User manual RYOBI BTS15

OPERATOR'S MANUAL 10 in. (254 mm) TABLE SAW BTS15 Your new Table Saw has been engineered and manufactured to Ryobi's high standards 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 Table Saw. SAVE THIS MANUAL FOR FUTURE REFERENCE TABLE OF CONTENTS Rules for Safe Operation ........................................ 3-6 Electrical ..................................................................... 7 Glossary of Terms ...................................................... 8 Unpacking and Tools Needed ................................... 9 Loose Parts List .................................................. 10-11 Features ............................................................... 12-14 Operating Components .............................................. 13 Power Switch ............................................................. 13 To Turn Your Saw On ................................................ 13 To Turn Your Saw Off ................................................ 13 To Lock Your Saw ...................................................... 13 Blades ........................................................................ 14 Product Specifications ................................................ 14 Assembly ............................................................. 15-17 Assembling Leg Stand ............................................... 15 Assembling Storage Brackets .................................... 15 To Install Rip Fence ................................................... 16 To Install Miter Table .................................................. 16 To Lock Miter Fence .................................................. 16 Blade and Guard Assembly To Check Saw Blade Installation ........................... 17 To Install Blade Guard Assembly .......................... 17 Operation ............................................................. 18-26 Basic Operation .......................................................... 18 Causes of Kickback and Avoiding Kickback .............. 18 Cutting Aids ................................................................ 18 Featherboard How to Make a Featherboard ................................ 19 How to Mount a Featherboard ............................... 19 Types of Cuts ............................................................. 20 To Adjust the Blade Depth ......................................... 21 To Adjust the Blade Angle .......................................... 21 To Set the Scale to the Blade .................................... 21 To Use the Outfeed Support ...................................... 22 To Use the Solid Table Extension .............................. 22 Making Cuts .......................................................... 21-26 To Make a Cross Cut ............................................ 22 To Make a Miter Cut .............................................. 23 To Make a Straight Rip Cut ................................... 23 To Make a Bevel Cross Cut .................................. 24 To Make a Bevel Rip Cut ...................................... 24 To Make a Compound Miter Cut ........................... 25 To Make Non-Through Cuts .................................. 25 To Make Dado Cuts .............................................. 26 Adjustments ........................................................ 27-34 Removing/Replacing the Throat Plate ....................... 27 To Check the Alignment of the Rip Fence to the Blade ........................................................... 27 To Remove the Blade ................................................ 28 Aligning Spreader with the Blade ............................... 29 To Set Blade at 0° or 45° ............................................. 30 To Adjust Sliding Miter Table Assembly ................ 31-34 Maintenance ............................................................. 35 General Maintenance ................................................. 35 Lubrication .................................................................. 35 Tilt/Elevating Mechanism ........................................... 35 Blade and Blade Wrench Storage .............................. 35 Miter Fence and Rip Fence Storage .......................... 35 Troubleshooting ....................................................... 36 Parts Ordering / Service .......................................... 38 Page 2 RULES FOR SAFE OPERATION 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 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 information or instructions vital to the operation or maintenance of the equipment. IMPORTANT Servicing requires extreme care and knowledge and should be performed only by a qualified service technician. For service we suggest you return the tool to your nearest Ryobi AUTHORIZED SERVICE CENTER for repair. When servicing, use only identical Ryobi replacement parts. WARNING: Do not attempt to use the tool 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 this tool properly and only for what it is intended, you will enjoy years of safe, reliable service. WARNING: Observe all normal safety precautions related to avoiding electrical shock. 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 tool 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. Page 3 RULES FOR SAFE OPERATION Safe operation of this power tool requires that you read and understand this operator's manual and all labels affixed to the tool. Safety is a combination of common sense, staying alert, and knowing how your table saw works. 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. DON'T OVERREACH. Keep proper footing and balance at all times. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. DISCONNECT TOOLS. When not in use, before servicing, or when changing attachments, blades, bits, cutters, etc., all tools should be disconnected. AVOID ACCIDENTAL STARTING. Be sure switch is off when plugging in. USE RECOMMENDED ACCESSORIES. The use of improper accessories may cause risk of injury. NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted. 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. USE THE RIGHT DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of blade or cutter only. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don't leave tool until it comes to a complete stop. PROTECT YOUR LUNGS. Wear a face or dust mask if the cutting operation is dusty. PROTECT YOUR HEARING. Wear hearing protection during extended periods of operation. DON'T ABUSE CORD. Never yank cord to disconnect from receptacle. Keep cord from heat, oil, and sharp edges. 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. ALWAYS KEEP THE BLADE GUARD AND SPREADER (SPLITTER) IN PLACE and in working order. KEEP BLADES CLEAN AND SHARP. Sharp blades minimize stalling and kickback. KEEP HANDS AWAY FROM CUTTING AREA. Keep hands away from blades. Do not reach underneath work or around or over the blade while blade is rotating. Do not attempt to remove cut material when blade is moving. READ ALL INSTRUCTIONS 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. GUARD AGAINST ELECTRICAL SHOCK BY PREVENTING BODY CONTACT WITH GROUNDED SURFACES. For example; pipes, radiators, ranges, refrigerator enclosures. KEEP GUARDS IN PLACE and in working order. Never operate the tool with any guard or cover removed. Make sure all guards are operating properly before each use. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. 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. AVOID DANGEROUS ENVIRONMENT. Don't use power tools in damp or wet locations or expose to rain. Keep work area well lit. 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. MAKE WORKSHOP CHILDPROOF with padlocks or master switches, or by removing starter keys. DON'T FORCE TOOL. It will do the job better and safer at the feed rate for which it was designed. USE RIGHT TOOL. Don't force tool or attachment to do a job it was not designed for. Don't use it for a purpose not intended. MAKE SURE YOUR EXTENSION CORD IS IN GOOD CONDITION. When using an extension cord, be sure to use one 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 gage 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 gage. The smaller the gage number, the heavier the cord. 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. ALWAYS WEAR SAFETY GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impactresistant lenses; they are NOT safety glasses. Page 4 RULES FOR SAFE OPERATION BLADES COAST AFTER TURN 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. 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. 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. USE RIP FENCE. Always use a fence or straight edge guide when ripping. SUPPORT LARGE PANELS. To minimize risk of blade pinching and kickback, always support large panels. BEFORE MAKING A CUT, ADJUSTMENTS ARE SECURE. BE SURE ALL WHEN SERVICING use only identical Ryobi replacement parts. Use of any other parts may create a hazard or cause product damage. REMOVE ALL FENCES AND AUXILIARY TABLES before transporting saw. Failure to do so can result in an accident causing possible serious personal injury. ALWAYS USE BLADE GUARD, SPREADER, AND ANTI-KICKBACK PAWLS on all "through-sawing" operations. Through-sawing operations are those in which the blade cuts completely through the workpiece as in ripping or crosscutting. Keep the blade guard down, the anti-kickback pawls down, and the spreader in place over the blade. ALWAYS SECURE WORK firmly against rip fence or miter fence. 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. 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. NEVER stand or have any part of your body in line with the path of the saw blade. NEVER reach behind, over, or within three inches of the blade or cutter with either hand for any reason. MOVE THE RIP FENCE out of the way when crosscutting. NEVER use rip fence as cutoff gage when crosscutting. NEVER attempt to free a stalled saw blade without first turning the saw OFF and disconnecting the saw from the power source. PROVIDE ADEQUATE SUPPORT to the rear and sides of the saw table for wide or long workpieces. Use a sturdy "outrigger" support if a table extension more than 24 inches long is attached to the saw. 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. AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the cutting tool. USE ONLY CORRECT BLADES. Do not use blades with incorrect size holes. Never use blade washers or bolts that are defective or incorrect. The maximum blade capacity of your saw is 10 in. (254 mm). AVOID CUTTING 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 THIS TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR ANY MEDICATION. GROUND ALL TOOLS. If tool is equipped with threeprong plug, it should be plugged into a three-hole electrical receptacle. Page 5 RULES FOR SAFE OPERATION 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. DO NOT MODIFY the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician. USE ONLY RECOMMENDED ACCESSORIES listed in this manual or addendums. Blades must be rated for at least 5,500 rpm. 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. 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. ALWAYS TURN OFF SAW before disconnecting it, to avoid accidental starting when reconnecting to power supply. 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. 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 · 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. SAVE THESE INSTRUCTIONS Page 6 ELECTRICAL DOUBLE INSULATION Double insulation is a concept in safety in electric power tools, which eliminates the need for the usual three-wire grounded power cord. All exposed metal parts are isolated from the internal metal motor components with protecting insulation. Double insulated tools do not need to be grounded. EXTENSION CORDS When using a power tool at a considerable distance from a power source, be sure to use an extension cord that has the capacity to handle the current the tool will draw. An undersized cord will cause a drop in line voltage, resulting in overheating and loss of power. Use the chart to determine the minimum wire size required in an extension cord. Only round jacketed cords listed by Underwriter's Laboratories (UL) should be used. When working outdoors with a tool, use an extension cord that is designed for outside use. This type of cord is designated with "WA" on the cord's jacket. Before using any extension cord, inspect it for loose or exposed wires and cut or worn insulation. **Ampere rating (on tool faceplate) 0-2.0 2.1-3.4 3.5-5.0 5.1-7.0 7.1-12.0 12.1-16.0 WARNING: The double insulated system is intended to protect the user from shock resulting from a break in the tool's internal insulation. Observe all normal safety precautions to avoid electrical shock. Important: Servicing of a tool with double insulation requires extreme care and knowledge of the system and should be performed only by a qualified service technician. For service, we suggest you return the tool to your nearest authorized service center for repair. Always use original factory replacement parts when servicing. Cord Length 25' 50' 100' 16 16 16 Wire Size (A.W.G.) 16 16 16 16 16 14 16 14 12 14 14 10 14 12 -- ELECTRICAL CONNECTION The saw has 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 your tool does not operate when plugged into an outlet, double-check the power supply. **Used on 12 gauge - 20 amp circuit. CAUTION: 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. Page 7 GLOSSARY OF TERMS Anti-Kickback Pawls (Fingers) 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 an angled blade. Compound Cut A cut with both a miter angle and a bevel angle. Crosscut A cutting or shaping operation made across the grain of the workpiece. Dado A non-through cut which produces a square sided notch or trough in the workpiece. Featherboard A device used to help control the workpiece by guiding it securely against the table or fence during any rip cut operation. Freehand Performing a cut without using a fence, miter gauge, fixture, hold down clamp, or other proper device to keep the workpiece from twisting during the cut. Gum A sticky, sap based residue from wood products. Heel Misalignment of the blade. Kerf The amount of material removed by the blade in a through cut or the slot produced by the blade in a non-through or partial cut. Kickback An uncontrolled grabbing and throwing of the workpiece back toward the front of the saw. Associated with the workpiece closing the kerf and pinching the blade or otherwise placing tension on the blade. Leading End The end of the workpiece which, during a rip type operation, is pushed into the cutting tool first. Miter Cut A cutting operation made with the wood at any angle other than 90 degrees. Molding A cut which produces a special shape in the workpiece, used for joining or decoration. Non-Through Cuts Any cutting operation where the blade does not extend completely through the thickness of the workpiece. Push Block A device used to feed the workpiece through the saw, except during narrow ripping type operations where a push stick should be used. It also helps keep the operator's hands well away from the blade. Push Stick A device used to feed the workpiece through the saw to help keep the operator's hands well away from the blade. Rabbet A notch in the edge of a workpiece. Resin A sticky, sap base substance that has hardened. Ripping Or Rip Cut A cutting or shaping operation made along the length or with the grain of the workpiece. Riving Knife/Spreader/Splitter A metal piece, slightly thinner than the saw blade which helps keep the kerf open and prevent kickback. Revolutions Per Minute (RPM) The number of turns completed by a spinning object in one minute. 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. Throw-Back Throwing of a workpiece in a manner similar to a kickback. Usually associated with a cause other than the kerf closing, such as a workpiece being dropped onto the blade or being placed inadvertently in contact with the blade. Through Sawing Any cutting operation where the blade extends completely through the thickness of the workpiece. Trailing End The workpiece end last cut by the blade in a ripping operation. Workpiece The item on which the cutting operation is being done. The surfaces of a workpiece are commonly referred to as faces, ends, and edges. Page 8 UNPACKING Your Model BTS15 Table Saw is shipped complete in one carton and includes a rip fence, a miter fence, and a blade guard. Separate all parts from packing materials and check each one with the illustration and the list of Loose Parts to make sure all items are accounted for before discarding any packing material. Important: Remove the foam block from between the saw's housing and the motor. If any parts are missing, do not attempt to assemble the table saw, plug in the power cord, or turn the switch on until the missing parts are obtained and are installed correctly. Call 1-800-525-2579 for assistance if any parts are missing or damaged. The saw is factory set for accurate cutting. After assembling it, check for accuracy. If shipping has influenced the settings, refer to specific procedures explained in the operation and maintenance sections of this manual. 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. TOOLS NEEDED 1/2 in. WRENCH #2 PHILLIPS SCREWDRIVER FRAMING SQUARE SOCKET WRENCH WITH 7/16 in. SOCKET ADJUSTABLE WRENCH Fig. 1 Page 9 LOOSE PARTS LIST 2 1 7 3 4 6 8 9 5 10 Fig. 2 Key No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Qty. Miter Fence ...................................................................................................................................................... 1 Blade Guard Assembly .................................................................................................................................... 1 Small Wrench ................................................................................................................................................... 1 Large Wrench ................................................................................................................................................... 1 Solid Table Extension ...................................................................................................................................... 1 Rip Fence ......................................................................................................................................................... 1 Sliding Miter Table ........................................................................................................................................... 1 Blade Adjusting Handle .................................................................................................................................... 1 Flat Washer ...................................................................................................................................................... 1 Phillips Screw ................................................................................................................................................... 1 Operator's Manual (Not Shown) Warranty Registration Card (Not Shown) Page 10 LOOSE PARTS LIST The following items are included with your table saw leg stand. L 0 I M D D J K B H A Q D D D H I G H M H D C D N G N C Q G H G N P E E P F Fig. 3 A. Storage Bracket ......................................................... 2 B. Screw (1/4-20 x 1/2 in. Pan Hd.) ................................ 2 C. Lower Side Brace ....................................................... 2 D. Hex Nut (5/16-18) .................................................... 28 E. Washer (5/16 in.) ........................................................ 2 F. Leveling Foot ............................................................. 1 G. Leg ............................................................................. 4 H. Carriage Bolt (5/16-18 x 3/4 in.) .............................. 24 I. Upper Brace ............................................................... 2 J. Hex Nut (1/4-20) ......................................................... 2 K. Washer (1/4 in.) ........................................................... 2 L. Bolt (5/16-18 x 2 in. Hex Hd.) ..................................... 4 M. Upper Side Brace ........................................................ 2 N. Foot ............................................................................. 3 O. Washers ...................................................................... 4 P. Hex Nut ....................................................................... 2 Q. Lower Brace ................................................................ 2 Page 11 FEATURES Your saw is designed to perform as a versatile, accurate, precision cutting tool that is easy to operate. It is equipped with the following features for convenience, ease of use, and high-quality performance: · a combination saw blade · a bevel indicator to set the exact angle of the blade, with locking lever · an adjustable sliding miter table · an adjustable miter fence · an adjustable rip fence with scale indicator · an adjustable riving knife (splitter) and blade guard with anti-kickback pawls · front and rear guide rails with an easy-to-read scale on front rail · blade adjusting handle to set depth of cut · a sliding outfeed support · switch with removable switch key to help prevent unauthorized use · leg stand for ease of operation These features provide ease of cutting with all types of wood. WARNING: Before attempting to use your table saw, familiarize yourself with all operating features and safety requirements. GETTING TO KNOW YOUR SAW RIVING KNIFE BLADE GUARD ASSEMBLY SAW BLADE RIP FENCE SLIDING MITER TABLE OUTFEED SUPPORT ANTI-KICKBACK PAWLS FRONT RAIL MITER FENCE LOCKING HANDLE SWITCH BLADE AND WRENCH STORAGE BEVEL LOCKING LEVER BLADE ADJUSTING HANDLE BEVEL HANDLE BEVEL INDICATOR FOOT LEVELING FOOT LEG STAND Fig. 4 Page 12 FEATURES WARNING: Although some of the illustrations in this manual are shown with the blade guard removed for clarity, do not operate the saw without the blade guard unless specifically instructed to do so. WARNING: Always remove the switch key when the tool is not in use and keep it in a safe place. In the event of a power failure, turn the switch off ( ) and remove the key. This action will prevent the tool from accidentally starting when power returns. OPERATING COMPONENTS The upper portion of the blade projects up through the table, surrounded by an insert called the throat plate. To cut wood at a bevel, the blade must be tilted, using the bevel handle, scale, and bevel indicator found on the front of the cabinet. Inside the cabinet, adjustable positive stops are provided for 0° and 45°. Your saw includes a rip fence and miter fence with under table storage for easy accessibility. The rip fence is used to position work that will be cut lengthwise. A scale on the front rail shows the distance between the rip fence and the blade. The leg stand places the table saw at convenient working level. The blade guard assembly includes a riving knife 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 riving knife for all through-sawing operations. The anti-kickback pawls (also a part of the blade guard assembly) are toothed plates mounted on the riving knife. Their teeth point away from the work in case the work should be pulled back, toward the operator. Then the teeth dig into the wood to help prevent or reduce the possibility of kickback. 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: To reduce the risk of accidental starting, ALWAYS make sure the switch is in the off ( ) position before plugging tool into the power source. SWITCH BUTTON IN ON POSITION POWER SWITCH 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: 1. With the switch key inserted into the switch, lift the switch button to turn on ( ). TO TURN YOUR SAW OFF: 1. Press the switch button down to turn off ( ). TO LOCK YOUR SAW : 1. Press the switch button down. 2. Remove the switch key from the switch and store in a safe, secure location. SWITCH BUTTON IN OFF POSITION SWITCH KEY SWITCH IN LOCKED POSITION Fig. 5 Page 13 FEATURES BLADES It is recommended that you use a RYOBI 10 in. (254 mm) Combination Blade, which is provided with the BTS15 Table Saw. You will get maximum performance with the following features: · · 36 precision ground, micro-grain carbide teeth tensioning for 4,800 rpm · kerf width of 2.7 mm + .02 This blade is provided with the saw. Additional blade styles of the same high quality are available for specific operations such as ripping. Your local RYOBI dealer can provide you with complete information. CAUTION: Be sure to use only blades that are rated for at least 5,500 RPM and recommended for use on this saw. PRECISION GROUND MICRO-GRAIN CARBIDE TEETH BLADE ROTATION Fig. 6 SPEED AND WIRING The no-load speed of your table saw is approximately 4,800 rpm. The speed will not remain constant but will be less under a load. The wiring in a shop is as important as the motor's horsepower rating. A line intended for lights only WILL NOT 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. WARNING: To prevent possible electrical hazards, have a qualified electrician check the line if you are not certain that it is properly wired. PRODUCT SPECIFICATIONS Blade Diameter ........................................ 10 in. (254 mm) Blade Arbor ............................................... 5/8 in. (16 mm) Cutting Depth at 0° ............................... 3-9/16 in. (90 mm) Cutting Depth at 45° ............................ 2-1/2 in. (63.5 mm) Rating ................. 120 Volts, 60 Hz-AC Only, 15 Amperes Output Speed ................................................... 4,800/min. Net Weight ............................................. 85 lbs. (38.5 kg.) Page 14 ASSEMBLY Assembly is best done in the area where the saw will be used. When you remove the table saw base, loose parts, and hardware from the packing materials, check all items with the loose parts list and drawing. If you are unsure about the description of any part, refer to the drawing. If any parts are missing, delay assembling until you have obtained the missing part(s). ASSEMBLING LEG STAND See Figures 7 and 8. Take the following hardware from the leg stand hardware bag: 24 carriage bolts (5/16-18 x 5/8 in.) 1 leveling foot 6 flat washers (5/16 in.) 28 hex nuts (5/16-18) 3 feet Note: Remaining hardware from this bag is used for mounting leg stand on the table saw base and mounting the storage bracket to the upper brace. Take 4 legs and 8 braces from loose parts. Place an upper side brace inside leg with the leg's wide end up. Note: Upper braces have large holes in each end; these holes should be on top when leg stand is completely assembled as shown in figure 8. Align the holes on the brace and the legs. Insert two carriage bolts and hand tighten using hex nuts. These are the front and back sets. For the side sets, install an upper brace on two legs. Add hardware and finger tighten. Repeat for the other upper brace. Use the same steps to install the lower braces. Tighten all hex nuts with a wrench. Place a hex nut and flat washer on the leveling foot. Install the leveling foot from the bottom of the leg with the bolts pointing up. Cap with the remaining flat washer and hex nut but do not tighten. Place one foot on the bottom of each of the remaining three legs. Move the leg set to desired location. Adjust the leveling foot with a wrench, then tighten the top hex nut. Fig. 7 ASSEMBLING STORAGE BRACKETS Take storage brackets from loose parts. Take the following hardware from the leg stand hardware bag: 2 screws (1/4-20 x 1/2 in. Pan Hd.) 2 hex nuts (1/4-20) 2 washers (1/4 in.) Secure storage brackets to upper braces of leg stand as shown in figure 7. Fig. 8 Page 15 ASSEMBLY TO MOUNT THE TABLE SAW TO THE LEG STAND See Figure 9. Take the following from a small hardware bag: 4 hex bolts (5/16-18 x 2 in.) 4 hex nuts, flanged (5/16-18) 4 flat washers (5/16 in.) Note: This hardware was in the bag with hardware for assembling the leg stand. HEX BOLT FLAT WASHER WARNING: The saw base is heavy. Do not lift the saw without help. When lifting, lift close to your body. Keep your knees bent and lift with your legs, not your back. Ignoring these precautions can result in back injury. Place the table saw on the leg stand. Align the holes in the table saw base with the holes in the upper braces. Place a flat washer on a hex bolt and insert through hole. Add a flanged hex nut. Hand tighten. See Figure 9. Repeat for three remaining holes. Tighten all hardware with a wrench. You may find it helpful to use one wrench to hold the head of the hex bolt and one to tighten the hex nut. SAW BASE LEG STAND FLANGED HEX NUT Fig. 9 WARNING: Do not connect to power supply until assembly is complete. Failure to comply could result in accidental starting and possible serious injury. SHAFT END WASHER SCREW TO INSTALL THE BLADE ADJUSTING HANDLE See Figure 10. The blade adjusting handle mounts to the bevel handle with a screw (M4 x 10 mm) and a flat washer. Align blade adjusting handle to the shaft end that extends from the front of the table saw base. Match the flat spots on the shaft with the flats inside the blade adjusting handle. Insert a screw and a flat washer in the center of the blade adjusting handle and tighten. BEVEL HANDLE BLADE ADJUSTIING HANDLE Fig. 10 Page 16 ASSEMBLY TO INSTALL RIP FENCE See Figure 11. To install the rip fence, place the rear lip on the rear rail and pull slightly toward the front of the unit. Lower front end onto the guide surfaces on top of the front rail. Check for a smooth gliding action. Swing the locking handle down to automatically align and secure the fence. RIP FENCE TO INSTALL MITER TABLE See Figure 12. Remove the solid table extension by turning the table lock knob counterclockwise. Lift the solid table extension. Place the sliding miter table in the slot where the solid table extension had been. Retighten table lock knobs. FRONT RAIL TO LOCK MITER TABLE See Figure 13. The miter table slides to let the operator slide the workpiece across the saw. A miter slide lock is mounted on the front of the miter table to lock it in place. The miter slide lock is placed in a slot on the base to align the miter table with the front edge of the saw table. The sliding miter table should be locked for any cut in which the operator prefers a fixed table. To lock the miter table with the base projecting to the front, place miter slide lock in the back slot on the base. To lock the miter table with the base projecting to the back, place miter slide lock in the front slot on the base. Fig. 11 TABLE LOCK KNOBS Fig. 12 MITER SLIDE LOCK SLOTS FOR LOCKING MITER TABLE Fig. 13 Page 17 ASSEMBLY BLADE AND GUARD ASSEMBLY WARNING: Do not connect to power supply until assembly is complete. Failure to comply could result in accidental starting and possible serious injury. LARGE WRENCH SMALL WRENCH TO CHECK SAW BLADE INSTALLATION To check the saw blade, first lower the blade and remove the screw holding the throat plate in place. Remove the throat plate. See Figure 14. Make sure the bevel locking lever is locked. Raise the blade arbor to its full height by turning the blade adjusting handle counterclockwise. Using the smaller wrench, insert the flat open end into the flats on the arbor shaft as shown. Insert the larger wrench over the flange nut, and, holding both wrenches firmly, pull the larger wrench forward to the front of the machine to loosen and push to tighten. Make sure the flange nut is securely tightened. Do not overtighten. Note: Arbor shaft has right-hand threads. Check all clearances for free blade rotation. Lower the blade by turning the blade adjustment handle clockwise. Reinstall the throat plate. Fig. 14 NOTE: PLACE BLADE BETWEEN INNER AND OUTER BLADE WASHER SMALL WRENCH LARGE WRENCH ARBOR TO LOOSEN TO INSTALL BLADE GUARD ASSEMBLY Lower the blade by turning the blade adjustment handle clockwise. Using an adjustable wrench, install the blade guard assembly by loosening the two attachment nuts enough to attach the separator (align holes and tabs). See Figure 15. Partially retighten the two attachment nuts. Check the blade and separator alignment. Correctly align the blade and separator as shown, repeating above step as needed. Tighten attachment nuts securely. If separator is not positioned correctly with blade up, it could contact saw table when blade is lowered and restrict blade elevation. SPACER/ WASHER FLANGE/SPACER FLANGE NUT TO TIGHTEN HOLES Fig. 15 SEPARATOR ATTACHMENT NUTS TABS MOUNTING PLATE DO NOT REMOVE ATTACHMENT NUTS Fig. 16 Page 18 OPERATION BASIC OPERATION OF THE TABLE SAW A table saw can be used for straight-line cutting operations such as cross cutting, ripping, mitering, beveling, and compound cutting. It can dado with optional accessories. The 2-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. Check with an electrician or service personnel if you are unsure about proper grounding. 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 page of this manual. Note: This table saw is designed to cut wood and wood composition products only. Use the right type of blade for the cut being made. Use the blade guard assembly for all through cuts. CUTTING AIDS See Figure 17. 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: 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 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 CAUTION: Be sure the screw is recessed to avoid damaging the saw or workpiece. PUSH STICKS AVOIDING KICKBACK 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. 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. Always use the rip fence when rip cutting and the miter gauge when cross cutting. This helps prevent twisting the wood in the cut. Always use clean, sharp, and properly-set blades. Never make cuts with dull blades. To avoid pinching the blade, support the work properly before beginning a cut. When making a cut, use steady, even pressure. Never force cuts. Do not cut wet or warped lumber. Always hold your workpiece firmly with both hands or with pushsticks. Keep your body in a balanced position to be ready to resist kickback should it occur. Never stand directly in line with the blade. PUSH BLOCKS Fig. 17 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. 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: All blades and dado sets must be rated for at least 5,500 RPM to prevent possible injury. Page 19 OPERATION FEATHERBOARD A featherboard is a device used to help control the workpiece by guiding it securely against the table or 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 could resist kickback. in the featherboard. Positioning the featherboard will depend on the placement of the bolt. Place the washer on the bolt and attach the adjusting clamp knob, loosely. Position the featherboard with the hex head of the bolt in the miter table slot but do not tighten. Completely lower the saw blade. Position the rip fence to the desired adjustment for the cut to be performed and lock. 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. Securely tighten the adjusting clamp knob to secure the featherboard in place. Attach a C-clamp to further secure the featherboard to the edge of the sliding miter 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. HOW TO MAKE A FEATHERBOARD See Figure 19. The featherboard is an excellent project for your BTS15. 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., 8 in., 10 in. and 12 in. Drill a 3/8 in. hole at the 8 in., 10 in., and 12 in. marks. 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. FEATHERBOARD PUSH STICK BEVEL LOCKING LEVER "C" CLAMP PUSH BLOCK HOW TO MOUNT A FEATHERBOARD Remove the adjusting clamp knob, bolt and washer from the Miter Fence Holder. Place the bolt through one of the holes Fig. 18 3/8 in. DIAMETER 30° 3-5/8 in. 1/4 in. 1-13/16 in. 45° 1/8 in. 3/4 in. 8 in. 10 in. 12 in. 18 in. 6 in. Fig. 19 Page 20