Klutch 49657 Owner's Manual
Thank you very much for choosing a Klutch product. For future reference, please complete the
owner’s record below:
Serial Number/Lot Date Code: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
This mini milling machine is designed for certain applications only. Northern Tool and
Equipment cannot be responsible for issues arising from modification or use of this product in
an application for which it was not designed. We strongly recommend that this product not be
modified and/or used for any application other than that for which it was designed.
For technical questions please call 1-800-222-5381.
Table of Contents
Intended Use.......................................................................................................................................1
Technical Specifications....................................................................................................................2
Important Safety Information.............................................................................................................2
Specific Operation Warnings..............................................................................................................4
Grounding...........................................................................................................................................5
Extension Cords..................................................................................................................................6
Main Parts...........................................................................................................................................7
Assembly Instructions........................................................................................................................7
Installation of the Milling Machine...................................................................................................8
Power Connection...........................................................................................................................8
Initial Start........................................................................................................................................9
Before Each Use.................................................................................................................................9
Pre-Start Checks Before Operation.................................................................................................9
Travel Adjustment...........................................................................................................................10
Adjust Tip Angle of Fuselage..........................................................................................................10
Installation of a Chuck or Cutter....................................................................................................10
Removal of a Chuck or Cutter........................................................................................................10
Operating Instructions......................................................................................................................10
Normal Starting..............................................................................................................................11
Drilling or Deep Milling...................................................................................................................11
Face Milling....................................................................................................................................11
During Operation............................................................................................................................12
After Each Use..................................................................................................................................12
Maintenance.....................................................................................................................................12
Daily Maintenance..........................................................................................................................12
Seasonal Maintenance...................................................................................................................12
Examine the circuitry (contact points, conductor, plugs, and switches) to ensure normal
conditions. Maintenance of Accessories.....................................................................................12
Lubrication......................................................................................................................................13
Miter Wedge Adjustment................................................................................................................13
Parts Diagram...................................................................................................................................16
Parts List ..........................................................................................................................................18
Replacement Parts...........................................................................................................................20
Limited Warranty...............................................................................................................................20
Intended Use
This milling machine is designed for drilling and deep milling with multiple functions for either face
milling or drilling including milling head and column tilts to 45°, left or right.
Mini Milling Machine
OWNER’S MANUAL
Mini Milling Machine
OWNER’S MANUAL
Item# 49657
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WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and
other basic safety precautions may result in serious personal injury.
Mini Milling Machine
OWNER’S MANUAL
Mini Milling Machine
OWNER’S MANUAL
Technical Specifications
T-Slot Specification (mm)
Important Safety Considerations
WARNING:
• Read and understand all instructions. Failure to follow all instructions may result in serious
injury or property damage.
• The warnings, cautions, and instructions in this manual cannot cover all possible conditions
or situations that could occur. Exercise common sense and caution when using this tool.
Always be aware of the environment and ensure that the tool is used in a safe and
responsible manner.
• Do not allow persons to operate or assemble the product until they have read this manual
and have developed a thorough understanding of how it works.
• Do not modify this product in any way. Unauthorized modification may impair the function
and/or safety and could affect the life of the product. There are specific applications for
which the product was designed.
• Use the right tool for the job. DO NOT attempt to force small equipment to do the work of
larger industrial equipment. There are certain applications for which this equipment was
designed. It will do the job better and more safely at the capacity for which it was intended.
DO NOT use this equipment for a purpose for which it was not intended.
• Industrial or commercial applications must follow OSHA requirements.
WARNING:
• This product may contain chemicals known to the State of California to cause cancer, birth
defects or other reproductive harm.
• 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.
• Handling power cords 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 your
hands after handling.
WARNING:
WORK AREA SAFETY
• Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well lit.
Cluttered, wet, or dark work areas can result in injury. Using the tool in confined work areas
may put you dangerously close to other cutting tools and rotating parts.
• Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the
presence of flammable liquids, gases, or dust. The product can create sparks, which may
ignite the flammable liquids, gases, or dust.
• Do not allow the product to come into contact with an electrical source. The tool is not
insulated and contact will cause electrical shock.
• Keep children and bystanders away from the work area while operating the tool. Do not allow
children to handle the tool.
• Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in
your work area. Some of these hazards may be hidden from your view and may cause
personal injury and/or property damage if contacted.
WARNING:
PERSONAL SAFETY
• Stay alert, watch what you are doing, and use common sense when operating the tool. Do
not use the tool while you are tired or under the influence of drugs, alcohol, or medication. A
moment of inattention while operating the tool may result in serious personal injury.
• Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry, or long hair can be
caught in moving parts. Air vents on the tool often cover moving parts and should be
avoided.
• Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant
safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a
dust mask in dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust
collection systems, and hearing protection when appropriate. This applies to all persons in
the work area.
• Do not overreach. Keep proper footing and balance at all times.
• Do not use the tool when tired or under the influence of drugs, alcohol or medication.
• Ensure the power switch is off prior to plugging in the tool.
• Remove keys or wrenches before connecting the tool to an air supply, power supply, or
turning on the tool. A wrench or key that is left attached to a rotating part of the tool may
cause personal injury.
• Secure the work with clamps or a vise instead of your hand when practical. This safety
precaution allows for proper tool operation using both hands.
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Property
Max. table travel
Max. cross slide
Max. spindle travel
Spindle Rotary Angle
Spindle Speed
Taper of hole in spindle*
Milling Capacity
Milling Capacity
Shipping Weight
Machine Weight
Noise levels
Dimensions
Specification
8-1/2” (220mm)
4” (100mm)
7” (180mm)
-45º to +45º
Low: 0-1100 rpm, High: 0-2500 rpm
MT #3 or R8
5/8” (16mm) Face
1-3/16” (30mm)
150 lbs. (68kg)
110 lbs. (50kg)
70~75dB (A)
20-1/2 (L) x 20-1/16 (W) x 29-15/16
Mini Milling Machine
OWNER’S MANUAL
Mini Milling Machine
OWNER’S MANUAL
WARNING:
ELECTRICAL SAFETY
• Grounded tools must be plugged into an outlet properly installed and grounded in accordance
with all codes and ordinances. Never remove the grounding prong or modify the plug in any
way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to
whether the outlet is properly grounded. If the tools should electrically malfunction or break
down, grounding provides a low resistance path to carry electricity away from the user.
• Double insulated tools are equipped with a polarized plug (one blade is wider than the other).
This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet,
reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized
outlet. Do not change the plug in any way. Double insulation eliminates the need for the three
wire grounded power cord and grounded power supply system.
• Do not allow the product to come into contact with an electrical source. The tool is not
insulated and contact will cause electrical shock.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and
refrigerators. There is an increased risk of electric shock if your body is grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
• Do not abuse the power cord. Never use the power cord to carry the tools or pull the plug
from an outlet. Keep the power cord away from heat, oil, sharp edges, or moving parts.
Replace damaged power cords immediately. Damaged power cords increase the risk of
electric shock.
• When operating a power tool outside, use an outdoor extension cords marked “W-A” or “W”.
These extension cords are rated for outdoor use, and reduce the risk of electric shock.
CAUTION:
PRODUCT USE AND CARE
• Do not force the product. Products do a better and safer job when used in the manner for
which they are designed. Plan your work, and use the correct product for the job.
• Check for damaged parts before each use. Carefully check that the product will operate
properly and perform its intended function. Replace damaged or worn parts immediately.
Never operate the product with a damaged part.
• Do not use a product with a malfunctioning switch. Any power tool that cannot be controlled
with the power switch is dangerous and must be repaired by an authorized service
representative before using.
• Disconnect the power/air supply from the product and place the switch in the locked or off
position before making any adjustments, changing accessories, or storing the tool. Such
preventive safety measures reduce the risk of starting the tool accidentally.
• Store the product when it is not in use. Store it in a dry, secure place out of the reach of
children. Inspect the tool for good working condition prior to storage and before re-use.
• Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure
than the tool itself.
• Keep guards in place and in working order. Never operate the product without the guards in
place.
• Do not leave the tool running unattended.
Specific Operation Warnings
WARNING:
• Moving Parts Hazard. Keep hands clear of rotating bit or work piece.
• Wear the proper safety gear including ANSI Z87.1 compliant eye protection.
• The noise level during operation is 70~75dB (A). Wear the appropriate hearing protection.
• DO NOT wear loose clothing, jewelry, gloves, or unrestrained hair that may get caught in
moving parts of the machine.
• Remove chuck key before starting the machine.
• Always secure work piece before machining operation.
• DO NOT operate without guards in place.
• Electric shock hazard. Be sure equipment is properly grounded.
• Turn power OFF before servicing.
• Only operate the milling machine in the temperature range of -4 to 104ºF (-20 to +40ºC).
• Not for use by or around children.
Grounding
WARNING:
• This machine must be grounded while in use to protect the operator from electrical shock.
This drill press is equipped with an electric cord that has an equipment-grounding conductor
and a grounding plug. The plug MUST be plugged into a matching receptacle 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 receptacle, have the proper
receptacle installed by a qualified electrician.
• CHECK with a qualified electrician or service person if you do not completely understand the
grounding instructions, or if you are not sure the tool is properly grounded.
Grounded Tools: Tools with 3-Prong Plugs
Tools marked with Grounding Required have a 3-wire cord and 3-prong grounding plug. The
plug must be connected to a properly grounded outlet. If the tool should electrically malfunction
or break down, grounding provides a low resistance path to carry electricity away from the
user, reducing the risk of electric shock. (See Figure A.)
The grounding prong in the plug is connected through the green wire inside the cord to the
grounding system in the tool. The green wire in the cord must be the only wire connected to the
tool’s grounding system and must never be attached to an electrically live terminal.
Your tool must be plugged into an appropriate outlet, properly installed and grounded in
accordance with all codes and ordinances. The plug and outlet should look like those in the
following illustration.
Double Insulated Tools: Tools with Two-Prong Plugs
Tools marked Double Insulated do not require grounding. They have a special double insulation
system which satisfies OSHA requirements and complies with the applicable standards of
Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical
Code. (See Figure B.)
Double insulated tools may be used in either of the 120 volt outlets shown in the following
illustration.
4 of 20 5 of 20
150'
14 AWG
12 AWG
12 AWG
Nameplate AMPS
25'
18 AWG
18 AWG
16 AWG
14 AWG
50'
16 AWG
16 AWG
16 AWG
12 AWG
100'
16 AWG
14 AWG
14 AWG
Minimum Wire Size Of Extension Cords
0-6
6-10
10-12
12-16
Cord Length
NOT RECOMMENDED
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Mini Milling Machine
OWNER’S MANUAL
Extension Cords
WARNING:
• USE A 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 cause overheating.
• Be sure your extension cord is properly wired and in good condition. Always replace a
damaged extension cord or have it repaired by a qualified person before using it. Protect
your extension cords from sharp objects, excessive heat and damp or wet areas.
• Grounded tools require a 3-wire extension cord. Double Insulated tools can use either a 2- or
3-wire extension cord.
• As the distance from the supply outlet increases, you must use a heavier gauge extension
cord. Using extension cords with inadequately sized wire causes a serious drop in voltage,
resulting in loss of power and possible tool damage.
• The smaller the gauge number of the wire, the greater the capacity of the cord. For example,
a 14-gauge cord can carry a higher current than a 16-gauge cord. Minimum extension cord
wire size is shown in the following table:
• When using more than one extension cord to make up the total length, make sure each cord
contains at least the minimum wire size required.
• If you are using one extension cord for more than one tool, add the nameplate amperes and
use the sum to determine the required minimum cord size.
• If you are using an extension cord outdoors, make sure it is marked with the suffix W-A (W in
Canada) to indicate it is acceptable for outdoor use.
• Make sure your extension cord is properly wired and in good electrical condition. Always
replace a damaged extension cord or have it repaired by a qualified electrician before using
it.
• Protect your extension cords from sharp objects, excessive heat, and damp or wet areas.
Mini Milling Machine
OWNER’S MANUAL
Main Parts
Assembly Instructions
When unpacking the milling machine, check the shipping crate contents to ensure all parts are
present. If any pieces are missing, call the distributor at the number in the Replacement Parts
section of this manual.
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