraction hose. − Only use dust extraction hose approved by the manufacturer. − Always ensure continuous electrostatic earthing when con- necting machines.
N2-38 / N3800 / N4400 Setup and installation Connect electrics 7.5.1 Safety instructions - Connect electrics NOTICE Electric current Damage due to incorrect power supply. − The electrical connection of the machine must be carried out by a licensed electrician on the day of installation.
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Setup and installation Check the loop impedance and the suitability of the overcurrent protective device at the machine's installation site. Check the rotation direction of the bandsaw blade Fig. 22: Rotation direction of the bandsaw blade Personnel: ● Qualified electrician Connect the plug to the power supply.
N2-38 / N3800 / N4400 Adjustments and tool changes Adjustments and tool changes Opening / closing the flywheel cover DANGER Opening the flywheel cover in the event of a broken saw blade or drive belt Serious injuries. − Stop the machine, wait until it comes to a standstill and keep your distance.
Adjustments and tool changes Tensioning / loosening the bandsaw blade Tensioning the band saw blade Fig. 24: Release blade tension Blade tension handwheel Saw blade width indicator Warning sign Personnel: ● Trained machine operator Open the flywheel cover. ⮫ Chapter 8.1 ‘Opening / closing the flywheel cover’...
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N2-38 / N3800 / N4400 Adjustments and tool changes Saw blade run correctly set according to the sketch. Saw blade run not set correctly according to the sketch. Loosen the clamping lever. Set the saw blade run using the saw blade run adjustment handwheel.
Fig. 27: Band saw blades Radius cut Saw blade width Tooth spacing It is recommended to use high quality saw blades. The following saw blades may be used. N2-38 / N3800 Art. no. Saw blade width (mm) Tooth Spacing (mm) 13.7.3806 13.7.3810 13.7.3815...
Adjustments and tool changes Pull the fixing pin out of the machine table. Fig. 29: Pull the fixing pin out of the machine table Fixing pin Slide the old saw blade through the machine table. Slide the new saw blade through the machine table and place it over both flywheels.
N2-38 / N3800 / N4400 Adjustments and tool changes Tighten the clamp. The saw blade guard is set. Lower blade guard Fig. 31: Lower blade guard Metal tongue Clamp Personnel: ● Trained machine operator The lower saw blade guard must be adjusted when the machine table is tilted.
Adjustments and tool changes NOTICE Incorrect setting of the saw blade guide Material damage − Deterioration in cutting quality − Increased wear − Readjustment of the saw blade guide after each saw blade change. − Readjustment of the saw blade guide after maintenance work. −...
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N2-38 / N3800 / N4400 Adjustments and tool changes Turn the upper flywheel by hand and observe the guide elements. Move the saw blade guide on the adjusting bolt until the lateral guide elements run behind the saw blade set.
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Adjustments and tool changes Open the flywheel cover. ⮫ Chapter 8.1 ‘Opening / closing the flywheel cover’ on page 41, ⮫ ‘Opening the flywheel cover in the event of a broken saw blade or drive belt’ on page 41 Loosen both thumb nuts. Use the adjustment screw to set the distance until the lateral guide elements lightly touch the saw blade.
N2-38 / N3800 / N4400 Adjustments and tool changes Pull the saw blade by hand in the direction of the rear guide. Turn the upper wheel by hand and observe the rear guide. The rear guide is set parallel to the back of the saw blade with a small distance.
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Adjustments and tool changes Disconnect the machine from the mains power supply. Open the flywheel cover. ⮫ Chapter 8.1 ‘Opening / closing the flywheel cover’ on page 41, ⮫ ‘Opening the flywheel cover in the event of a broken saw blade or drive belt’ on page 41 Loosen the clamping screw.
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N2-38 / N3800 / N4400 Adjustments and tool changes Protective equipment: ● Protective gloves Only adjust the saw blade guide after setting the blade tension and blade run. ⮫ Chapter 8.2 ‘Tensioning / loosening the bandsaw blade’ on page 42 Switch off the machine and secure it from being switched on again.
Adjustments and tool changes Press the saw blade by hand towards the rear guide. Turn the upper wheel by hand and observe the rear guide. The rear guide is set parallel to the back of the saw blade with a small distance.
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N2-38 / N3800 / N4400 Adjustments and tool changes Protective equipment: ● Protective gloves Only adjust the saw blade guide after setting the blade tension and blade run. ⮫ Chapter 8.2 ‘Tensioning / loosening the bandsaw blade’ on page 42 Switch off the machine and secure it from being switched on again.
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Adjustments and tool changes Fig. 39: Setting lateral guides Direction B Clamping lever Lateral guides Adjustment direction Direction B Personnel: ● Trained machine operator Protective equipment: ● Protective gloves Only adjust the saw blade guide after setting the blade tension and blade run. ⮫ Chapter 8.2 ‘Tensioning / loosening the bandsaw blade’...
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N2-38 / N3800 / N4400 Adjustments and tool changes Fig. 40: Setting the rear guide Clamping lever Adjusting bolt Rear guide Setting the rear guide Personnel: ● Trained machine operator Protective equipment: ● Protective gloves Only adjust the saw blade guide after setting the blade tension and blade run.
Adjustments and tool changes Close the flywheel cover. The rear guide is set. 8.5.3.2 X-Life Set the lower bandsaw blade guide (Option) Setting the lateral guide elements The lateral guide elements are set in directions A and B. They should only touch the saw blade lightly without deforming it.
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N2-38 / N3800 / N4400 Adjustments and tool changes Turn the upper flywheel by hand and observe the guide elements. Move the saw blade guide on the adjusting bolt until the lateral guide elements run behind the saw blade set.
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Adjustments and tool changes Close the flywheel cover. The lateral guide elements are set in direction B. Fig. 43: Setting the rear guide Thumb screws Adjustment bolt Setting the rear guide Personnel: ● Trained machine operator Protective equipment: ● Protective gloves Tool: ●...
N2-38 / N3800 / N4400 Adjustments and tool changes Turn the upper wheel by hand and observe the rear guide. The rear guide is set parallel to the back of the saw blade with a small distance. Continue with next step.
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Adjustments and tool changes Fig. 45: Fitting rip fence right Fig. 46: Fitting the rip fence plate left Loosen the clamping screw. Clamping screws Fence plate Pull the fence plate out to the rear. Unscrew the clamping screw completely and pull out the clamping rail. 62 / 86...
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N2-38 / N3800 / N4400 Adjustments and tool changes Clamping screws Clamping rail Push the clamping rail on the opposite side of the rip fence into the hole with the help of the spring bolt. Explosive bolt Fit the clamping rail to the rip fence using the clamping screw.
Adjustments and tool changes Fig. 47: Flat fence plate Loosen the fence plate clamping screw. Pull the fence plate out to the rear. Turn the fence plate and slide it onto the clamping rail with the corresponding groove. Tighten the clamping screw. Align the saw blade guard with the height of the fence plate.⮫ Chapter 8.4 ‘Setting the saw blade guard’...
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N2-38 / N3800 / N4400 Adjustments and tool changes Turn the 0° reference stop to tilt the machine table: ● -5° - Position. ● -10° -Position (N4400). The preparation is complete. Tilting the table Personnel: ● Trained machine operator Fig.
Operate Operate Auxiliary aids for safe operation ● Support long workpieces with additional supports (e.g. table extensions, roller supports). ● Keep tools for processing short and narrow workpieces close at hand (e.g. push grip, push stick, workpiece holder). Switch on / switch off / shutdown due to an emergency stop WARNING Insufficient preparation Severe injuries and damage to property...
N2-38 / N3800 / N4400 Operate ● Only with alternating current: ○ Press the green [Start]-button on the control panel and keep it pressed. ○ Release the green [start] button once the machine has reached the maximum rotational speed. ●...
Operate Fig. 51: Workplace/work position Working position Processing direction Danger zone - 120 mm The danger zone is the area 120 mm to the left, right, in front of and in front of the saw blade. Do not reach into the danger zone with your hand. Never place your hands on the workpiece in the danger zone.
N2-38 / N3800 / N4400 Operate Working techniques for bandsaws 9.6.1 Longitudinal cut along a line Fig. 52: Rip cut All uses which differ from the following work techniques have not been intended for this machine and are therefore not authorised.
Operate 9.6.4 Longitudinal cut of narrow workpieces with longitudinal stop Fig. 55: Push stick Push stick Use a push stick as depicted in the illustration, to prevent your hands from coming too close to the saw blade. 9.6.5 Mitre cuts Fig.
N2-38 / N3800 / N4400 Operate 9.6.7 Diagonal cross-cut of rectangular workpieces Fig. 58: Separation cut FB 510/610/710 For diagonal cuts of rectangular workpieces, use an auxiliary device as shown in the illustration. 71 / 86...
Maintenance Maintenance 10.1 Maintenance plan The following maintenance work must be performed at the prescribed intervals. Chap. Task to execute 10.2 Cleaning and lubrication 10.3 Check the drive belt 10.4 Check flywheel bandage support ...
N2-38 / N3800 / N4400 Maintenance 10.3 Check the drive belt Fig. 59: Check the drive belt Drive belt The drive belt must be inspected monthly; if tears are discovered, the drive belt must be replaced. Belt tension drive belt ●...
Maintenance NOTICE Wear of the flywheel bandage A defective flywheel bandage leads to overheating of the machine and inaccurate cuts. − Check the flywheel bandages regularly. − Exchange if excessively worn. Switch off the machine and secure it from being switched on again. Disconnect the machine from the mains power supply.
N2-38 / N3800 / N4400 Maintenance Tool: ● 5 mm x 150 mm slotted-head screwdriver Switch off the machine and secure it from being switched on again. Use a flat-blade screwdriver to lift the table insert out of the machine table.
Maintenance Press the green [Start] button on the control panel. The machine cannot be started. The machine can be started. Switch off the machine and secure it from being switched on again. Disconnect the machine from the mains power supply. Contact the Felder-Group service centre.
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N2-38 / N3800 / N4400 Maintenance Press the red [Stop] button. Machine stops immediately. Repeat the test on the next red [Stop] button. Repeat with all red [Stop] buttons on the machine. Machine does not stop immediately. If present: Switch off [Main switch] (position "O" / "OFF").
Troubleshooting Troubleshooting 11.1 What to do in the event of malfunction WARNING Improper troubleshooting Severe injuries and damage to property − Troubleshooting may only be carried out by authorised, trained personnel who are familiar with how to operate the machine and are in strict observance of all safety instructions. Malfunctions and faults on the machine (including the guards and tools) must be reported immediately after they have been noticed.
N2-38 / N3800 / N4400 Troubleshooting Fault description Cause Remedy The saw blade has cracks at the Width of saw blade is too thick in rela- Replace the bandsaw blade. base of the individual teeth. tion to the diameter of the flywheel.
Troubleshooting Fig. 62: Setting the rip fence Rip fence Lock nuts right Adjusting screw Move the rip fence to the left and clamp it. Measure the distance X and Y. Distance X and Y are the same. Distance X and Y are not the same. Loosen the lock nuts on the right.
N2-38 / N3800 / N4400 Troubleshooting Fig. 63: Drive belts Mounting nut Clamping screws Loosen the clamping screw. Tension the drive belt with the tensioning nut. Tighten the clamping screw. The drive belt is re-tensioned. 11.6 Changing the flywheel support bandages Personnel: ●...
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Troubleshooting Fig. 65: Change flywheel bandage Cable ties Slide the flywheel bandage over the flywheel. Remove the cable tie. Turn the wheel by hand and check that the running surface is seated cor- rectly. 82 / 86...
N2-38 / N3800 / N4400 Attachment Attachment 12.1 Information relating to spare parts Use incorrect or faulty spare parts Spare parts that do not meet the manufacturer's specifications may compromise the machine's operational safety and result in accidents. ● Only use authorised, approved spare parts approved by the manufacturer.
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Attachment ENVIRONMENT Disposing of batteries Batteries are subject to special waste treatment regulations and must be disposed of in accordance with locally enforced regula- tions. The improper handling of batteries, can due to their potentially dangerous substances, have a negative environmental effect and consequences for human health.
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FELDER KG KR-Felder-Straße 1, 6060 Hall in Tirol, AUSTRIA Telephone: +43 5223 5850 0 Email: info@felder-group.com Internet: www.felder-group.com...
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