9 x 12 METAL BAND SAW

Transcription

1 9 x 12 METAL BAND SAW Owner s Manual 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. Item # SAVE THESE INSTRUCTIONS

2 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 this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This band saw is designed for certain applications only. Northern Tool and Equipment is not responsible for issues arising from modification or improper use of this product such as 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 Page 2 of 30

3 Table of Contents Intended Use... 4 Technical Specifications... 4 Important Safety Information... 4 Specific Operation Warnings... 8 Grounding... 9 Assembly Instructions Before Each Use Operating Instructions Work Set Up Work Stop Adjustment Manual of Gear Type Speed Changing Blade Speeds Blade Direction of Travel Starting the Saw Blade Selection Changing the Blade Tru-Lock Vise System Blade Guide Bearing Adjustment Blade Track Adjustment After Each Use Maintenance Lubrication Troubleshooting Parts Diagram Parts List Replacement Parts Limited Warranty Page 3 of 30

4 Intended Use This large-capacity band saw is used to cut larger pieces of metal up to 9 x 12 inches as given in the specifications below. The saw features a gear drive and fully adjustable downfeed control to regulate the saw s rate of descent. The unit rolls on casters for maneuverability. Technical Specifications Property Specification Dimensions L x W x H (in.) 52.2" x 18.2" x 42.6" Wheel Diameter (in.) Blade Type HP Speed (RPM) Blade Included Cutting Depth at 90 (in.) BI-METAL 3ph=1hp, 1ph=1.5hp MOTOR=1720RPM Yes Round: 9 / rectangular: 7 x12 Cutting Depth at 45 (in.) Round: 6 / rectangular: 5 x 6 Blade Size L x W x Thickness (in.) x 1 x Cutting Capacity (SFPM) Cutting Capacity - Flat Stock (in. x in.) 60Hz = 148/216/282 FPM Round: 9 / rectangular: 7 x12 Bed Height (in.) 24 Important Safety Information 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. Page 4 of 30

5 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. 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. Page 5 of 30

6 PERSONAL SAFETY Stay alert, watch what you are doing, and use common sense when operating the saw. Do not use the saw while you are tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating the saw 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. 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 saw 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 saw. A wrench or key that is left attached to a moving part of the saw 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. 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. Page 6 of 30

7 SAW USE AND CARE Do not force the saw. 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 saw 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 the saw 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 saw 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 saw 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. Page 7 of 30

8 Specific Operation Warnings Wear the proper safety gear including ANSI Z87.1 compliant eye protection. Cutting Hazard. DO NOT operate with guard removed. Keep hands clear of blade. Be especially careful to keep fingers and hands out of path of blade when using band saw in a vertical position. Hold work piece firmly against table. Electric shock hazard. Be sure equipment is properly grounded. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. Ground fault circuit interrupters. If work area is not equipped with a permanently installed Ground Fault Circuit Interrupter outlet (GFCI), use a plug-in GFCI between power tool or extension cord and power receptacle. 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. Avoid accidental starting. Ensure the switch is in the off position before plugging tool into power outlet. In the event of a power failure, while a tool is being used, turn both the switches off to prevent surprise starting when power is restored. When moving the saw, ALWAYS have the head lowered to the horizontal position. Turn power OFF before servicing. Not for use by or around children. Page 8 of 30

9 Grounding This machine must be grounded while in use to protect the operator from electrical shock. This drill press is equipped with an electrical 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 PROVIDED PLUG. 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. Page 9 of 30

10 Assembly Instructions Put both the power switches in the locked or off position before making any adjustments or changing parts. Such preventive safety measures reduce the risk of starting the saw accidentally. Mount the Motor (see Parts Diagram 2) 1. Align the Motor (300) with the gear box input plate (800-1) so the keyway slot in the motor shaft and the input gear line up. 2. Put the key (300-1) into the aligned slot of the motor shaft and input gear then push the motor up against the gear box input plate. 3. Secure the motor to the gear box with the four screws (300-2) and spring washers (300-3) provided then tighten the screws. Mount the Drive and Idler Wheels 4. Assemble the Drive Wheel (264), the smaller of the two provided, to the Drive Gear Shaft (800-37) then tighten the set screw (264-1) enough to hold the wheel in place. (See Parts Diagrams 2 and 3) 5. Assemble the Idler Wheel Set (235S), the larger of the two provided, to the protruding drive Shaft then tighten the set screw of the wheel set enough to hold the wheel in place. (See Parts Diagram 2). Mount the Blade (see Changing the Blade for details of this procedure) 6. Carefully place the blade loop onto the two wheel grooves so that the vertical edge of the teeth engage the workpiece first (see below). 7. Align the blade and both wheels such that the blade is parallel in the wheel grooves. 8. Tighten the set screws of both wheels to maintain the alignment. Page 10 of 30

11 Before Each Use DO NOT attempt to use this machine until you are totally familiar with how to operate it safely. Read operator s manual for details. DO NOT place hands near cutter while machine is operating. DO NOT perform any set-up work while machine is operating. Always wear safety glasses/face shields while operating this machine. Always disconnect machine from power source before performing any maintenance or repair to this machine. Operators should not wear loose clothing, jewelry or unrestrained hair styles while using this machine. Check for damaged parts before each use. Carefully check that the tool will operate properly and perform its intended function. Replace damaged or worn parts immediately. Never operate the tool with a damaged part. Check the saw for correct function before starting each cutting operation. Ensure that the saw is clean to perform its function correctly and that all the parts of the machine are present and in place Operating Instructions Put the power switch in the locked or off position before making any adjustments or changing parts to reduce the risk of starting the saw accidentally. Do not use the saw tool with a malfunctioning power 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. Do not leave the saw running unattended. Keep guards in place and in working order. Never operate the saw without the guards in place. Avoid accidental starts: Make sure the power switch is in the off position before inserting the power cord plug into a wall outlet. Keep your work surface clean: cleanliness in the cutting area is essential if you are to work in safety. Always use the vice: pieces to be cut must always be held with the vice. Never hold a piece to cut with your hand. Work Set Up 1. Raise the saw to the highest position. 2. Open the vise to accept the workpiece by rotating the wheel at the end the base ( ). 3. Place the workpiece on the saw bed. If the piece is long, support the end by other means. 4. Close the vice to securely clamp the workpiece in place. Page 11 of 30

12 Work Stop Adjustment 1. Loosen the thumb screw (48) holding the work stop casting (51) to the shaft. 2. Adjust the work stop casting to the desired length position then rotate it to as close to the bottom of the cut as possible. 3. Tighten the thumb screw. Manual of Gear Type Speed Changing Exactly set the handle to the 3 position 1. Disconnect the metal belt saw from the electrical power supply. 2. Select the proper cutting speed according to the material of work-pieces and blade select chart. 3. Turn the speed-changing handle (A) directly for the necessary speed. 4. Changing speed during cutting is prohibited. 5. But changing speed when machine is stopped and running (before cutting) is available. A ***Please make sure the oil of gear box is between 950cc~1000cc to maintain the machine in a proper operation. ***Let the metal belt saw run for a few minutes before beginning the oil change. This will heat the oil, making it flow more easily out of the outlet hole. Page 12 of 30

13 Blade Speeds When using the saw always change the blade speed to best suit the material being cut the table below gives suggested settings for several materials. Material Tool, Stainless Alloy Steels Bearing Bronze Medium to High Carbon Steels Hard Brass or Bronze Low to Medium Carbon Steel Soft Brass Speed F.P.M 60Hz 50Hz Aluminum,Plastic Blade Direction of Travel Be sure the Made is assembled to the pulleys such that the vertical edge engages the work piece first. Blade Movement Blade Direction Page 13 of 30

14 Starting the Saw Note: The coolant switch is integrated with the motor start switch. The coolant function is ON while the saw is operating, If you do not need the coolant function, turn the rocker switch on the coolant pump OFF. A B Stop button Start button Never operate the saw without the blade guards in place to protect against personal injury. 1. Be sure the blade is not in contact with the work when the motor is started. 2. Start the motor, allow the saw to come to full speed, and then begin the cut by letting the head down slowly onto the work. DO NOT DROP OR FORCE the cut. Let the weight of the saw head provide the cutting force. 3. The saw automatically shuts off at the end of the cut. Blade Selection An 8-tooth per inch, general-use blade is furnished with the saw. Additional blades in 4, 6, 8, and 10 tooth sizes are available. The choice of blade pitch is governed by the thinness of the work to be cut: the thinner the work piece, the more teeth advised. A minimum of three (3) teeth should engage the work piece at all times for proper cutting. If the teeth of the blade are so far apart that they straddle the work, severe damage to the workpiece and to the blade can result. Changing the Blade 1. Ensure power is disconnected from saw. 2. Raise saw head to the highest position and open the blade guards (292S and 317S) using the hand wheels. 3. Remove the blade back cover (327). 4. Loosen the tension screw knob (218) sufficiently to allow the saw blade to slip off the wheels. 5. Install the new blade with teeth slanting toward the motor (see Blade Direction of Travel above) as follows: a. Place the blade in between each of the guide bearings (293S/294S and 315S/316S). b. Slip the blade around the drive wheel (264) with the left hand and hold in position. c. Hold the blade taut against the drive wheel by pulling the blade upward with the right hand which is placed at the top of the blade. d. Remove the left hand from drive wheel and place is at the top side of the blade to continue the upward pull on the blade. e. Remove the right hand from the blade and adjust the position of the idler wheel (235S) to permit the left hand to slip the blade around the wheel using the thumb, index and little finger as guides. f. Adjust the blade tension knob clockwise until it is just right enough so no blade slippage occurs. Do not tighten excessively. 6. Replace the blade back cover. 7. Place 2-3 drops of oil on the blade. Page 14 of 30

15 Tru-Lock Vise System The Tru-Lock vise system uses two controls to move and lock the vise as shown below. Rotating handle (b) is used to move the vise in to hold a workpiece or out to release it. Lever (a) is lowered to lock the vise in its present position or lifted to allow movement. (a) (b) (1) (2) (3) (1) The position of the vise when locked. (2) The position of the vise when half-unlocked. (3) The position of the vise when unlocked. Operation 1. Raise the cutting head above the work piece and close the cylinder valve to maintain the head height. 2. Put the work piece on the table. Move the vise handle (a) upwards to an angle of 45 degree to unlock the vise. 3. Move the vise jaw bracket tight against the work piece by turning the rotating handle (b). 4. Push down on the vise handle (a) to lock the work piece in position. To loosen a workpiece from the vise, hold the workpiece, lift the vise handle to vertical, unscrew the vice a little with the rotating handle, and remove workpiece. Quick Vise Angle Adjustment 1. Loosen screws A, B, C, and D (shown below). 2. Adjust the rear vise (E) to the desired angle shown on the scale. 3. Adjust the front vise (F) to parallel the rear vise(e) 4. Retighten screws A, B, C, and D. Page 15 of 30

16 Blade Guide Bearing Adjustment This is the most important adjustment on your saw. It is impossible to get satisfactory work from your saw if the blade guides are not properly adjusted. The blade guide bearings on your band saw are adjusted and power tested with several test cuts before leaving the factory to insure proper setting. The need for adjustment should rarely occur if the saw is used properly. If the guides do get out of adjustment though, it is extremely important to readjust immediately. If improper adjustment in maintained, the blade will not cut straight, and if the situation is not corrected it will cause serious blade damage. Because guide adjustment is a critical factor in the performance of your saw, it is always best to try a new blade to see if this will correct poor cutting before beginning to adjust the bearings. If a blade becomes dull on one side sooner than the other, for example, it will not cut straight. A blade simple change should correct this problem, the more difficult guide adjustment will not. If a new blade does not correct the problem, check the blade guides for proper spacing. There should be from 000 (just touching) to 001 clearance between the blade and guide bearings. The inner guide bearing is fixed and cannot be adjusted. The outer guide bearing is mounted to an eccentric bushing and can be adjusted. To obtain this clearance adjust as follows, referencing the figures below: 1. Adjust the tension of the blade (A) until its back is lightly against the blade wheel. 2. Loosen the nut (E). 3. Turn the eccentric shaft (B) counterclockwise until the bearing (D) touches the saw blade then retighten the nut (E). 4. Loosen set screw (F) and move the blade vertically up or down until it lightly touches the back of the blade then retighten the set screw. 5. The carbide blade guides (L) can also be adjusted so they lightly touch the blade by loosening screws (M), adjusting the guides then retightening the screws. 6. Repeat steps 1-5 to adjust the other side's blade guide bearings (G). If it is necessary to adjust the vise halves perpendicular to the blade, perform steps Loosen set screw (F). 8. Lower the cutting head frame, adjust the rear jaw vise (H) by loosening screw (I), position the vise with the blade using a scale then tighten the screw. 9. Loosen set screw (K), move the front vise (J) up against the rear jaw vise (H), then retighten the screw. M C A D G Fig.1 L Fig.2. Page 16 of 30

17 Blade Track Adjustment 1. Open the blade guard (327). 2. Remove the blade guide assemblies (top and bottom)(327) 3. Loosen the hex head screw in the tilting mechanism to a point where it is loose but snug (216). 4. With the machine running, adjust both the set crew and blade tension knob (218) simultaneously to keep constant tension on the blade. The set screw (264-1) and blade tension knob (218) are always turned in opposite directions, when one is turned clockwise the other is turned counterclockwise. The blade is tracking properly when the back side just touches the shoulder of the wheel or a slight gap appears near the center line of the wheel. Care should be taken not to over-tighten the saw blade since this will give a false adjustment and limit the life of the blade. 5. Tighten the hex head screw in the tilting mechanism. IMPORTANT: Sometimes in trying to make this critical adjustment it is possible to cause the basic setting to be misaligned. Should this occur, proceed as follows: a. Loosen the set screw (264-1) and back it out as far as it can go and still remain in the threaded hole. b. Turn the hex head screw clockwise until it stops (do not tighten)(216). c. Turn the set screw (264-1) clockwise until it bottoms out, then continue for half a turn and check the tracking by turning on the saw. d. If further adjustment is required, go back to step Turn off power to the machine. 7. Replace the blade guide assemblies (327)--it may be necessary to loosen the blade tension slightly (216). 8. Adjust the vertical position of blade guide bearing assemblies so that the back side of the blade just touches the ball bearings. 9. Make a final run to check tracking. If required, touch up adjustment (See step 4) 10. Replace the blade guards. Page 17 of 30

18 After Each Use When you finished your work, clean the saw of debris and scraps of metal and spread a thin coat of oil on the surfaces that not painted to prevent rust. Store the tool 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. Maintenance Maintain the saw by adopting a program of conscientious repair and maintenance in accordance with the following recommended procedures. It is recommended that the general condition of any tool be examined before it is used. Keep your tool in good repair. Keep all cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. Keep handles dry, clean, and free from oil and grease. Put both the power switches in the locked or off position before making any adjustments or changing parts. Such preventive safety measures reduce the risk of starting the saw accidentally. Daily Maintenance (by operator) Fill (top off) the gear box with lubricant every day before starting machine. If the temperature of the spindle causes over-heating or strange noises, stop the machine immediately to check it for accurate functionality. Weekly Maintenance Clean and coat the leading screw with oil. Check to see if the sliding surfaces and rotating parts lack lubricant. If needed, lubricate any parts needing it. Monthly Maintenance Check all the bolts nuts and fastening fixtures and tighten any that are loose. Lubricate the bearings, worm, and worm shaft to avoid wear on them. Yearly Maintenance Readjust the table to horizontal position to maintain cutting accuracy. Check the electric cord, plugs, and switches at least once a year. Change the lubricant in the gear box (see Lubrication below). Lubrication Lubricate the following components using SAE-30 oil as noted. Ball-bearing: none needed Driven pulley bearing: 6-8 drops a week Vise lead screw: as needed The gear box drive gears run in an oil bath and do not require a lubricant change more often than once a year, unless the lubricant is accidentally contaminated or a leak occurs because of Page 18 of 30

19 improper replacement of the gear box cover. During the first few days of operation, the worm gear drive will run hot. Unless the temperature exceeds 200ºF, there is no cause for alarm. The following lubricants may be used in the gear box: Atlantic Refinery Co, Mogul Cyl. Oil Cities Service Gptimus No. 6 Gulf Refinery Co, Medium Gear Oil Troubleshooting Use the table below to troubleshoot problems before contacting service personnel or your local dealer. If the problem continues after troubleshooting, call your local dealer for assistance. Failure Possible Cause(s) Corrective Action Excessive Blade Breakage Premature Blade Dulling Unusual Wear on Side/Back of Blade Teeth Ripping from Blade. 1. Materials loosen in vise. 2. Incorrect speed or feed 3. Blade teeth spacing too large 4. Material too coarse 5. Incorrect blade tension 6. Teeth in contact with material before saw is started 7. Blade rubs on wheel flange 8. Miss-aligned guide bearings 9. Blade too thick 10. Cracking at weld 1. Teeth too coarse 2. Too much speed 3. Inadequate feed pressure 4. Hard spots or scale on material 5. Work hardening of material. 6. Blade twist 7. Insufficient blade 8. Blade slide 1. Blade guides worn. 2. Blade guide bearings not adjust properly 3. Blade guide bearing bracket is loose 1. Tooth too coarse for work 2. Too heavy pressure; too slow speed. 3. Vibrating work-piece. 4. Gullets loading 1. Clamp work securely 2. Adjust speed or feed 3. Replace with a small teeth spacing blade 4. Use a blade of slow speed and small teeth spacing 5. Adjust to where blade just does not slip on wheel 6. Place blade in contact with work after motor is starred 7. Adjust wheel alignment 8. Adjust guide bearings 9. Use thinner blade 10. Weld again, note the weld skill. 1. Use finer teeth 2. Decrease speed 3. Decrease spring tension on side of saw 4. Reduce speed, increase feed pressure 5. Increase feed pressure by reducing spring tension 6. Replace with a new blade, and adjust blade tension 7. Tighten blade tension adjustable knob 8. Tighten blade tension 1. Replace. 2. Adjust as per operators manual 3. Tighten. 1. Use finer tooth blade. 2. Decrease pressure, increase speed 3. Clamp work piece securely 4. Use coarser tooth blade or brush to remove chips. Page 19 of 30

20 Failure Possible Cause(s) Corrective Action Motor Running Too Hot Bad Cuts (Crooked) Bad Cuts (Rough) Blade is Twisting 1. Blade tension too high. 2. Drive belt tension too high. 3. Blade is too coarse for work 4. Blade is too fine for work 5. Gears aligned improperly 6. Gears need lubrication 7. Cut is binding blade 1. Feed pressure too great. 2. Guide bearings not adjusted properly 3. Inadequate blade tension. 4. Dull blade. 5. Speed incorrect. 6. Blade guides spaced out too much 7. Blade guide assembly loose 8. Blade truck too far away from wheel flanges 1. Too much speed or feed 2. Blade is too coarse 3. Blade tension loose 1. Cut is binding blade. 2. Too much blade tension. 1. Reduce tension on blade. 2. Reduce tension on drive belt. 3. Use finer blade. 4. Use coarse blade. 5. Adjust gears so that worm is in center of gear. 6. Check oil path. 7. Decrease reed anti speed 1. Reduce pressure by increasing spring tension on side of saw 2. Adjust guide bearing, the clearance cannot greater than Increase blade tension by adjust blade tension 4. Replace blade 5. Adjust speed 6. Adjust guides space. 7. Tighten 8. Re-track blade according to operating instructions. 1. Decrease speed or feed. 2. Replace with finer blade. 3. Adjust blade tension. 1. Decrease reed pressure. 2. Decrease blade tension. Page 20 of 30

21 Parts Diagram Page 21 of 30

22 Page 22 of 30

23 Page 23 of 30

24 Parts List Part No. Description Quantity 1 Swivel Base 1 2 Acme Screw 1 9 Acme Nut 1 15 Fixed Bolt 1 16 Washer 2 17 Vise Jaw Bracket(Front) 1 18 Hex. Head Screw 1 19 Hex. Nut 1/2" 1 20 Washer 2 21 Carriage Screw 1 22 Hex. Head Screw 1 24 Vise Jaw Bracket(Rear) 1 25 Cross Round Head Screw 2 26 Washer 2 27 Scale 1 28 Spring 1 29 Spring Adjusting Rod 1 30 Spring Handle Bracket 1 31 Washer 1 32 Hex. Head Screw 1 33 Washer 1 34 Hex. Nut 3/8" 1 35 Bushing 1 36 Support Rod 1 37 Hex. Head Screw 1 38 Pivot Bracket 1 39 Washer 1 40 Hex. Head Screw 2 41 Wire Nipple 5/8" 1 43 Washer 1 44 Hex. Head Screw 1 45 Cylinder Lower Support 1 46 Washer 1 47 Hex. Head Screw 1 48 Thumb Screw 1 49 Hex. Head Screw 1 50 Stock Stop Rod 1 51 Stop Block 1 56 Fixed Plate 1 57 Washer 1 58 Hex. Head Screw 1 59 Hex. Head Screw 1 60 Support Plate 1 61 Hex. Head Screw 2 62 Washer 2 63 Hex. Nut 3/8" 2 64 Cylinder Complete Set 1 65 Hex. Socket Head Screw 1 66 Washer 1 67 Cylinder Upper Support 1 68 Switch Cut Off Tip 1 Page 24 of 30

25 Part No. Description Quantity 69 Hex. Nut 3/8" 1 70 Hex. Head Screw 3 71 Washer 3 72S Stand Complete Assembly 1 73 Hex. Head Screw 7 74 Washer 7 75 Hex. Nut 7 76 Hex. Head Screw 1 77 Hex. Nut 3/8" 1 78 Filter 1 79 Hex. Head Screw 1 83 Hex. Nut 5/16" 1 84 Wheel Rod 1 85 Washer 4 86 Cotter Pin 2 87 Coaster of Stand 1/2" 2 88 Hex. Nut 1/2" Wheel 2 93 Hand Rod 1 94 Hex. Nut 5/16" Washer 8 96 Hex. Head Screw 4 97S Coolant Tank 1 98S Pump 1 99 Washer Cross Round Head Screw Hose Coupler Washer Warning mark Way Valve Tube Clamp Hose Hex. Socket Head Screw Valve Hose Hose Hose Bib Hose Clamp Body Frame Spring Washer Hex. Head Screw Support Plate Washer Cross Socket Hex. Head Screw Hex. Head Screw Switch Cut Off Tip Washer Cross Socket Hex. Head Screw Knob Hex. Socket Head Screw Washer Blade Tension Bar Handle Body 1 Page 25 of 30

26 Part No. Description Quantity 219 Knob Blade Tension Sliding Block Sliding Plate Spring Hex. Socket Headless Screw Spring Washer Hex. Head Screw Washer Hex. Head Screw 2 235S Idler Wheel Set Blade Cover 1 261S Box 1 263S Control Box Drive Wheel Hex. Socket Headless Screw C-Retainer Ring Washer Hex. Head Screw 1 292S Adjustable Bracket 1 293S Guide Pivot (Right) 1 294S Bearing Shaft Motor Key Hex. Head Screw Spring Washer 4 308S Brush Assembly Cross Round Head Screw 2 315S Guide Pivot (Right) 1 316S Bearing Shaft 1 317S Adjustable Bracket(Front) Set Washer Blade Adjustable Knob Blade Cover(Front) Cross Round Head Screw Blade Back Cover Washer Cross Round Head Screw Washer Knob Nut 1/2" Washer Control Base Cross Round Head Screw M6x12L Hex. Socket Head Screw Knob Knob Hex. Socket Headless Screw Pressure Lump Washer M12xt Hex. Head Screw Washer Pressure Shaft Knob W/Shaft 1 Page 26 of 30

27 Part No. Description Quantity 374 Plastic Round Knob Bearing Washer M Spring Power Cable Pump-Cable Limit-Cable Motor-Cable 1 800S Oil Seal Gear Box Gear Box Cover Speed-Changing Gear Shaft Speed Lever Spring Steel Ball Speed Indicator Dial Hex. Socket Head Screw M5x28L Worm Shaft Speed-Changing Rod Speed-Changing Key Twisted Spring Pin Gear Gear Gear Washer Bushing Bracket C-Retainer Ring Hex. Socket Headless Screw M6x6L Bearing Cover Gear Shaft Gear Gear Gear Key C-Retainer Ring S Bearing 6003LLU Bearing 6007ZZ C-Retainer Ring Oil Seal Drive Gear Shaft Worm Gear C-Retainer Ring Key Bearing 60205LLU Bearing Spacer Cover O-Retainer Ring Cross Round Head Screw M5X12L Plug Hex. Socket Head Screw M6x20L Vent Plug Scale 1 Page 27 of 30

28 Part No. Description Quantity Rivet Bearing Cover Cross Round Head Screw M5x10L Gear Box Gasket Plug Oil level gage O-Retainer Ring C-Retainer Ring 1 Replacement Parts For replacement parts and technical questions, please call Customer Service at Not all product components are available for replacement. The illustrations provided are a convenient reference to the location and position of parts in the assembly sequence. When ordering parts, the following will be required: Model Number, Serial Number/Lot Date Code, and Description. The distributor reserves the rights to make design changes and or improvements to product lines and manuals without notice. Page 28 of 30

29 Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or '"Us'') warrants to the original purchaser only ("You'' or Your ) that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of one year from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions. There are no other warranties, express or implied, including the warranty of merchantability or fitness for a particular purpose. If the product does not comply with this limited warranty, Your sole and exclusive remedy is that We will, at our sole option and within a commercially reasonable time, either replace the product or product component without charge to You or refund the purchase price (less shipping). This limited warranty is not transferable. Limitations on the Warranty This limited warranty does not cover: (a) normal wear and tear; (b) damage through abuse, neglect, misuse, or as a result of any accident or in any other manner; (c) damage from misapplication, overloading, or improper installation; (d) improper maintenance and repair; and (e) product alteration in any manner by anyone other than Us, with the sole exception of alterations made pursuant to product instructions and in a workmanlike manner. Obligations of Purchaser You must retain Your product purchase receipt to verify date of purchase and that You are the original purchaser. To make a warranty claim, contact Us at , identify the product by make and model number, and follow the claim instructions that will be provided. The product and the purchase receipt must be provided to Us in order to process Your warranty claim. Any returned product that is replaced or refunded by Us becomes our property. You will be responsible for return shipping costs or costs related to Your return visit to a retail store. Remedy Limits Product replacement or a refund of the purchase price is Your sole remedy under this limited warranty or any other warranty related to the product. We shall not be liable for: service or labor charges or damage to Your property incurred in removing or replacing the product; any damages, including, without limitation, damages to tangible personal property or personal injury, related to Your improper use, installation, or maintenance of the product or product component; or any indirect, incidental or consequential damages of any kind for any reason. Assumption of Risk You acknowledge and agree that any use of the product for any purpose other than the specified use(s) stated in the product instructions is at Your own risk. Governing Law This limited warranty gives You specific legal rights, and You also may have other rights which vary from state to state. Some states do not allow limitations or exclusions on implied warranties or incidental or consequential damages, so the above limitations may not apply to You. This limited warranty is governed by the laws of the State of Minnesota, without regard to rules pertaining to conflicts of law. The state courts located in Dakota County, Minnesota shall have exclusive jurisdiction for any disputes relating to this warranty. Page 29 of 30

30 Distributed by Northern Tool and Equipment Company, Inc. Burnsville, Minnesota NorthernTool.com Made in Taiwan Page 30 of 30