7”X 12” DUAL SWIVEL METAL CUTTING BANDSAW MODEL: KC-712DS INSTRUCTION MANUAL COPYRIGHT © 2004 ALL RIGHTS RESERVED BY KING CANADA TOOLS INC. WARRANTY INFORMATION 2-YEAR LIMITED WARRANTY FOR THIS 7” X 12” METAL CUTTING BANDSAW KING CANADA TOOLS OFFERS A 2-YEAR LIMITED WARANTY FOR INDUSTRIAL USE. PROOF OF PURCHASE Please keep your dated proof of purchase for warranty and servicing purposes. REPLACEMENT PARTS Replacement parts for this tool are available at our authorized KING CANADA service centers across Canada. For servicing, contact or return to the retailer where you purchased your product along with your proof of purchase. LIMITED TOOL WARRANTY KING CANADA makes every effort to ensure that this product meets high quality and durability standards. KING CANADA warrants to the original retail consumer a 2-year limited warranty as of the date the product was purchased at retail and that each product is free from defects in materials. Warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents, repairs or alterations and lack of maintenance. KING CANADA shall in no event be liable for death, injuries to persons or property or for incidental, special or consequential damages arising from the use of our products. To take advantage of this warranty, the product or part must be returned for examination by the retailer. Shipping and handling charges may apply. If a defect is found, KING CANADA will either repair or replace the product. KING CANADA TOOLS INC. DORVAL, QUEBEC, CANADA H9P 2Y4 GENERAL & SPECIFIC SAFETY INSTRUCTIONS VOLTAGE WARNING: Before connecting the tool to a power source (receptacle, outlet, etc.) be sure the voltage supplied is the same as that specified on the nameplate of the tool. A power source with voltage greater than that for the specified tool can result in SERIOUS INJURY to the user - as well as damage to the tool. If in doubt DO NOT PLUG IN THE TOOL. Using a power source with voltage less than the nameplate is harmful to the motor. 1. KNOW YOUR TOOL Read and understand the owners manual and labels affixed to the tool. Learn its application and limitations as well as its specific potential hazards. 2. GROUND THE TOOL. This tool is equipped with an approved 3-conductor cord and a 3-prong grounding type plug to fit the proper grounding type receptacle. The green conductor in the cord is the grounding wire. NEVER connect the green wire to a live terminal. 3. KEEP GUARDS IN PLACE. Keep in good working order, properly adjusted and aligned. 4. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. 5. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. Make sure the floor is clean and not slippery due to wax and sawdust build-up. 6. AVOID DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet locations or expose them to rain. Keep work area well lit and provide adequate surrounding work space. 7. KEEP CHILDREN AWAY. All visitors should be kept a safe distance from work area. 8. MAKE WORKSHOP CHILD-PROOF. Use padlocks, master switches or remove starter keys. 9. USE PROPER SPEED. A tool will do a better and safer job when operated at the proper speed. 10. USE RIGHT TOOL. Don’t force the tool or the attachment to do a job for which it was not designed. 11. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties or jewelry (rings, watch) because they could get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. Roll up long sleeves above the elbows. 12. ALWAYS WEAR SAFETY GLASSES. Always wear safety glasses (ANSI Z87.1). Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses. Also use a face or dust mask if cutting operation is dusty. 13. DON’T OVERREACH. Keep proper footing and balance at all times. 14. MAINTAIN TOOL WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. 15. DISCONNECT TOOLS. Before servicing, when changing accessories or attachments. 16. AVOID ACCIDENTAL STARTING. Make sure the switch is in the ‘’OFF’’ position before plugging in. 17. USE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories. Follow the instructions that accompany the accessories. The use of improper accessories may cause hazards. 18. NEVER STAND ON TOOL. Serious injury could occur if the tool tips over. Do not store materials such that it is necessary to stand on the tool to reach them. 19. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other parts that are damaged should be carefully checked to ensure that they will operate properly and perform their intended function. Check for alignment of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other parts that are damaged should be properly repaired or replaced. 20. NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power ‘’OFF’’. Don’t leave any tool running until it comes to a complete stop. SPECIFIC SAFETY INSTRUCTIONS 1. If you are not thoroughly familiar with the operation of Band saws, obtain advice from your supervisor, instructor or other qualified person. 2. Adjust and position the blade guide arm before starting the cut. 3. Keep blade guide arm tight. A loose blade guide arm will affect sawing accuracy. 4. Make sure that blade tension and blade tracking are properly adjusted. 5. To prolong blade life always release blade tension at the end of each work day. 6. Make sure blade speed is set correctly for material being cut. 7. Always have stock firmly clamped in vise before starting cut. 8. Check coolant daily: Low coolant level can cause foaming and high blade temperatures. Dirty or weak coolant can clog pump, cause crooked cuts, low cutting rate and permanent blade failure. Dirty coolant can cause the growth of bacteria with ensuing skin irritation. ELECTRICAL CONNECTIONS SPECIFICATIONS & STARTING WARNING! ALL ELECTRICAL CONNECTIONS MUST BE DONE BY A QUALIFIED ELECTRICIAN. ALL ADJUSTMENTS OR REPAIRS MUST BE DONE WITH THE MACHINE DISCONNECTED FROM THE POWER SOURCE. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY! 220V POWER SUPPLY & OPERATION WARNING: YOUR BAND SAW MUST BE CONNECTED TO A 220V, 20 AMP. BRANCH CIRCUIT. GROUNDING This band saw must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current, to reduce the risk of electric shock. This band saw is equipped with a cord having an equipment-grounding conductor and grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances. Your band saw is ready to operate on 220V circuit. This band saw is intended for use on a circuit that has an outlet and a plug which looks like the one illustrated in Fig.1. WARNING: DO NOT USE A TWO-PRONG ADAPTOR FOR THEY ARE NOT IN ACCORDANCE WITH LOCAL CODES AND ORDINANCES. NEVER USE IN CANADA. EXTENSION CORDS The use of any extension cord will cause some loss of power. Use the table Fig.2 to determine the minimum wire size (A.W.G-American Wire Gauge) extension cord. Use only 3-wire extension cords which have 3-prong grounding type plugs and 3-hole receptacles which accept the tool’s plug. For circuits that are further away from the electrical circuit box, the wire size must be increased proportionately in order to deliver ample voltage to the motor. PROPERLY GROUNDED OUTLET CURRENT CARRYING PRONGS GROUNDING PRONG FIGURE 1 LENGTH OF CONDUCTOR 0-25 FEET 26-50 FEET 51-100 FEET WIRE SIZES REQUIRED (AMERICAN WIRE GAUGE) 220V LINES NO.14 NO.12 NO.10 FIGURE 2 SPECIFICATIONS Your band saw comes almost completely assembled. Handwheels need to be installed to the band saw along with the work stop (#’s 38, 39, 40 & 41. See instructions below). The vise extension base (#468) can also be installed if a capacity of 12” is required. When this band saw comes out of its wooden crate, the head (A) Fig.3 is bolted to the base, undo bolt (B) to unlock and to raise head. FIGURE 3 ASSEMBLY & OPERATION WORK SET UP 1. 2. 3. 4. Raise the saw head to vertical position. Open vise to accept the piece to be cut by rotating the wheel at the end of the base. Place workpiece on saw bed. If the piece of long, support the end. Clamp workpiece securely in vise. STARTING AND STOPPING MACHINE 1) Raise the saw frame to the up position. 2) The machine is started by pushing the start button (A) Fig.4, and it will continue to run until the emergency stop button (B) is pushed. WORK STOP ADJUSTMENT 1. Loosen the thumb screw holding the work stop casting to the shaft. 2. Adjust the work stop casting to the desired length position. 3. Rotate the work stop to as close to the bottom of the cut as possible. 4. Tighten thumb screw. 5. DO NOT ALLOW the blade to rest on the work while the motor is shut off. FIGURE 4 BLADE SPEEDS When using your band saw, always change the blade speed to best suit the material being cut. The speed and material cutting chart below gives suggested settings for several materials using a bi-metal blade. ADJUSTING SPEED/ CHANGING BELT CONFIGURATION/ TENSIONING BELT Disconnect the machine from the power source. To adjust blade speed, the belt configuration on the pulleys must be changed. Open pulley cover (A) Fig.5 by removing lock knob. The motor fixing bolts (B) must be loosened in order to slide motor in and release belt tension. Remove belt from pulleys (C) and reposition in the desired speed/belt configuration. See Fig.4. Slide motor away from pulleys to retension belt until you obtain a 1/2” depression of the belt at the center, then retighten fixing bolts (B). Close pulley cover (A) and lock with lock knob. FIGURE 5 OPERATION STARTING SAW CAUTION: NEVER OPERATE SAW WITHOUT BLADE GUARDS IN PLACE. Be sure the blade is not in contact with the work when the motor is started. Start the motor, allow the saw to come to full speed, then begin the cut by letting the head down slowly onto the work. DO NOT DROP OR FORCE. Let the weight of the saw head provide the cutting force. FEED RATE CONTROL When the feed rate control knob (A) Fig.6 on the hydraulic cylinder (B) is turned clockwise as far as it will go, the saw frame will not move down. It can be raised to the up position, turn the feed rate control knob (A) counterclockwise, the flow of oil from the cylinder is regulated and determines the speed at which the saw frame will lower and the blade will feed through the work. There are two methodes to lock the cylinder in place, either by closing the feed rate control knob (A) or by using the cylinder lock lever (C).Too many factors are involved to make tabulated data practical on feed rates. As a general rule, an even downward pressure without forcing the blade gives best results. Burned chips indicate excessive feed, which causes the teeth to break off as the blade overheats. The ideal feed rate is indicated by chips that have a free curl and this will give the fastest cutting time and longest blade life. BLADE SELECTION A general-use blade is furnished with this Metal Cutting Band Saw (usually an 8 TPI blade). Additional blades of various sizes are available. The choice of blade pitch is governed by the thickness of the work to be cut: the thinner the workpiece, the more teeth advised. A minimum of three (3) teeth should engage the workpiece 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. FIGURE 6 MAKE PROPER TOOTH SELECTION For maximum cutting efficiency and lowest cost per cut, it is important to select the blade with the right number of teeth per inch (TPI) for the material being cut. The material size and shape dictate tooth selection. You need to consider: 1. THE WIDTH OF CUT. That is, the distance in the cut that each tooth must travel from the point it enters the workpiece until it leaves the workpiece. 2. THE SHAPE OF THE WORKPIECE - Squares, rectangles, flats (Solid square symbol). Locate the width of cut on the chart. Select the tooth pitch on the ring marked with the square shape which aligns with the width of cut. EX.: 6” (150mm) Square, use a 2/3 Vari-Tooth. - Round solids (Solid circle symbol). Locate the diameter of your workpiece on the chart. Select the tooth pitch on the ring marked with the round shape which aligns with the size of stock you are cutting. EX.: 4” (100mm) round, use a 3/4 Vari-Tooth. - Tubing, pipe, angles & structurals ( O H V symbol). Determine the average width of cut by dividing the area of the workpiece by the distance the saw blade must travel to finish the cut. Locate the average width or cut on the chart. Select the tooth pitch on the ring marked with the tubing and structural shape which aligns with the average width you are cutting. Inches on exterior/ Millimeters on inside of circle OPERATION BI-METAL SPEEDS AND FEEDS The chart Fig.7 is a guide to cutting 4” (100mm) material (with a 3/4 Vari-Tooth) when using a cutting fluid. Increase band speed: 15% When cutting 1/4” (6.4mm) (10/14 Vari-Tooth) 12% When cutting 3/4” (19mm) (6/10 Vari-Tooth) 10% When cutting 1-1/4” (32mm) (5/8 Vari-Tooth) 5% When cutting 2-1/2” (64mm) (4/6 Vari-Tooth) MATERIAL ALLOY ASTM NO. Copper Alloy 173, 932 330, 365 623, 624 230, 260, 272 280, 464, 632, 655 101, 102, 110, 122, 172 1751, 182, 220, 510 625, 706, 715, 934 630 811 1117 1137 1141, 1144 1144 HI STRESS 1030 1008, 1015, 1020, 1025 1035 1018, 1021, 1022 1026, 1513 A36 (SHAPES), 1040 1042, 1541 1044, 1045 1060 1095 8615, 8620, 8622 4340, E4340, 8630 8640 E9310 A-6 A-2 A-10 D-2 H-11, H-12, H-13 420 430 410, 502 414 431 440C 304, 324 304 L 347 316, 316 L 416 Decrease band speed: 12% When cutting 8” (200mm) (2/3 Vari-Tooth) Carbon Steel METAL CHIPS TELL ALL Chips are the best indicator of correct feed force. Monitor chip information and adjust the feed accordingly. Thin or powdered chips - increase feed rate or reduce band speed. Burned heavy chips - reduce feed rate and/or band speed. Curly silvery and warm chips - optimum feed rate and band speed. Ni-Cr-Mo Alloy Steel COOLANT The use of proper cutting fluid is essential to obtain maximum efficiency from a band saw blade. The main cause of tooth failure is excessive heat build-up. This is the reason that correct cuttting fluid is necessary for long blade life and high cutting rates. Place coolant inside coolant tank in base. The rate of coolant flow is controlled by the stop valve lever (A) Fig.8, which directs the coolant onto the blade. Tool Steel Stainless Steel FIGURE 7 FIGURE 8 BAND SPEED FT./MIN. M/MIN. 314 284 264 844 244 234 234 234 229 214 339 289 279 279 329 319 309 299 299 269 249 219 199 184 239 219 199 174 199 179 159 90 189 189 149 140 115 95 80 120 115 110 100 189 96 87 81 74 74 71 71 71 70 65 103 88 85 85 100 97 94 91 91 82 76 67 61 56 73 67 61 53 61 55 49 27 58 58 46 43 35 29 24 36 35 33 30 58 OPERATION CHANGING BLADE Raise Saw head to vertical position, lock cylinder and open the blade guards. Loosen tension screw knob sufficiently to allow blade with teeth slanting toward the motor as follows: 1. Place the blade in between each of the guide bearings. 2. Slip the blade around the bottom blade wheel with the left hand and hold in position. 3. Hold the blade taut against the blade wheel by pulling the blade upward with the right hand which is placed at the top of the blade. 4. Remove left hand from bottom blade wheel and place it at the top aide of the blade to continue the application on the upward pull on the blade. 5. Remove right hand from blade and adjust the position of the top blade wheel to permit left hand to slip the blade around the blade wheel using the thumb, index and little finger as guides. 6. Adjust the blade tension knob clockwise until it is just enough so no blade slippage occurs. Do not tighten excessively. 7. Replace the blade guards. 8. Place 2-3 drops of oil on the blade. BLADE GUIDE BEARING ADJUSTMENT ATTENTION: 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 metal Cutting Band Saw are adjusted and powertested with several test cuts before leaving the factory to ensure proper setting. The need for adjustment should rarely occur when the saw is used properly. If the guides do get out of adjustment, it is extremely important to readjust immediately. If improper adjustment is maintained, the blade will not cut straight, and 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. If a blade becomes dull on one side sooner than the other, for example, it will begin cutting crooked. A blade change will correct this problem; the guide adjustment will not. If a new blade does not correct the problem, check the blade guides for proper spacing. NOTE: There should be from .000 (just touching) 0.3mm clearance between the blade and guide bearings. To obtain this clearance adjust as follows: FIGURE 9 1. The inner guide bearing is fixed and cannot be adjusted. 2. The outer guide bearing is mounted to an eccentric bushing and can be adjusted. 3. Adjust the tension of the blade until the back of the blade is against the blade wheel (front) lightly. 4. Loosen blade guide shaft nut (A) Fig.9. 5. Turn the eccentric shaft (B) counterclockwise. When the bearing (C) touches the saw blade properly, tighten the nut (A). 6. To adjust height of bearing guides, loosen cap screw (D) and move the bearing (C) up or down until it lightly touches the back of the blade. 7. Repeat steps 4, 5, and 6 to adjust the other side's blade guide. It is important that the blade guide assemblies be placed as closely as possible to the material being cut before starting a cut. To move blade guide assemblies, undo hex. bolt (E) and slide blade guide bracket close to workpiece in vise. Retighten hex. bolt (E). Do the same adjustment to the other blade guide assembly. OPERATION BLADE TRACKING ADJUSTMENT 1. Open the blade guard. 2. Remove the blade guide assemblies (top and bottom). 3. Loosen the hex bolts (A) Fig.10 in the tilting mechanism to a point where it is loose but snug. 4. With the machine running, adjust both the set screw (B) and blade tension knob (C) simultaneously to keep constant tension on the blade. The set screw and blade tension knob are always turned in opposite directions, ie. when one is turned clockwise, the other is turned counterclockwise. The blade is tracking properly when the back side just touches the shoulder of blade wheel or a slight gap appears near the center line of the blade wheel. Care should be taken not to overtighten the saw blade since this will give a false adjustment and limit life of the blade. 5. Tighten the hex bolts (A) in 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: FIGURE 10 a. Loosen the set screw (B) and back it out as far as it can go and still remain in the threaded hole. b. Turn the hex bolts (A) clockwise until they stops (do not tighten). c. Turn the set screw (B) clockwise until it bottoms, then continue for half a turn and check the tracking by turning on the machine. d. If further adjustment is required, go back to step 4. 6. Turn off power to the machine. 7. Replace the blade guide assemblies--it may be necessary to loosen the blade tension slightly. 8. Adjust the vertical position of the blade guide bearing assemblies so that the back side of the blade just touches the ball bearing. 9. Make a final run to check tracking. If required, touch up adjustment (See stop 4). 10. Replace the blade guards. TRU-LOCK VISE SYSTEM To operate, proceed as follows: 1) Raise the arm 2" above the workpiece, close the hydraulic cylinder valve to maintain the arm 2" above the workpiece. 2) Put your workpiece on the table. Move the vice handle (A) Fig.11 upwards to an angle of 45 degrees (A-Half opened) to loosen the vise. Move the jaw vise bracket against the workpiece by turning the rectangular handwheel (B). Push down on the vise handle (A) to a 90 degree position. 3) To loosen the workpiece from the vise, hold the workpiece and lift the vise handle (A) to a 90 degree position (completely opened). Remove workpiece. When you need to cut a workpiece many times, just raise the vise handle (A) to loosen and adjust workpiece position. Then push down on the same handle to retighten. You can also push the vice handle (A) down first, then tightening the vise by turning the rectangular handle (B) clockwise. After finishing the cut, you can loosen the workpiece by turning rectagular handle only. FIGURE 11 When straight cutting 12" width is required, the Vise Base Extension (C) MUST be installed to the vise base, by following these steps: 1. Remove hex. bolts (D), and remove the Rear Vise Jaw Bracket (E). 2. Link the Vise Base Extension (C) to the end of the Vise Base. Fix it using extra hex. bolts supplied as shown in Fig.11. 3. Replace the Vise Bracket (E). Vise Base Extension is only good for straight cutting, not for angle cutting. OPERATION & MAINTENANCE ADJUSTING HEAD PIVOT ANGLE The main head assembly can be pivoted in both directions (clockwise and counterclockwise) up to 45 degrees. To pivot head, first loosen pivot lock handle (A) Fig.12. Move head to the desired pivot angle using the angle scale (B) on the base. There are three degree positive stops which allow you to quickly set the head to predetermined angles. Positive stop (C) sets the head at a 90 degree angle. Positive stop (D) sets the head at a 45 degree angle, it is necessary to flip the 90 degree positve stop (C) out of the way to reach the 45 degree positive stop (D). If a counterclock pivot direction at a 45 degree angle is desired, pivot head until it comes in contact with 45 degree positive stop (E). Retighten pivot lock handle (A) after setting pivot angle. FIGURE 12 MAINTENANCE CAUTION: MAKE CERTAIN THAT THE UNIT IS DISCONNECTED FROM THE POWER SOURCE BEFORE ATTEMPTING TO SERVICE OR REMOVE ANY COMPONENT. It’s easier to keep machine in good condition or best performance by maintaining it than remedy it after it is out of order. (1) Daily Maintenance (by operator) (a) Fill the coolant tank with cutting lubricant before starting machine. (b) If the temperature of spindle caused over-heating or strange noice, stop machine immediately to check it. (c) Keep work area clean; release vise, cutter, work-piece from table; switch off power source; take chips or dust away from machine and lubricate surface to prevent rusting. (2) Weekly Maintenance (a) Clean and coat lead screw with oil. (b) Check to see if sliding surface and turning parts lack lubricant. Lubricate as necessary. (3) Monthly Maintenance (a) Lubricate bearing, work, and work shaft with light machine oil to avoid wearing. (4) Yearly Maintenance (a) Adjust table to horizontal position for maintenance of accuracy. (b) Check electric cord, plugs, switches. PARTS DIAGRAM & PARTS LISTS Refer to the Parts section of the King Canada web site for the most updated parts diagram and parts list.
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