KG 50 - Sander PROXXON - Free user manual and instructions

USER MANUAL KG 50 PROXXON

• makes it easier to get familiar with the device

• prevents malfunctions caused by improper handling, and

• lengthens the service life of your device. Please keep these instructions readily accessible at all times. Use the device only when you have understood it exactly and always adhere to the instructions. PROXXON is not liable for the safe functioning of the device in cases of:

• handling that does not conform to the usual usage,

• purposes of use not designated in the instructions,

• disregard of the safety instructions. You are not entitled to guarantee claims in cases of:

• inadequate maintenance. For your own safety, please follow the safety instructions exactly. Use only genuine PROXXON replacement parts. We reserve the right to make improvements in the sense of tech- nical progress. We wish you much success with the device. Contents:

5. Working with the capping device …………………………10

6.1. Retightening or replacing the cogged belt (see Fig 7) ……11

1. General safety instructions

CAUTION! When using electric power tools, the following safety measures must be observed for protection from electric shock, risk of injury, and fire hazards. Make sure you read all these instructions before using the power tool and keep the safety instructions in a safe place.

- Keep your work area tidy - Untidiness in the work area can result in accidents.

2. Take the environmental influences into consideration

- Do not expose the power tools to rain. - Do not use power tools in moist or wet environments. - Ensure good illumination of the work area. - Do not use power tools if a fire- or explosion hazard exists.

3. Protect yourself from electric shock

- Prevent contact between your body and grounded parts (e.g. pipes, radiators, electric ranges, cooling appliances)

4. Keep other persons at a distance

- Do not let other people, especially children, touch the power tool or the cable. Keep them out of your work area.

5. Store the power tools safely

- Power tools not in use should be stored in a dry, high, or closed place, out of the reach of children.

6. Do not overload your power tools

- You will work better and more safely within the stated power range.

7. Use the right power tool for the job

- Do not use a low power machine for a heavy-duty job. - Do not use the power tool for any purpose for which it was not intended. For instance, do not use a portable circular saw to cut tree branches or logs.

8. Wear suitable clothing

- Do not wear loose clothing or jewelry. They could become entangled in the moving parts. - Skid-proof shoes are recommended when working out- doors. - If your hair is long, wear a hairnet.

9. Use personal protective gear

- Wear safety glasses - Wear a breathing mask when performing dust-evolving work.

10. Connect the dust-exhaust system

- If connections for dust-suction and collection equipment are available, make sure that these have been connected and are being used correctly.

11. Do not use the cable for any use other than the one it was

intended. - Do not use the cable to pull the plug from the receptacle. Protect the cable from heat, oil, and sharp edges.

12. Secure the workpiece

- Use clamping fixtures or a vice to hold the workpiece in place. This is safer than holding it in your hand.

13. Avoid abnormal posture

- Make sure you have a firm stance and keep your balance at all times.

14. Maintain your tool with care

- Keep cutting tools sharp and clean for safer and better work. - Follow the instructions about lubrication and tool replacement. - Check the power tool’s connection lead at regular intervals and have these replaced by an authorized specialist in case of damage. - Check the extension cords regularly and replace them if damaged.

GB- Keep handles dry, clean, and free of oil and grease.

15. Pull the plug from the electric socket

- when the power tool is not being used, before maintenance, and when replacing tool parts such as the saw blade, drill, or milling cutter.

16. Never leave any tools keys or chucks plugged in

- Before switching on, check to see if the key, chuck, and adjusting tools have been removed.

17. Prevent unintended starts

- Ensure the switch is switched to the off position when plug- ging the plug into the electrical outlet.

18. Use an extension cable for outdoor areas

- Use only approved and accordingly marked extension cables when working outdoors.

- Pay attention to what you are doing. Tackle the work with a reasonable attitude. Do not use the power tool if you lack concentration.

20. Check the power tool for any possible damage

- Before continued use of the power tool, protective equip- ment and slightly damaged parts must be carefully checked for their flawless functioning and that they function as intended. - Check to see if movable parts are working perfectly and do not jam and if there are any damaged parts. All parts must be correctly installed and all conditions fulfilled to ensure the flawless operation of the power tool. - Damaged protective equipment and parts must be repaired or replaced by an authorized specialist workshop as direc- ted unless otherwise specified in the operating instructions - Damaged switches must be replaced by a customer service- center. - Do not use any power tools in which the switch cannot be switched on and off.

- The use of other tools and accessories can result in the risk of injury.

22. Have your power tool repaired by a trained and skilled elec-

trician - This power tools complies with the relevant safety regula- tions. Repairs may only be carried out by skilled and trained electricians with use of genuine spare parts. Otherwise, accidents could result for the user.

2. General view (fig. 1)

2. Cutting disk cover

9. Spindle for clamping device

3. Description of the machine

Thank you very much for acquiring a PROXXON KG 50 capping device: It is perfectly suited for small but precise applications when cutting metal bars of up to diameters of ca. 10 mm, for cutting wood, and plastic bars or profiles. The device consists of a cutting head and a device foot made from die-cast aluminum. The cutting head houses the device’s electrical components as well as the synchronous belt-drive for actuating the cutting blade. It can be swiveled up and down through the use of a joint on the device foot and is held by a spring in the upper setting in the neutral position. The device foot contains a circular table that can be rotated 45°: This allows simple and precise fabrication even of diagonal cuts. On top of that, the scale on the side permits an exact and comfor- table angular adjustment: after that, the circular table can be lok- ked in place using a thumbscrew. You can clamp the workpiece into the desired position using the vice. The vice has a span of max. 20 mm and can hold size HO model-railroad tracks by using a prism on the top (see fig. 6). Fixating round materials is also made easy through the use of the groove worked into the jaw. Even cutting workpieces to length is perfectly possible with this device through use of the limit stop: this can be set to a maxi- mum length of 140 mm. 5-each ceramic-bonded cutting disks and a hollow hexagon wrench are included with the device. 3.1. Technical data Dimensions and weights: Device foot: ca. 100/135 x 132 mm Height: ca. 100 mm (when the cutting head is in the rest position) Width: ca. 140 mm Vice jaw width: 30 mm Span: 20 mm Weight: ca. 1.4 kg Motor: Voltage: 220 - 240 Volt, 50/60 Hz Power consumption: 85 Watt 10 min Speed: 8000/min Cutting speed: ca. 25 m/sec. Noise emission: < 70 dB(A) For use in dry environments only Protection class II device Please do not dispose in domestic waste!

94. Before starting work:

For safety reasons, the Proxxon KG 50 capping device comes delivered with a cardboard disk instead of a cutting disk. That means you need to install the cutting disk yourself, which is easily done. 5-each cutting disks are supplied in the scope of delivery of the device. Furthermore, after having used the device for a long time, replacing the cutting disk may become necessary if the old one is too worn. The procedure for replacement is the same and is described as follows: 4.1. Installing or replacing the cutting blade Please note: You can acquire replacement-cutting blades for the machine in businesses under the no. 28 152! Caution: You must pull the mains plug before installation!

1. Unscrew fastening screw 1 (see fig. 2) from the yellow pro-

tective cover 2 and pull up the cover.

2. Lock shaft-1 (fig. 3) in place by pressing stopper 2. To do

that, you need to turn the shaft a bit to find the corresponding notching position

3. Remove fastening screw 3 and remove washer 4. Watch out

4. Put on the new cutting disk

Caution! The ceramic-bonded cutting disk is very sensitive to being bent. Do not take hold of the disk to remove or pull the fastening screw. The disk is very fragile. Make sure that cutting disk 4 is correctly seated!

5. Reassemble by simply using the reverse sequence.

5. Working with the capping device

Note: Safe and precise work is only possible if the device has been cor- rectly fastened to a tabletop. This can be done with the enclosed C-clamp (shown in fig. 1), or with the help of screws. Bores (13, fig. 1) are available in the footplate. Caution: Make sure you always pull the plug before fixating or transporting the device! Danger! Never operate the capping device without the yellow protective cover and safety glasses! The red safety lever (Fig. 1, pos. 3) must always be folded comple- tely back into the resting position as otherwise, it could slip off if the cutting head is pushed by mistake and thus loses its blocking action. You can start work after the device is standing on a stable support and the cutting disk has been installed. There are no other prepa- rations necessary and the workpiece to be cut can be clamped into the vice and separated (fig. 4 a/b). This is how it’s done: 5.1. If you want to make straight cuts (Fig 4a)

1. Make sure circular table 1 is in the 0° position: The lug on

black rotary table 2 must point to the 0° mark on the scale in device foot 3. If not, please adjust it. If it is necessary to do so, remove thumbscrew 4 and push the rotary table into the corresponding position. Caution: the rotary table snaps-in at 0°. After that, make sure you retighten the thumbscrew.

2. Place workpiece 6 into vice 5, then align and tighten it. While

doing so, mind the desired length of the „free“ end!

3. If in doubt, after unlocking blocking lever 7 you can swivel

cutting head 9 out of the switched-off (!) device so far that cutting blade 8 is seated on the workpiece. With this method, you can better estimate the later length of the work- piece. 5.2. If you want to make miter cuts (Fig 4b)

1. Loosen thumbscrew 4 and set rotary table 1 to the desired

angle. Use scale to help do this. Then retighten the stop screw.

2. Place workpiece 6 into vice 5, then align and tighten it. While

doing so, mind the desired length of the „free“ end!

3. To do that, after unlocking blocking lever 7 you can swivel

cutting head 9 from the switched-off (!) device so far that the cutting blade is seated on the workpiece here also. With this method, you can better estimate the later length of the work- piece. 5.3. Severing a workpiece Switch the device on using on-off switch 10 and guide it down using slight pressure on recessed grip 11 until the cutting disk touches the workpiece. Caution: While doing so, please actuate the red blocking lever: otherwise, the cutting head cannot be swiveled! Increase the pressure on the workpiece only so much that the motor speed does not greatly decrease. That is how to sever a workpiece. Caution! It is not the contact pressure but the speed that generates high cutting power! Never use force! This unnecessarily stresses the device’s mechanics and leads to poor results and increased wear! Caution! Never actuate the stopper while the device is running. 5.4. Working with the longitudinal stop (fig. 5) The KG 50 capping device is supplied with an adjustable longitu- dinal stop (1). This means any desired number of workpieces can be cut to the same length. To do so, insert the workpiece to be cut into the vice pushed up to the limit stop and then clamp it in place. After severing the workpiece and loosening the vice, push 10the material back to the limit stop, clamp it with the vice, and then cut it. This can be repeated as often as desired. 5.5. This is how to set the limit stop

1. Loosen setscrew 2 using a hollow hexagon wrench (included

in the scope of delivery). After that, the limit stop can be pushed into guide 3 up to the desired length. Make sure short-rod 4 is correctly oriented and that the workpiece meets the stop correctly!

2. Using the setscrew, tightly clamp the limit stop.

6. Service and maintenance

Caution: Pull the mains plug before making any adjustments, performing maintenance work, or carrying out repairs! Note: The capping device is basically maintenance free. However, to ensure a long service life you should clean the device after each use with a soft cloth, swab, or brush. A vacuum cleaner is also advisable for this. External cleaning of the housing can be carried out using a soft, possibly moist cloth. While doing so, a mild detergent or other suitable cleansing agent can be used. Do not use solvents or cle- ansing agents containing alcohol (e.g. benzene, cleaning alcohol, etc.) as these can corrode the plastic housings. Please do not dispose of the device in domestic waste! The device contains valuable substances that can be recycled. If you have any questions about this, please contact your local waste management enterprise or other corresponding municipal facili- ties. After longer use, it could become necessary to retighten the cog- ged belt. To do so, please follow these instructions: 6.1. Retightening or replacing the cogged belt (see Fig 6) Caution: Pull the mains plug! Danger!

1. Unscrew fastening screw 1 and remove side cover 2.

2. Slightly loosen motor fastening-screw 3 and push pulley 4 to

the rear until the necessary tension has been reached. Caution! The cogged belt must never be too tight! The cogged belt must be able to be pushed-in 6-8 mm when lightly pressed with your finger!

3. Retighten the fastening screws and install the cover.

7. EU conformity declaration

Device name: KG 50 Part no.: 27150 We hereby declare the named product fulfills the regulations in the following EU directives: EU low voltage directive 73/23/EEC 93/68/EEC Applicable standards: DIN EN 61029 / 12.2003 EU EMC-directive 89/336/EEC Applicable standards: DIN EN 55014-1 / 09.2002