Kawasaki 840076 User Manual

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

KAWASAKI™ IS A TRADEMARK LICENSED BY KAWASAKI™ MOTORS CORP., U.S.A., WHICH DOES NOT MANUFACTURE OR DISTRIBUTE THIS PRODUCT. CONSUMER INQUIRES SHOULD BE DIRECTED TO:

840076 – Horizontal/Vertical 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 UNDERSTAND ALL CAUTIONS, WARNINGS, INSTRUCTIONS AND PRODUCT LABELS. FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR PROPERTY DAMAGE.

IF YOU SHOULD HAVE ANY QUESTIONS OR EXPERIENCE A PROBLEM WITH YOUR ALLTRADE PRODUCT, DO NOT RETURN THIS PRODUCT TO THE STORE. PLEASE CALL OUR CUSTOMER SERVICE DEPARTMENT AT 1-800-590-3723. BEFORE YOU CALL, HAVE THE FOLLOWING INFORMATION AVAILABLE: MODEL No., DATE PURCHASED AND STORE LOCATION. AN ALLTRADE REPRESENTATIVE CAN RESOLVE YOUR PROBLEM OVER THE PHONE. IF YOU WOULD LIKE TO MAKE A SUGGESTION OR COMMENT, GIVE US A CALL OR EMAIL US AT: INFO@ALLTRADETOOLS.COM. YOUR FEEDBACK IS VITAL TO US.

HORIZONTAL /VERTICAL METAL CUTTING BAND SAW

INSTRUCTION MANUAL

87-1904-60957

SECTION FOUR

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-30

MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

OTHER CONSUMER DO-IT-YOURSELF (DIY) TOOLS . . . . . . . . . . . . . . 33

SECTION FIVE

3 YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36

CONGRATULATIONS!

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 Service. 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 professional 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 UNDERSTAND ALL INSTRUCTIONS. Failure to

follow all instructions in this manual may result severe personal injury 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 injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

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

TABLE OF CONTENTS

CONGRATULATIONS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION ONE

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS . . . . . . . . . . . . 2-3

IMPORTANT SAFEGUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION TWO

GENERAL SAFETY RULES – FOR ALL ELECTRIC POWER TOOLS . . . . 4-5

GROUNDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

EXTENSION CORD USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

IMPORTANT SAFETY RULES FOR METAL CUTTING BAND SAWS . . . . 7-10

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION THREE

FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21

ATTACHING THE LEGS TO THE BAND SAW BASE . . . . . . . . . . . . . 13-15

INSTALLING PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ATTACHING THE VISE HAND WHEEL . . . . . . . . . . . . . . . . . . . . . . . 15-16

ATTACHING THE VERTICAL CUTTING TABLE . . . . . . . . . . . . . . . . . 16-17

BLADE GUIDE BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 17

BLADE GUIDE ASSEMBLY ADJUSTMENT . . . . . . . . . . . . . . . . . . . 18

BLADE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

ADJUSTING BLADE TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

CHANGING BLADE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

BAND SAW BLADE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

LASER GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23

LASER SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

OPERATING THE LASER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

OPERATING THE METAL CUTTING BAND SAW . . . . . . . . . . . . . . . . . . 24-28

ADJUSTING THE BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

HORIZONTAL CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26

ADJUSTING THE FEED RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

VERTICAL CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

CUTTING CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

GENERAL SAFETY RULES – FOR ALL ELECTRIC POWER TOOLS

READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instruc-

tions listed below may result in electric shock, fire and/or serious personal injury.

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 STARTER 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 APPLICATION. Do not force 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. Everyday 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 situations.

MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

DISCONNECT TOOLS BEFORE SERVICING AND WHEN CHANGING ACCESSORIES, SUCH AS BLADES, BITS, CUTTERS AND THE LIKE.

REDUCE THE RISK OF UNINTENTIONAL STARTING. Be sure switch is in the

“OFF” position before plugging in.

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

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

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

NOTE provides additional information that is useful for proper use and maintenance of this tool. If a NOTE is indicated make sure it is fully understood.

IMPORTANT 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 masonry 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.

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

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 unapproved, 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 circuitry acceptable for this and other power tools you use. Repair or replace any damaged electrical wiring IMMEDIATELY.

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 voltage 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 recommended accessories. The use of improper accessories may cause cause risk of injury.

NEVER STAND ON TOOL. Serious injury 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 perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions 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 direction 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 personal injury, or death.

The electrical power source 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 service 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 especially true if used in damp or wet locations or near metallic plumbing. The reaction from electrical shock could possibly cause your hands to make contact 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.

FIGURE 1. CONNECTING THE BAND SAW TO THE AC POWER RECEPTACLE

UNGROUNDED AC RECEPTACLE

GROUNDED RECEPTACLE

GROUNDING ADAPTER

TOOL POWER CORD

COVERPLATE

MOUNTING SCREW

KEEP BYSTANDERS, 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 injury 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 horizontal band saw can cause unexpected accidents if the debris comes in contact with the moving parts of the Horizontal band saw.

MAINTAIN 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 injury 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 Service at 1-800-590-3723 (toll free) for authorized accessories.

USE ONLY METAL CUTTING BAND SAW BLADES that 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 performed at the proper speeds as expressed in this manual.

ALWAYS EASE THE BAND SAW BLADE AGAINST THE WORKPIECE when starting a cutting operation.

DO NOT USE THE BAND SAW IF THE BLADE VIBRATES. 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 VIBRATION can cause severe damage to both the workpiece and the horizontal band saw. DISCONNECT AC POWER BEFORE ANY ADJUSTMENTS TO THE BLADE ARE MADE.

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 receptacle are the primary 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.

IMPORTANT SAFETY RULES FOR METAL CUTTING BAND SAWS

AVOID PROLONGED CONTACT WITH DUST CREATED BY THE HORIZONTAL BAND SAW. 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 UNDERSTAND ALL INSTRUCTIONS. If there are instructions in this manual that are not completely understood, seek the advice of a trained professional or contact Alltrade Customer Service at 1-800-590-3723 before attempting to perform the procedures. Failure to follow all instructions listed in this manual may result in property damage, damage to the tool, or serious personal injury or even death.

UNPACK THE HORIZONTAL BAND SAW COMPLETELY FROM ITS CARTON.

Inspect the saw and accessories and ensure they are free from defects or breakage due to shipping.

DO NOT OPERATE THIS HORIZONTAL BAND SAW until it is completely assembled according to the instructions in this manual. Failure to adhere to these instructions could result in serious and/or permanent injury 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. Everyday 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 grounded 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.

EXTREME CARE SHOULD BE TAKEN WHEN THE BAND SAW IS IN THE VERTICAL 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 workpiece 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 BELT GUARD AND BLADE COVER IN PLACE. It is very 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 HORIZONTAL BAND SAW TO THE “OFF” POSITION AND UNPLUG THE POWER CORD FROM THE ELECTRICAL RECEPTACLE when the cutting operations are finished. Thoroughly clean the area sur-

rounding the horizontal band saw making it ready for the next use.

NEVER LEAVE THE HORIZONTAL BAND SAW RUNNING UNATTENDED. WHEN FINISHED WITH A CUTTING OPERATION, TURN “OFF” THE HORIZONTAL BAND SAW AND WAIT UNTIL IT COMES TO A COMPLETE STOP.

SECURE THE ELECTRICAL POWER CORD WHEN THE HORIZONTAL BAND SAW 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 INFORMATION 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 tightened 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 unexpectedly move causing the abrasive wheel to seize resulting in damage to it or possible severe injury 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 workpiece and horizontal band saw as well as possible severe injury to the operator.

NEVER START THE HORIZONTAL BAND SAW WITH THE WORKPIECE IN CONTACT WITH THE BAND SAW 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 injury to the operator.

DISCONNECT THE HORIZONTAL BAND SAW 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 injury to the operator.

THOROUGHLY CLEAN THE HORIZONTAL BAND SAW BEFORE CHANGING TYPES OF WORKPIECES. CONSULT EXPERT ADVICE BEFORE CUTTING IN WORKPIECES MADE OF MAGNESIUM. The friction generated by the band saw

blade could the magnesium to ignite resulting in a very 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” RATING. ONLY A CLASS “D” EXTINGUISHER (FOR FLAMMABLE METALS) SHOULD BE USED. Do not attempt to extinguish a

magnesium fire with water or other liquid. The result will be an explosive reaction that could result in severe burns or death to the operator.

NEVER PERFORM CUTTING OPERATIONS NEAR FLAMMABLE GAS OR LIQUIDS. The resulting fire and/or explosion could cause permanent serious

injuries to the operator and damage to the horizontal band saw and surrounding work area.

ALWAYS KEEP ARMS, HANDS, AND FINGERS away from the workpiece while it is on the table and the horizontal band saw is turned on. Severe injury could result.

+ 13 hidden pages