Rikon Power Tools 15-400 Product Manual

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Rikon Power Tools 15-400 Product Manual | Manualzz

15-400

Horizontal Metal Bandsaw

Operator’s Manual

Record the serial number and date of purchase in your manual for future reference.

Serial Number: _________________________ Date of purchase: _________________________

For technical support or parts questions, email [email protected] or call toll free at (877)884-5167

15-400M1

www.rikontools.com

TABLE OF CONTENTS

Specifications.....................................................................................................................2

Safety Instructions ......................................................................................................3 - 6

Getting To Know Your Tile Saw ..............................................................................................7

Contents of Package .....................................................................................................8

Assembly ................................................................................................................. 9 - 11

Adjustments ..................................................................................................................12 - 15

Operation...................................................................................................15-17

Maintenance ....................................................................................................................18

Electricals & Wiring Diagram .......................................................................................5 & 18

Troubleshooting .........................................................................................................19

Parts Diagram & Parts Lists ..................................................................................20 - 22

Warranty ..........................................................................................................................23

SPECIFICATIONS

Motor ...........................................................................................................3/4 HP

Motor Speed (no load)......................................................................... 1,720 RPM

Volts ............................................................................................................ 120 V

Amps, Hertz, Phase .................................................................. 4.6 A, 60 Hz, 1Ph

Blade Length.............................................................................64-1/2” (1638 mm)

Blade Speeds ............................................................................. 80/120/180 FPM

Max Depth of Square Cut @ 90 ° ..........................................4” x 6” (101 x 152mm)

Max Depth of Square Cut @ 45 ° ..................................................... 2-3/4” (70mm)

Max Depth of Circular Cut @ 90 ° ................................................... 4-1/2” (114mm)

Max Depth of Circular Cut @ 45 ° ..................................................... 2-3/4” (70mm)

Cutting Angle...................................................................................................0-45 °

Horizontal Table Size (W x D) .............................. 9-5/8” x 9-3/8” (245 x 238 mm)

Horizontal Height

.

...................................................................... 37-1/2” (953 mm)

Vertical Height .............................................................................. 54” (1,372 mm)

Width ......................................................................................... 37-1/2” (953 mm)

Depth .........................................................................................

18-1/4” (464 mm)

Net Weight .....................................................................................

115lbs (52 kg)

NOTE: The specifications, photographs, drawings and information in this manual represent the current model when the manual was prepared. Changes and improvements may be made at any time, with no obligation on the part of Rikon

Power Tools, Inc. to modify previously delivered units. Reasonable care has been taken to ensure that the information in this manual is correct, to provide you with the guidelines for the proper safety, assembly and operation of this machine.

2

SAFETY INSTRUCTIONS

IMPORTANT!

Safety is the single most important consideration in the operation of this equipment. The following instructions must be followed at all times. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious personal injury.

There are certain applications for which this tool was designed. We strongly recommend that this tool not be modified and/or used for any other application other than that for which it was designed. If you have any questions about its application, do not use the tool until you have contacted us and we have advised you.

SAFETY SYMBOLS

SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, or CAUTION. This symbol may be used

in conjunction with other symbols or pictographs.

Indicates an imminently hazardous situation, which, if not avoided, could result in death or

serious injury.

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

injury.

Indicates a potentially hazardous situation, which, if not avoided, could result in minor or

moderate injury.

NOTICE: Shown without Safety Alert Symbol indicates a situation that may result in property damage.

GENERAL SAFETY

KNOW YOUR POWER TOOL. Read the owner’s manual carefully. Learn the tool’s applications, work capabilities, and its specific potential hazards.

4. AVOID A DANGEROUS WORKING ENVIRONMENT.

DO NOT use electrical tools in a damp environment or expose them to rain.

BEFORE USING YOUR MACHINE

To avoid serious injury and damage to the tool, read and follow all of the Safety and Operating Instructions before operating the machine.

5. DO NOT use electrical tools in the presence of flammable liquids or gasses.

6. ALWAYS keep the work area clean, well lit, and organized. DO NOT work in an environment with floor surfaces that are slippery from debris, grease, and wax.

1. Some dust created by using power tools 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, cement, and other

• masonry products.

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

2. READ the entire Owner’s Manual. LEARN how to use the tool for its intended applications.

7. KEEP VISITORS AND CHILDREN AWAY.

DO NOT permit people to be in the immediate work area, especially when the electrical tool is operating.

8. DO NOT FORCE THE TOOL to perform an operation for which it was not designed. It will do a safer and higher quality job by only performing operations for which the tool was intended.

9. WEAR PROPER CLOTHING. DO NOT wear loose clothing, gloves, neckties, or jewelry. These items can get caught in the machine during operations and pull the operator into the moving parts. The user must wear a protective cover on their hair, if the hair is long, to prevent it from contacting any moving parts.

3. GROUND ALL TOOLS.

If the tool is supplied with a 3 prong plug, it must be plugged into a 3-contact electrical receptacle. The 3rd prong is used to ground the tool and provide protection against accidental electric shock. DO

NOT remove the 3rd prong. See Grounding Instructions on the following pages.

10. CHILDPROOF THE WORKSHOP AREA by removing switch keys, unplugging tools from the electrical receptacles, and using padlocks.

3

11. ALWAYS UNPLUG THE TOOL FROM THE

ELECTRICAL RECEPTACLE when making adjustments, changing parts or performing any maintenance.

SAFETY INSTRUCTIONS

12. KEEP PROTECTIVE GUARDS IN PLACE AND IN

WORKING ORDER.

13. AVOID ACCIDENTAL STARTING. Make sure that the power switch is in the “OFF” position before plugging in the power cord to the electrical receptacle.

14. REMOVE ALL MAINTENANCE TOOLS from the immediate area prior to turning “ON” the machine.

15.

USE ONLY RECOMMENDED ACCESSORIES. Use of incorrect or improper accessories could cause serious injury to the operator and cause damage to the tool. If in doubt, check the instruction manual that comes with that particular accessory.

16. NEVER LEAVE A RUNNING TOOL UNATTENDED.

Turn the power switch to the “OFF” position. DO NOT leave the tool until it has come to a complete stop.

25. ALWAYS WEAR A DUST MASK TO PREVENT

INHALING DANGEROUS DUST OR AIRBORNE

PARTICLES , including wood dust, crystalline silica dust and asbestos dust. Direct particles away from face and body. Always operate tool in well ventilated area and provide for proper dust removal. Use dust collection system wherever possible. Exposure to the dust may cause serious and permanent respiratory or other injury, including silicosis (a serious lung disease), cancer, and death. Avoid breathing the dust, and avoid prolonged contact with dust. Allowing dust to get into your mouth or eyes, or lay on your skin may promote absorption of harmful material. Always use properly fitting NIOSH/OSHA approved respiratory protection appropriate for the dust exposure, and wash exposed areas with soap and water.

17. DO NOT STAND ON A TOOL.

Serious injury could result if the tool tips over, or you accidentally contact the tool.

18. DO NOT store anything above or near the tool where anyone might try to stand on the tool to reach it.

19. MAINTAIN YOUR BALANCE. DO NOT extend yourself over the tool. Wear oil resistant rubber soled shoes. Keep floor clear of debris, grease, and wax.

26. USE A PROPER EXTENSION CORD IN GOOD

CONDITION.

When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. The table on the following page shows the correct size to use depending on cord length and nameplate amperage rating. If in doubt, use the next heavier gauge.

The smaller the gauge number, the larger diameter of the extension cord. If in doubt of the proper size of an extension cord, use a shorter and thicker cord. An undersized cord will cause a drop in line voltage resulting in a loss of power and overheating.

USE ONLY A 3-WIRE EXTENSION CORD THAT HAS

A 3-PRONG GROUNDING PLUG AND A 3-POLE

RECEPTACLE THAT ACCEPTS THE TOOL’S PLUG.

20. MAINTAIN TOOLS WITH CARE.

Always keep tools clean and in good working order. Keep all blades and tool bits sharp, dress grinding wheels and change other abrasive accessories when worn.

27. ADDITIONAL INFORMATION regarding the safe and proper operation of this product is available from:

21. EACH AND EVERY TIME, CHECK FOR DAMAGED

PARTS PRIOR TO USING THE TOOL.

Carefully check all guards to see that they operate properly, are not damaged, and perform their intended functions. Check for alignment, binding or breaking of moving parts. A guard or other part that is damaged should be immediately repaired or replaced.

• Power Tool Institute

1300 Summer Avenue

Cleveland, OH 44115-2851

www.powertoolinstitute.org

• National Safety Council

1121 Spring Lake Drive

Itasca, IL 60143-3201

www.nsc.org

22. DO NOT OPERATE TOOL WHILE TIRED, OR

UNDER THE INFLUENCE OF DRUGS, MEDICATION

OR ALCOHOL.

23. SECURE ALL WORK. Use clamps or jigs to secure the work piece. This is safer than attempting to hold the work piece with your hands.

• American National Standards Institute

25 West 43rd Street, 4th Floor

New York, NY 10036

www.ansi.org

• ANSI 01.1 Safety Requirements for

Woodworking Machines and the

U.S. Department of Labor regulations

www.osha.gov

24. STAY ALERT, WATCH WHAT YOU ARE DOING,

AND USE COMMON SENSE WHEN OPERATING A

POWER TOOL.

A moment of inattention while operating power tools may result in serious personal injury.

28. SAVE THESE INSTRUCTIONS.

Refer to them frequently and use them to instruct others.

4

SAFETY INSTRUCTIONS

ELECTRICAL SAFETY EXTENSION CORDS

THIS TOOL IS PRE-WIRED FOR 120V

CIRCUITS, AND MUST BE GROUNDED WHILE IN USE TO

PROTECT THE OPERATOR FROM ELECTRIC SHOCK.

IN THE EVENT OF A MALFUNCTION OR BREAKDOWN, grounding provides the path of least resistance for electric current and reduces the risk of electric shock. This tool is equipped with an electric cord that has an equipment grounding conductor and requires a grounding plug (not included). The plug MUST be plugged into a matching electrical receptacle that is properly installed and grounded in accordance with ALL local codes and ordinances.

DO NOT MODIFY ANY PLUG. If it will not fit the electrical receptacle, have the proper electrical receptacle installed by a qualified electrician.

THE USE OF AN EXTENSION CORD

WITH THIS MACHINE IS NOT RECOMMENDED. For best power and safety, plug the machine directly into a dedicated, grounded electrical outlet that is within the supplied cord length of the machine.

If an extension cord needs to be used, it should only be for a limited operation of the machine. The extension cord should be as short as possible in length, and have a minimum gauge size of 14AWG.

Check extension cords before each use. If damaged replace immediately. Never use a tool with a damaged cord, since touching the damaged area could cause electrical shock, and serious injury.

IMPROPER ELECTRICAL CONNECTION of the equipment grounding conductor can result in risk of electric shock. The conductor with the green insulation

(with or without yellow stripes) is the equipment grounding conductor. DO NOT connect the equipment grounding conductor to a live terminal if repair or replacement of the electric cord or plug is necessary.

Use a proper extension cord. Only use cords listed by

Underwriters Laboratories (UL). Other extension cords can cause a drop in line voltage, resulting in a loss of power and overheating of tool. When operating a power tool outdoors, use an outdoor extension cord marked “W-A” or “W”.

These cords are rated for outdoor use and reduce the risk of electric shock.

CHECK with a qualified electrician or service personnel if you do not completely understand the grounding instructions, or if you are not sure the tool is properly grounded when installing or replacing a plug.

USE ONLY A 3-WIRE EXTENSION CORD THAT HAS

THE PROPER TYPE OF A 3-PRONG GROUNDING PLUG

THAT MATCHES THE MACHINE’S 3-PRONG PLUG AND

ALSO THE 3-POLE RECEPTACLE THAT ACCEPTS THE

TOOL’S PLUG. * See Figures A and B.

REPLACE A DAMAGED OR WORN CORD

IMMEDIATELY.

Keep the extension cord clear of the working area. Position the cord so that it will not get caught on lumber, tools or other obstructions while you are working with your power tool.

* Canadian electrical codes require extension cords to be certified SJT type or better.

** The use of an adapter in Canada is not acceptable.

FIG. A FIG. B

COVER

RAILS

5

SAFETY INSTRUCTIONS

SPECIFIC SAFETY INSTRUCTIONS FOR METAL CUTTING SAWS

This machine is intended for the cutting of metal material. The permissible workpiece dimensions must be observed (see

Technical Specification). Any other use not as specified, including modification of the machine or use of parts not tested and approved by the equipment manufacturer, can cause unforeseen damage and invalidate the warranty.

ATTENTION: Use of this saw still presents risks that cannot be eliminated by the manufacturer. Therefore, the user must be aware that machines producing stone dust are dangerous if not used with care and all safety precautions are adhered to.

1. READ and become familiar with the entire Operator’s Manual. LEARN the tool’s application, limitations and possible

hazards.

2. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

3. ALWAYS SECURE WORK FIRMLY to the saw with the use of the vise.

4. ALWAYS WEAR EYE PROTECTION. Wear goggles for protection against projected chips.

5. USE GLOVES when handling sharp metal.

6. NEVER STAND or have any part of your body in line with the path of the saw blade. Keep your hands out of the saw

blade path.

7. NEVER REACH behind or over the cutting tool for any reason.

8. The machine must be switched off before inserting material to be cut in the vice or before removing material to be cut

from the vice.

9. NEVER remove the cutting chips by hand. Use a brush at all times. DO NOT use compressed air.

10. NEVER ATTEMPT TO FREE A STALLED SAW BLADE without first turning the saw OFF. Turn power switch OFF

immediately to prevent kickback and motor damage.

11. PROVIDE ADEQUATE SUPPORT to the front and rear of the saw for long workpieces.

12.

WEAR PROPER APPAREL. Do not wear loose clothing, neckties, rings, bracelets, or other jewelry that may

get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.

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

saw blade.

14. NEVER USE SOLVENTS to clean plastic parts. Solvents could possibly dissolve or otherwise damage the material.

Only a soft damp cloth should be used to clean plastic parts.

15. DON’T FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.

16. DO NOT use power tools in the presence of flammable liquids or gases.

17. NEVER LEAVE THE SAW RUNNING UNATTENDED.

Do not leave the saw until blade comes to a complete stop.

SAVE THESE INSTRUCTIONS.

Refer to them often.

California Proposition 65 Warning

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 and birth defects or other reproductive harm. Your risk from exposure to these chemicals varies, depending on how often you do this type of work.

To reduce your exposure, work in a well-ventilated area and with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles.

For more detailed information about California Proposition 65 log onto rikontools.com.

This owner’s manual is not a teaching aid. Use of this owner’s manual is intended to

show assembly, adjustments, and general use.

6

GETTING TO KNOW YOUR METAL CUTTING SAW

Lifting Handle

Blade Tension

Knob

Feed Speed

Handle

Vise Handle

Mobility Handle

Drive Belt Cover

Vise

Work Stop

Switch

Motor

Stand

Mobility Wheels

7

CONTENTS OF PACKAGE

Model 15-400 4” x 6” Horizontal Metal Cutting Bandsaw is shipped complete in one box.

Unpacking, Checking Contents & Clean-up

1. Carefully remove all contents from the shipping carton. Compare the contents with the list of contents to make sure that all of the items are accounted for, before discarding any packing material. Place parts on a protected surface for easy identification and assembly. If any parts are missing or broken, please call RIKON

Customer Service (877-884-5167) as soon as possible for replacements. DO NOT turn your machine ON if any of these items are missing. You may cause injury to yourself or damage to the machine.

2. Report any shipping damage to your local distributor. Take photos for any insurance claims.

3. With the help of another person, carefully lift the saw from the packaging and place it on a level bench.

4. Clean all rust protected surfaces with ordinary house hold type grease or spot remover. Do not use; gasoline, paint thinner, mineral spirits, etc. These may damage painted surfaces.

5. Apply a coat of paste wax to the table to prevent rust. Wipe all parts thoroughly with a clean dry cloth.

6. Set packing material and shipping carton aside. Do not discard until the machine has been set up and is running properly.

D

A

E

F

I

J

K

G H

P

L

M N O

B C

A. Bandsaw

C. Stand Legs B

D. Table

TABLE OF LOOSE PARTS

E. Table Support

G. Work Stop Rod

H. Work Stop

I. Drive Belt Housing

J. Drive Belt

K. Motor & Drive Pulleys

L. Long Brace

8

M. Short Brace

N. Wheel Bracket

O. Wheel Shaft

P. Wheels

ASSEMBLY

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

STAND ASSEMBLY

1. With the help of an assistant, lift the band saw

onto a suitable support. Example: Figure 1.

2. Attach the legs to the band saw with M8-1.25 x

25 hex bolts, 8mm flat washers, 8mm lock

washers, and M8-1.25 hex nuts.

Short Brace

(x2)

FIGURE 1

3. Attach the short braces to the legs with M6-1.0

x 16 carriage bolts, 6mm flat washers, 6mm

lock washers and M6-1.0 hex nuts.

4. Lift the band saw onto floor, attach the long

braces to legs with the M6-1.0 x 16 carriage

bolts, 6mm flat washers, 6mm lock washers

and M6-1.0 hex nuts. Figure 2.

Long Brace

(x2)

Carriage Bolt

FIGURE 2

5. Use M6 x 12 hex bolts, M6 hex nuts,

6mm lock washers and 6mm flat washers to

install the wheel mounting bracket to the legs.

Figure 3.

STAND ASSEMBLY Continued on page 10.

9

Wheel Mounting

Bracket

FIGURE 3

ASSEMBLY

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

STAND ASSEMBLY Continued from page 9.

6. Slide the shaft through the holes in the wheel

mounting bracket. Slide the wheels onto the

shaft on the outside of the mounting bracket,

and secure them with the cotter pins. SEE

Figure 4.

7. On the opposite stand legs, insert the handle

into the pre-drilled holes and secure it with

cotter pins. SEE Figure 5.

8. Check to see if the bands saw is level and

tighten all the stand nuts.

Cotter Pin

FIGURE 4

INSTALLING THE BELT COVER

1. Remove the pre installed screws and washers

from the band saw near the gear shaft

assembly. Place the belt house over the motor

and gear shafts and secure it with the removed

screws and washers. SEE Figures 6 & 7.

Cotter Pin

FIGURE 5

FIGURE 6

10

FIGURE 7

ASSEMBLY

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

MOTOR & DRIVE PULLEY INSTALLATION

Motor Pulley

1. Open the pulley cover and slide the motor

pulley over the motor shaft. Make sure to

engage the motor pulley to the shaft key.

Largest pulley step is closest to the motor.

SEE Figure 8.

2. Install the drive pulley on the shaft closest to

the gear box. Smallest pulley step is facing

downward. SEE Figure 8.

3. Use a straightedge to check the alignment of

the pulley wheels, and adjust them as needed.

4. When the pulley wheels are aligned, tighten

the set screws on both pulleys and install the

V-belt.

5. After the V-belt is installed on the desired

speed, adjust the tension with the drive

belt tension bolt. SEE Figure 9.

FIGURE 8

Drive Pulley

Drive Belt

Tension Bolt

FIGURE 9

WORK STOP INSTALLATION

1. Install the work stop shaft into the side of the

band saw. Lock it in place by tightening the

set screw (A-Fig.10).

2. Slide the work stop onto the end of the shaft

and clamp it into position with the wing nut and

hex head bolt. (B-Fig.10).

A

B

FIGURE 10

11

ADJUSTMENTS

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

Fixed Jaw

VISE ADJUSTMENTS

For Straight Cuts:

1. Loosen the two hex bolts on the fixed jaw

(A-Fig. 11).

2. Position the fixed plate until it reads 0° on the

scale (B-Fig.11) and tighten the two hex bolts.

3. Loosen the hex bolt on the slip jaw so the jaw

can float (A-Fig. 12). Tighten the slip jaw

against the workpiece by turning the vise

handle. SEE Figure 13.

4. Tighten the hex bolt (A-Fig. 12) on the slip jaw

before starting the cutting operation.

A

FIGURE 11

Slip Jaw

For Angle Cuts:

1. Loosen the two hex bolts on the fixed jaw

(A-Fig. 11).

2. Position the fixed plate until it reads the

desired degree angle on the scale (B-Fig.11)

and tighten the two hex bolts.

3. Loosen the hex bolt on the slip jaw so the jaw

can float (A-Fig. 12). Match the angle of the

workpiece. Tighten the slip jaw against the

workpiece by turning the vise handle.

SEE Figure 13.

4. Tighten the hex bolt (A-Fig. 12) on the slip jaw

before starting the cutting operation.

Vise

Handle

FIGURE 12

A

FIGURE 13

12

B

ADJUSTMENTS

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

ADJUSTING THE BLADE GUIDES

1. Loosen the guide post knob and slide the

blade guide as close to the workpiece as

possible. SEE Figure 14.

2. Re-tighten the guide post knob before starting

the cutting operation.

Knob

Blade

Guides

FEED RATE ADJUSTMENT FIGURE 14

The rate of descent (feed rate) of the main cutting arm is controlled by the feed speed handle. SEE

Figure 15.

To adjust the feed rate:

Slower: Twist the handle clockwise to add tension to the spring.

Faster: Twist the handle counterclockwise to remove tension from the spring.

NOTE: Feed rate is one of the most important adjustments on the saw. Incorrect feed rate can result in poor performance including crooked cuts, tooth stripping, motor stalling and the blade coming off the blade wheels.

Spring

Feed Speed

Handle

Drive Pulley

FIGURE 15

Motor Pulley

CHANGING BLADE SPEED

Blade speed selection is another important adjustment needed to ensure optimal cutting performance. Similar to correct feed rate above, incorrect blade speed selection can result in poor performance including crooked cuts, tooth stripping, motor stalling and the blade coming off the blade wheels. SEE Figure 16: Blade Speed

Chart.

CHANGING BLADE SPEED Continued on page 14.

13

FIGURE 16

ADJUSTMENTS

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

CHANGING BLADE SPEED Continued from page 13.

1. Open the motor cover. SEE Figure 17.

NOTE: The Speed Change Label shown in

Figure 16, page 13, can be found inside the motor cover.

2. Loosen the motor lock bolt (A-Fig.18) to allow

the motor to pivot. Raise the motor to relieve

the belt tension and position the belt in the

desired pulley step alignment per the chart

shown in Figure 19.

3. Release the motor and let its own weight

tension the belt. Tighten the motor lock bolt

(A-Fig.18) against the frame of the band saw

to retain belt tension.

NOTE: Blade speed and performance depend on proper blade selection. Consult your blade manufacturer for the proper blade style and speed required for the material to be cut.

Blade speed differs for each type or grade of metal to be cut. Below is a chart of common materials and the suggested blade speeds. The speeds shown have been reduced by 30% for dry cutting operations. It may be necessary to reduce an additional 15% due to material hardness. Changing blade type/style will also help performance.

METAL TYPE

Brass Alloys

Bronze Alloys

Cast Iron

Copper Alloys

Cr-Mo Alloy

Low/Med Carbon Steel

Stainless Steel

BLADE SPEED -Ft/Min

140-154

80-230

80-157

112-206

136-164

161-189

80-95

Motor Cover

Drive Pulley

FIGURE 17

FIGURE 18

FIGURE 19

A

Motor Pulley

14

ADJUSTMENTS

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

HEAD LOCK PIN

The head locking pin safely secures the head

(bow) in the down position. To ensure the head does not unexpectedly spring up and tip the band saw over, this locking pin must be properly inserted when the band saw is not in use or before moving it.

To use the head locking pin:

Fully lower the head down, then insert the locking pin through the holes in the head pivot arm and base. SEE Figure 20.

OPERATION

HORIZONTAL CUTTING

1. Clamp the workpiece firmly in the vise jaws

(A-Fig.21) to ensure straight cut through the

material. SEE “VISE ADJUSTMENTS” on

Page 12.

2. If needed, use the work stop (B-Fig.21) to

quickly and accurately cut multiple pieces of

stock to the same length.

3. DO NOT turn on machine until workpiece is

secured and blade has been lowered to just

above workpiece.

4. Turn on the saw (C-Fig.21) and let the blade

reach full speed before engaging the

workpiece. Never start a cut with the blade

in contact with the workpiece.

5. When the cutting operation is complete the

saw will automatically shut off. The stop tab

(Figure 22) will engage the switch, disconnect-

ing power to the motor.

A

Stop Tab

Use gloves when handling sawn material as the edges can be sharp and very hot!

15

Lock Pin

FIGURE 20

C

FIGURE 21

B

FIGURE 22

OPERATION

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

Safety Bracket

VERTICAL CUTTING

1. Raise the saw head and engage the safety

bracket.

2. Lock the safety bracket in place with

the supplied pin (on front of saw) to keep the

saw head from falling. SEE Figure 23.

FIGURE 23

3. Remove the two flat head screws and the

blade guide cover. SEE Figure 24.

Pin

Notch

4. Install the table in place of the blade guide

cover and replace the two screws removed in

Step 3.

Blade Guide Cover

FIGURE 24

5. Install the table support (Circled, Fig-25) with

the pre installed hex bolt on the saw head

(next to the gearbox), M6x16 flat head screw,

M6 flat washer and 6mm hex nut.

16

FIGURE 25

OPERATION

THE MACHINE MUST NOT BE

PLUGGED IN AND THE POWER SWITCH MUST BE IN

THE OFF POSITION UNTIL ASSEMBLY IS COMPLETE.

CHANGING THE SAW BLADE

1. Turn the on/off switch to the OFF position and

disconnect saw from power source.

2. Raise the saw head and engage the safety

bracket.

3. Lock the safety bracket in place with

the supplied pin (on front of saw) to keep the

saw head from falling. SEE Figure 26.

Safety Bracket

FIGURE 26

Take care when handling saw blades, blade teeth are very sharp! Wear gloves.

Pin

Notch

4. Open the wheel access cover (A-Fig.27).

5. Loosen the tension knob (B-Fig.27) and slip

the blade off of the wheels.

6. Install the new blade through both blade guide

bearing assemblies and around the bottom

wheel.

7. Hold the blade around the bottom wheel with

one hand and slip it around the top wheel with

the other hand, keeping the blade between the

blade guide bearings.

8. Tighten the tension knob and close the wheel

access cover before starting the saw. If the

blade slips during startup or operation turn off

the saw, tighten the tension knob further and

restart the saw to test.

B

A

FIGURE 27

17

MAINTENANCE

BEFORE CLEANING OR CARRYING OUT MAINTENANCE WORK, DISCONNECT

THE MACHINE FROM THE POWER SOURCE (WALL SOCKET). DO NOT USE COMPRESSED AIR

NEAR BEARINGS. REGULAR MAINTENANCE OF THE MACHINE WILL PREVENT UNNECESSARY

PROBLEMS.

3. Use a brush and a shop vacuum to remove chips and other debris from the machine.

4. Remove metal filings from the cutting area and the blade guides whenever necessary.

6. Check guide bearings frequently to make sure they are properly adjusted and running freely.

7. Wipe saw down with a clean dry cloth and oil all unpainted surfaces with light machine oil.

8. Before each use: Check the power cord and plug for any wear or damage. Check for any loose screws,

remnants, cleaning supplies, etc. that could hamper the safe operation of the machine.

WIRING DIAGRAM

This machine must be grounded. Replacement of the power supply cable should only be done by a qual ified electrician. DO NOT perform maintenance if water is present. See page 5 for additional electrical information.

As received from the factory, your Metal Cutting Saw is ready to run at 120V operation.

Black

White

Green

Black

White

Green

18

TROUBLESHOOTING

SYMPTOM

Saw will not start

POSSIBLE CAUSES

1. Power cord is not plugged in

2. Fuse or circuit tripped

3. Damaged power cord

4. Burnt or failed switch

SOLUTIONS

1. Plug in saw to power source

2. Replace fuse or reset breaker

3. Contact Technical Support 877-884-5167

or [email protected]

4. Contact Technical Support 877-884-5167

or [email protected]

Blade is slow or does not come up to speed

Excessive Vibration

Premature blade dulling.

Motor overheating.

Bad, crooked or rough cuts.

Blade is twisting.

1. Wrong size extension cord

2. Extension cord too long

3. Low house voltage

1. Tile blade damaged or unbalanced

2. V-belt worn or loose

3. Loose Motor or Drive Pulley

1. Blade tpi is too high.

2. Incorrect speed - too fast.

3. Inadequate feed pressure.

4. Hard spots or scale on the workpiece.

5. Blade installed backwards.

6. Insufficient blade tension.

7. Work hardened material especially

stainless

1. See recommended size on page 5

2. See recommended length on page 5

3. Check household voltage

1. Replace blade

2. Inspect/Replace V-Belt

3. Inspect/Tighten Pulleys

1. Replace with a smaller tpi blade.

2. Reduce speed.

3. Increase feed pressure by unscrewing

tension bar. This will decrease the spring

tension on the arm.

4. Reduce speed, increase feed pressure.

5. Remove blade, twist inside out and

reinstall.

6. Increase blade tension.

7. Increase feed pressure by reducing spring

pressure.

1. Blade tension too high.

2. Drive belt tension too high.

3. Blade too coarse or too fine.

4. Gears need lubrication.

5. Blade is binding in the cut.

1. Reduce blade tension.

2. Reduce drive belt tension.

3. Use a blade more suitable for the

workpiece.

4. Lubricate the gears.

5. Decrease feed and speed.

1. Feed pressure too great.

2. Blade guide bearings not properly

adjusted.

3. Inadequate blade tension.

4. Blade is dull.

5. Incorrect speed.

6. Blade guides are spaced out too far.

7. Blade guide assembly is loose.

8. Blade is too coarse.

1. Blade is binding in the cut.

2. Blade tension is too high.

1. Reduce feed pressure by increasing the

spring tension on the arm.

2. Adjust blade guide bearing in accordance

with manual.

3. Increase blade tension a little at a time.

4. Replace the blade.

5. Check manual for recommended speed.

6. Move guides closer to workpiece.

7. Tighten the guide assembly.

8. Use a finer tooth blade.

1. Decrease feed pressure.

2. Decrease blade tension.

19

PARTS DIAGRAM

20

&167A

PARTS LIST

KEY NO.

45

46

47

48

41

42

43

44

37

38

39

40

33

34

35

36

49

50

51

52

53

54

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

DESCRIPTION PART NO.

Worm gear pulley

8-1.25x8mm Set screw

4-0.7x8mm Pan head screw

4mm Flat washer

4-0.7x8mm Flat head screw

Bearing cover

Oil seal

6202zz Ball bearing

Bearing bushing

6202zz Ball bearing

Worm gear

V belt O-508

6-1.0x16mm Hex head bolt

6mm Lock washer

6mm Flat washer

Gear box cover

Gear box gasket

5x28mm Key

Worm assembly

5x26mm Spring pin

Shaft

8-1.25x30mm Hex head bolt

8-1.25x16mm Hex head bolt

8-1.25x30mm Hex head bolt

8mm Flat washer

6-1.25x12mm Hex head bolt

6mm Lock washer

Sliding block

6mm Flat washer

Guide plate

Shaft block

Shaft

Blade tension nut

Spring

10mm Flat washer

Blade tension knob

Bushing

6202zz Ball bearing

35mm Retaining ring

Rear blade wheel

Washer

5mm Flat washer

5-0.8x16mm Socket head screw

Blade

Switch cut off finger

6mm Flat washer

6mm Lock washer

6-1.0x14mm Pan head screw

Rear guide tighten knob

10mm Flat washer

Bushing

6202zz Ball bearing

Oil seal

Bearing cover

P15-400-33

P15-400-34

P15-400-35

P15-400-36

P15-400-37

P15-400-38

P15-400-39

P15-400-40

P15-400-41

P15-400-42

P15-400-43

P15-400-44

P15-400-45

P15-400-46

P15-400-47

P15-400-48

P15-400-49

P15-400-50

P15-400-51

P15-400-52

P15-400-53

P15-400-54

P15-400-1

P15-400-2

P15-400-3

P15-400-4

P15-400-5

P15-400-6

P15-400-7

P15-400-8

P15-400-9

P15-400-10

P15-400-11

P15-400-12

P15-400-13

P15-400-14

P15-400-15

P15-400-16

P15-400-17

P15-400-18

P15-400-19

P15-400-20

P15-400-21

P15-400-22

P15-400-23

P15-400-24

P15-400-25

P15-400-26

P15-400-27

P15-400-28

P15-400-29

P15-400-30

P15-400-31

P15-400-32

KEY NO.

DESCRIPTION

95

96

97

98

99

100

101

102

91

92

93

94

87

88

89

90

103

104

105

106

107

108

83

84

85

86

79

80

81

82

75

76

77

78

71

72

73

74

67

68

69

70

63

64

65

66

59

60

61

62

55

56

57

58

PART NO.

4-0.7x8mm Flat head screw

Bushing

Front blade wheel

8-1.25x8mm Set screw

15mm Retaining ring

4mm Flat washer

4-0.7x6mm Pan head screw

Frame

6-1.0x25mm Hex head bolt

6mm Hex nut

10-1.5x30mm Hex head bolt

10mm Flat washer

6-1.0x10mm Pan head screw

6mm Lock washer

6mm Flat washer

Hex head bolt

Motor support plate

8-1.25x55mm Hex head bolt

8-1.25mm Hex nut

8-1.25mm Hex nut

8mm Lock washer

8mm Flat washer

8-1.25x20mm Hex head bolt

12-1.75x35mm Hex head bolt

Belt cover

Knob

4mm Flat washer

4-0.7x8mm Pan head screw

8-1.25x8mm Set screw

Motor pulley

5x28mm Key

Motor

Front guide base

8mm Flat washer

8mm Lock washer

8-1.25x30mm Hex head bolt

8-1.25mm Hex nut

8mm Lock washer

629zz Ball bearing

Shaft

Front blade guide

Shaft

629zz Ball bearing

9mm Retaining ring

Front blade guard

6-1.0x16mm Flat head screw

8-1.25mm Hex nut

8mm Lock washer

8-1.25x30mm Hex head bolt

8mm Lock washer

8mm Flat washer

629zz Ball bearing

Shaft

Rear blade guide

P15-400-87

P15-400-88

P15-400-89

P15-400-90

P15-400-91

P15-400-92

P15-400-93

P15-400-94

P15-400-95

P15-400-96

P15-400-97

P15-400-98

P15-400-99

P15-400-100

P15-400-101

P15-400-102

P15-400-103

P15-400-104

P15-400-105

P15-400-106

P15-400-107

P15-400-108

P15-400-55

P15-400-56

P15-400-57

P15-400-58

P15-400-59

P15-400-60

P15-400-61

P15-400-62

P15-400-63

P15-400-64

P15-400-65

P15-400-66

P15-400-67

P15-400-68

P15-400-69

P15-400-70

P15-400-71

P15-400-72

P15-400-73

P15-400-74

P15-400-75

P15-400-76

P15-400-77

P15-400-78

P15-400-79

P15-400-80

P15-400-81

P15-400-82

P15-400-83

P15-400-84

P15-400-85

P15-400-86

NOTE: Please reference the Manufacturer’s Part Number when calling for Replacement Parts. For Parts under Warranty, the Serial Number of your machine is required.

21

PARTS LIST

KEY NO.

149

150

151

152

153

154

155

156

141

142

143

144

145

146

147

148

157

158

159

160

161

162

133

134

135

136

137

138

139

140

125

126

127

128

129

130

131

132

117

118

119

120

121

122

123

124

109

110

111

112

113

114

115

116

DESCRIPTION PART NO.

Shaft

629zz Ball bearing

9mm Retaining ring

Rear blade guard

4mm Flat washer

4-0.7x6mm Pan head screw

Rear guide base

6-1.0x10mm Pan head screw

6mm Flat washer

Frame guard

Extension guard

Knob

Pin with chain

10-1.5x35mm Socket head screw

10mm Lock washer

10mm Flat washer

8-1.25x8mm Set screw

Pivot block

Spring

Spring adjusting screw

6-1.0x12mm Hex head bolt

6mm Lock washer

6mm Flat washer

Screw support plate

Adjusting rod

Knob

Adjusting rod support

8-1.25x20mm Hex head bolt

8mm Flat washer

8mm Lock washer

H8-1.25mm Hex nut

Pivoting rod

4x25mm Spring pin

16mm Flat washer

Hex head bolt

8mm Flat washer

8-1.25x40mm Hex head bolt

8mm Flat washer

Vise jaw

10-1.5x25mm Hex head bolt

10mm Flat washer

Sliding vise jaw

Base

5-0.8x8mm Pan head screw

5mm Flat washer

Strain relief

Strain relief mounting plate

12-1.75x70mm Hex head bolt

12-1.75mm Hex nut

8-1.25x12mm Set screw

Safety bracket

8mm Flat washer

8-1.25x16mm Hex head bolt

5-0.8mm Hex nut

P15-400-141

P15-400-142

P15-400-143

P15-400-144

P15-400-145

P15-400-146

P15-400-147

P15-400-148

P15-400-149

P15-400-150

P15-400-151

P15-400-152

P15-400-153

P15-400-154

P15-400-155

P15-400-156

P15-400-157

P15-400-158

P15-400-159

P15-400-160

P15-400-161

P15-400-162

P15-400-109

P15-400-110

P15-400-111

P15-400-112

P15-400-113

P15-400-114

P15-400-115

P15-400-116

P15-400-117

P15-400-118

P15-400-119

P15-400-120

P15-400-121

P15-400-122

P15-400-123

P15-400-124

P15-400-125

P15-400-126

P15-400-127

P15-400-128

P15-400-129

P15-400-130

P15-400-131

P15-400-132

P15-400-133

P15-400-134

P15-400-135

P15-400-136

P15-400-137

P15-400-138

P15-400-139

P15-400-140

KEY NO.

DESCRIPTION

202

203

204

205

206

207

208

209

194

195

196

197

198

199

200

201

210

211

212

213

214

215

186

187

188

189

190

191

192

193

178

179

180

181

182

183

184

185

170

171

172

173

174

175

176

177

163

164

165

166

167

167A

168

169

Cord clamp

Pin with chain

5mm Flat washer

5-0.8x20mm Pan head screw

5-0.8X30mm Hex head bolt

5-0.8mm wing nut

Work stop

Work stop rod

8-1.25mm Hex nut

8mm Flat washer

Switch box

Switch mounting plate

Thread forming screw

Strain relief

Power cord

5mm Serrated washer

5-0.8x10mm Pan head screw

Switch

Angle scale

Rivet

Screw support block

6mm Flat washer

6mm Lock washer

6-1.0x16mm Hex head bolt

Vise nut

Lead screw

Bushing

6-1.0x6mm Set screw

6-1.0x12mm Hex head bolt

Crank handle

2.5x25mmCotter pin

Transport handle

Leg A

Leg B

8-1.25mm Hex nut

8mm Lock washer

8mm Flat washer

8-1.25x16mm Carriage bolt

Long brace

Short brace

6-1.0mm Hex nut

6mm Flat washer

Transport wheel

6-1.0x12mm Hex head bolt

6mm Flat washer

6mm Lock washer

Wheel stand

Shaft

2.5x25mm Cotter pin

Table

6-1.0x16mm Flat head screw

Table support

6mm Flat washer

6-1.0mm Hex nut

PART NO.

P15-400-194

P15-400-195

P15-400-196

P15-400-197

P15-400-198

P15-400-199

P15-400-200

P15-400-201

P15-400-202

P15-400-203

P15-400-204

P15-400-205

P15-400-206

P15-400-207

P15-400-208

P15-400-209

P15-400-210

P15-400-211

P15-400-212

P15-400-213

P15-400-214

P15-400-215

P15-400-163

P15-400-164

P15-400-165

P15-400-166

P15-400-167

P15-400-167A

P15-400-168

P15-400-169

P15-400-170

P15-400-171

P15-400-172

P15-400-173

P15-400-174

P15-400-175

P15-400-176

P15-400-177

P15-400-178

P15-400-179

P15-400-180

P15-400-181

P15-400-182

P15-400-183

P15-400-184

P15-400-185

P15-400-186

P15-400-187

P15-400-188

P15-400-189

P15-400-190

P15-400-191

P15-400-192

P15-400-193

NOTE: Please reference the Manufacturer’s Part Number when calling for Replacement Parts. For Parts under Warranty, the Serial Number of your machine is required.

22

®

5-Year Limited Warranty

RIKON Power Tools Inc. (“Seller”) warrants to only the original retail consumer/purchaser of our products that each product be free from defects in materials and workmanship for a period of five (5) years from the date the product was purchased at retail. This warranty may not be transferred.

This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs, alterations, lack of maintenance or normal wear and tear.

Under no circumstances will Seller be liable for incidental or consequential damages resulting from defective products.

resulting from defective products. All other warranties, expressed or implied, whether of merchantability, fitness for purpose, or otherwise are expressly disclaimed by Seller. This five-year warranty does not cover products used for commercial, industrial or educational purposes. The warranty term for these claims will be limited to a two-year period.

This limited warranty does not apply to accessory items such as blades, drill bits, sanding discs, grinding wheels, belts, guide bearings and other related items.

Seller shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special, or consequential damages arising from the use of our products.

To take advantage of this warranty, proof of purchase documentation must be provided which has the date of purchase and an explanation of the complaint.

The Seller reserves the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever.

To register your machine online, visit RIKON at www.rikontools.com/warranty

To take advantage of this warranty, or if you have any questions, please contact us at 877-884-5167 or email [email protected]

WARRANTY

®

5-Year Limited Warranty

RIKON Power Tools Inc. (“Seller”) warrants to only the original retail consumer/purchaser of our products that each product be free from defects in materials and workmanship for a period of five (5) years from the date the product was purchased at retail. This warranty may not be transferred.

This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs, alterations, lack of maintenance or normal wear and tear.

Under no circumstances will Seller be liable for incidental or consequential damages resulting from defective products.

resulting from defective products. All other warranties, expressed or implied, whether of merchantability, fitness for purpose, or otherwise are expressly disclaimed by Seller. This five-year warranty does not cover products used for commercial, industrial or educational purposes. The warranty term for these claims will be limited to a two-year period.

This limited warranty does not apply to accessory items such as blades, drill bits, sanding discs, grinding wheels, belts, guide bearings and other related items.

Seller shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special, or consequential damages arising from the use of our products.

To take advantage of this warranty, proof of purchase documentation must be provided which has the date of purchase and an explanation of the complaint.

The Seller reserves the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever.

To register your machine online, visit RIKON at www.rikontools.com/warranty

To take advantage of this warranty, or if you have any questions, please contact us at 877-884-5167 or email [email protected]

23

For more information:

16 Progress Road

Billerica, MA 01821

877-884-5167 / 978-528-5380 [email protected]

15-400M1

www.rikontools.com

15-400

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