TOOLMAN 1G-KE2-160 Cut-Off Machines Owner’s Manual

: June 5, 2024
: TOOLMAN

Owner’s Manual
Abrasive Cut-Off Machines

TOOLMAN 1G KE2 160 Cut Off Machines - fig

WARNING! READ ALL INSTRUCTIONS Always check the safety regulations applicable in your country to reduce the risk of fire, electric shock, and personal injury. Understand the following safety instructions before attempting to operate this product. Keep these instructions at a safe place.

SAVE THESE INSTRUCTIONS

Work Area

Keep your work area clean. Cluttered benches and dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks that may ignite dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to be lost control.

Electrical Safety

The grounded tool must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tool occurs electricity malfunction or breaks down, grounding provides a low resistance path to carry electricity away from the user.
Double insulated tools are equipped with polarized plug. This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plugin any way. Double insulation eliminates the need for the three-wire grounded power cord and grounded power supply systems.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.
Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
When operating a power tool outside, use an outdoor extension cord marked “W—A” or “w” These cords are rated for outdoor use and reduce the risk of electric shock.

Personal Safety

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tools while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating may cause personal injury.
Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. “Avoid accidental starting. Be sure the switch is off before plugging in. Carrying tools with your finger on that switch or plugging in tools that have the switch on leads to accidents.
Remove adjusting keys or switches before turning the tool
on. A wrench or a key that is left attached to a rotating part of the tool may result in a personal injury “Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enable better control of the tool in unexpected situations.
Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat or hearing protection must be used for appropriate conditions.

Tool Use and Care

Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
Do not use the tool if the switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired. ‘Disconnect the plug from the power source before making any adjustment, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally.
Accessories must be rated for at least the RPM of the grinder.
Store tools out of reach of children and other untrained persons when tools are not in use. Tools are dangerous in the hands of untrained users. “Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the tool serviced before using.

Many accidents are caused by poorly maintained tools.

Use only accessories that are recommended by the manufacturer for your model. Accessories that are suitable for one tool may not fit another, check the size and fitting prior use.

Service

Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. •When servicing a tool, use only identical replacement parts. Follow instructions in the maintenance section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury.

ADDITIONAL SAFETY RULES FOR CUT-OFF SAW

Use only abrasive wheels rated for at least 8800 RPM wheels rated below the tool speed can break apart and cause injury
Check new or replacement wheels before mounting replace a cracked wheel immediately.
Do not tighten the abrasive wheel excessively since this can cause cracks in the abrasive wheel.
Always use proper guard with an abrasive wheel. A guard protects the operator from broken wheel fragments. ‘Abrasive wheel must be securely attached as described in the
operation manual before connecting the tool to a power supply. ‘Never use the tool if its cover or any bolts are missing. If the cover or bolts have been removed, replace them prior to use. Maintain all parts in good working order. ‘Never start a tool when its rotating component is in contact with the work piece. Allow the machine to run at idle speed for one minute before applying for work.
Do not touch the abrasive wheel or workpiece immediately after operation.
Use this machine only for approved applications. Never use coolants or water, or use the abrasive wheel side as a grinder.

FUNCTIONAL DESCRIPTION

This abrasive cut-off saw is used for cutting steel bars, and angles. pipes. and similar metallic material. Use only the proper wheel made for this tool. DO NOT use any type of saw table.
Please refer to Figure I on page 1 to familiarize yourself with the major components of this tool before use.

Assembly

Check for damage to the tool, parts or accessories that may have occurred during transit. Take the time to thoroughly read and understand this manual prior to operation.
This package contains: – Abrasive cut-off saw

Abrasive cut-off wheel
Open-end wrench
Instruction manual

GROUNDING

This tool has a three-prong plug for proper grounding with a grounded outlet. If a temporary adapter is used to connect to a two-prong outlet, the green ground tab of the adapter(not included)must be connected to a permanent ground such as a properly grounded outlet box or grounding, call a qualified electrician. Do not modify the plug provided.
WARNING! This tool must be grounded while in use to protect the operator from electric shock. Improperly connecting the grounding wire can result in injury. Do not expose the tool to rain or use in damp locations.

EXTENSION CORDS

Use proper extension cords. Make sure your extension cords in good condition and is a 3-wire extension cord ground type plug and a 3-pole receptacle that will accept the tool’s plug. When using an extension cord, be sure to use one heavy enough to carry the current of the tool. An undersized cord will cause a drop in line voltage, resulting in loss of power and possible tool damage Please refer to Figure 2for the correct gauge extension cord to use depending on the cord length.

The total length of Gauge of extension cord in feet cord to use

0-25	18AWG
26 – 100	16AWG
101 – 150	14AWG

Figure 2
WARNING! Always wear safety glasses or eye shields when operating tools. Failure to do so could result in dust, shavings or loose particles being thrown into your
eyes.

OPERATION

Removing and Installing Abrasive Wheel
WARNING! Always unplug the tool before changing accessories or servicing your tool.

Move the depth stop and raise the handle to its maximum position.
Loosen wing nuts and pull back on the arbor cover located on the stationary wheel guard to expose the outer flange.
Press the straight (1#)wrench in the gutter (joint of the gear case and wheel guard) and hold, and use a curly(2#)wrench to loosen (counterclockwise) the outer flange.
Remove inner flange, outer flange, and abrasive wheel if installed.
Check the abrasive wheel for damage and replace if necessary.
Install the inner flange, abrasive wheel, outer flange as shown in
Figure 3.
Press in and hold the straight (1#) wrench, and the tight (clockwise) outer flange with the curly (2#) wrench.
Put the arbor cover back to its original position and hand-tighten wing nuts.

WARNING! Do not use the tool with the wheel guard removed, or use the tool as a grinder with the abrasive wheel exposed. Such usage may cause serious injury.
‘WARNING! Always wear safety glasses or eye shields when operating tools. Failure to do so could result in dust, shavings or loose particles being thrown into your eyes.
Use the chain to lock on the handle to hold the cut-off at the lowest position. easy storage. (Fig. 4-1) Make sure the tool is powered off when stored.

Power on Operation

When all adjustment has been made start the cut by

Press in Switch Lock with thumb and pull in Power Switch index finger.
Allow the motor to reach full speed.
Slowly lower the abrasive wheel into the workpiece.
NOTE: Always start the cut gently. Never bang or bump the abrasive wheel against the workpiece.
When the cut is complete, slowly raise the abrasive wheel completely from the workpiece before releasing the trigger.
Allow the motor to come to a complete stop before making another cut.

CAUTION! If any of the following events occurs during normal operation the power supply should be cut off at once and the tool thoroughly inspected by a qualified person and repaired if necessary:

The turning parts get stuck and speed drops abnormally low.
The tool shakes abnormally accompanied by some abnormal noise.
Heavy sparks occur around the motor area.

MAINTENACE

WARNING! Do not allow brake fluids, gasoline, petroleum-based products penetrating oils, etc. to come in contact with plastic parts. They contain chemicals that can damage, weaken or destroy the housing, thus compromising the integrity of the double insulation.
‘Ensure that the abrasive wheel is free of carracks and surface defects. Replace the abrasive wheel when if has been worn out.
The motor unit winding is the “heart” of the power tool. Check to ensure the winding does not become damaged and/or wet with oil or water.
‘Repairs should be done only by a qualified service technician using identical parts to ensure safe and effective use of this product.
Clean dust and debris from vents. Clogged vents can cause heat buildup due to insufficient airflow.
Under normal conditions, this tool has a sufficient supply of lubrication to ensure smooth running. When it is time to repair the carbon brushes, have the technology if necessary.
Do not open the motor housing for any reason. Electrical shock may occur that would cause serious bodily injury. Only have a qualified technician repair the tool.

Fence Placement

There are two possible positions for the fence (Fig.5) as determined by the bolt position. Install the fence according to your need and tighten bolts. The fence should be placed so that the center of the abrasive wheel (when lowered)is most aligned with the center of the workpiece.

Fence Angle Adjustment

For cutting at an angle, loosen both fence bolts and tighten after the fence is adjusted at the proper angle.

Quick Release Vise

Pull up on the quick release lever to allow free movement of the vise. Note: when the vise is closed tight, release the tension by turning the vise handle in a counter-clockwise direction before pulling up on the quick-release lever.
Move vise plate back to allow placement of workpiece
Position workpiece pushes vise plate against it.
Reposition quick release lever and turn the vise handle in a clockwise direction to tighten the vise.
To remove the workpiece, repeat steps 1 and 2 above.

ACCESSORIES

This cut-off saw comes with one abrasive wheel and two open-end wrenches. Extra wheels and wrenches can be purchased from your local dealers.
CAUTION! Use only abrasive wheels rated at least 8800 RPM or injury due to flying debris may result.
WARNING! Always unplug the tool before changing accessories or servicing your tools.