KEENCUT Excalibur 6000 User manual

Excalibur 6000 user guide
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Excalibur 6000 user guide
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Contents
1. Introduction 3 .........................................................................................................................................................
1.1 The Excalibur 6000 user guide 3 ................................................................................................................................
2. Get to know your cutter 4 .........................................................................................................................................
2.1 Using the measuring stops 4 ....................................................................................................................................
2.2 Using the clamp 6 .................................................................................................................................................
2.3 The multi-tool cutter and the twin wheel cutter 7 ..........................................................................................................
2.4 Cutting using the ratchet latch 9 ...............................................................................................................................
2.5 Using the cutting blade 10 .......................................................................................................................................
2.6 Using the cutting blade support plates 11 ....................................................................................................................
2.7 Using the scoring blade 13 ......................................................................................................................................
2.8 Using the glass cutter 15 ........................................................................................................................................
2.9 Using the twin wheel cutter 18 .................................................................................................................................
3. Maintenance 20 ......................................................................................................................................................
3.1 Clean your machine 20 ...........................................................................................................................................
3.2 Lubrication 21 ......................................................................................................................................................
3.3 Adjusting the clamp pressure 23 ...............................................................................................................................
3.4 Adjusting the clamp alignment 24 .............................................................................................................................
3.5 Changing the blue support boards 26 .........................................................................................................................
3.6 Changing the cutting blade 30 ..................................................................................................................................
3.7 Changing the scoring blade 32 ..................................................................................................................................
3.8 Changing the glass cutting wheel 34 ..........................................................................................................................
3.9 Changing the twin wheel cutter 36 ............................................................................................................................

Excalibur 6000 user guide
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1. Introduction
1.1 The Excalibur 6000 user guide
This User Guide for the Excalibur 6000 gives advice on cutting
techniques, care and maintenance of your machine.
Before using your machine make sure that you have installed
and calibrated it correctly. Full details are in the Installation
Manual.
Visit the Excalibur 6000 installation manual >

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2. Get to know your cutter
2.1 Using the measuring stops
The right and left hand measuring stops enables the operator to
slide in and position the materials to be cut at a set length, as
decided by the fixed position of the stop.
As seen in the picture, the edges (with the arrows pointed at
them) indicate the exact same length at which the material will
be pushed up against the measuring stop. Ensure that both
scales on the machine are calibrated as defined within the
“Calibrating the squaring arm scales >” and “Calibrating
the Easy Measuring Scale >” sections of the instruction
manual.
Rotate the black knob on the measuring stop counter-clockwise
to loosen the stop and move it to the desired length
measurement on either scale.

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Rotate the black knob on the measuring stop clockwise to fasten
the stop and set the material (to be cut) against the measuring
stop.

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2.2 Using the clamp
The clamping system enables the operator to control the grip
pressure by means of an integral friction brake, that maintains
the clamping force at the pressure applied by the operating
lever.
Soft materials can be held firmly without sustaining damage and
solid materials are held rigidly without movement.
By following the guidelines below it will help you to get the
most from the machine.
Material Clamping Instructions

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2.3 The multi-tool cutter and the twin wheel cutter
The Excalibur 6000 is fitted with two Cutting Heads running on two vertical stainless steel tracks. The lower or multi-tool
cutter head has a rotating turret arrangement where any one of the three cutting tools can be selected:
1) Cutting Blade – Using a standard Medium Duty utility blade (not Heavy Duty – they will not fit) to cut PVC Foamboards
like Forex®, corrugated plastic such as Correx®, card, matboard and many other types of rigid boards up to 13mm (1/2″) thick.
2) Scoring Blade – An inversely positioned Medium Duty utility blade is used to score the surface of any brittle plastics
including Acrylic’s such as Perspex® and Plexiglass. Once scored the plastic sheet is removed from the machine and
‘snapped’ along the score line. Any thickness (up to 13mm 1/2″) can be scored but tests should be carried out on a sample of
the sheet to ensure it does ‘snap’ and to an acceptable quality (remember to use hand and face protection when doing this).
3) Glass Cutting – A high quality tungsten carbide wheel is used to score glass.
The top carriage in a standard machine is fitted with the TW (Twin Wheel) cutter for use with rigid boards such as MDF,
hardboards, and some mountboards up to 4mm. Refer to Using the twin wheel cutter > or Changing the twin wheel cutter >
for more details.
The cutting wheels are made from high grade tool steel and are heat treated to give a long life but this is dependent upon
daily use and the materials being cut.
The signs of the wheels wearing out are:
1) A rough finish predominately on the right hand side of the cut, with flaking on materials such as MDF.
2) The bottom of the cut bursting out rather than being cut neatly.
3) The board trying to turn under the clamp when being cut (also check the clamp pressure).
To select a different cutter pull the turret handle out to the left
about 6mm (1/4”) and rotate in either direction, the turret will
click into the correct position for the cutter indicated.

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The indicator label on the turret handle, that faces the user,
shows which cutter is active.

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2.4 Cutting using the ratchet latch
A unique feature of the Excalibur is the ‘ratchet latch’. This
enables thick dense materials such as PVC foam board to be cut
easily in stages. Count the number of ‘clicks’ to position the
blade just below the surface of the material to make your first
cut, and then add an extra ‘click’ for the second and subsequent
cuts.
As a rough guide when cutting PVC foam board:
3MM (1/8”) Initial surface cut + 1 additional cut
5MM (1/4”) Initial surface cut + 1 or 2 additional cuts
10MM (3/8”) Initial surface cut + 3 or 4 additional cuts
Should you engage the cutter by mistake or for any reason want
to disengage the cutter without moving it to the bottom of the
machine, pull down the cutter release lever.
For some operations (such as scoring acrylic) the ratchet latch
needs to be disengaged, so that finger pressure can be used to
make the score/cut. This is done by turning the black knob with
the ‘On’/’Off’ stickers such that ‘Off’ faces towards the user. To
re-engage the ratchet latch, turn the black knob such that ‘On’
faces towards the user.

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2.5 Using the cutting blade
Select the cutting blade position on the turret and clamp the
material in the machine.
Press to engage the cutter. Draw the cutter down to the bottom
of the machine where it will disengage automatically.

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2.6 Using the cutting blade support plates
The two support plates either side of the blade are designed to
give maximum rigidity of the blade when cutting hard or dense
materials. To adjust the support plates, swing down the cutter
guard by undoing the black locking knob (on the guard) facing
towards the operator.
Turn the turret ½ turn until the blade is pointing towards you.
Then unlock the blade clamping screw.
The support plates can be adjusted by sliding the black pin in the
slot. Move the plates to suit the material and ensure that the
blade is pushed as far back as it will go. Tighten the clamping
screw once the support plates are in position.

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For cutting most materials the support plates can be set about 12mm (1/2”) from the blade tip

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2.7 Using the scoring blade
CAUTION: ALWAYS USE HAND AND EYE PROTECTION WHEN SNAPPING PLASTIC
NOTE : The scoring blade is designed to score acrylics, Plexiglas and other similar rigid plastics. Trials should be carried
out on scrap materials first to ensure you obtain the required standard of cut.
Select the scoring blade position on the turret and clamp the
plastic to be scored in the machine.
Turn the ratchet’s black knob to ‘Off’ to disengage the ratchet.

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Position and depress the cutting head so the blade touches the
plastic at the top. Apply thumb pressure to the cutter and draw
the blade down the material in one continuous motion.
Remove the plastic from the machine and snap it by hand.
Ensure that the plastic is snapped in the opposite direction to
which the score faces.

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2.8 Using the glass cutter
CAUTION: ALWAYS WEAR EYE PROTECTION AND GLOVES WHEN CUTTING GLASS
Select the glass cutting position on the turret and place the
glass on the machine from the right hand side. Clamp the glass
lightly in the machine.
Raise the cutting head above the top edge of the glass and press
to engage the cutter fully (with the black ratchet knob switched
to ‘On’). Then lower the cutting head to the top edge of the glass
to be cut. The glass cutting wheel will automatically adjust itself
for the thickness of the glass.

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Gently draw the cutter onto the glass and down to the bottom of
the machine in one gentle smooth and continuous motion where
it will disengage automatically.
Check the score line, as it should be very faint and continuous.
If the score is too deep, the line will appear white and small slithers of glass may be seen falling from it. The scoring
pressure will need reducing.
If the score is too light, the glass cutting wheel ‘skips’ and does not produce a continuous line. The scoring pressure
will need increasing.
Should the score pressure require increasing or decreasing, the
scoring pressure adjustment screw can be adjusted by turning it
clockwise or counter-clockwise accordingly.

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To break the glass, apply firm pressure to the left hand side of
the score line adjacent to the top edge of the glass.
The glass should break easily, however if it resists breaking or
feels springy, check the spring pressure setting.
Note: On large sheets of glass the break may only go part way down the score line, press again near the end of the break
to continue it. Never score the same line twice. We recommend the use of glass nibbling pliers for the removal of
amounts less than 25mm (1”)

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2.9 Using the twin wheel cutter
The twin wheel cutter is mounted on the upper cutting head and is used for cutting rigid materials such as medium density
fibreboard (MDF, also known as SBS) and standard hardboard up to 3mm (1/8”) or harder materials like high density
fibreboard (HDF) up to 2mm (1/16”). Many other softer boards and card can also be cut. Trials should be carried out to
ensure the desired quality of cut is obtained.
Position the material in the machine and apply the clamp.
Bring the twin wheel cutter down until it makes contact with the
sheet edge and stop. Take a firm grip and then push the cutter
down through the material without stopping.
The cutting wheels generally last more than a year with average use, but this is dependent upon the daily usage and the
material being cut.
Signs that the wheels are wearing out are:
1) A rough finish predominantly on the right hand side of the cut, with flaking on material such as MDF.
2) The bottom of the cut bursting out rather than being cut neatly.

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3) The board trying to turn under the clamp when being cut (also check the clamp pressure).

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3. Maintenance
3.1 Clean your machine
Keencut machines are designed to be virtually maintenance free, however we do recommend regular cleaning
Do not wipe the Squaring Arm channels or remove any debris
with fingers, as it may contain sharp particles such as glass.
Use a vacuum cleaner if possible. If a soft brush is used, work
slowly and do not allow particles to flick off the bristles.