KEENCUT EXCALIBUR 3S User manual

Excalibur 3S user guide
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Excalibur 3S user guide
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Contents
1. Introduction 3 .........................................................................................................................................................
1.1 The Excalibur 3S user guide 3 ...................................................................................................................................
2. Get to know your cutter 4 .........................................................................................................................................
2.1 Using the clamp 4 .................................................................................................................................................
2.2 The multi-tool cutter and the counterbalance 6 .............................................................................................................
2.3 Using & changing the cutting blade 8 .........................................................................................................................
2.4 Changing the scoring blade 11 ..................................................................................................................................
2.5 Changing the twin wheel cutter 12 ............................................................................................................................
3. Making your first cut 13 ...........................................................................................................................................
3.1 Cutting thick material using the ratchet latch 13 ............................................................................................................
3.2 Using the scoring blade 14 ......................................................................................................................................
3.3 Using the twin wheel cutter 16 .................................................................................................................................
4. Maintenance 18 ......................................................................................................................................................
4.1 Clean your machine 18 ...........................................................................................................................................
4.2 Lubrication 19 ......................................................................................................................................................
4.3 Adjusting the sliding bearings 20 ..............................................................................................................................
4.4 Changing the sliding bearings 22 ...............................................................................................................................
4.5 Adjusting the clamp pressure 25 ...............................................................................................................................
4.6 Fitting the sightline strip 26 .....................................................................................................................................

Excalibur 3S user guide
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1. Introduction
1.1 The Excalibur 3S user guide
This User Guide for the Excalibur 3S 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 3S installation manual >

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2. Get to know your cutter
2.1 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.
Soft materials such as Foamcore boards, lightweight card, etc.
Use light to medium pressure. The underside of the clamp grips
an area nearly 4cm (11/2”) wide with a non-marking sponge
rubber
and reasonable force can be applied. If in doubt clamp a sample
first with the good surface facing outwards.
Do this gently

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For harder materials such as PVC foam board, MDF or composite
boards such as Diabond, use medium to heavy pressure.
Do this firmly
When cropping to trim lines, pencil marks, etc. (see drawing),
place material in approximate position under clamp, apply light
clamp pressure to allow the material to be repositioned. Align
the trim marks with the edge of the sightline strip and clamp.

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2.2 The multi-tool cutter and the counterbalance
The Excalibur 3S is fitted with two sliding carriages running on a vertical slideway and each carriage is fitted with a cutting
head. The top carriage is fitted with a twin wheel cutter for use with rigid boards such as aluminium composite panels,
MDF, hardboards. Refer to Changing the twin wheel cutter > or Using the twin wheel cutter > for more details. The lower or
multi-tool cutter head has a rotating turret arrangement where either of the two cutting tools can be selected (the cutting
blade or the scoring blade).
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. Please note
that there are three positions on the turret but only two positions
are used on this version of the Excalibur.
The indicator label seen in the cutter guard window shows
which cutter is active.

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The counterbalance can be attached to either cutting head for
easy, fatigue free working. it is normally attached to the twin
wheel cutter but to attach it to the multi-cutter head, lock the
twin wheel carriage in place using the white plastic thumb
screw. Raise the multi-cutter to engage the counterbalance
rocker, press the lower head of the rocker to connect it to the
carriage.

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2.3 Using & changing the cutting blade
Select the cutting blade position on the turret and clamp the
material in the machine. Move the cutting head beyond the top
of the material to be cut.
Press to engage the cutter. Draw the cutter down to the bottom
of the machine where it will disengage automatically.
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 and release lever.

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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 guard locking knob. Turn the turret ½ turn
until blade is pointing towards you.
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 tighten the
clamping screw once the support plates are in position.
For cutting most materials the support plates can be set about 12mm (1/2”) from the blade tip

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To change the cutting blade, undo the blade clamping screw a
number of turns to release the blade.
Change or turn over the blade, insert it back into the turret as far
as it will go. Tighten the blade clamping screw, the safety pin
will engage to hold the blade in position. At this point the
position of the blade support plates can be adjusted to suit the
thickness of material being cut, further tightening of the screw
will clamp the blade in position.
Rotate the turret back to the cutting position. Replace the guard
ensuring it is locked closed.

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2.4 Changing the scoring blade
Replacement medium utility blades are available from Keencut or your distributor.
Unlock and swing down the cutter guard, rotate the turret so
the scoring blade is facing outwards.
Release the blade clamping screw
Eject the medium duty utility blade using the black ejector pin,
replace the blade to the right of the clamping plate, push the
blade in as far as it will go and tighten the blade clamping
screw. Rotate the turret back to the cutting position. Replace the
guard ensuring it is locked closed.

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2.5 Changing the twin wheel cutter
Replacement wheels or cutters are available from Keencut or your distributor
Lock the cutting head at a convenient height using the white
nylon locking screw.
Hold the twin wheel cutter and its guard to prevent them from
falling and remove the screw with a 6mm Allen (hex) key. Slide
the cutter towards the top of the main body and lift out.

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3. Making your first cut
3.1 Cutting thick material 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 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 is used to make
the score/cut. This is done by pulling the black knob on the edge
of the spring spool down to face towards the user. To re-engage
the ratchet latch push the small black knob away so it points
upwards.

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3.2 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
material in the machine.
Turn the ratchet hold-off knob to disengage the ratchet.
Clamp the plastic to be scored in the machine, 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

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Remove the plastic from the machine and snap it by hand.

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3.3 Using the twin wheel cutter
The twin wheel cutter must be parked above the top level of the clamp when not in use otherwise the cutter will interfere
with the sightline strip if the clamp is operated.
The twin wheel cutter is mounted on the upper cutting head and is used for cutting rigid materials such as aluminium
composite panel and MDF up to 3mm (1/8”). 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 dependant upon daily use and the material

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

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4. Maintenance
4.1 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 or if a soft brush is used, work
slowly and do not allow particles to flick off the bristles.

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4.2 Lubrication
DO NOT USE OIL ON ANY PART OF THE MACHINE
The slideway can be cleaned and lubricated occasionally using a
silicone lubricant. Removing any excess with a cloth.
The multi cutter assembly may require dusting out periodically
do not lubricate or adjust without seeking further advice from
your distributor or Keencut.

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4.3 Adjusting the sliding bearings
Attach the balance weight (see The multi-tool cutter and the
counterbalance >) to the other cutting head, hold the cutter at
waist height and place a 2mm hexagon wrench on the top
adjustment screw.
Move the cutting head up and down and tighten the screw very
gradually until the cutting head does not fall under its own
weight.