KEENCUT Big Bench Assembly Instructions Manual

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� ASSEMBLY INSTRUCTIONS

Thank you for choosing the Keencut Big Bench. Every effort has been made to bring you a superbly built product with the promise of many years of good service. Keencut – the world’s finest cutting machines

You should have;

Packed in the Rectangular Boxes: Short beam 4 6 8 10 Long beam 4 8 12 16 Leg 4 6 8 10 Joining Bracket 16 28 40 52 Grub Screw 48 84 120 156 Worktop Fixing 4 6 8 10 Long Screw 4 6 8 10 Height Adjuster 4 6 8 10 4mm Hexagon Wrench 1 1 1 1 Spacer 1 1 1 1 QUANTITY FOR BIG BENCH ITEM 1.0,1.5 2.0, 2.5, 3.0 3.5, 4.0, 4.5 5.0 Packed in the TUBE: Lift & Hold (Left & Right) (1,1) (1,1) (1,1) (1,1) Base Extrusion 1 1 1 1 Large Screw 6 6 6 6 Silicon Cord 1 1 1 1 Base Clamp 2 3 4 5 Cap Screw 2 3 4 5 Square Nut 2 3 4 5 Worktop Connector 2 4 6 8 Small Screw 2 4 6 8 5mm Hexagon Wrench 1 1 1 1 Levelling Bracket & Screw 2 4 6 8 QUANTITY FOR BIG BENCH ITEM 1.0,1.5 2.0, 2.5, 3.0 3.5, 4.0, 4.5 5.0

Order of Assembly

3 The Order of assembly is important – the following diagrams are for quick reference only and are to enable the reader to familiarise themselves with the general assembly of the Big bench, the detailed assembly is described in 4 stages. Stage 1 Fix the brackets to the legs. The 1.0m & 1.5m Big bench have only 4 legs, please disregard the middle pair of legs. x1 x1 x1 Stage 2 Construct the end frames. Disregard the middle frame if you are building a 1.0m or 1.5m Big bench. 2.0m, 2.5m & 3.0m Big bench x2 3.5m, 4.0m & 4.5m Big bench x3 5m Big bench x1 2.0m, 2.5m & 3.0m Big bench x2 3.5m, 4.0m & 4.5m Big bench x3 5m Big bench Stage 3 Join the end frames and cross beams to produce the bench. Middle legs Middle frame 1.0 & 1.5 Big bench 2.0, 2.5 & 3.0m Big bench 3.5, 4.0 & 4.5m Big bench 5m Big bench Stage 4 Attach the Javelin lift & hold mechanisms and base extrusion.

Put a grub screw backwards into each of the joining brackets – do not place screws in the

other holes. NOTE: The following instructions will assume the Big bench has six legs (2.0, 2.5 or 3.0). If you are constructing a (1.0 or 1.5) Big bench please omit the middle frame. ✗ ✗ ✗ ➤ a 2. Using the spacer, fit the brackets to the top of each leg as shown – ensure: a). The brackets are fitted the correct way round. b). The spacer is slightly above the top level of the leg, so when constructed the top level of the leg is not above the beam. c). The grub screws are tightened fully. 3. Attach brackets to the bottom of the legs (and the same way round as shown above), using a tape measure or spacer to position them to suit your requirements. a ✗ ✔ 3.1 Assembly 3.1

Fit the two short beams between

each pair of leg assemblies ensuring the small groove in the beam is uppermost. 2. Pulling the two legs together (to close any gaps between the end of the beam and the legs) tighten all the grub screws. Stage 3 1. Place one end frame on the floor with the brackets pointing upwards and position a long beam over each bracket (again ensure the small groove in the beam will be uppermost). 2. Place either: the other end frame (if you are constructing a 1.0m or 1.5m big bench) or The centre frame (if you are constructing a 2.0m, 2.5m or 3.0m Big bench) over the beams and tighten the grub screws ensuring there are no gaps between the beam ends and the legs. 3. 2.0m, 2.5m or 3.0m Big bench only Stand the frame onto its feet and position the remaining long beams between the frame and the remaining end frame, tighten all the grub screws again ensuring there are no gaps between the beam ends and the legs. TOP 3.2 Assembly 3.2 4. Put grub screws in each of the two large holes of the bracket, only screw them in 2 or 3 turns. 5. Fix the height adjusters into the bottom of each leg. Position the adjuster in one of the internal grooves of the leg (ie. the same groove the brackets are fitted). Position the bottom of the aluminium bracket level with the bottom of the leg and tighten the grub screw fully. TOP

Place the base extrusion on the edge of the

bench so the lip hangs over the front edge of the legs. Slide the square nuts into the recess as shown and place one near to each leg. Slide the workshop fixing plates into their groove and position them at approximately equal spaces along the base extrusion. 2. Using the 5mm hexagon wrench fix the base extrusion in place on the bench with the base clamps and cap screws. 3. Fix the lift & hold mechanisms to each end of the base extrusion with three self taping large screws on each end, do not at this stage tighten the screws fully. View from underneath SQUARE NUT WORKTOP FIXING PLATE

Stage 4 – cont’d

4. Fix the Worktop in place using a) The large workshop fixing and large screws as shown. b) the small screws to fix the worktop fixing plates. 5. Position the Javelin cutter onto the two lift & hold mechanisms by sliding the tongue into the slot inside the end caps of the Javelin. 6. Move the cutting head to one end of the Javelin and depress the blade, adjust the position of the lift & hold mechanism so the blade runs centrally in the slot on the base extrusion, tighten the three screws to fasten the lift & hold. Repeat for the other end. Move lift & hold to align blade in slot Position brackets approximately as shown NOTE: The friction knob on each mechanisms can be adjusted to hold the Javelin at any height which makes accurate lining up easier when in use. 7. Position the bench in place and using an accurate spirit level adjust the feet to ensure the top surface of the table is flat. If the table is not flat, particularly along it’s length, there may be difficulty in holding the workpiece in place along the full cut length. Plan View

If a thin film or paper is being cut check that the material can be gripped along the full length of the

bench. Pass a small piece of the material about 25cm (10") wide under the cutter and ensure it is held in place, carry this out along its full length. Should the cutter not grip adjacent to a bench leg, adjust the foot to slightly raise that part of the bench and test again. Should the paper not be gripped by the cutter bar between the legs, place a levelling bracket and screw in the beam on the underside of the base extrusion. Position it in the middle of the area that is not clamping and tighten the screw until the paper is clamped efficiently. Check the whole cutter bar is clamping, add more levelling brackets and adjust if necessary.