Kolbe K430, K440 Operator Manual

OPERATING MANUAL

(GB)

KOLBE – Meat Cutting Band Saw

Model K 430 / K 440

KOLBE GmbH – Nirotechnik-Maschinenbau

Gewerbestraße 5

D-89275 Elchingen

Telefon [phone] – 0

Telefax + 49 (0) 73 08 / 96 10 – 98

www.kolbe-maschinenbau.com

e-mail [e-mail]

Machine no. .............................................

Table of Contents

1. Safety Instructions

2. List of Dangers (residual risks)

3. Technical Data

4. Delivery of the Machine

5. Installation of the Machine

6. Commissioning

7. Cleaning Instructions

8. Guarantee Claims and Deficiencies

9. Maintenance and Servicing

10. Troubleshooting

11. Declaration of Conformity to EEC

1. Safety Instructions

Before commissioning the machine, read the operating
manual and safety instructions carefully and observe
them at all times.
Also ensure that all other users are familiar with the
safety instructions.

• Anybody involved at the user’s plant with the

installation, dismantling, commissioning, operation and
maintenance (servicing, maintenance and repairs) of
KOLBE butchery machines must have read and
understood the relevant operating manual and in
particular the safety instructions in full. We recommend
that the user obtains written confirmation of this.

• KOLBE butchery machines are built to the state of the

art and are safe to use. However, if these machines
are used incorrectly or for improper purposes by
untrained personnel they may represent a danger.

• KOLBE butchery machines (band saws, mincers and

portioning units) are exclusively designed for
processing meat and fish. Any other usage shall be
regarded as improper. The manufacturer may not be
held liable for any damage resulting from this; this risk
shall be borne solely by the user.

• Proper usage also includes the observance of the

operating, maintenance and servicing instructions
issued by the manufacturer.

• KOLBE butchery machines (band saws, mincers and

portioning units) may only be operated, maintained and
serviced by authorised, trained and instructed
personnel. This personnel must have been given
special training in the possible dangers which may
occur.

• Responsibility for the installation, dismantling,

maintenance, commissioning, servicing and operating
must be clearly defined and observed so that no
unclear competence can occur which may involve
aspects of safety.

• Before starting work get to know all the equipment and

control elements on the machine and their function.
When the machine is working you will not have time to
do so and it will then be too late!

• The shut down procedures described in the operating

manual for installation, dismantling, maintenance,
commissioning, servicing and operating work must be
observed at all times.

• No action is to be taken which may reduce the safety

level of the machine.

• The operator must ensure that unauthorised persons

are not allowed to use the machine.

• The operator ist obliged to report any changes to the

machine which may reduce its safety level to his
superior immediately.

• The user must undertake to operate the machine only

if it is in perfect condition.

• By issuing the appropriate instructions and completing

the necessary checks the user must ensure the
cleanliness and clarity of the work station around the
machine.

• Unauthorised modifications or changes to the machine

are not allowed and will render the liability of the
manufacturer for any resulting damage null and void.

• Do not reach into the infeed and outfeed area of the

machine or into the tools when they are operating (e.g.
belt saw blade, mincer work, cross knives, and stroke
knives).

• Do not complete adjustment work when the machine is

operating. Wait until the machine has reached a
standstill.

• Electrical and mechanical safety equipment must not

be removed.

• Before looking for faults or completing maintenance

and repair work, disconnect the electrical supply and
have this work completed by an authorised specialist (if
necessary secure the machine using warning signs).

• Before restarting the machine after maintenance or

repair work, check whether all the guards have been
refitted correctly.

• The general safety and accident prevention regulations

as well as other generally acknowledged safety
regulations are to be observed.

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2. List of Dangers (residual risks)

Please note the following danger areas on the
machine !

2.1 Mechanical dangers

- Risk of injury by the band saw blade at and beyond the

cutting point (e. g. cutting injuries at the hands and
fingers or cutting off the fingers).

the running respectively standing saw blade!
When removing the saw blade wear cut-resistant

gloves! During saw ing on the machine do not use

protective metal (Niroflex) gloves!

-

- Risk of crushing the fingers/hand when closing the

door

- Risk of crushing or severance of the fingers, hand or

lower arm respectively feet and other parts of the body
between:

Do not reach into

• portioning detent and working table

• material pusher and working table

• material pusher and machine stand

• table plate and machine stand

• clamping resp. counter lever and machine stand

• working table and support table construction

• at the draw-in points of driving- and running wheel

• at the spokes of driving- and running wheel

• saw blade protection and machine stand

• table plate resp. stand and all attaching parts

• machine and table carriage

• at the mobile version on a wall resp. other objects

as well as between floor and rollers

• when installing or removing all removable parts

by slipping them out

2.2 Risk due to instability

Risk of bodily injury through impacts or squashing when the
machine, in particular the mobile version, falls over.

2.3 Electrical dangers

• Risk of injury by direct or indirect contact with the

electricity supply.

• Risk of injury from defective electrical components.

2.4 Risks from noise

Risk of hearing damage by noise emissions of over
85d(BA)
An idling noise level of 78,6 dB (A) pursuant to EN
ISO3746 : 1995 (constant K = 4dB) has been measured on
the band saw, during sawing 81,5 dB(A).

These values are emission values and do not necessarily
also represent safe workplace values. Although there is a
correlation between emission and emission noise levels it
is not possible to derive from them with any degree of
reliability whether additional precautionary action,
according to EN ISO 11690-1/-2, is necessary. Factors
which influence the emission levels which currently affect
the workplace include the type of working area, other
sources of noise, for example the number of machines and

other neighbouring procedures and other operating
conditions other than those which are normal.
The permission workplace values may also vary from
country to country. However, this information is intended to
enable the user to make a better assessment of the risk
involved. The operator must take appropriate personal
sound protection measures if the noise levels go above 85
d(BA), which means that he should wear ear plugs or ear
protection equipment.

2.5 Danger to health

Damage to the health of persons due to low environmental
temperatures. Use heat insulating clothing if the
environmental temperature goes below 7 °C.

2.6 Danger to health due to non-observance of
hygiene principles and cleaning instructions:

Danger to the health of persons and unacceptable changes
in the food to be processed, for example

 Ruination of the food (food poisoning)
 Internal acid attacks for the consumer due to

residual quantities of cleaning and disinfecting
materials in the food.
 Internal injuries for the consumer due to the
presence of foreign bodies (e. g. parts of the
machine or solid objects from other sources).

3. Technical Data

3.1 Manufacturer KOLBE GmbH

Gewerbestraße 5
D-89275 Elchingen

3.2 Designation Meat cutting band saw

3.3 Product number Type K 430 / K 440

3.4 Technical data

Wheel diameter 430 mm
Band saw blade 3370 x 16 mm

Band speed 32 m/s
Pass of depth of cut max. 415 mm
Pass of cut side max. 410 mm
Cutting storke max. 410 mm

Width of table 830 mm
Depth of table 880 mm
Height of table 900 mm
Width of sliding table (K 430) 430 mm
Depth of sliding table (K 430) 440 mm
Width of roll-sliding table (K 440) 425 mm
Depth of roll-sliding table (K 440) 440 mm

Width of unit 935 mm
Depth of unit 935 mm
Height of unit 1845mm
Motor capacity, IP 54 2,5 resp. 4,0 kW
Motor speed 1420 1/min

Motor tension/rotation current 230/400 V
Rated current (at 2,5 kW) 9,4,/5,4 A
Rated current (at 4,0 kW) 15,5/9,0 A
Motor brake serial

Weight net/gross (K 430 and K 440) 225/245 kg

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Every KOLBE product undergoes a thorough
acceptance test before being despatched, where
all of the functions and safety equipment is
checked.

4. Delivery of the Machine

The machine is supplied bolted to a wooden pallet and
shrink-packed in polyethylene protective foil. The operating
manual is also enclosed and placed in a separate foil (we
only use reusable and recyclable packaging).
Please inform your supplier immediately if the contents of
the consignment do not agree with the pack list. In the
event of transport damage the forwarding company is to be
notified immediately and given an opportunity to inspect the
damage.

5. Installation of the Machine

5.1 Installation Instructions

Remove the band saw, after de-assembling the four fixing
screws, out of its packing. Lift the band saw safely and
remove the pallet by fork-lift truck or crane. Screw the four
enclosed wheels of anti-vibration metal feet (8) into the
threaded holes respectively at the mobile version,
according to model, fit the two support- and two steering
rollers in front. Elevating adjustment of the anti-vibration
metal feet (8) by the thread in case of uneveness of the
floor.

The K 430 should be stored in a cooled or air-conditioned
room for hygiene reasons.
The machine must only be used in a room which is lit to an
intensity of at least 500 Lux.

All components which can be installed or removed weigh
less than 20 kgs, which means that it is not necessary to
arrange for a transporting device of the same height.

5.2 To connect the machine

Compare the motor voltage (see rating plate) with the
mains voltage. The machine must be connected by an
authorised electrician (following any local regulations).
Pursuant to EN 60204 the machine is to be connected
either using a plug device or a main switch is to be inserted
in the fixed supply lead.

The electrical circuit diagram for the machine is as follows:

- for 400 V rotary current (5 conductor system)
No. 96.163.3

- for 230 V rotary current (5 conductor)
No. 96.164.3

- for 400 V rotary current (no neutral conductor)
No. 96.165.3.

Connection cable 5 x 1,5mm²
(three phases + protective conductor yellow/green + blue
neutral conductor)

6. Commissioning

Important!

Before commissioning the machine read this operating
manual carefully. Please also pay attention to the
pictures shown on page 11 to 15.

6.1 To switch on the machine

The machine can be set in motion only, if the door is closed
and locked. The green on-button (2) and the red off-button
(1) are located laterally at the upper part of the saw.

Important!

Check the motor rotating direction. At the table
plate, the saw band has to move downwards
along the cutting direction and the saw teeth have to
look down!

6.2 Electronic brake device

By means of an electronic motor brake device the
band saw slows down up to its stoppage without
abrasion within 4 seconds after the switch-off or
opening of the door.

new switch-on is not possible before the final
running down of the stoppage time and an addition
safety time (total waiting time about 10 sec.).

6.3 Change of the band saw blade

- Switch off the unit, wait for the stoppage and interrupt

the main current feed

- Open both doors (26 + 30) by lifting up the door

locking device (34)

- Take off the roll-sliding table (6) of the floor-model K

440 by lifting the locking device (22) of the sliding­table and adjusting it in vertical position, than pull out
the roll-sliding table (6).

- Wear cut-resistance gloves

- Release the band saw blade (13) by the bolt lever (10)

and take it off

- Fit a new band saw blade (13) onto the bearing

surface of the two wheels

- Insert a new band saw blade (13) between the

scrapers (19) and into the band guides (16 + 17).
(Direction of the saw teeth at the band guides to the
bottom!)

- Tighten the band saw blade with the bolt lever (10)

- Check the saw band movement by turning the upper

wheel (14) to the right and to the left

- The distance of the back of the band saw blade to the

wheel edge behind has to be about 0,5 – 1 mm

- If the distance is larger or smaller, adjust the band

movement by the star grip (12) by unscrewing the
counter lever (11) at the star grip (12) and adjust the
band movement by turning the star grip to the right

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respectively to the left, then tighten the counter lever
(11) again

- Insert and lock the roll-sliding table (6) again

- Close both doors (26 + 30)

- The band saw is ready for work again

6.4. Band guide

The band guides above and below (16 + 17) are of
special alloy with best sliding and abrasion properties.
Below the lower band guide additional a carbide backside­plate support is posted
The upper band guide (16) with additional saw blade
protection (3) can be adjusted to the height of the goods to
be cut and is granting the safe and best guide of the band
saw blade (13). The vertically adjustable saw band guide
(16) can be locked by means of the star grip (15).

6.5. Scrapers

The high efficient wheel and band scrapers (19) are
screwed onto the scraper holders (20) and can easily be
drawn off from the extension shafts (32) without tool for
cleaning and replacement. The periodical wear-test of the
scrapers (19) is absolutely necessary. Scrapers, which do
not work correctly, will cause disturbing, undesired
sediments on the saw band and on the surfaces of the
treated goods.

6.6 Portioning detent

The stoppage of the portioning detent (7) can be released
by the upper cross grip (8), it is now adjustable. If you
release the cross grip (8), the portioning detent (7) can be
turned up 90º and taken off to the front.

On request: Portioning detent with fine adjustment
The portioning detent (7) can be adjustet exactly to the

desired cutting width by means of a star grip and the
devision scale in order to obtain a very exact portioning.
The second star grip is for the setting of the portioning
detent (7). If the portioning detent should be removed, turn
the setting star grip about 4 times, lift the adjusting star grip
to the top, then turn up the complete portioning detent (7)
by 90° and take if off to the front.

6.7 Table construction
K 430 - With fixed table plate, which can be hinged up

for cleaning (see page 7).
The sliding table (5) is used for the fine portioning.

It is equipped with a finger protector according to
the safety prescriptions, it can be hinged down
and adjusted laterally.

K 440 - With easy going roll-sliding table (6), equipped

with stainless ball-bearings serially, which enables
a long-lasting easy movement. The change into a
fixed table-plate is very easy.

For this, pull the roll-sliding table (6) to the front
up to detent, turn up the folding table (25) behind
and insert it forward. The folding table snaps by

low pressure. The finger-protector (21) on the roll-sliding
table (6) can be hinged down by relaxing the both cross­grips (23 + 24) to the left and can be adjusted in the lower
position by means of the cross-grip (24).

6. 8. Material pusher

The material pusher (4) is a pushing aid during the sawing
of bones, cutlets, etc. If it is not used during the carving of
larger parts, the material pusher (4) can be unhinged and
restored easily accessible underneath the table. As the
floor model saws K430/K440 are equipped with a motor
brake device and a vertically adjustable saw blade
protection (3), these units may also work without material
pusher according to the prescriptions.

6.9 Thermic motor protection

The motor of the unit is fitted with a motor guarding (thermo
couple contacts in the motor winding). In case of an
overload and consequent undue elevation of temperature
of the motor winding, the unit switches off itself
automatically.
This happens i. e. in case of phase failure, unsufficient
cooling or blocking of the unit. After a corresponding
cooling time, the unit can be started again. But if the cause
has not been cleared, the motor guarding comes into force
again after a short time.

6.10 Band saw - mobile version

The mobile bandsaw is, depending on the model, equipped
with two steering rollers with hand brake and two support
rollers. Always disconnect the mains plug before moving
the machine and take care for the power supply cable as
well as the plug.

parking brake must be pushed down again.

fter moving the bandsaw the wheel

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7. Cleaning Instructions

Important!

Switch off the machine, w ait until it has reach a
standstill and disconnect the main power supply,
when completing any cleaning w ork (remo ve the plug,
turn the main switch off).
Do not start any work before the band saw has not
stopped finally.
While cleaning wear protective clothes (e. g. goggles,
cut-resistant gloves (saw blade), etc.

7.1 Cleaning as detailed on the Cleaning Schedule

The band saw is to be cleaned every day as detailed on
the cleaning schedule (see page 7) to maintain its function
and hygiene standard.
Shorter cleaning intervals may be required depending on
the application and the hygiene regulations. Cleaning
products which are approved for food use has only to be
used.

7.2 Cleaning Instructions

- Switch off the machine, wait until it reaches a standstill

(remove the plug)

- Open both doors (26 + 30)

- Remove the band saw blade (13) as well as the

portioning detent (7) and material pusher (4)

- Remove the upper band guide (16) and clean it

carefully

- Lock vertically adjustable saw blade protection (3) by

means of the star grip (15) in the highest position

- Push the sliding table (5), if available, on the table

plate against the detent on the backside

- Release the both door lockings (27) in the front and

underneath the table plate (28) and lift the table.

- Secure the lifted table plate (28) by means of a table

support (29

- Remove the band wheel scrapers (19) and clean them

- Take off the lower band guide (17) and clean it

thoroughly. (Clean band guides and scrapers
periodically in order that the run of the band saw blade
(13) remains save and unprevented).

- Remove the bone meal box (31), empty and clean it

thoroughly

- Clean the complete unit

- Please observe the detailed cleaning instructions on

page 8.

All KOLBE machines are suitable for cleaning with
surge and jet water; nevertheless it must be ensured
that the electric switch parts an d the bearings are only
exposed to the jet of water for a short time.

8. Guarantee Claims and Deficiencies

8.1 According to the German law, we offer a guarantee of

24 months on our goods for single shift operation
starting from the date of delivery. This assumes,
however, that the customer complies with the
requirements of maintenance and servicing as shown
on page 8. The first service has to take place within 12
months by an authorised workshop, after date of
delivery.

8.2 This guarantee covers the repair or replacement of
all products which become defective during the
guarantee period as a result of proven material or
workmanship deficiencies by ourselves as the factory
or authorised contractual workshops.

8.3 The guarantee does not include any parts which are
subject to natural wear, the consequences of
excessive loads, improper cleaning or treatment and
the non-observance of the operating manual.

8.4 If any work is completed on the goods by the

client or third parties without our consent, we
refuse to accept any liability.

8.5 The products we manufacture comply with the

EC-Machine Directives.

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