AllTrade Kawasaki Vertical Horizontal Band Saw 840076 User Manual
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MODEL#840076 FOR CUSTOMER SERVICE POUR LE SERVICE APRÉS VENTE OU DU CONSOMMATEUR PARA EL SERVICIO PARA EL CONSUMIDOR 1-800-590-3723 Printed in China 87-1904-60957 KAWASAKI™ IS A TRADEMARK LICENSED BY KAWASAKI™ MOTORS CORP ., U.S.A., WHICH DOES NOT MANUF ACTURE OR DISTRIBUTE THIS PRODUCT . CONSUMER INQUIRES SHOULD BE DIRECTED TO: ©COPYRIGHT 2006 ALLTRADE TOOLS, LLC. 1431 VIA PLATA LONG BEACH, CA 90810-1462 USA 840076 – Horizontal/V ertical Metal Cutting Band saw - Rev.9/26/06 THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING SAFETY,OPERATION, MAINTENANCE AND STORAGE OF THIS PRODUCT.BEFORE USE,READ CAREFULLY AND UNDERST AND ALL CAUTIONS, WARNINGS, INSTR UCTIONS AND PRODUCT LABELS. FAILURE TO DO SO COULD RESUL T IN SERIOUS PERSONAL INJUR Y AND/OR PROPER TY DAMAGE. IF YOU SHOULD HAVE ANY QUESTIONS OR EXPERIENCE A PROBLEM WITH YOUR ALL TRADE PRODUCT ,DO NOT RETURN THIS PRODUCT TO THE STORE. PLEASE CALL OUR CUSTOMER SERVICE DEP ARTMENT AT 1-800-590-3723 .BEFORE YOU CALL, HAVE THE FOLLOWING INFORMA TION AVAILABLE:MODEL No.,DATE PURCHASED AND STORE LOCATION.AN ALLTRADE REPRESENT ATIVE CAN RESOL VE YOUR PROBLEM OVER THE PHONE. IF YOU WOULD LIKE TO MAKE A SUGGESTION OR COMMENT ,GIVE US A CALL OR EMAIL US AT:INFO@ALL TRADETOOLS.COM. YOUR FEEDBACK IS VITAL TO US. HORIZONTAL /VERTICAL METAL CUTTING BAND SAW INSTRUCTION MANUAL
SECTION FOUR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30 MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32 SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 OTHER CONSUMER DO-IT -YOURSELF (DIY) TOOLS . . . . . . . . . . . . . . 33 SECTION FIVE 3 YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36 CONGRA TULA TIONS! Thanks for choosing this product. At Alltrade, our aim is to provide you with quality products at an affordable price, and we want you to be totally satisfied with your product and our Customer Ser vice. If any help and advice is needed, please contact us at 1-800-590-3723. Properly cared for , this product will give you many years of satisfaction. INTENDED USE This product is intended for consumer use only . This tool is not designed for pro- fessional use. The power cord should only be used in approved electrical outlets as described in this manual. Failure to use the proper power cords and/or extension cords may result in fire or possible damage to the band saw . RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS READ AND UNDERST AND ALL INSTRUCTIONS. Failure to follow all instructions in this manual may result severe personal injur y or death. Keep this manual and refer to it for Safety Instructions, Operating Procedures and Warranty . The safety instructions provided in this manual are not intended to cover all possible conditions and practices that may occur when operating, maintaining and cleaning power tools. Always use common sense and pay particular attention to all the DANGER , WARNING , CAUTION and NOTE statements of this manual. This is the safety alert symbol. It is used to alert you to potential personal injur y hazards. Obey all safety messages that follow this symbol to avoid possible injur y or death. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injur y. TABLE OF CONTENTS CONGRA TULA TIONS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION ONE RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS . . . . . . . . . . . . 2-3 IMPOR TANT SAFEGUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SECTION TWO GENERAL SAFETY RULES – FOR ALL ELECTRIC POWER TOOLS . . . .4-5 GROUNDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 EXTENSION CORD USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 IMPOR TANT SAFETY RULES FOR MET AL CUTTING BAND SA WS . . . .7-10 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION THREE FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ASSEMBL Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21 ATTACHING THE LEGS TO THE BAND SA W BASE . . . . . . . . . . . . . 13-15 INST ALLING PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ATTACHING THE VISE HAND WHEEL . . . . . . . . . . . . . . . . . . . . . . . 15-16 ATTACHING THE VER TICAL CUTTING TABLE . . . . . . . . . . . . . . . . . 16-17 BLADE GUIDE BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 17 BLADE GUIDE ASSEMBL Y ADJUSTMENT . . . . . . . . . . . . . . . . . . . 18 BLADE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19 ADJUSTING BLADE TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20 CHANGING BLADE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 BAND SA W BLADE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 LASER GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23 LASER SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23 OPERA TING THE LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 OPERA TING THE MET AL CUTTING BAND SA W . . . . . . . . . . . . . . . . . . 24-28 ADJUSTING THE BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 HORIZONT AL CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26 ADJUSTING THE FEED RA TE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VER TICAL CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CUTTING CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1
GENERAL SAFETY RULES – FOR ALL ELECTRIC POWER TOOLS READ AND UNDERST AND ALL INSTRUCTIONS. Failure to follow all instruc- tions listed below may result in electric shock, fire and/or serious personal injur y. KEEP GUARDS IN PLACE AND IN WORKING ORDER. REMOVE ADJUSTING KEYS AND WRENCHES. Form a habit of checking to see that keys and adjusting wrenches are removed from the tool before turning it on.KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. DO NOT USE TOOL IN A DANGEROUS ENVIRONMENT. Do not use power tools in damp or wet locations, or expose them to rain. Keep work area well lit. KEEP CHILDREN AWAY.All visitors should be kept a safe distance from the work area. MAKE YOUR WORKSHOP CHILD PROOF, WITH PADLOCKS, MASTER SWITCHES, OR BY REMOVING ST AR TER KEYS. DO NOT FORCE TOOL. The correct tool will do the job better and safer at the rate for which it is designed. USE THE CORRECT TOOL FOR YOUR APPLICA TION. Do not for ce tool or attachment to do a job for which it was not designed. ALWAYS USE SAFETY GLASSES. Also use a face mask or dusk mask if cutting operation is dusty . Ever yday eyeglasses only have impact lenses, they are NOT safety glasses. SECURE WORK. Use clamps or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. DO NOT OVERREACH. Keep proper footing and balance at all times. Proper footing and balance enables better control of the power tool in unexpected sit- uations.MAINT AIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest per formance. Follow instructions for lubricating and changing accessories. DISCONNECT TOOLS BEFORE SERVICING AND WHEN CHANGING ACCES- SORIES, SUCH AS BLADES, BITS, CUTTERS AND THE LIKE. REDUCE THE RISK OF UNINTENTIONAL ST AR TING. Be sure switch is in the “OFF” position before plugging in. 4 WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injur y. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injur y. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. NOTEprovides additional information that is useful for proper use and maintenance of this tool. If a NOTE is indicated make sure it is fully understood. IMPOR TANT SAFEGUARDS People with electronic devices, such as pacemakers, should consult their physician(s) before using this product. Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker . WARNING: Some dust created by power sanding, sawing, grinding, drilling and other construction activities contains chemicals known to the State of California to cause cancer , birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints. • Crystalline silica from bricks and cement and other masonr y products, and arsenic and chromium from chemically-treated lumber . Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles. WARNING: Handling the power cord on corded products may expose you to lead, a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. SA VE THESE INSTRUCTIONS FOR FUTURE REFERENCE. 3
This metal cutting band saw is equipped with a grounded 3-wire power cord with a 3-prong plug. If the power cord will not fit into the wall plug, an approved adapter can be used as long as it is connected to the center screw in the wall plate. Never modify the electrical plug by cutting off the grounding prong so it will fit into unap- proved, un-grounded electrical receptacles. See Figure 1 and the steps below to use an AC grounding adapter: 1. Remove the cover plate mounting screw . 2. Insert the AC grounding adapter into the bottom receptacle so the green grounding lug fits over the screw hole. 3. Install the mounting screw back into the cover plate securely attaching the adapter to the receptacle. If you have questions about hooking up the band saw , contact a certified electrical contractor to install the proper circuitr y acceptable for this and other power tools you use. Repair or replace any damaged electrical wiring IMMEDIA TEL Y. EXTENSION CORD USAGE Extension cords are not recommended for use with this band saw. Extension cords, if used, must be properly grounded with a 3-prong plug on one and a 3-hole receptacle on the other. DO NOT use grounding adapters with an extension cord. Extension cords must be UL listed and use a minimum of 18 A.W.G. wiring. Extension cords should never exceed 25 feet in length. Extension cords, that are too long, cause a volt- age drop over the extra distance causing the band saw motor to run slower with the possibility of causing damage to the motor. Using extension cords with smaller than the recommended wire gauge run the risk of getting too hot, melting, and/or causing fires. See table,“Extension Cord Specifications”,on page 31-32. USE RECOMMENDED ACCESSORIES.Consult the owners manual for recommend- ed accessories. The use of improper accessories m ay cause cause risk of injury. NEVER ST AND ON TOOL. Serious injur y could occur if the tool is tipped or if the cutting tool is unintentionally contacted. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and per form its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other con- ditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced. DIRECTION OF FEED. Only feed work into a blade or cutter against the direc- tion of rotation of the blade or cutter . GROUNDING INSTRUCTIONS NEVER use appliances or equipment that has motors with automatic reset overload protective devices. These protective devices can cause unexpected startups that can cause property damage, severe per- sonal injur y, or death. The electrical power sour ce for this band saw MUST be grounded in order prevent possible electric shock or even death should the tool malfunction or breakdown. Grounding provides a path of least resistance for electric current thus reducing the risk of electrical shock. The power source must also use a minimum 20A ser vice and not used if other power tools on the same circuit are in use. Failure to properly ground this metal cutting band saw could result in burns, severe electrical shock, and even death. This is espe- cially true if used in damp or wet locations or near metallic plumbing. The reaction from electrical shock could possibly cause your hands to make con- tact with the cutting tools. Not all outlets are properly grounded, regardless of the type of receptacle they have. If you are not sure if the receptacle is properly grounded or not, consult a certified electrician. The AC receptacle must be protected by a dual element time delay or a circuit breaker . 6 5 FIGURE 1. CONNECTING THE BAND SAW TO THE AC POWER RECEPTACLE UNGROUNDED AC RECEPTACLE GROUNDED RECEPTACLE GROUNDING ADAPTER TOOL POWER CORD TOOL POWER CORD COVERPLATE MOUNTING SCREW
KEEP BYST ANDERS, CHILDREN, AND VISITORS at a safe distance from the horizontal band saw while it is in operation. Distractions can cause inadvertent misuse resulting in possible injur y to the bystanders or to the operator . WEAR PROPER APPAREL.Do not wear loose clothing, gloves, neckties, rings, bracelets, or other apparel that could possibly become caught in the moving parts of the horizontal band saw. When working in a shop environment around power tools, wear nonslip footwear. Use protective hair covering to contain long hair. KEEP THE WORK AREA CLEAN AT ALL TIMES. Cluttered areas around the hor- izontal band saw can cause unexpected accidents if the debris comes in contact with the moving parts of the Horizontal band saw . MAINT AIN A PROPER WORK ENVIRONMENT .Do not operate the horizontal band saw in damp or wet locations or expose it to rain. Water can cause the electrical components to malfunction resulting in damage to the Horizontal band saw and/or serious injur y or death to the operator . ALWAYS USE APPROVED TABLE CLAMPS AND VICES to clamp workpieces to the horizontal band saw table to prevent breakage, damage to the tool, the workpiece, and possible severe injury to the operator. Contact Alltrade Customer Ser vice at 1-800-590-3723 (toll free) for authorized accessories. USE ONLY METAL CUTTING BAND SAW BLADESthat were designed for this tool. Unsuitable blades can break without warning throwing fragments outward at high speeds possibly causing severe injuries. DO NOT FORCE THE TOOL. The horizontal band saw will do a better job and be safer if cutting operations are per formed at the proper speeds as expressed in this manual. ALWAYS EASE THE BAND SA W BLADE AGAINST THE WORKPIECE when start- ing a cutting operation. DO NOT USE THE BAND SA W IF THE BLADE VIBRA TES. Visually inspect the blade wheels to ensure the blade is properly positioned in the guides. If the vibration still exists, check the bearings and the motor shaft and repair or replace them as soon as possible. EXCESSIVE VIBRA TION can cause severe damage to both the workpiece and the horizontal band saw . DISCONNECT AC POWER BEFORE ANY ADJUSTMENTS TO THE BLADE ARE MADE. 8 A substantial voltage drop can occur when using an extension cord. This voltage drop will cause a loss of power and possibly saw overheating. Overheating of the motor due to extension cords and multiple tools operating from the same recepta- cle are the primar y causes of power loss for the metal cutting band saw . Do not use the metal cutting band saw if the power cord (or extension cord, if used) is worn, cut, or damaged in any other way. A worn or damaged power cord must be replaced immediately. Contact Alltrade Customer Service to obtain the proper replacement power cord. Failure to adhere to this warning could result in damage to the metal cutting band saw motor, fire, or severe electrical shock or even death to the operator. IMPOR TANT SAFETY RULES FOR MET AL CUTTING BAND SA WS AVOID PROLONGED CONT ACT WITH DUST CREA TED BY THE HORIZONT AL BAND SA W. Allowing the dust to get into your mouth, eyes, or lay on your skin promotes the absorption of harmful chemicals into your body . READ AND UNDERST AND ALL INSTRUCTIONS . If there are instructions in this manual that are not completely understood, seek the advice of a trained profes- sional or contact Alltrade Customer Ser vice at 1-800-590-3723 before attempt- ing to per form the procedures. Failure to follow all instructions listed in this manual may result in property damage, damage to the tool, or serious person- al injur y or even death. UNP ACK THE HORIZONT AL BAND SA W COMPLETEL Y FROM ITS CAR TON. Inspect the saw and accessories and ensure they are free from defects or break- age due to shipping. DO NOT OPERA TE THIS HORIZONT AL BAND SA W until it is completely assem- bled according to the instructions in this manual. Failure to adhere to these instructions could result in serious and/or permanent injur y to the operator . MAKE SURE APPROVED EYE PROTECTION IS BEING WORN and properly adjusted and secured at all times the horizontal band saw is in use. Ever yday eyeglasses only have impact resistant lenses and ARE NOT safety glasses. Safety glasses must conform to ANSI Z87.1 requirements. Approved safety glasses and goggles will have Z87 printed or stamped on them. FOLLOW ALL WIRING CODES. Use only properly grounded three-hole ground- ed receptacles. DO NOT cut the third prong off the power cord. When using an extension cord, use only UL Listed extension cords with minimum 16 AWG wiring and a maximum length of 25 feet. See ELECTRICAL SAFETY section in this manual. 7
EXTREME CARE SHOULD BE TAKEN WHEN THE BAND SA W IS IN THE VER TI- CAL POSITION. It is important to keep hands away from the moving blade both above and below the work table. A sudden slip could bring hands in contact with the moving blade possibly resulting in severe injuries to the operator . ALWAYS CLAMP THE WORKPIECE FIRMLY AGAINST THE WORK TABLE.Never attempt to hold the workpiece by hand. The band saw blade can seize in the work- piece resulting in loss of control of the workpiece possibly causing severe injuries to the operator and/or damage to the workpiece and horizontal band saw. KEEP THE BEL T GUARD AND BLADE COVER IN PLACE. It is ver y important that these covers be in place and in proper working condition when the band saw is being used. REDUCE THE RISK OF UNINTENTIONAL STARTING.Ensure the “ON/OFF” switch is set to the “OFF” position before plugging the power cord into the AC outlet. TURN THE ON/OFF SWITCH ON THE HORIZONT AL BAND SA W TO THE “OFF” POSITION AND UNPLUG THE POWER CORD FROM THE ELECTRICAL RECEP- TACLE when the cutting operations are finished. Thoroughly clean the area sur- rounding the horizontal band saw making it ready for the next use. NEVER LEA VE THE HORIZONT AL BAND SA W RUNNING UNA TTENDED. WHEN FINISHED WITH A CUTTING OPERA TION, TURN “OFF” THE HORIZONT AL BAND SA W AND WAIT UNTIL IT COMES TO A COMPLETE STOP . SECURE THE ELECTRICAL POWER CORD WHEN THE HORIZONT AL BAND SA W IS NOT IN USE to prevent unauthorized use of the tool and/or to prevent children from accidentally turning it on. Department of Labor OSHA 1910.213 Regulations.ADDITIONAL INFORMA TION about the proper use of metal cutting band saws is available from the Power Tool Institute; 1300 Sumner Avenue, Cleveland, OH 44115-2851 or at the following website, www.powertoolinstitute.com. Information is also available from the National Safety Council; 1121 Spring Lake Drive, Itasca, IL 60143-3201. Additionally , you can refer to the U.S. Department of Labor Occupational Safety and Health Act (OSHA) 1910.213 Regulations. 9 10 ADJUST THE TOOL TABLE BEFORE EACH USE. The tool table should be tight- ened and placed at the proper angle for the cutting job before the horizontal band saw is put into use. If not properly adjusted, the workpiece can unexpect- edly move causing the abrasive wheel to seize resulting in damage to it or possible severe injur y to the operator . PROPERLY SUPPORT EXTRA LONG OR EXTRA WIDE WORKPIECES. Workpieces that are too long or tool wide can tip and cause the band saw blade to seize resulting in a sudden kick back motion resulting in damage to the work- piece and horizontal band saw as well as possible severe injur y to the operator . NEVER ST AR T THE HORIZONT AL BAND SA W WITH THE WORKPIECE IN CON- TACT WITH THE BAND SA W BLADE. The sudden start-up of the band saw blade could cause it to break resulting in pieces flying away from the horizontal band saw resulting in damage the workpiece, the horizontal band saw , and/or serious injur y to the operator . DISCONNECT THE HORIZONT AL BAND SA W POWER CORD FROM THE AC OUTLET before making adjustments to the worktable, clamps, vises or work- pieces to prevent the tool from accidentally turning on. Failure to adhere to this step could result in damage to the workpiece and the horizontal band saw as well as possible severe injur y to the operator . THOROUGHL Y CLEAN THE HORIZONT AL BAND SA W BEFORE CHANGING TYPES OF WORKPIECES. CONSUL T EXPER T ADVICE BEFORE CUTTING IN WORKPIECES MADE OF MAGNESIUM. The friction generated by the band saw blade could the magnesium to ignite resulting in a ver y intense fire that could cause severe burns to the operator and/or seriously damage the horizontal band saw . MAGNESIUM FIRES CANNOT BE EXTINGUISHED USING FIRE EXTINGUISHER WITH AN “A”, “B” OR “C” RA TING. ONL Y A CLASS “D” EXTINGUISHER (FOR FLAMMABLE MET ALS) SHOULD BE USED. Do not attempt to extinguish a magnesium fire with water or other liquid. The result will be an explosive reac- tion that could result in severe burns or death to the operator . NEVER PERFORM CUTTING OPERA TIONS NEAR FLAMMABLE GAS OR LIQ- UIDS. The resulting fire and/or explosion could cause permanent serious injuries to the operator and damage to the horizontal band saw and surround- ing work area. ALWAYS KEEP ARMS, HANDS, AND FINGERSaway from the workpiece while it is on the table and the horizontal band saw is turned on. Severe injury could result.
SYMBOLS IMPOR TANT : Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer . SYMBOL NAME EXPLANA TION V Volts Voltage (Potential) A Amperes Current Hz Hertz Frequency (Cycles per Second) W Watt Power Kg Kilograms Weight Alternating Current Type of Current Direct Current Type of Current Alternating or Direct Current Type of Current Earthing Terminal Grounding Terminal Class II Construction Denotes Double Insulation min Minutes Time s Seconds Time ! Diameter Size of Drill Bits, Grinding Wheels, etc. No load speed No-load Rotational Speed .../min Revolutions per Minute Revolutions, Sur face Speed, Strokes, etc. per Minute 1,2,3, … Ring Selector Settings Speed, Torque or Position Settings FUNCTIONAL DESCRIPTION CONTROLS AND COMPONENTS: 1. Band Saw Assembly 2. Legs (2 pcs) 3. Connecting Plate (2 pcs) 4. Tray 5. Floor Stand Handle 6. Axel Assembly 7. Wheel (2 pcs) 8. Hex Wrench 9. Stock Stop Assembly 12 11 1 913 14 10 11 2 4 12151617 7 5 6 3 28 10. Vise Adjusting Handle 11. Table Support Bracket 12. Belt 13. Bandsaw Pulley 14. Motor Pulley 15. Belt /Pulley Housing 16. Vertical Saw Table 17. Hardware Bag
6. Repeat this step for the remaining three legs. 7. Position the floor stand handle in the holes on the front legs. Adjust the legs slightly so the handle will fit. 8. Using two 1/2 (12 mm) box-end wrenches, place one on the hex nut on the inside of the attached leg and one on the outside hex screw head. Holding the hex nut in place, securely tighten the four screws attaching the front legs. 14 ASSEMBL Y The KA WASAKI™ Horizontal /Vertical Metal Cutting Band saw requires ver y little assembly . The band saw head and motor assemblies are assembled and adjusted at the factor y. The assembly includes attaching the stand legs to the band saw base and attaching the adjustment wheels to their proper spindles. Before beginning the assembly , carefully unpack the band saw and all included parts and accessories. Visually inspect all items for damage. Should anything be broken or bent, DO NOT attempt to assemble the band saw . Contact Alltrade Customer Ser vice at 1-800-590-3723 (toll free) IMMEDIA TEL Y for replacement parts. DO NOT connect the band saw to the AC power source until tool is completely assembled and adjusted per instructions in this m anual. ATTACHING THE LEGS TO THE BAND SA W BASE Attaching the legs to the metal cutting band saw also includes attaching the wheel assembly and the floor stand handle. The metal cutting band saw weighs ±60 lbs (± 27 kg). The band saw and base unit will need to be positioned on its side for various assem- bly procedures. It is recommended that two people be used to position the band saw for these assemblies. Proceed with the following steps to assemble the legs, wheels and floor stand han- dle. See Figure 2. 1.Place a large piece of cardboard or other protective material on the floor so the band saw will not be damaged during assembly . 2.Using two people, carefully place the band saw and base unit so that it rest on the bow assembly and the motor assembly . 3.Place one of the metal legs in the inside corner and align the two holes. NOTE: There are two legs with mounting holes several inches below the holes that attach the legs to the base. The legs should be on the opposite end of the base from where the motor is mounted (the front of the band saw). The remaining tow legs have holes near the bottom. These legs mount under the end where the motor is mounted (the rear of the band saw). 4.Insert a 1/4 X 20 X 1 1/4 hex head screw through each of the two holes in the base and through the holes in the leg. 5.Insert a washer on the screw followed by a 1/4 X 20 hex nut. Finger -tighten the screws at this time. Do not use any tools. G FIGURE 2. ASSEMBLING THE BAND SAW 13
1. Set the metal cutting band saw upright on the leg set. 2. Slide the vise hand wheel onto the vise adjusting shaft on the front end of the band saw base. 3. Securely tighten the setscrew on the hand wheel locking it on the shaft. 4. Ensure the setscrew is tightened against the flat part of the adjusting rod. ATTACHING THE VER TICAL CUTTING TABLE There will be times when the metal cutting band saw will need to be used in the vertical position. Use the following steps to attach the vertical cutting table. See Figure 5. 1. Raise the band saw arm to the vertical position and secure with the locking lever. 2. Loosen the hex bolt on the side of the band saw bow assembly . 3. Slide the vertical table bracket beneath the loos- ened hex bolt. 4. Securely tighten the hex bolt locking the vertical table bracket in place. 5. Remove the two flathead screws and bearing plate. 6. Position the vertical table so the holes align with the two holes on the bear plate and the single hole on the vertical table bracket. 7. Insert the two flat-head screws back into the bearing assembly . 8. Insert an additional flat-head screw (from loose parts) through the table and the vertical table bracket. Place a lock washer on the screw and tighten with a hex nut. 9. Securely tighten all three screws ensuring the vertical table is locked in place. 9. Position the wheel assembly so the holes in the two rear legs align. Insert a 1/4 X 20 X 3/4 hex head screw into the wheel cross-member followed by a split-lock washer . On the inside of the leg, place a washer and a 1/4 X 20 hex nut. Finger -tighten the screw at this time. Repeat this step for the other side. 10. Using two 1/2 (12 mm) box-end wrenches, place one on the hex nut on the inside of the attached leg and one on the outside hex screw head. Holding the hex nut in place, securely tighten the two screws attaching the wheel assembly to the rear legs. 11.Using two people, carefully pick up the m etal cutting band saw and set it on its legs. 12. To move the saw to different positions, lift up on the floor stand handle (See Step 7) allowing the band saw to roll on the wheels attached to the rear legs. INST ALLING PULLEYS 1.Remove the existing screw from the band saw . 2.Position the belt housing as shown and secure to the band saw using the screw from the previous step and a 6MM pan head phillips screw and a rubber washer from the hardware kit. 3.Insert the pulleys into the shafts as shown and tighten set screws. 4.Install the belt over the pulleys. ATTACHING THE VISE HAND WHEEL The vise hand wheel permits the tightening and holding of material to be cut by the metal cutting band saw . Refer to the following steps and Figure 4 to install the hand wheel. 15 16 FIGURE 3. INSTALLING THE PULLEYS EXISTING SCREW 6MM SCREW AND RUBBER WASHER FIGURE 4. ATTACHING THE VISE HAND WHEEL FIGURE 5. ATTACHING THE VERTICAL CUTTING TABLE
18 Check to ensure there are no parts of the flat-head screws raised above the vertical table work surface. Edges of the screws protruding above the work surface could damage workpieces or cause irregular cuts. BLADE GUIDE BEARING ADJUSTMENT The proper alignment of the blade guide bearings is the most important adjustment on the metal cutting band saw . The blade guide bearings are adjusted and tested before the band saw leaves the factor y. The need for further adjustment will be unnecessar y if the band saw is used and maintained properly . Should the blade guide bearing get out of adjustment, it is important they be re-adjusted immediate- ly. If the blade guide bearings are out of adjustment, the blade will not cut straight. If the problem is not immediately corrected, damage to the blade will occur . Blade guide bearing adjustment is a critical adjustment to the metal cutting band saw . Before attempting to correct the blade guide bear- ing adjustment, try installing a new band saw blade. This could correct the poor per formance. If a new blade becomes dull on one side sooner than the other , it will start cutting crooked. Simply changing the blade should correct this prob- lem whereas the more difficult blade guide bearing adjustment will not. If a new blade does not correct the cutting problem, check the blade guides for proper spacing. See Figure 6. 1. Ensure there is 0.001 clearance between the 0.025 blade thickness and the guide bearings. 2. The inner guide bearing is fixed and cannot be adjusted. 3. The outer guide bearing is mounted to an eccentric bolt and can be adjusted. 4. Loosen the nut while holding the bolt with a wrench. 5. Position the eccentric bolt by turning it to the desired clearance. Check this clearance with a thickness gauge. 6. Securely tighten the nut. 7. Repeat steps 4 through 6 to adjust the second blade guide bearing. 8. The back edge of the band saw blade should just barely touch the guide bearing. BLADE GUIDE ASSEMBL Y ADJUSTMENT The metal cutting band saw is equipped with two adjustable blade guide assemblies permitting the adjustment of blade guide position for various widths of workpieces. To ensure the most accurate cut and prolonging the life of the blade, the blade guide assemblies should be adjusted to just clear the workpiece being cut. 1. Place the workpiece in the vise and securely clamp in place.2. Adjust the catch blade guide assembly by loosening the hand knobs and positioning the guides as needed. 3. Securely tighten the hand knobs. BLADE TENSION ADJUSTMENT In order for the metal cutting band saw to cut effectively , the proper tension must be put on the blade. If the tension is too loose, the blade may bind and possibly break. If the blade tension is too tight, the blade could damage to the blade guide bearings and possibly break.DO NOT connect the band saw to the AC power source until tool is completely assembled and adjusted per instructions in this m anual. FIGURE 6. ADJUSTING THE BLADE GUIDE BEARING FIGURE 7. ADJUSTING THE BLADE GUIDE ASSEMBLY