OPERATOR'S MANUAL WIDE TABLE KIT 4730301 FOR USE WITH RYOBI BT3100 AND RYOBI BT3100-1 TABLE SAW WIDE TABLE KIT SHOWN ATTACHED TO BT3100/BT3100-1 TABLE SAW LUMBER NOT INCLUDED WITH THIS KIT TABLE SAW AND STAND NOT INCLUDED WITH THIS KIT Your new Wide Table Kit has been engineered and manufactured to Ryobi's high standard for dependability, ease of operation, and operator safety. Properly cared for, it will give you years of rugged, trouble-free performance. WARNING: To reduce the risk of injury, the user must read and understand the operator's manual before using this product. Thank you for buying a Ryobi accessory kit. SAVE THIS MANUAL FOR FUTURE REFERENCE TABLE OF CONTENTS Introduction....................................................................................................................................................................... 2 Rules For Safe Operation ................................................................................................................................................. 2 Symbols............................................................................................................................................................................ 3 Unpacking......................................................................................................................................................................... 3 Loose Parts ...................................................................................................................................................................... 4 Tools Needed.................................................................................................................................................................... 4 Assembly .......................................................................................................................................................................5-8 Parts Ordering / Service ................................................................................................................................................... 9 INTRODUCTION This Wide Table Kit has many features for making the use of your table saw more pleasant and enjoyable. Safety, performance, and dependability have been given top priority in the design of this product making it easy to maintain and operate. WARNING: Do not attempt to use this product until you read thoroughly and understand completely the operator's manual. Pay close attention to the safety rules, including Dangers, Warnings, and Cautions. If you use your product properly and only as intended, you will enjoy years of safe, reliable service. WARNING: The operation of any tool can result in foreign objects being thrown into your eyes, which can result in severe eye damage. Before beginning operation, always wear safety goggles or safety glasses with side shields and a full face shield when needed. We recommend Wide Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always wear eye protection which is marked to comply with ANSI Z87.1. Look for this symbol to point out important safety precautions. It means attention!!! Your safety is involved. RULES FOR SAFE OPERATION Safe operation of this accessory requires that you read and understand this operator's manual, the operator's manual for the table saw and all labels affixed to the tool. BEFORE MAKING A CUT, BE SURE ALL ADJUSTMENTS ARE SECURE. SAVE THESE INSTRUCTIONS. Refer to them frequently and use them to instruct other users. If you loan someone this product, also loan these instructions. READ ALL INSTRUCTIONS KNOW YOUR ACCESSORY. Read the operator's manual carefully. Learn the product's applications and limitations as well as the specific potential hazards related to this product. KEEP THE WORK AREA CLEAN. Cluttered work areas and work benches invite accidents. DO NOT leave tools or pieces of wood on the saw while operating. ALWAYS WEAR SAFETY GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impactresistant lenses; they are NOT safety glasses. DO NOT USE THIS PRODUCT WITH OTHER EQUIPMENT or for other purposes. ALWAYS DISCONNECT THE SAW FROM THE POWER SUPPLY BEFORE ASSEMBLING THIS KIT. Make sure the switch is off when reconnecting the saw to a power supply. 2 WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: · lead from lead-based paints, · crystalline silica from bricks and cement and other masonry products, and · arsenic and chromium from chemically-treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. SYMBOLS The purpose of safety symbols is to attract your attention to possible dangers. The safety symbols, and the explanations with them, deserve your careful attention and understanding. The safety warnings do not by themselves eliminate any danger. The instructions or warnings they give are not substitutes for proper accident prevention measures. SYMBOL MEANING DANGER: Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices that may cause property damage. Note: Advises you of additional information concerning the operation or maintenance of the equipment. SAFETY AND INTERNATIONAL SYMBOLS This operator's manual describes safety and international symbols and pictographs that may appear on this product. Read the operator's manual for complete safety, assembly, operating and maintenance, and repair information. SYMBOL NAME Wet Condition Alert MEANING · Do not expose to rain or use in damp locations. No Hands Symbol · Failure to keep your hands away from the blade will result in serious personal injury. Read the Operator's Manual · To reduce the risk of injury, the user must read and understand the operator's manual before using this product. Eye Protection · Always wear safety goggles or safety glasses with side shields and a full face shield when operating this product. SAVE THESE INSTRUCTIONS UNPACKING Your new Wide Table Kit includes two 41 in. extension rails, plus the necessary brackets and connecting hardware required to make one wide support base and a rear extension table for your BT3100/BT3100-1 table saw. All you have to supply is the lumber required for table tops and table legs, plus the wood screws, nails, bolts, etc. required to secure the table legs to the table top. Remove the parts from the box. Make sure that all items listed in the loose parts list are included. 3 Inspect all parts carefully to make sure no breakage or damage occured during shipping. If any parts are damaged or missing, please call 1-800525-2579 for assistance. WARNING: If any parts are missing do not assemble the kit until the missing parts are replaced. Failure to do so could result in serious personal injury LOOSE PARTS Table Bracket.....................................................................8 Connector..........................................................................4 Front Extension Rail ..........................................................1 Square Head Bolt (1/4-20 x 1/2 in.)...................................4 Hex Nut (1/4-20)................................................................4 T-Nut................................................................................12 Washer (5/16 in.) .............................................................12 T-NUT HEX BOLT SQUARE HEAD BOLT WASHER HEX NUT HEX BOLT WASHER FRONT EXTENSION RAIL REAR EXTENSION RAIL Hex Bolt (5/16-18 x 1/2 in)...............................................10 Wood Screw (#10 x 5/8 in. Rd. Hd.) ................................16 Washer (1/4 in.) .................................................................4 Rear Extension Rail...........................................................1 Hex Bolt (5/16-18 x 5/8 in.)................................................2 Spacer ...............................................................................2 SPACER TABLE BRACKET CONNECTOR WOOD SCREW Fig. 1 TOOLS NEEDED #2 PHILLIPS SCREWDRIVER 1/2 IN. SOCKET 4 ASSEMBLY TO ATTACH FRONT EXTENSION RAIL See Figure 2 and 4. Remove end caps from right end of front rail on your BT3100/BT3100-1 table saw. See Figure 4. Slide one of the T-nuts into bottom channel of front rail on your saw. Slide a second T-nut into back channel of front rail. Attach one of the connectors provided to T-nut on bottom of front rail and secure with a washer (5/16 in.) and a hex bolt (5/16-18-x 1/2 in.). Finger tighten only. Orient front extension rail so that it matches front rail of your saw. Place two T-nuts in matching channels of front extension rail. Connect bottom T-nut to connector on front rail of your saw and secure with a washer (5/16 in.) and a hex bolt (5/16 in. x 1/2 in.). Finger tighten only. Attach a second connector to back channel of front rail and front extension rail. Secure it to each T-nut with a washer (5/16 in.) and hex bolt (5/16 in. x 1/2 in.). Finger tighten only. FRONT EXTENSION RAIL T-NUT CONNECTOR WASHER TABLE BRACKET HEX BOLT TO ATTACH REAR EXTENSION RAIL See Figure 3 and 5. The rear extension rail attaches to rear rail on your BT3100/ BT3100-1 table saw by repeating the above procedure for attaching front extension rail. The only difference being the rear rail has a different configuration. See Figure 3. NOTE: There are several repetitive steps required for assembling this kit. Please study and review illustrations closely for clarification when asked to repeat a procedure. After attaching rear rail extension to your saw you should now have the front and rear extension rails attached to your saw using four connectors, eight T-nuts, eight washers (5/16 in.), and eight hex bolts (5/16 in. x 1/2 in.). Using a 1/2 in. socket or the small wrench supplied with your table saw, tighten all eight bolts securely. Assure the two rail sets are straight before, during and after tightening. T-NUT CONNECTOR WASHER HEX BOLT FRONT RAILS SHOWN ATTACHED Fig. 2 REAR EXTENSION RAIL TABLE BRACKET SPACER REAR RAILS SHOWN ATTACHED Fig. 3 5 ASSEMBLY TO ATTACH TABLE BRACKETS Slide two T-nuts into channel on rear portion of front extension rail. See Figures 2 and 4. Attach two table brackets and secure with washers (5/16 in.) and hex bolts (5/16 in. x 1/2 in.) supplied. Hand tighten only. Slide two T-nuts into channel on front portion of rear extension rail. See Figures 3 and 5. Place a spacer between table brackets and T-nuts on rear extension rail as shown in figure 5. Secure table brackets and spacers with two washers (5/16 in.) and two hex bolts (5/16 in. x 5/8 in.) supplied. Hand tighten only. NOTE: These bolts are longer to accomodate spacers. Spacers are needed to provide clearance for the rip fence when sliding along extension rails. SPACER END CAP FRONT EXTENSION RAIL TABLE BRACKET T-NUT WASHER HEX BOLT Fig. 4 REAR EXTENSION RAIL AUXILIARY TABLE TOP (not supplied) We suggest you make the auxiliary table top from a piece of plywood cut 22 in. wide by 44 in. long by 3/4 in. thick. Space table brackets on each of the four corners so that they are approximately 6 in. from the ends of extension rails. See Figures 4 and 5. Place table top in desired position on table brackets and adjust table brackets as needed. NOTE: End of table top closest to saw will rest on lip of accessory table. See Figure 6. Tighten the four table bracket bolts securely. Slide rip fence the entire length of extension rails to make sure it will clear your new extension table. Make adjustments as needed for clearance and smooth operation of rip fence. Cut a piece of 2 x 4 approximately 19 in. long and secure to bottom of table top with wood screws. See Figure 8. NOTE: Use flat head wood screws (not included) if attaching this piece thru table top. Make sure these screw heads are below the surface of table top. We suggest you mount it from underneath table top if possible. This piece should also be located close to the end of your table top. We suggest that you turn it on its edge as shown in figure 8. NOTE: Table legs will be secured to this piece of wood. Reposition table top on table brackets and secure with wood screws (#10 x 5/8 in.) provided. See Figure 7. NOTE: These screws m ...