User manual RYOBI BTS10

OPERATOR'S MANUAL 10 in. TABLE SAW BTS10 Your table saw has been engineered and manufactured to Ryobi's high standard for dependability, ease of operation, and operator safety. When 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 product. SAVE THIS MANUAL FOR FUTURE REFERENCE TABLE OF CONTENTS n Introduction ..................................................................................................................................................................... 2 n General Safety Rules .................................................................................................................................................... 3-4 n Specific Safety Rules.................................................................................................................................................... 4-5 n Symbols........................................................................................................................................................................ 6-7 n Electrical .......................................................................................................................................................................... 8 n Glossary of Terms............................................................................................................................................................ 9 n Features.................................................................................................................................................................... 10-12 n Tools Needed................................................................................................................................................................. 13 n Loose Parts ................................................................................................................................................................... 14 n Assembly .................................................................................................................................................................. 15-17 n Operation.................................................................................................................................................................. 18-28 n Adjustments.............................................................................................................................................................. 28-29 n Maintenance .................................................................................................................................................................. 30 n Troubleshooting ............................................................................................................................................................. 31 n Parts Ordering / Service ................................................................................................................................................ 32 INTRODUCTION This tool has many features for making its use 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. 2 GENERAL SAFETY RULES WARNING: Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury. n SECURE WORK. Use clamps or a vise to hold work when practical. It's safer than using your hand and frees both hands to operate tool. n DON'T OVERREACH. Keep proper footing and balance at all times. n MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. n DISCONNECT TOOLS. When not in use, before servicing, or when changing attachments, blades, bits, cutters, etc., all tools should be disconnected. n AVOID ACCIDENTAL STARTING. Be sure switch is off when plugging in any tool. n USE RECOMMENDED ACCESSORIES. Consult the operator's manual for recommended accessories. The use of improper accessories may risk injury. n NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted. n 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 of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation. A guard or other part that is damaged must be properly repaired or replaced by an authorized service center to avoid risk of personal injury. n USE THE RIGHT DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of blade or cutter only. n NEVER LEAVE TOOL RUNNING UNATTENDED. TURN THE POWER OFF. Don't leave tool until it comes to a complete stop. n PROTECT YOUR LUNGS. Wear a face or dust mask if the cutting operation is dusty. n PROTECT YOUR HEARING. Wear hearing protection during extended periods of operation. n DO NOT ABUSE CORD. Never yank cord to disconnect from receptacle. Keep cord away from heat, oil, and sharp edges. n USE OUTDOOR EXTENSION CORDS. When tool is used outdoors, use only extension cords with approved ground connection that are intended for use outdoors and so marked. n ALWAYS KEEP THE BLADE GUARD AND SPREADER (SPLITTER) IN PLACE and in working order. n KEEP BLADES CLEAN, SHARP, AND WITH SUFFICIENT SET. Sharp blades minimize stalling and kickback. n KEEP HANDS AWAY FROM CUTTING AREA. Keep hands away from blades. Do not reach underneath 3 READ ALL INSTRUCTIONS n KNOW YOUR POWER TOOL. Read the operator's manual carefully. Learn the saw's applications and limitations as well as the specific potential hazards related to this tool. n GUARD AGAINST ELECTRICAL SHOCK BY PREVENTING BODY CONTACT WITH GROUNDED SURFACES. For example, pipes, radiators, ranges, refrigerator enclosures. n KEEP GUARDS IN PLACE and in good working order. n REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. n KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. DO NOT leave tools or pieces of wood on the saw while it is in operation. n DO NOT USE IN DANGEROUS ENVIRONMENTS. Do not use power tools in damp or wet locations or expose to rain. Keep the work area well lit. n KEEP CHILDREN AND VISITORS AWAY. All visitors should wear safety glasses and be kept a safe distance from work area. Do not let visitors contact tool or extension cord while operating. n MAKE WORKSHOP CHILDPROOF with padlocks and master switches, or by removing starter keys. n DON'T FORCE TOOL. It will do the job better and safer at the feed rate for which it was designed. n USE RIGHT TOOL. Don't force the tool or attachment to do a job it was not designed for. Don't use it for a purpose not intended. n USE THE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. Use only a cord heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A wire gauge size (A.W.G.) of at least 14 is recommended for an extension cord 25 feet or less in length. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord. n DRESS PROPERLY. Do not wear loose clothing, gloves, neckties, or jewelry. They can get caught and draw you into moving parts. Rubber gloves and nonskid footwear are recommended when working outdoors. Also wear protective hair covering to contain long hair. n ALWAYS WEAR SAFETY GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impactresistant lenses, they are NOT safety glasses. GENERAL SAFETY RULES work or around or over the blade while blade is rotating. Do not attempt to remove cut material when blade is moving. BLADE COASTS AFTER BEING TURNED OFF. NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal sparking of the motor could ignite fumes. INSPECT TOOL CORDS PERIODICALLY. If damaged, have repaired by a qualified service technician at an authorized service facility. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Repair or replace a damaged or worn cord immediately. Stay constantly aware of cord location and keep it well away from the rotating blade. INSPECT EXTENSION CORDS PERIODICALLY and replace if damaged. GROUND ALL TOOLS. If tool is equipped with threeprong plug, it should be plugged into a three-hole electrical receptacle. CHECK WITH A QUALIFIED ELECTRICIAN or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the tool is properly grounded. USE ONLY CORRECT ELECTRICAL DEVICES: 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug. DO NOT MODIFY the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician. KEEP TOOL DRY, CLEAN, AND FREE FROM OIL AND GREASE. Always use a clean cloth when cleaning. Never use brake fluids, gasoline, petroleum-based products, or any solvents to clean tool. STAY ALERT AND EXERCISE CONTROL. Watch what you are doing and use common sense. Do not operate tool when you are tired. Do not rush. DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switches replaced by an authorized service center. USE ONLY CORRECT BLADES. Do not use blades with incorrect size holes. Never use blade washers or blade bolts that are defective or incorrect. The maximum blade capacity of your saw is 10 in. (254 mm). BEFORE MAKING A CUT, BE SURE ALL ADJUSTMENTS ARE SECURE. BE SURE BLADE PATH IS FREE OF NAILS. Inspect for and remove all nails from lumber before cutting. NEVER TOUCH BLADE or other moving parts during use. NEVER START A TOOL WHEN ANY ROTATING COMPONENT IS IN CONTACT WITH THE WORKPIECE. DO NOT OPERATE A TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR ANY MEDICATION. WHEN SERVICING use only identical replacement parts. Use of any other parts may create a hazard or cause product damage. USE ONLY RECOMMENDED ACCESSORIES listed in this manual or addendums. Use of accessories that are not listed may cause the risk of personal injury. Instructions for safe use of accessories are included with the accessory. DOUBLE CHECK ALL SETUPS. Make sure blade is tight and not making contact with saw or workpiece before connecting to power supply. n n n n n n n n n n n n n n n n n n n n SPECIFIC SAFETY RULES n FIRMLY BOLT THE SAW TO A WORKBENCH OR LEG STAND at approximately hip height. n NEVER OPERATE THE SAW ON THE FLOOR. n GUARD AGAINST KICKBACK. Kickback occurs when the blade stalls rapidly and workpiece is driven back towards the operator. It can pull your hand into the blade resulting in serious personal injury. Stay out of blade path and turn switch off immediately if blade binds or stalls. n USE RIP FENCE. Always use a fence or straight edge guide when ripping. n SUPPORT LARGE PANELS. To minimize risk of blade pinching and kickback, always support large panels. n REMOVE ALL FENCES AND AUXILIARY TABLES before transporting saw. Failure to do so can result in an accident causing possible serious personal injury. n ALWAYS USE BLADE GUARD, SPREADER, AND ANTI-KICKBACK PAWLS on all "through-sawing" op4 erations. Through-sawing operations are those in which the blade cuts completely through the workpiece as in ripping or cross cutting. Keep the blade guard down, the anti-kickback pawls down, and the spreader in place over the blade. n ALWAYS SECURE WORK firmly against the rip fence or miter gauge. NEVER use the rip fence during the same operation as the miter gauge. n ALWAYS USE A PUSH STICK FOR RIPPING NARROW STOCK. A push stick is a device used to push a workpiece through the blade instead of using your hands. Size and shape can vary but the push stick must always be narrower than the workpiece to prevent the push stick from contacting the saw blade. When ripping narrow stock, always use a push stick, so your hand does not come close to the saw blade. Use a featherboard and push blocks for non-through cuts. SPECIFIC SAFETY RULES n NEVER perform any operation "freehand" which means using only your hands to support or guide the workpiece. Always use either the rip fence or miter fence to position and guide the work. n NEVER stand or have any part of your body in line with the path of the saw blade. n NEVER reach behind, over, or within three inches of the blade or cutter with either hand for any reason. n MOVE THE RIP FENCE out of the way when cross cutting. n DO NOT USE THE MITER GAUGE AND RIP FENCE during the same operation. n NEVER use rip fence as cutoff gauge when cross cutting. n NEVER attempt to free a stalled saw blade without first turning the saw OFF and disconnecting the saw from the power source. n PROVIDE ADEQUATE SUPPORT to the rear and sides of the saw table for wide or long work pieces. Use a sturdy "outrigger" support if a table extension more than 24 inches long is attached to the saw. n AVOID KICKBACKS (work thrown back toward you) by: a) Keeping blade sharp. b) Keeping rip fence parallel to the saw blade. c) Keeping spreader, anti-kickback pawls, and blade guard in place and operating. d) Not releasing the work before it is pushed all the way past the saw blade using a push stick. e) Not ripping work that is twisted or warped or does not have a straight edge to guide along the fence. n AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the cutting tool. n USE ONLY RECOMMENDED ACCESSORIES listed in this manual or addendums. Use of accessories that are not listed may cause the risk of personal injury. Instructions for safe use of accessories are included with the accessory. n MAKE SURE THE WORK AREA HAS AMPLE LIGHTING to see the work and that no obstructions will interfere with safe operation BEFORE performing any work using the table saw. n ALWAYS TURN OFF SAW before disconnecting it, to avoid accidental starting when reconnecting to power supply. n THIS TOOL should have the following markings: a) Wear eye protection. b) Use saw blade guard and spreader/riving knife for every operation for which it can be used, including all through sawing. c) Keep hands out of the line of saw blade. d) Use a push stick when required. e) Pay particular attention to instructions on reducing risk of kickback. f) Do not perform any operation freehand. g) Never reach around or over the saw blade. n SAVE THESE INSTRUCTIONS. Refer to them frequently and use to instruct other users. If you loan someone this tool, loan them these instructions also. 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. 5 SYMBOLS Some of the following symbols may be used on this tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer. SYMBOL V A Hz W min Volts Amperes Hertz Watt Minutes Alternating Current Direct Current no No Load Speed Class II Construction .../min Per Minute Wet Conditions Alert NAME Voltage Current Frequency (cycles per second) Power Time Type of current Type or a characteristic of current Rotational speed, at no load Double-insulated construction Revolutions, strokes, surface speed, orbits etc., per minute Do not expose to rain or use in damp locations. To reduce the risk of injury, user must read and understand operator's manual before using this product. Always wear safety goggles or safety glasses with side shields and a full face shield when operating this product. Precautions that involve your safety. Failure to keep your hands away from the blade will result in serious personal injury. Failure to keep your hands away from the blade will result in serious personal injury. Failure to keep your hands away from the blade will result in serious personal injury. Failure to keep your hands away from the blade will result in serious personal injury. To reduce the risk of injury or damage, avoid contact with any hot surface. 6 DESIGNATION/EXPLANATION Read The Operator's Manual Eye Protection Safety Alert No Hands Symbol No Hands Symbol No Hands Symbol No Hands Symbol Hot Surface SYMBOLS The following signal words and meanings are intended to explain the levels of risk associated with this product. SYMBOL SIGNAL MEANING Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. (Without Safety Alert Symbol) Indicates a situation that may result in property damage. DANGER: WARNING: CAUTION: CAUTION: SERVICE Servicing requires extreme care and knowledge and should be performed only by a qualified service technician. For service we suggest you return the product to the nearest AUTHORIZED SERVICE CENTER for repair. When servicing, use only identical replacement parts. WARNING: To avoid serious personal injury, do not attempt to use this product until you read thoroughly and understand completely the operator's manual. Save this operator's manual and review frequently for continuing safe operation and instructing others who may use this product. WARNING: The operation of any power tool can result in foreign objects being thrown into your eyes, which can result in severe eye damage. Before beginning power tool operation, always wear safety goggles, safety glasses with side shields, or a full face shield when needed. We recommend Wide Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always use eye protection which is marked to comply with ANSI Z87.1. SAVE THESE INSTRUCTIONS 7 ELECTRICAL EXTENSION CORDS Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug. When using a power tool at a considerable distance from the power source, use an extension cord heavy enough to carry the current that the tool will draw. An undersized extension cord will cause a drop in line voltage, resulting in a loss of power and causing the motor to overheat. Use the chart provided below to determine the minimum wire size required in an extension cord. Only round jacketed cords listed by Underwriter's Laboratories (UL) should be used. **Ampere rating (on tool data plate) SPEED AND WIRING The no-load speed of this tool is approximately 4,800 rpm. This speed is not constant and decreases under a load or with lower voltage. For voltage, the wiring in a shop is as important as the motor's horsepower rating. A line intended only for lights cannot properly carry a power tool motor. Wire that is heavy enough for a short distance will be too light for a greater distance. A line that can support one power tool may not be able to support two or three tools. GROUNDING INSTRUCTIONS 0-2.0 2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0 Cord Length 25' 50' 100' 16 16 16 16 16 16 Wire Size (A.W.G.) 16 16 14 16 14 12 14 14 10 14 12 -- In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician. Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded. Repair or replace a damaged or worn cord immediately. This tool is intended for use on a circuit that has an outlet like the one shown in figure 1. It also has a grounding pin like the one shown. **Used on 12 gauge - 20 amp circuit. NOTE: AWG = American Wire Gauge When working with the tool outdoors, use an extension cord that is designed for outside use. This is indicated by the letters "WA" on the cord's jacket. Before using an extension cord, inspect it for loose or exposed wires and cut or worn insulation. WARNING: Keep the extension cord clear of the working area. Position the cord so that it will not get caught on lumber, tools or other obstructions while you are working with a power tool. Failure to do so can result in serious personal injury. WARNING: Check extension cords before each use. If damaged replace immediately. Never use tool with a damaged cord since touching the damaged area could cause electrical shock resulting in serious injury. ELECTRICAL CONNECTION This tool is powered by a precision built electric motor. It should be connected to a power supply that is 120 volts, 60 Hz, AC only (normal household current). Do not operate this tool on direct current (DC). A substantial voltage drop will cause a loss of power and the motor will overheat. If the saw does not operate when plugged into an outlet, double check the power supply. GROUNDING PIN 120V GROUNDED OUTLET Fig. 1 8 GLOSSARY OF TERMS Anti-Kickback Pawls (radial arm and table saws) A device which, when properly installed and maintained, is designed to stop the workpiece from being kicked back toward the front of the saw during a ripping operation. Arbor The shaft on which a blade or cutting tool is mounted. Bevel Cut A cutting operation made with the blade at any angle other than 90° to the table surface. Chamfer A cut removing a wedge from a block so the end (or part of the end) is angled rather than at 90°. Compound Cut A cross cut made with both a miter and a bevel angle. Cross Cut A cutting or shaping operation made across the grain or the width of the workpiece. Cutterhead (planers and jointer planers) A rotating cutterhead with adjustable blades or knives. The blades or knives remove material from the workpiece. Dado Cut A non-through cut which produces a square-sided notch or trough in the workpiece (requires a special blade). Featherboard A device used to help control the workpiece by guiding it securely against the table or fence during any ripping operation. FPM or SPM Feet per minute (or strokes per minute), used in reference to blade movement. Freehand Performing a cut without the workpiece being guided by a fence, miter gauge, or other aids. Gum A sticky, sap-based residue from wood products. Heel Alignment of the blade to the fence. Kerf The material removed by the blade in a through cut or the slot produced by the blade in a non-through or partial cut. Kickback A hazard that can occur when the blade binds or stalls, throwing the workpiece back toward operator. Leading End The end of the workpiece pushed into the tool first. Miter Cut A cutting operation made with the workpiece at any angle to the blade other than 90°. Non-Through Cuts Any cutting operation where the blade does not extend completely through the thickness of the workpiece. Push Blocks (for jointer planers) Device used to feed the workpiece over the jointer planer cutterhead during any operation. This aid helps keep the operator's hands well away from the cutterhead. Push Blocks and Push Sticks (for table saws) Devices used to feed the workpiece through the saw blade during cutting operations. A push stick (not a push block) should be used for narrow ripping operations. These aids help keep the operator's hands well away from the blade. Pilot Hole (drill presses) A small hole drilled in a workpiece that serves as a guide for drilling large holes accurately. Resaw A cutting operation to reduce the thickness of the work-piece to make thinner pieces. Resin A sticky, sap-based substance that has hardened. Revolutions Per Minute (RPM) The number of turns completed by a spinning object in one minute. Ripping or Rip Cut A cutting operation along the length of the workpiece. Riving Knife/Spreader/Splitter (table saws) A metal piece, slightly thinner than the blade, which helps keep the kerf open and also helps to prevent kickback. Saw Blade Path The area over, under, behind, or in front of the blade. As it applies to the workpiece, that area which will be or has been cut by the blade. Set The distance that the tip of the saw blade tooth is bent (or set) outward from the face of the blade. Snipe (planers) Depression made at either end of a workpiece by cutter blades when the workpiece is not properly supported. Through Sawing Any cutting operation where the blade extends completely through the thickness of the workpiece. Throw-Back The throwing back of a workpiece usually caused by the workpiece being dropped into the blade or being placed inadvertently in contact with the blade. Workpiece or Material The item on which the operation is being done. Worktable Surface where the workpiece rests while performing a cutting, drilling, planing, or sanding operation. 9 FEATURES PRODUCT SPECIFICATIONS Blade Diameter..........................................................10 in. Blade Arbor ..............................................................5/8 in. Cutting Depth at 0°......................................................3 in. Cutting Depth at 45°............................................. 2-1/2 in. Table Size ...............................................25-3/4 in. x 16 in. Input ............................. 120 Volt, 60Hz, AC Only, 13 Amps No Load Speed .................................................4,800 RPM Net Weight............................................ 31.09 lbs. (14.1 kg) BLADE GUARD ASSEMBLY SPREADER BLADE TOOL STORAGE RIP FENCE ANTI-KICKBACK PAWLS FRONT RAIL MITER GAUGE BEVEL LOCKING LEVER BLADE ADJUSTING HANDLE HEIGHT ADJUSTING HANDWHEEL BEVEL INDICATOR SWITCH TRIGGER LOCK LOCKING LEVER Fig. 2 10 FEATURES KNOW YOUR TABLE SAW See Figure 2. Before attempting to use this product, familiarize yourself with all operating features and safety rules. BLADE - This saw comes with a 10 in, 24-tooth blade. The blade is adjusted with bevel adjusting handwheel on the front of the cabinet. Bevel angles are locked with a bevel lock lever below the front rail. OVERVIEW The upper portion of the blade projects up through the table, surrounded by an insert called the throat plate. The height of the blade is set with a height adjusting handwheel on the front of the cabinet. To cut wood at a bevel, the blade must be tilted using the height adjusting handwheel, the bevel lock lever, and the bevel indicator found on the front of the cabinet. Detailed instructions are provided in the Operation section of this manual for the basic cuts: rip cuts, cross cuts, miter cuts, bevel cuts, and compound cuts. This saw includes a rip fence and miter gauge with storage on the side of the cabinet for easy accessibility. The rip fence is used to position work that will be cut lengthwise (rip cuts). Push smaller pieces with a push block or push stick. A scale on the front of the saw table shows the distance between the rip fence and the blade. For cuts with the blade straight up and cutting across the grain (cross cuts or miter cuts), use the miter gauge to set the angle and push the wood into the blade. Use the miter gauge for a bevel cross cut (compound cut) and the rip fence for a bevel rip cut. The blade guard assembly includes a spreader which is a metal device directly behind and above the blade. It is used to help keep the cut wood from binding together and causing possible kickback. It is very important to use the spreader for all through-sawing operations. The anti-kickback pawls (also a part of the blade guard assembly) are toothed plates mounted on the spreader. Their teeth point away from the work in case the work should be thrown or pulled back toward the operator. Then the teeth dig into the wood to help prevent or reduce the possibility of kickback. ANTI-KICKBACK PAWLS - Kickback is a hazard in which the workpiece is thrown back toward the operator. The toothed pawls are designed to snag the workpiece to prevent or reduce injury should kickback occur. BEVEL SCALE - The easy-to-read scale on the front of the cabinet shows the exact blade angle. WARNING: Do not use blades rated less than the speed of this tool. Failure to heed this warning could result in personal injury. BLADE GUARD - Always keep the guard down over the blade for through-sawing cuts. BEVEL LOCKING LEVER - This lever, placed just under the worktable surface on the front of the cabinet, locks the angle setting of the blade. Be sure the lever is unlocked before tilting the blade. If it is not unlocked, it may jam and bend the locking bolt. HEIGHT ADJUSTING HANDWHEEL - Use this handwheel to set the angle of the blade for bevel cuts. It is located on the front of the cabinet. MITER GAUGE - This miter gauge aligns the wood for a cross cut. The easy-to-read indicator shows the exact angle for a miter cut. MITER GAUGE GROOVES - The miter gauge rides in these grooves on either side of the blade. RIP FENCE - A metal fence guides the workpiece and is secured with a locking lever. When the locking lever is in the locked position, it cannot be unlocked until the trigger lock is pulled. SCALE - Found on the front of the saw table, the easy-toread scale provides precise measurements in rip cuts. SPREADER - A metal piece, slightly thinner than the saw blade, which helps keep the kerf open and prevent kickback. SWITCH ASSEMBLY - The saw has an easy access power switch located below the front rail. The switch key must be inserted into the switch before the saw can be operated. To lock the switch in the OFF position, remove the switch key from the switch. Place the key in a location that is inaccessible to children and others not qualified to use the tool. 11 FEATURES BLADES For maximum performance, it is recommended that you use the 10 in., 24-tooth blade provided with your saw. Additional blade styles of the same high quality are available for specific operations such as ripping. Your local dealer can provide you with complete information. WARNING: ALWAYS make sure your workpiece is not in contact with the blade before operating the switch to start the tool. Failure to heed this warning may cause the workpiece to be kicked back toward the operator and result in serious personal injury. WARNING: Do not use blades rated less than the speed of this tool. Failure to heed this warning could result in personal injury. WARNING: To reduce the risk of accidental starting, ALWAYS make sure the switch is in the OFF position before plugging tool into the power source or resetting the overload reset button. WARNING: To prevent possible electrical hazards, have a qualified electrician check the line if you are not certain that it is properly wired. POWER SWITCH See Figure 3. Your table saw is equipped with a power switch that has a built-in locking feature. This feature is intended to prevent unauthorized and possible hazardous use by children and others. TO TURN YOUR SAW ON: n With the switch key inserted into the switch, lift the switch button to turn ON. TO TURN YOUR SAW OFF: n Press the switch button down to turn OFF. TO LOCK YOUR SAW: n With the saw turned OFF, pull the switch key from the switch and store in a safe, secure location. OVERLOAD RESET BUTTON SWITCH ON SWITCH OFF OVERLOAD RESET BUTTON See Figure 3. This saw features an overload reset button located to the right of the power switch. If your saw shuts off during operation, turn the saw off and allow the motor to cool down (approximately 3 minutes). Check all power cords for proper connection. Push the reset button then turn the saw on. NOTE: If the saw fails to start, contact an authorized service center. SWITCH KEY REMOVED Fig. 3 WARNING: In the event of a power failure or when the tool is not in use, turn the switch OFF and remove the switch key. This action will prevent the tool from accidentally starting when power returns. 12 TOOLS NEEDED The following tools (not included) are needed for assembly and making adjustments: WRENCH (2) 10 mm, 11 mm PHILLIPS SCREWDRIVER FLATHEAD SCREWDRIVER FRAMING SQUARE Fig. 4 13 LOOSE PARTS LIST 2 1 6 3 4 13 14 11 15 5 12 17 14 16 9 10 7 8 Fig. 5 Key No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description Qty. Blade Guard Assembly......................................................................................................................................1 Lock Nut ............................................................................................................................................................1 Blade Adjusting Handle.....................................................................................................................................1 Shoulder Bolt.....................................................................................................................................................1 Rip Fence .........................................................................................................................................................1 Flat Washer .......................................................................................................................................................1 Miter Gauge ......................................................................................................................................................1 Small Wrench ....................................................................................................................................................1 Large Wrench ....................................................................................................................................................1 Hex Key (5 mm) .................................................................................................................................................1 Flat Washer (1/4 in.)...........................................................................................................................................2 Internal Tooth Lock Washer (1/4 in.)..................................................................................................................1 Socket Head Bolt (1/4 - 20 x 2-1/4 in.) .............................................................................................................1 External Tooth Lock Washer (1/4 in.).................................................................................................................3 Mounting Bracket..............................................................................................................................................1 Socket Head Cap Screw ...................................................................................................................................2 Flat Washer .......................................................................................................................................................2 Operator's Manual (Not Shown) Warranty Registration Card (Not Shown) 14 ASSEMBLY UNPACKING This product requires assembly. n Carefully remove the tool and any accessories from the box. Place it on a level work surface. n Inspect the tool carefully to make sure no breakage or damage occurred during shipping. n Do not discard the packing material until you have carefully inspected the tool, identified all loose parts, and satisfactorily operated the tool. n If any parts are damaged or missing, please call 1-800525-2579 for assistance. MOUNTING HOLES The table saw must be mounted to a firm supporting surface such as a workbench or leg stand (not included). Four bolt holes have been provided in the saw's base for this purpose. Each of the four mounting holes should be bolted securely using 3/8 in. machine bolts, lock washers, and hex nuts (not included). Bolts should be of sufficient length to accommodate the saw base, lock washers, hex nuts, and the thickness of the workbench. Tighten all four bolts securely. Carefully check the workbench after mounting to make sure that no movement can occur during use. If any tipping, sliding, or walking is noted, secure the workbench to the floor before operating. WARNING: If any parts are missing do not operate this tool until the missing parts are replaced. Failure to do so could result in possible serious personal injury. TO INSTALL THE BLADE ADJUSTING HANDLE See Figure 6. The blade adjusting handle mounts to the height adjusting handwheel with a shoulder bolt, washer, and lock nut. n Insert the shoulder bolt in the center of the blade adjusting handle. Place the washer over the bolt and insert into the hole in the height adjusting handwheel. n Place the lock nut behind the height adjusting handwheel, and thread the lock nut onto the shoulder bolt. n Holding the nut in place, tighten with a screwdriver. WARNING: Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury. WARNING: Do not connect to power supply until assembly is complete. Failure to comply could result in accidental starting and possible serious personal injury. WARNING: Never stand directly in line with the blade or allow hands to come closer than 3 in. to the blade. Do not reach over or across the blade. Failure to heed this warning can result in serious personal injury. LOCK NUT WASHER SHOULDER BOLT BLADE ADJUSTING HANDLE Fig. 6 WARNING: To avoid serious personal injury, always make sure the table saw is securely mounted to a workbench or an approved leg stand. NEVER operate the saw on the floor. HEIGHT ADJUSTING HANDWHEEL 15 ASSEMBLY TO REMOVE/REPLACE THE THROAT PLATE See Figure 7. n Lower the blade by turning the height adjusting handwheel clockwise. n Loosen the screws in the throat plate. n Lift the throat plate and spacers from the saw. n To reinstall the throat plate, place the spacers of the holes and align the holes in the throat plate with the holes in the saw housing. n Retighten the screws, being careful not to overtighten, which can cause the throat plate to bow or bend. THROAT PLATE SPACER REMOVING THE THROAT PLATE SCREW SPACER TO CHECK SAW BLADE INSTALLATION See Figures 8 - 9. To check the saw blade: n Lower the blade by turning the height adjusting handwheel clockwise. n Remove the throat plate. n Push the bevel lock lever to the right to lock the blade angle in place. NOTE: If the bevel lock lever needs to be tightened further, pull the spring-loaded lever out and rotate it back to the left. Release the lever allowing it to seat itself then push it to the right until it is tightened securely. To loosen the blade: n Raise the blade to its full height by turning the height adjusting handwheel counterclockwise. n Place the open end of the large blade wrench on the flats on the arbor shaft and insert the smaller wrench over the hex nut. n Holding both wrenches firmly, pull the smaller wrench forward to the front of the machine to loosen the hex nut. To tighten the blade: n Raise the blade to its full height by turning the height adjusting handwheel counterclockwise. n Place the open end of the large blade wrench on the flats on the arbor shaft and insert the smaller wrench over the hex nut. n Holding both wrenches firmly, push the smaller wrench to the back of the machine. Make sure the hex nut is securely tightened. Do not overtighten. NOTE: Arbor shaft has right-hand threads. Check all clearances for free blade rotation. n Lower the blade by turning the height adjusting handwheel clockwise. n Reinstall the throat plate. HEX NUT TO LOOSEN INNER BLADE WASHER Fig. 9 SMALL WRENCH TO TIGHTEN ARBOR HEX NUT LARGE WRENCH SMALL WRENCH Fig. 7 Fig. 8 LARGE WRENCH 16 ASSEMBLY WARNING: It is important to install and adjust the blade guard assembly correctly. Poor alignment could cause kickback and throw the workpiece at the operator. If the spreader and saw blade are not in alignment, adjustment is needed. To adjust: n Unplug the saw then raise the blade guard assembly. n Loosen the socket head cap screws holding the blade guard assembly to the mounting bracket. n Reposition the blade guard assembly left or right as needed to align the spreader with the saw blade. n Once properly aligned, securely retighten the screws. SOCKET HEAD BOLT EXTERNAL TOOTH LOCK WASHER FLAT WASHER EXTERNAL TOOTH LOCK WASHER SOCKET HEAD CAP SCREWS INTERNAL TOOTH LOCK WASHER TO INSTALL BLADE GUARD ASSEMBLY See Figure 10. n Lower the blade by turning the height adjustment handwheel clockwise. n Feed an external tooth lock washer, flat washer, and internal tooth lock washer on the socket head bolt then slide the bolt and washers into the hole in the mounting bracket. n Slide the mounting bracket into the back of the saw over the rod and tighten the socket head bolt using the hex key provided. NOTE: Before tightening the bolt, be sure there is at least 1/8 in. between the blade and the spreader. n Securely tighten the bolt using the hex key provided. n Attach the blade guard assembly to the mounting bracket using the socket head cap screws, flat washers, and external tooth lock washers as shown in figure 10. The blade guard assembly must be aligned with the saw blade. See the following section for instructions. MOUNTING BRACKET BLADE GUARD ASSEMBLY TO CHECK AND ALIGN THE SAW BLADE AND BLADE GUARD ASSEMBLY See Figure 11. This saw has been adjusted at the factory and, unless damaged in shipping, should not require adjustments during assembly. After extensive use, it may need to be checked. If the blade guard assembly is out of alignment with the saw blade, adjust the alignment of the blade guard assembly. The spreader must be aligned with the saw blade. To check alignment of the spreader: n Raise the saw blade by turning the height adjusting handwheel counterclockwise. n Place a framing square or straight edge beside the saw blade on the left. Fig. 10 FRAMING SQUARE WARNING: Do not loosen the screws holding the spreader to the blade guard assembly. Unsecured pawls or riving knife could cause personal injury while making adjustments. HEIGHT ADJUSTING HANDWHEEL Fig. 11 17 OPERATION WARNING: Do not allow familiarity with tools to make you careless. Remember that a careless fraction of a second is sufficient to inflict serious injury. n n n n Not following correct operating procedures Misusing the saw Failing to use the anti-kickback pawls Cutting with a dull, gummed-up, or improperly set blade AVOIDING KICKBACK WARNING: Always wear safety goggles or safety glasses with side shields when operating power tools. Failure to do so could result in objects being thrown into your eyes resulting in possible serious injury. n Always use the correct blade depth setting. The top of the blade teeth should clear the workpiece by 1/8 in. to 1/4 in. n Inspect the work for knots or nails before beginning a cut. Knock out any loose knots with a hammer. Never saw into a loose knot or nail. n Always use the rip fence when rip cutting and the miter gauge when cross cutting. This helps prevent twisting the wood in the cut. Never use both for the same operation. n Always use clean, sharp, and properly-set blades. Never make cuts with dull blades. n To avoid pinching the blade, support the work properly before beginning a cut. n When making a cut, use steady, even pressure. Never force cuts. n Do not cut wet or warped lumber. n Always hold your workpiece firmly with both hands or with push sticks. Keep your body in a balanced position to be ready to resist kickback should it occur. Never stand directly in line with the blade. n Use the right type of blade for the cut being made. WARNING: Do not use any attachments or accessories not recommended by the manufacturer of this tool. The use of attachments or accessories not recommended can result in serious personal injury. APPLICATIONS You may use this tool for the purposes listed below: n Straight line cutting operations such as cross cutting, ripping, mitering, beveling, and compound cutting. n Cabinet making and woodworking. NOTE: This table saw is designed to cut wood and wood composition products only. BASIC OPERATION OF THE TABLE SAW The 3-prong plug must be plugged into a matching outlet that is properly installed and grounded according to all local codes and ordinances. Improper connection of the equipment can result in electric shock. Do not modify the plug if it will not fit the outlet. Have the correct outlet installed by a qualified electrician. Refer to the Electrical section of this manual. CUTTING AIDS See Figure 12. Push sticks are devices used for safely pushing a workpiece through the blade instead of using your hands. They can be made in various sizes and shapes from scrap wood to use in a specific project. The stick must be narrower than the workpiece, with a 90° notch in one end and shaping for a grip on the other end. A push block has a handle fastened by recessed screws from the underside. Use it on non-through cuts. CAUSES OF KICKBACK Kickback can occur when the blade stalls or binds, kicking the workpiece back toward you with great force and speed. If your hands are near the saw blade, they may be jerked loose from the workpiece and may contact the blade. Obviously, kickback can cause serious injury, and it is well worth using precautions to avoid the risks. Kickback can be caused by any action that pinches the blade in the wood, such as the following: n n n n n n n Making a cut with incorrect blade depth Sawing into knots or nails in the workpiece Twisting the wood while making a cut Failing to support work Forcing a cut Cutting warped or wet lumber Using the wrong blade for the type of cut 18 PUSH STICKS PUSH BLOCKS Fig. 12 OPERATION TYPES OF CUTS See Figure 13. There are six basic cuts: 1) the cross cut, 2) the rip cut, 3) the miter cut, 4) the bevel cross cut, 5) the bevel rip cut, and 6) the compound (bevel) miter cut. All other cuts are combinations of these basic six. Operating procedures for making each kind of cut are given later in this section. 1 CROSS CUT WARNING: Always make sure the blade guard and anti-kickback pawls are in place and working properly when making these cuts to avoid possible injury. Cross cuts are straight 90° cuts made across the grain of the workpiece. The wood is fed into the cut at a 90° angle to the blade, and the blade is vertical. Rip cuts are made with the grain of the wood. To avoid kickback while making a rip cut, make sure one side of the wood rides firmly against the rip fence. Miter cuts are made with the wood at any angle to the blade other than 90°. The blade is vertical. Miter cuts tend to "creep" during cutting. This can be controlled by holding the workpiece securely against the miter gauge. 2 RIP CUT 3 MITER CUT 4 WARNING: Always use a push stick with small pieces of wood, and also to finish the cut when ripping a long narrow piece of wood, to prevent your hands from getting close to the blade. Bevel cuts are made with an angled blade. Bevel cross cuts are across the wood grain, and bevel rip cuts are with the grain. The rip fence must always be on the right side of the blade for bevel rip cuts. Compound (or bevel) miter cuts are made with an angled blade on wood that is angled to the blade. Be thoroughly familiar with making cross cuts, rip cuts, bevel cuts, and miter cuts before trying a compound miter cut. BEVEL CROSS CUT 5 BEVEL RIP CUT 6 COMPOUND (BEVEL) MITER CUT Fig. 13 n Make sure the kerf is made on the waste side of the measuring line. n Cut the wood with the finish side up. n Knock out any loose knots with a hammer before making the cut. n Always provide proper support for the wood as it comes out of the saw. CUTTING TIPS Dado and rabbet cuts are non-through cuts which can be either rip cuts or cross cuts. Carefully read and understand all sections of this operator's manual before attempting any operation. WARNING: Do not use blades rated less than the speed of this tool. Failure to heed this warning could result in personal injury. n The kerf (the cut made by the blade in the wood) will be wider than the blade to avoid overheating or binding. Make allowance for the kerf when measuring wood. 19 OPERATION FEATHERBOARD A featherboard is a device used to help control the workpiece by guiding it securely against the table or rip fence. Featherboards are especially useful when ripping small workpieces and for completing non-through cuts. The end is angled, with a number of short kerfs to give a friction hold on the workpiece. Lock it in place on the table with a C-clamp. Test that it can resist kickback by restricting the forward motion of the workpiece. HOW TO MOUNT A FEATHERBOARD See Figure 15. Completely lower the saw blade. Position the rip fence to the desired adjustment for the cut to be performed and lock the rip fence. Place the workpiece against the fence and over the saw blade area. Adjust the featherboard to apply resistance to the workpiece just forward of the blade. Attach a C-clamp to secure the featherboard to the edge of the saw table. WARNING: Place the featherboard against the uncut portion of the workpiece, to avoid kickback that could cause serious personal injury. WARNING: Do not locate the featherboard to the rear of the workpiece. Kickback can result from the featherboard pinching the workpiece and binding the blade in the saw kerf if positioned improperly. Failure to heed this warning can result in serious personal injury. FEATHERBOARD PUSH STICK HOW TO MAKE A FEATHERBOARD See Figure 14. The featherboard is an excellent project for this saw. Select a solid piece of lumber approximately 3/4 in. thick, 3-5/8 in. wide and 18 in. long. Mark the center of the width on one end of the stock. Miter one-half of the width to 30° and miter the other half of the same end to 45°. See page 24 for information on miter cuts. Mark the board from the point at 6 in. Prepare the saw for ripping as discussed on page 24. Set the rip fence to allow approximately a 1/4 in. "finger" to be cut in the stock. Feed the stock only to the mark previously made at 6 in. Turn the saw OFF and allow the blade to completely stop rotating before removing the stock. Reset the rip fence and cut spaced rips into the workpiece to allow approximately 1/4 in. fingers and 1/8 in. spaces between the fingers. PUSH BLOCK "C" CLAMPS BEVEL LOCKING LEVER Fig. 15 30° 3-5/8 in. 1/4 in. 45° 3/4 in. 1/8 in. 18 in. 6 in. 1-13/16 in. Fig. 14 20