Kett KD-441 User manual

SAFETY RULES
MODEL KD-441
ELECTRIC SHEAR
The KD-441 has a
DOUBLE INSULATED
power unit equipped with a
2 wire cord and
2 prong plug

IMPORTANT SAFETY INSTRUCTIONS
Warning
When using electric tools basic safety precautions should always be followed to reduce the risk of fire, electric shock, and personal injury, including the
following:
Read all instructions.
Save these instructions.
For KD-441 and all double insulated tools:
When servicing, use only identical replacement parts.
SPECIFIC SAFETY RULES
Keep Work Area Clean
Cluttered areas and benches invite accidents. Keep work area well lit.
Avoid Dangerous Environment Don’t expose power tools to rain or snow. Don’t use power tools in damp or wet locations.
The symbol on the Caution Label is mean to convey this message. Ne pas exposer a la pluie et ne pas utiliser dans les emplacements humides.
Definitions of Symbols Underwriters Labratory
No - No load speed
/min - per minute
Double insulated motor
Guard Against Electric Shock
Prevent body contact with grounded surfaces, for example: pipes, radiators, ranges, refrigerator enclosures.
Keep Children Away
Do not let visitors contact tool or extension cord. All visitors should be kept away from work area.
Store Idle Tools
When not in use, tools should be stored in dry, high or locked-up place out of reach of children.
Don’t Force Tool
It will do the job better and safer at the rate for which it was designed.
Use Right Tool
Don’t force a small tool to do the job of a heavy duty tool. Don’t use tool for on purpose not intended, for example-don’t use a circular saw for cutting tree
limbs or logs.
Dress Properly
Do not wear loose clothing or jewelry. They can be caught in moving parts. Rubber gloves and footwear are recommended when working out doors.
Wear protective hair covering to contain long hair.
Use Safety Glasses
Use safety equipment. Always wear eye protecion.
Don’t Abuse Cord
Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat, oil, and sharp edges. Replace damaged cords immediately.
Secure Work
Use clamps or vise to hold work. It’s safer than using your hand and it frees both hands to operate tool.

Don’t Overreach.
Keep proper footing and balance at all times.
Maintain Tools with Care
Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing center blades and side knives. Inspect tool
cords periodically and if damaged, have repaired by authorized service facility. Inspect extension cords periodically and if damaged or replace. Keep
handles dry, clean, and be free from oil and grease.
Disconnect Tools
When not in use; before servicing; when changing Center Blades, Side Knives, Brushes, etc.
Remove Adjusting keys and Wrenches
Form Habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.
OPERATION
Avoid Accidental Starting
Don’t carry plugged-in tool with finger on switch. Be sure switch is OFF when plugging in. Use of any accessory with this power unit might increase the
hazard. The tool should be used only for the purpose for which it is designed.
Plug
THE POLARIZED PLUG IS A SAFETY FEATURE. This tool is equipped with a polarized two wire AC line plug. The two wire polarized plug (having one
blade wider than the other) will fit into the power outlet only one way. DO NOT DEFEAT THE SAFETY PURPOSE OF THE POLARIZED PLUG, by tam-
pering with it. If the plug does not fit you should still be unable to fully insert the plug into the socket, you may find that a proper outlet is needed to meet
today’s electrical standards.An electrician will replace your outlet safely.
Extension Cords
Always check the extension cord and repair or replace if damaged.
Outdoor Use Extension Cords
When tool is used outdoors, use only extension cords marked W-Aor W.
Stay Alert
Watch what you are doing, use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol or medi-
cation.
Check Damaged Parts
Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment if moving parts, binding or moving parts, breakage of parts, mounting, and any other conditions that may affect
its operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated
elsewhere in this instruction manual. Have defective switches replaced by authorized service center. Do not use tool if switch does not turn it on or off.
DO NOT OPERATE power tools in explosive atmospheres such as in the presence of flammable liquids, gases, or dust. Motors in these tools normally
spark and sparks can possibly ignite fumes.
Read all instruction.
Save these instructions.
FUNCTIONAL DESCRIPTION
Please read carefully all safety rules and operating instructions. The Model KD-441 Shear is recommended for CR sheet steel up to 24 gage. Secure
work piece. To start cut, place the material being cut in between the blades and ready it for the cut. Depress the trigger switch and guide shear into the
work. Do not force it. Avoid double thicknesses of material which exceed the 24 gage recommended capacity. If resistance to tool develops or cutting
becomes difficult, discontinue cutting and check the following: lubrication; thickness of material; sharpness of cutting blades.
Motor
Be sure your power supply agrees with nameplate marking. Use Alternating Current Only (50 to 60 Cycles), 120 volts. Voltage variation of more than
10% will cause loss of power and overheating. Motors are factory tested. If this shear does not operate, check the following: supply line for blown fuses;
plug and receptacle for contact. This tool will stop when the brushes wear to a preset length. Damage to the motor is thus avoided.

THE KETT TOOL COMPANY 5055 Madison Road, Cincinnati, Ohio 45227
[phone] fax [phone] www.kett-tool.com
Component Motor Unit Model 253-59
Used on KD-400, KD-480, KD-440, KD-441, KD-442, KD-1493 and KD-1495 Shears
KS-421, KS-423, KS-424, KS-426 and KSV-432 Saws
PARTS LIST
ITEM PART DESCRIPTION REQ’D
NO. NO. TOOL
1 382299-01 Armature & Fan (6 Teeth) 1
2 176883-00 Field 1
3 176846-02 Brush 2
5 176801-02 Left Brush Holder (gray) 1
6 176800-02 Right Brush Holder (black) 1
*7 176830-39 Switch 1
*7 621884-04 Switch 1
*8 330072-98 Cord & Plug (18-2SJ) 1
*9 176950-00 Ball Bearing 1
*10 176950-00 Ball Bearing 1
13 396969-09 Field Case 1
14 176899-02 Handle Cover 1
*15 176829-00 Cord Clamp 1
16 330005-01 Cord Protector 1
*17 330019-13 Screw 3
*18 176951-00 Screw 2
*19 389824-00 Cup 1
20 176811-01 Baffle 1
21 949638-02 Rubber Plug 2
*24 388657-00 Gear Case 1
*26 330003-09 Ball Bearing 1
27 388668-00 Spindle & Gear 1
*28 176650-00 Gear Case Cover 1
*29 23813-00 Fiber Washer 1
43 136086-02 Terminal 4
*45 330019-14 Screw 1
46 176655-00 Gasket 1
ITEM PART DESCRIPTION REQ’D
NO. NO. TOOL
*50 93128-00 Needle Bearing 2
*54 93129-00 Needle Bearing 1
55 176731-00 Pinion & Gear (15/37 teeth) 1
56 176732-00 Thrust Washer 3
57 143079-00 Thrust Washer 1
*58 330019-16 Screw 2
61 136086-08 Terminal 2
62 176860-00 Lead 1
65 449892-00 Washer 1
66 449368-00 Bearing Cap 1
*NOTES:
7 Use Switch 176830-39 for tools made before 11-25-2009 and 621884-04
on tools made after 11-25-2009.
8, 15 Cord clamp should be positioned, so that 30mm of cord jacket
extends above the clamp.
9 Seal to face commutator. Press to the tubing on armature shaft.
10 To remove from shaft, place bearing in vise and crush outer race.
Remove all internal bearing components, so that the inner race is all
that is left. Use SRT320, Small Bearing Separator, to clamp the inner
race and press off. Bearing presses to shoulder.
17,45,58 Torque to 18-23 inch-Ibs.
18 Torque to 13 inch-Ibs.
19 Small diameter end to face commutator. Lightly lubricate before
installing into field case.
26 Press Bearing until seated completely in pocket. Rubber seal to face
spindle and gear assembly.
28 Includes 10 and 50.
29 Press to bearing (item 10).
54 Press flush with surface facing spindle and gear assembly. K11-371

THE KETT TOOL COMPANY 5055 Madison Road, Cincinnati, Ohio 45227
[phone] fax [phone] www.kett-tool.com
INSTRUCTIONS FOR THE CARE OF
THE KETT 41-20 SHEAR HEAD
CAUTION
Disconnect Power Unit
Before Servicing Tool
PARTS LIST
41-21 Center Blade
40-23 Shear Housing
41-24 Eccentric Bearing Assembly
40-27 Spacer Bushing
92-28 Cap Screw (3)
92-31 Knurled Insert (3)
41-22 Side Knife
70-05 Side Spacer
60-25 Thin Washer, Large
60-27 Spacer Bushing
60-29 (150-4) Allen Wrench
DISASSEMBLY: To remove the shear head from the
motor loosen three cap screws (92-28). Remove shear
head from motor by pulling head firmly forward. Slight
tapping with a mallet may be required if head does not
slide off easily.
To remove cutter blades from shear head remove
three cap screws (92-28) from shear housing (40-23).
Be careful not to lose rear spacer bushing (60-27) when
removing the middle cap screw. Remove center blade
(41-21) from shear housing by tapping blade gently rear-
ward. Be careful not to lose spacer bushing (40-27) from
hole in center blade. Side knife (41-22) and side spacer
(70-05) will now drop out of the shear housing.
To remove eccentric bearing assembly (41-24)
from shaft use an appropriate wrench to loosen eccen-
tric nut by turning counter clockwise.
ASSEMBLY: To install eccentric bearing assembly (41-
24) onto shaft, make sure the large thin washer (60-25)
is first inserted over the shaft. Screw eccentric bear-
ing assembly on to shaft and tighten with appropriate
wrench. Lubricate bearing with a good grade of bearing
grease.
To install cutter blades into shear housing (40-
23) place the side knife (41-22) and side side spacer
(70-05) into position in the shear housing (40-23). Insert
center cap screw (92-28) through the 41-21 and 70-05
with rear spacer bushing (60-27) between them and
start cap screw into thread just enough to hold blades in
place. DO NOT TIGHTEN. Insert spacer bushing (40-
27) into hole in center blade (41-21) and lubricate with
Molybdenum Disulfide grease (264-2) or equivalent.
Install center blade into shear housing by tapping blade
gently forward using a drift to line up hole in center blade
with forward holes in housing. Insert and tighten forward
cap screw (92-28) making sure spacer bushing (40-27)
in center blade stays in position. Apply Molybdenum
Disulfide grease (264-2) or equivalent to clevis or yoke
in center blade where it rides on the eccentric bearing
assembly. Insert rear cap screw (92-28) into shear hous-
ing, but do not completely tighten.
To install shear head assembly onto drive motor
make sure all cap screws (92-28) are loosened about
three or four complete turns. Spread shear housing
(40-23) slightly using a spreader (drift) near the rear cap
screw (92-28). Place shear head onto unit, tap side knife
rearward as far as it will go, and tighten cap screws to
40-45 inch pounds. It may be necessary to gently tap
the shear head into place if it does not readily slip onto
the nose of the power unit.
WARNING: THE KETT TOOL CO. CANNOT ASSUME RESPONSIBLITY FOR DAMAGE TO OR
MALFUNCTION OF A KETT SHEAR HEAD USED IN COMBINATION WITH ANY DRILL OTHER
THAN THOSE REGULARLY SUPPLIED BY US.
40-61 Not Shown
Adapter (1 3/8”-20 LH thread) fits
253-58 power unit on KD-441 power
shear.

MAINTENANCE
When servicing, use only identical replacement parts. Tool may be cleaned and lubricated by the user, but any other servicing, including the changing of
carbon brushes, should be performed by the manufacturer or any authorized representative or service station.
Cable
The cable or cord is the “life line” of your tool. Keep it clean by wiping it off occasionally. Keep it out of oils and greases. Coil it neatly when not in use
and avoid dragging it across sharp surfaces or using it as a handle to lift the tool.
When using the tool at a considerable distance from power source, an extension cable of adequate size must be used to prevent loss of power and over-
heating.
For extension cables up to 75 feet use number 18; for 100 feet use number 16; and for up to 200 feet use number 14 wire gage. If you are working with
a 230 volt fool, cable lengths may be doubled using the same wire gage sizes as prescribed above for the 120 volt tool.
Lubrication
Always disconnect KD-441 Electric Shear from power source before lubricating.
Once every three months, depending upon usage, remove the shear Head from the power unit following the instructions given on the service sheet un-
der the heading “Disassembly-To remove the shear head assembly (41-20) from the drive motor.” Put a few drops of heavy oil on the Eccentric Bearing
Assembly (41-24), so that it saturates the needle bearing (41-24-2). Grease is even better if it can be forced or pressed into the needle bearing rollers.
The outside surface of the Eccentric Bearing Ring (41-24-3) should also be greased.
Tools that have seen continuous use should also have the gear train lubricated periodically, preferably at the same time the eccentric bearing assembly
is serviced. To lubricate the gears remove the screws that hold the gear case to the motor shell. Remove the gear case from the cover plate and wipe
out the old grease with a cloth. Wash the gears and spindles with kerosene or cleaning fluid. Refill the gear case ONLY 1/3 FULL with a good standard
gear grease. Never fill more than 1/3. The Ball bearing in the gear case is a closed type bearing. It has been permanently lubricated at the factory to last
the life of the bearing. This bearing should NEVER be immersed in a solvent or cleaning fluid.
Adherence to these maintenance instructions will greatly increase the life of your Model KD-441 Electric Shear, so it will give you long and satisfactory
service.
The Kett Tool Company
5055 Madison Road
Cincinnati, Ohio 45247
[phone]
fax [phone]
www.kett-tool.com
[email protected]
K11-392