Delta ShopMaster SM400 User Manual

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9" Bench Band Saw

(Model SM400)

PART NO. 638518-0011-05

Copyright © 2005 Delta Machinery

To learn more about DELTA MACHINERY

 

ESPAÑOL: PÁGINA 25

visit our website at: www.deltamachinery.com.

 

For Parts, Service, Warranty or other Assistance,

FRANÇAIS: PAGE 48

please call 1-800-223-7278(In Canada call 1-800-463-3582).

MANUAL INSTRUCTION

SAFETY GUIDELINES - DEFINITIONS

This manual contains information that is important for you to know and understand. This information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the symbols to the right. Please read the manual and pay attention to these sections.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Used without the safety alert symbol indicates potentially hazardous situation which, if not avoided, may result in property damage.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

lead from lead-basedpaints,

crystalline silica from bricks and cement and other masonry products, and

arsenic and chromium from chemically-treatedlumber (CCA).

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 those dust masks that are specially designed to filter out microscopic particles.

Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

Wear appropriate hearing protection during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

GENERAL SAFETY RULES

READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT. Failure to follow all instructions listed below, may result in electric shock, fire, and/or serious personal injury or property damage.

IMPORTANT SAFETY INSTRUCTIONS

Woodworking can be dangerous if safe and proper operating procedures are not followed. As with all machinery, there are certain hazards involved with the operation of the product. Using the machine with respect and caution will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result. Safety equipment such as guards, push sticks, hold-downs,featherboards, goggles, dust masks and hearing protection can reduce your potential for injury. But even the best guard won’t make up for poor judgment, carelessness or inattention.Always use common sense and exercisecaution in the workshop. If a procedure feels dangerous, don’t try it. Figure out an alternative procedure that feels safer.REMEMBER: Your personal safety is your responsibility. For additional information please visit our websitewww.deltamachinery.com.

This machine was designed for certain applications only. Delta Machinery strongly recommends that this machine not be modified and/or used for any application other than that for which it was designed. If you have any questions relative to a particular application,DO NOT use the machine until you have first contacted Delta to determine if it can or should be performed on the product.

Technical Service Manager

Delta Machinery

4825 Highway 45 North

Jackson, TN 38305

(IN CANADA: 505 SOUTHGATE DRIVE, GUELPH, ONTARIO

N1H 6M7)

2

GENERAL SAFETY RULES

Read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

1.FOR YOUR OWN SAFETY, READ THE INSTRUCTION MANUAL BEFORE OPERATING THE MACHINE. Learning the machine’s application, limitations, and specific hazards will greatly minimize the possibility of accidents and injury.

2.USE CERTIFIED SAFETY EQUIPMENT. Eye protection equipment should comply with ANSI Z87.1 standards, hearing equipment should comply with ANSI S3.19 standards, and dust mask protection should comply with MSHA/NIOSH certified respirator standards. Splinters, air-borne debris, and dust can cause irritation, injury, and/or illness.

3.DRESS PROPERLY. Do not wear tie, gloves, or loose clothing. Remove watch, rings, and other jewelry. Roll up your sleeves. Clothing or jewelry caught in moving parts can cause injury.

4.DO NOT USE THE MACHINE IN A DANGEROUS ENVIRONMENT. The use of power tools in damp or wet locations or in rain can cause shock or electrocution. Keep your work area well-lit to prevent tripping or placing arms, hands, and fingers in danger.

5.MAINTAIN ALL TOOLS AND MACHINES IN PEAK CONDITION. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. Poorly maintained tools and machines can further damage the tool or machine and/or cause injury.

6.CHECK FOR DAMAGED PARTS. Before using the machine, check for any damaged parts. Check for alignment of moving parts, binding of moving parts, breakage of parts, and any other conditions that may affect its operation. A guard or any other part that is damaged should be properly repaired or replaced.Damaged parts can cause further damage to the machine and/or injury.

7.KEEP THE WORK AREA CLEAN. Cluttered areas and benches invite accidents.

8.KEEP CHILDREN AND VISITORS AWAY. Your shop is a potentially dangerous environment. Children and visitors can be injured.

9.REDUCE THE RISK OF UNINTENTIONALSTARTING.

Make sure that the switch is in the “OFF” position before plugging in the power cord. In the event of a power failure, move the switch to the “OFF” position. An accidental start-upcan cause injury.

10.USE THE GUARDS. Check to see that all guards are in place, secured, and working correctly to prevent injury.

11.REMOVE ADJUSTING KEYS AND WRENCHES BEFORE STARTING THE MACHINE. Tools, scrap pieces, and other debris can be thrown at high speed, causing injury.

12.USE THE RIGHT MACHINE. Don’t force a machine or an attachment to do a job for which it was not designed. Damage to the machine and/or injury may result.

13.USE RECOMMENDED ACCESSORIES. The use of accessories and attachments not recom-

mended by Delta may cause damage to the machine or injury to the user.

14.USE THE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. See the Extension Cord Chart for the correct size depending on the cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

15.SECURE THE WORKPIECE. Use clamps or a vise to hold the workpiece when practical. Loss of control of a workpiece can cause injury.

16.FEED THE WORKPIECE AGAINST THE DIRECTION OF THE ROTATION OF THE BLADE, CUTTER, OR ABRASIVE SURFACE. Feeding it from the other direction will cause the workpiece to be thrown out at high speed.

17.DON’T FORCE THE WORKPIECE ON THE MACHINE. Damage to the machine and/or injury may result.

18.DON’T OVERREACH. Loss of balance can make you fall into a working machine, causing injury.

19.NEVER STAND ON THE MACHINE. Injury could occur if the tool tips, or if you accidentally contact the cutting tool.

20.NEVER LEAVE THE MACHINE RUNNING UNATTENDED. TURN THE POWER OFF. Don’t leave the machine until it comes to a complete stop.Achild or visitor could be injured.

21.TURN THE MACHINE “OFF”,AND DISCONNECT THE MACHINE FROM THE POWER SOURCE before installing or removing accessories, before adjusting or changing set-ups, or when making repairs. An accidental start-up can cause injury.

22.MAKE YOUR WORKSHOP CHILDPROOF WITH PADLOCKS, MASTER SWITCHES, OR BY REMOVING STARTER KEYS. The accidental start-up of a machine by a child or visitor could cause injury.

23. STAY ALERT, WATCH WHAT YOU ARE DOING,

AND USE COMMON SENSE. DO NOT USE THE MACHINE WHEN YOU ARE TIRED OR UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR MEDICATION. A moment of inattention while operating power tools may result in injury.

24.THE DUST GENERATED by certain woods and wood products can be injurious to your health. Always operate machinery inwell-ventilatedareas, and provide for proper dust removal. Use wood dust collection systems whenever possible.

3

ADDITIONAL SAFETY RULES FOR

BAND SAWS

Read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

1.DO NOT OPERATE THIS MACHINE UNTIL it is assembledand installedaccording to the instructions.

2.OBTAIN ADVICE from your supervisor, instructor, or another qualified person if you are not familiar with the operation of this tool.

3.FOLLOW ALL WIRING CODES and recommended electrical connections.

4.ALWAYS USE BLADE GUARD. Check to see that they are in place, properly adjusted, secured, and working correctly.

5.USE PROPER BLADE SIZE and type.

6.ADJUST THE UPPER BLADE GUIDE so that it is about 1/8" above the workpiece.

7.PROPERLY ADJUST the blade tension, tracking, blade guides, and blade support bearings.

8.KEEP ARMS, HANDS, AND FINGERS away from the blade.

9.AVOID AWKWARD OPERATIONS and hand positions where a sudden slip could cause a hand to move into the blade.

10.NEVER START THE MACHINE before clearing the table of all objects (tools, scrap pieces, etc.).

11.NEVER START THE MACHINE with the workpiece against the blade.

12.HOLD WORKPIECE FIRMLY against the table. DO NOT attempt to saw a workpiece that does not have a flat surface against the table.

13.HOLD WORKPIECE FIRMLY and feed into blade at a moderate speed.

14.NEVER REACH UNDER THE TABLE while the machine is running.

15.TURN THE MACHINE “OFF” to back out of an uncompleted or jammed cut.

16.MAKE “RELIEF” CUTS prior to cutting long curves.

17.TURN THE MACHINE “OFF” and wait for the blade to stop prior to cleaning the blade area, removing debris near the blade, removing or securing workpiece, or changing the angle of the table. A coasting blade can be dangerous.

18.NEVER PERFORM LAYOUT, ASSEMBLY, or set-up work on the table/work area when the machine is running.

19. TURN THE MACHINE “OFF” AND DISCONNECT THE MACHINEfrom the power source before installing or removing accessories, before adjusting or changing set-ups, or when making repairs.

20.TURN THE MACHINE “OFF”, disconnect the machine from the power source, and clean the table/work area before leaving the machine. LOCK THE SWITCH IN THE “OFF” POSITIONto prevent unauthorized use.

21. THIS BAND SAW IS INTENDED FOR INDOOR USE ONLY.

22.YOUR BAND SAW MUST be securely fastened to a stand or workbench. If there is any tendency for the stand or workbench to move during operation, the stand or workbenchMUST be fastened to the floor.

23.MAKE SURE blade is properly tensioned before operating saw.

24.MAKE SURE the blade teeth point downward toward the table.

25.DO NOT cut material that is too small to be safely supported.

26.NEVER attempt to cut a curve that is too tight for the blade being used.

27.THE USE of attachments and accessories not recommended by Delta may result in the risk of injuries.

28.SHOULD any part of your Band Saw be missing, damaged or fail in any way, or any electrical component fail to perform properly, shut off switch and remove plug from power supply outlet. Replace missing, damaged or failed parts before resuming operation.

29.ADDITIONAL INFORMATION regarding the safe and proper operation of power tools (i.e. a safety video) is available from the Power Tool Institute, 1300 Sumner Avenue, Cleveland, OH 44115-2851 (www.powertoolinstitute.com). Information is also available from the National Safety Council, 1121 Spring Lake Drive, Itasca, IL 60143-3201. Please refer to the American National Standards Institute ANSI 01.1 Safety Requirements for Woodworking Machines and the U.S. Department of Labor OSHA 1910.213 Regulations.

SAVE THESE INSTRUCTIONS.

Refer to them often

and use them to instruct others.

4

POWER CONNECTIONS

A separate electrical circuit should be used for your machines. This circuit should not be less than #12 wire and should be protected with a 20 Amp time lag fuse. If an extension cord is used, use only 3-wireextension cords which have 3- prong grounding type plugs and matching receptacle which will accept the machine’s plug. Before connecting the machine to the power line, make sure the switch is in the “OFF” position and be sure that the electric current is of the same characteristics as indicated on the machine. All line connections should make good contact. Running on low voltage will damage the machine.

SHOCK HAZARD: DO NOT EXPOSE THE MACHINE TO RAIN OR OPERATE THE MACHINE IN DAMP LOCATIONS.

GROUNDING INSTRUCTIONS

SHOCK HAZARD:THIS MACHINE MUST BE GROUNDED WHILE IN USE TO PROTECT THE OPERATOR FROM ELECTRIC SHOCK.

Your machine is wired for 120 volt, 60 HZ alternating current. Before connecting the machine to the power source, make sure the switch is in the “OFF” position.

1. All grounded, cord-connectedmachines:

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This machine is equipped with an electric cord having an equipment-groundingconductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Do not modify the plug provided - if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Improper connection of the equipment-groundingconductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipmentgrounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect theequipment-groundingconductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the machine is properly grounded.

Use only 3-wireextension cords that have3-pronggrounding type plugs and matching3-conductorreceptacles that accept the machine’s plug, as shown in Fig. A.

Repair or replace damaged or worn cord immediately.

GROUNDED OUTLET BOX

CURRENT

CARRYING

PRONGS

2. Grounded, cord-connectedmachines intended for use on a supply circuit having a nominal rating less than 150 volts:

If the machine is intended for use on a circuit that has an outlet that looks like the one illustrated in Fig. A, the machine will have a grounding plug that looks like the plug illustrated in Fig. A. A temporary adapter, which looks like the adapter illustrated in Fig. B, may be used to connect this plug to a matching2-conductorreceptacle as shown in Fig. B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. Thegreen-coloredrigid ear, lug, and the like, extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box. Whenever the adapter is used, it must be held in place with a metal screw.

NOTE: In Canada, the use of a temporary adapter is not permitted by the Canadian Electric Code.

SHOCK HAZARD: IN ALL CASES, MAKE CERTAIN THE RECEPTACLE IN QUESTION IS PROPERLY GROUNDED. IF YOU ARE NOT SURE HAVE A QUALIFIED ELECTRICIAN CHECK THE RECEPTACLE.

GROUNDED OUTLET BOX

GROUNDING

MEANS

ADAPTER

GROUNDING BLADE

IS LONGEST OF THE 3 BLADES

Fig. A

5

Fig. B

 

EXTENSION CORDS

Use proper extension cords. Make sure your extension cord is in good condition and is a3-wireextension cord which has a3-pronggrounding type plug and matching receptacle which will accept the machine’s plug. When using an extension cord, be sure to use one heavy enough to carry the current of the machine. An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. Fig. C, shows the correct gauge to use depending on the cord length. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the

cord.

MINIMUM GAUGE EXTENSION CORD

RECOMMENDED SIZES FOR USE WITH STATIONARY ELECTRIC MACHINES

Ampere

 

Total Length

Gauge of

Rating

Volts

of Cord in Feet

Extension Cord

 

 

 

 

0-6

120

up to 25

18 AWG

0-6

120

25-50

16 AWG

0-6

120

50-100

16 AWG

0-6

120

100-150

14 AWG

6-10

120

up to 25

18 AWG

6-10

120

25-50

16 AWG

6-10

120

50-100

14 AWG

6-10

120

100-150

12 AWG

 

 

 

 

10-12

120

up to 25

16 AWG

10-12

120

25-50

16 AWG

10-12

120

50-100

14 AWG

10-12

120

100-150

12 AWG

12-16

120

up to 25

14 AWG

12-16

120

25-50

12 AWG

12-16

120

GREATER THAN 50 FEET NOT RECOMMENDED

 

 

 

 

Fig. C

OPERATING INSTRUCTIONS

FOREWORD

The ShopMaster Model SM400 is built for precision and performance. The SM400 comes with a powerful 3 amp motor, rack and pinion upper blade guide assembly, table tilting assembly, and a flexible lamp.

UNPACKING AND CLEANING

Carefully unpack the machine and all loose items from the shipping container. Remove the protective coating from all unpainted surfaces. This coating may be removed with a soft cloth moistened with kerosene (do not use acetone, gasoline or lacquer thinner for this purpose). After cleaning, cover the unpainted surfaces with a good quality household floor paste wax.

NOTICE: THE MANUAL COVER PHOTO ILLUSTRATES THE CURRENT PRODUCTION MODEL. ALL OTHER ILLUSTRATIONS ARE REPRESENTATIVE ONLY AND MAY NOT DEPICT THE ACTUAL COLOR, LABELING OR ACCESSORIES AND MAY BE INTENDED TO ILLUSTRATE TECHNIQUE ONLY.

ASSEMBLY TOOLS REQUIRED

1.) 3mm hex wrench - supplied

3.) flat-headscrewdriver

2.) 4mm hex wrench - supplied

4.) phillips screwdriver

ASSEMBLY TIME ESTIMATE

1 hour or less

6

9" BENCH BAND SAW PARTS

1

1 - Band Saw

2 - Lamp

3 - Lamp Cord Clamps(2)

4 - 1/4" Lockwashers (2)

5 - M6x1x12mm Cap

Head Screws (2)

2

4

3

5

Fig. 2

 

 

 

 

 

6

- Table

 

 

 

 

 

7

- M6x1 Wing Nut

 

 

 

 

 

8

- M6 Flat Washer

 

 

 

6

 

9

- M6x1x30mm Pan

 

 

 

 

 

 

 

 

 

 

 

Head Screw

 

 

 

 

 

10

- 4mm Hex Wrench

 

 

 

19

11

- 3mm Hex Wrench

 

 

 

 

 

12

- Pointer

 

 

 

 

 

16

 

 

 

 

13

- M5x.8x10mm Pan

 

 

 

 

 

 

Head Screw

17

 

 

 

 

14

- M10 Flat Washer

18

 

 

 

 

15

- Lever Assembly

 

14

 

 

 

16

- Pinion Knob

 

 

 

7

 

17

- Spring

 

15

 

 

18

- Special Screw

 

 

8

 

 

 

10

 

 

 

 

 

9

 

19

- Miter Guage

 

 

 

 

13

 

11

 

 

 

(Optional)

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 3

 

 

 

 

7

ASSEMBLY

FOR YOUR OWN SAFETY, DO NOT CONNECT THE MACHINE TO THE POWER SOURCE U N T I L T H E M A C H I N E I S C O M P L E T E LY ASSEMBLED AND YOU READ AND UNDERSTAND THE ENTIRE INSTRUCTION MANUAL.

ASSEMBLING TABLE

TO MACHINE

1.Locate table locking lever (shown disassembled) Fig. 4, M10 flat washer (B) and 4mm wrench (C).

2.Using the 4mm wrench (C) Fig. 4, supplied, remove screw (D) and spring (E) from handle (A) and remove handle from nut (G). Do not lose spring (E).

A

B

G

C

E

D

Fig. 4

3.Place table (H) Fig. 5, onto the band saw frame so that stud (J) Fig. 6, and keepers (K) protrude through the slot of trunnion (L) Fig. 7.

4.Open hinged door. (See section “OPENING AND

CLOSING DOOR”.)

H

Fig. 5

5. While pressing in on stud (M) Fig. 8 with a pencil, place an M10 flat washer (B) Fig. 7, onto stud and thread nut (G) onto stud as shown in Fig. 7.

L

BG

K

J

K

Fig. 6

M

Fig. 7

8

Fig. 8

 

 

6. Locate pinion knob (N) Fig. 9, spring (O), and special screw (P).

7. Position pinion knob (N) Fig. 10, onto the back of saw so that the teeth on the pinion knob (N) engage the teeth on the trunnion (R). Fasten in place with special screw (P) and spring using the supplied 4mm wrench.

8.Fasten pointer (S) Fig. 11, to the back of band saw using the M5x.8x10mm pan head screw (T).

9.Place locking handle (F) Fig. 4, onto stud (G). Place spring (E) Fig. 4, inside hole of lock handle and fasten in place with screw (D) as shown in Fig. 11. NOTE: Handle

(F) is spring-loadedand can be repositioned on the stud by pulling out the handle and repositioning it on the nut.

10. Insert M6x1x30mm screw (W) Fig. 12, down through hole in table, as shown, and place an M6 flat washer (Z) onto the M6x1x30mm screw (W) and thread the M6x1 wing nut (X) onto screw (W) and tighten securely.

N

O

P

Fig. 9

R

P

N

Fig. 10

D

F

S

T

Fig. 11

W

Z

X

Fig. 12

9

ATTACHING LAMP TO MACHINE

1.Fasten the lamp bracket (A) Fig. 13, to the top cover of the machine, using two M6x1x12mm cap head screws

(B) and 1/4" lockwashers as shown.

2.Peel backing from cord clamps (C) Fig. 13A, and apply one clamp at each of the locations shown. Make certain the lamp cord is routed out of the way of the blade, then secure cord (D) to cord clamps (C) as shown in Fig. 13A.

3.The flexible lamp operates independently of the band saw. To turn the lamp on and off, rotate switch (E) Fig. 13A.

FIRE HAZARD: To reduce the risk of fire, use 40 watt or less, 120 volt, reflector track type light bulb (not supplied). A standard household light bulb should not be used. The reflector track type light bulb should not extend below the lamp shade.

A

B

Fig. 13

E

D

F

C

C

Fig. 13A

FASTENING BAND SAW

TO SUPPORTING SURFACE

A

The machine must be secured to a supporting surface. Four holes are provided in the band saw base for this purpose, three of which are shown at

(A) Fig. 14.

A

Fig. 14

10