Rikon Power Tools 15-400 Product Manual
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Rikon Power Tools 15-400 is a horizontal metal bandsaw designed for precise cutting of various metals. With a powerful 3/4 HP motor and variable blade speeds of 80/120/180 FPM, it offers efficient and versatile cutting performance. The saw features a spacious horizontal table for stable workpiece support and a cutting capacity of up to 4" x 6" for square cuts at 90 degrees. It also allows for miter cuts at angles up to 45 degrees, with a maximum depth of 2-3/4" for square cuts and circular cuts.
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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
4. Contact Technical Support 877-884-5167
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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