Proxxon KG 50 User manual

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Manual
KG 50

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Fig. 2 Fig. 3

Operating instructions
Capping deviceKG 50
Dear customer!
Using these instructions
•makes it easier to get familiar withthe device
•prevents malfunctions caused by improper handling, and
•lengthens the service life of your device.
Please keep these instructions readily accessible at all times.
Usethe device only when you haveunderstood it exactly and
always adheretothe instructions.
PROXXON is not liable for the safe functioning of the device in
cases of:
•handling that does not conformtothe usualusage,
•purposes of use not designated in the instructions,
•disregard of the safety instructions.
You are not entitled to guarantee claims in cases of:
•operator errors,
•inadequate maintenance.
For your ownsafety,please follow the safety instructions exactly.
Use only genuine PROXXON replacement parts.
Wereservethe right to make improvements in the sense of tech-
nical progress.Wewishyou muchsuccess withthe device.
Contents:
1. Generalsafety instructions…………………………………8
2.Generalview (fig. 1) ………………………………………9
3.Description of the machine…………………………………9
3.1. Technical data………………………………………………9
4. Beforestarting work:……………………………………10
4.1. Installing or replacing the cutting blade …………………10
5. Working withthe capping device …………………………10
5.1. Ifyou want to make straight cuts (Fig 4a) ………………10
5.2.Ifyou want to make miter cuts (Fig 4b) …………………10
5.3.Severing aworkpiece ……………………………………10
5.4. Working withthe longitudinalstop (fig. 5) ………………10
5.5. This is how toset the limit stop …………………………11
6.Serviceand maintenance …………………………………11
6.1. Retightening or replacing the cogged belt (see Fig 7) ……11
7.EU conformity declaration ………………………………11
8. Spare-parts list……………………………………………44
9. Exploded view……………………………………………45
1. Generalsafety instructions
CAUTION!When using electricpower tools,the following safety
measures must be observed for protection from electricshock,
risk of injury, and fire hazards.
Make sureyou readall these instructions beforeusing the power
tool and keep the safety instructions in asafe place.
1. Working safely
-Keep your workareatidy
-Untidiness in the workarea canresult in accidents.
2.Take the environmental influences intoconsideration
-Do not exposethe power tools torain.
-Do not use power tools in moist or wet environments.
-Ensure good illumination of the workarea.
-Do not use power tools if afire- or explosion hazard exists.
3.Protect yourself from electricshock
-Prevent contact between your body and grounded parts
(e.g. pipes,radiators,electricranges, cooling appliances)
4. Keep other persons at adistance
-Do not let other people,especially children,touchthe power
tool or the cable. Keep them out of your workarea.
5. Storethe power tools safely
-Power tools not in useshould bestored in adry,high,or
closed place,out of the reach of children.
6.Do not overloadyour power tools
-You will workbetter and moresafely within the stated
power range.
7.Usethe right power tool for the job
-Do not usealow power machine for aheavy-duty job.
-Do not usethe power tool for any purpose for which it was
not intended. For instance,do not useaportable circular
saw tocut tree branches or logs.
8. Wear suitable clothing
-Do not wear looseclothing or jewelry.They could become
entangled in the moving parts.
-Skid-proof shoes arerecommended when working out-
doors.
-Ifyour hair is long,wear ahairnet.
9. Use personal protective gear
-Wear safety glasses
-Wear a breathing maskwhen performing dust-evolving
work.
10.Connect the dust-exhaust system
-Ifconnections for dust-suction and collection equipment
areavailable,make surethat these havebeen connected
and arebeing used correctly.
11. Do not usethe cable for any use other thanthe one it was
intended.
-Do not usethe cable to pull the plug from the receptacle.
Protect the cable from heat,oil, and sharp edges.
12.Securethe workpiece
-Useclamping fixtures or aviceto hold the workpiece in
place. This is safer than holding it in your hand.
13.Avoid abnormal posture
-Make sureyou haveafirmstanceand keep your balanceat
all times.
14. Maintain your tool withcare
-Keep cutting tools sharpand clean for safer and better work.
-Follow the instructions about lubrication and tool replacement.
-Checkthe power tool’s connection leadat regular intervals
and havethesereplaced by anauthorized specialist in case
of damage.
-Checkthe extension cords regularly and replacethem if
damaged.
8
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.
19. Be alert
- 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.
21. CAUTION!
- 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)
1. Cutting head
2. Cutting disk cover
3. Blocking lever
4. Cutting disk
5. Device foot
6. Setscrew
7. Rotary plate
8. Stop screw
9. Spindle for clamping device
10. Limit stop
11. Clamping device
12. Scale
13. Fixing bore
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!
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4. 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
for flat washer 5.
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
10

the 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
DIN EN 55014-2 / 08.2002
DIN EN 61000-3-2 / 12.2001
DIN EN 61000-3-3 / 05.2002
EU machine directive 98/37/EEC
Applicable standards: DIN EN 61029 / 12.2003
Date: 12.11.04
Jörg Wagner
PROXXON S.A.
Device safety division
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Spare Parts List
PROXXON KG 50
ET - Nr.: Description ET - Nr.: Description
27150 - 01 Device Base
27150 - 02 Rotary table
27150 - 03 Spindle
27150 - 04 Clamp
27150 - 05 Clamping screw
27150 - 06 Nut
27150 - 07 Rod (long)
27150 - 08 Connector
27150 - 09 Rod (short)
27150 - 10 Grub screw
27150 - 11 Upper housing shell
27150 - 12 Screw
27150 - 13 Cut-off wheel cover
27150 - 14 Cover for switch
27150 - 15 On-Off switch
27150 - 16 Stopper
27150 - 17 Cover for belt drive
27150 - 18 Screw
27150 - 19 Toothed belt
27150 - 20 Screw
27150 - 21 Strain relief bracket
27150 - 22 Lower housing shell
27150 - 23 Shaft pulley
27150 - 24 Shaft
27150 - 25 Ball bearing
27150 - 26 Bushing
27150 - 27 Washer
27150 - 28 Washer
27150 - 29 Screw
27150 - 30 Leg spring
27150 - 31 Locking lever
27150 - 32 Bushing
27150 - 33 Washer
27150 - 34 Screw
27150 - 35 Engine
27150 - 36 Motor pulley
27150 - 37 Washer
27150 - 38 Screw
27150 - 39 Axle
27150 - 40 Leg spring
27150 - 41 Bracket
27150 - 42 Plate
27150 - 43 Clamping screw
27150 - 44 Allen key
27150 - 45 Rubber piece
27150 - 46 Grommet
27150 - 47 Power cable
27150 - 48 Grub screw
27150 - 49 Nameplate
27150 - 99 Instructions included
safety notices

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