Kett KL-2040 User manual

SAFETY RULES
MODEL KL-2040
ELECTRIC SHEAR
The KL-2040 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 KL-2040 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
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 KL-2040 Shear is recommended for CR sheet steel up to 13 gage
Pre-starting procedure (Fig. 1)
Check all fasteners to make sure they are tight.
Check blades to make sure they are sharp.
Check that gap S (Fig. 2) between blades corresponds to thickness (K) of cut material.
Thickness (K) of cut
material, mm 0.5-0.8 0.9-1.3 1.4-1.8 2-2.5
Gauge 26-21 20-17 16-14 13
Gap, S,mm, approx. 0.1 0.2 0.3 0.4
Inches .004 .008 .012 .016
The gap is set at 0.4 mm (.016”) from the factory.
Switching on and off (Fig. 1)
Move the trigger (3) forward to turn the nibbler ON; moving the trigger back turns the nibbler OFF.
Red dot on housing (4) near the trigger (2) shows that switch is in ON position.
Test run
Perform a no-load test run of 10-15 seconds prior to starting cutting.
Working procedure (Fig. 1)
• With the shears ‘ON’, insert it into the cutting sheet between the moving blade (10) and stationary blade (11).
• Begin cutting by putting consistent pressure in the direction of the cut.
• When trimming off a narrow strip off the sheet, place shears so that strip is on the right side and the yoke (8) is down.
• The minimum cutting radius (R) for 13 gauge material is 10 inches. For thinner materials the curved cut can be made tighter.
• Don’t overload the tool when cutting – the temperature of the gear housing (1) and the front motor housing (4) should not exceed accordingly 108°F
and 90°F above ambient. The cooling holes should always be clean and un-obstructed.
Blades adjustment and replacement
To change the gap S (Fig.2) between blades (4):
• Move plunger (8, Fig 2) to the bottom stroke by manually rotating electric motor armature by the fan blades with the wooden or plastic stick through
the opening in the housing (1, Fig.1).
• Loosen up nut (5, Fig.2) by one revolution with an 8-mm wrench
• Loosen up screw (6, Fig. 2) by 1…2 revolutions with a flat screwdriver
• Loosen up screw (7, Fig. 2) by 1…2 revolutions with a 5-mm allen wrench (supplied)
• Place a corresponding to the material thickness adjustment gage (set of 4 gages supplied, see gap S chart above) between blades and tighten
screws (7), then screw (6) and then nut (5). Screw (7) should be very tight to prevent the bottom blade from moving during the cut.
If shears stopped cutting or cutting became difficult, check the blades cutting edges for excessive wear and rotate, if necessary:
• Loosen up nut (5), stop screw (6), then screws (1) and (7) by 1…2 revolutions.
• Turn the blades to a fresh cutting edge (each blade has 4 cutting edges).
• Tighten the screws and adjust gap S, following the above procedure.
• When all cutting edges are worn, it is necessary to replace the blades. Notice that the blades sides are slightly tapered (creating a clearance angle).
They should be placed with the smaller face down, tapering outside.
Maintenance
• Before performing any work, unplug the power cord.
• Any maintenance work should be performed by a qualified specialist.
• For safe and proper operation, always keep the tool and the ventilation slots clean.
• Periodically, depending on operation intensity, check the brushes and change them when their height is lower than 7.5 mm. (Don’t change the brush
position in brush holder).
• After installing brand new brushes, run the tool no-load for several minutes to allow pre-shaping the ends of the new brushes to to the commutator.

1-gear housing; 2-trigger; 3-electric motor; 4-front motor housing; 5-switch; 6-power cord;
7- shield; 8-yoke; 9-plunger; 10-moving blade; 11-stationary blade .
Fig.1
1- screw; 2- yoke; 3- nut; 4- blade; 5- nut; 6- screw;
7- screw; 8- plunger; 9- screw.
Fig. 2

THE KETT TOOL COMPANY 5055 Madison Road, Cincinnati, Ohio 45227
[phone] fax [phone] www.kett-tool.com
ITEM PART DESCRIPTION REQ’D
NO. NO. TOOL
1 L1012 Armature 1
2 L1011 Fields 1
3 L1044 Brush 2
4 872824 Power Cord 1
5 L1013 Gear Housing 1
6 L1004 Capacitor 1
7 L1003 Switch 1
8 L1000 Motor Housing, Rear 1
9 L1014 Diaphragm 1
10 L1009 Trigger 1
11 L1008 Lever 1
12 L1046 Insert 1
13 L1045 Brush Holder 2
14 L1050 Spring 2
15 L1018 Intermediate Disk 1
16 L1029 Disk 1
17 L1017 Seal 1
18 L1010 Motor Housing, Front 1
19 L1055 Screw 4
20 L1049 Screw 2
21 L1005 Screw 2
22 L1030 Screw 4
23 L1048 Screw 1
24 L1038 Screw 2
25 L1002 Cord Releif 1
26 L1064 Planet Carrier 1
27 L1027 Shaft 2
ITEM PART DESCRIPTION REQ’D
NO. NO. TOOL
28 L1020 Satellite 2
29 L1028 Washer 2
30 L1019 E-Ring 2
31 L1021 Ring Gear 1
32 L1031 Race 1
33 L1025 Washer 1
34 L1057 Washer 1
35 L1034 Nut 1
36 L1036 Yoke 1
37 L1037 Blade 2
38 L1035 Shield 1
39 L1033 Guide 1
40 L1032 Plunger 1
41 L1016 Bearing 1
42 L1007 Bearing 1
43 L1023 Bearing 2
44 L1022 Needle 40
45 L1024 Retaining Ring 1
46 L1054 Screw 2
47 L1051 Washer 2
48 L1052 Washer 2
49 L1053 Washer 2
50 L1041 Washer 1
51 L1039 Washer 3
52 L1040 Washer 1
53 L1043 Screw 1
54 L1042 Nut 1 K11-369
Model KL-2040
13 GAUGE THROATLESS SHEAR
COMPONENT PARTS LIST

The Kett Tool Company
5055 Madison Road
Cincinnati, Ohio 45247
[phone]
fax [phone]
www.kett-tool.com
[email protected]
K11-374