User manual RYOBI TS1353

OPERATOR'S MANUAL 10 in. Compound Miter Saw TS1353DXL - Double Insulated Your miter 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................................................................................................................................................................. 12 n Loose Parts ................................................................................................................................................................... 13 n Assembly .................................................................................................................................................................. 14-21 n Operation.................................................................................................................................................................. 22-28 n Adjustments.............................................................................................................................................................. 29-30 n Maintenance ............................................................................................................................................................. 30-31 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 is safer than using your hand and frees both hands to operate the tool. n DO NOT 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 from power source. 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 result in injury. n NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped. 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, cutter, or sanding spindle against the direction or rotation of the blade, cutter, or sanding spindle 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 carry tool by the cord or yank it to disconnect from receptacle. Keep cord 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 KEEP BLADES CLEAN, SHARP, AND WITH SUFFICIENT SET. Sharp blades minimize stalling and kickback. n BLADE COASTS AFTER BEING TURNED OFF. READ ALL INSTRUCTIONS n KNOW YOUR POWER TOOL. Read the operator's manual carefully. Learn the 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 tool 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, master switches, or by removing starter keys. n DON'T FORCE THE TOOL. It will do the job better and safer at the feed rate for which it was designed. n USE THE RIGHT TOOL. Do not force the tool or attachment to do a job for which it was not designed. 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, neckties, or jewelry that 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. 3 GENERAL SAFETY RULES n NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal sparking of the motor could ignite fumes. n 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. n INSPECT EXTENSION CORDS PERIODICALLY and replace if damaged. n POLARIZED PLUGS. To reduce the risk of electric shock, this tool has a polarized plug (one blade is wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install the proper outlet. Do not change the plug in any way. n 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. n 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. n DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switches replaced by an authorized service center. n 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. n BEFORE MAKING A CUT, BE SURE ALL ADJUSTMENTS ARE SECURE. n BE SURE BLADE PATH IS FREE OF NAILS. Inspect for and remove all nails from lumber before cutting. n NEVER TOUCH BLADE or other moving parts during use. n NEVER START A TOOL WHEN ANY ROTATING COMPONENT IS IN CONTACT WITH THE WORKPIECE. n DO NOT OPERATE A TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR ANY MEDICATION. n WHEN SERVICING use only identical replacement parts. Use of any other parts may create a hazard or cause product damage. 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 DOUBLE CHECK ALL SETUPS. Make sure blade is tight and not making contact with saw or workpiece before connecting to power supply. SPECIFIC SAFETY RULES n FIRMLY CLAMP OR BOLT the tool to a workbench or table at approximately hip height. n KEEP HANDS AWAY FROM CUTTING AREA. Do not reach underneath work or in blade cutting path with hands and fingers for any reason. Always turn the power off. n ALWAYS SUPPORT LONG WORKPIECES while cutting to minimize risk of blade pinching and kickback. Saw may slip, walk or slide while cutting long or heavy boards. n ALWAYS USE A CLAMP to secure the workpiece when possible. n BE SURE THE BLADE CLEARS THE WORKPIECE. Never start the saw with the blade touching the workpiece. Allow motor to come up to full speed before starting cut. n MAKE SURE THE MITER TABLE AND SAW ARM (BEVEL FUNCTION) ARE LOCKED IN POSITION BEFORE OPERATING YOUR SAW. Lock the miter table by securely tightening the miter lock levers. Lock the saw arm 4 (bevel function) by securely tightening the bevel lock knob. n NEVER USE A LENGTH STOP ON THE FREE SCRAP END OF A CLAMPED WORKPIECE. NEVER hold onto or bind the free scrap end of the workpiece in any operation. If a work clamp and length stop are used together, they must both be installed on the same side of the saw table to prevent the saw from catching the loose end and kicking up. n NEVER cut more than one piece at a time. DO NOT STACK more than one workpiece on the saw table at a time. n NEVER PERFORM ANY OPERATION FREEHAND. Always place the workpiece to be cut on the miter table and position it firmly against the fence as a backstop. Always use the fence. SPECIFIC SAFETY RULES n NEVER hand hold a workpiece that is too small to be clamped. Keep hands clear of the cutting area. n NEVER reach behind, under, or within three inches of the blade and its cutting path with hands and fingers for any reason. n NEVER reach to pick up a workpiece, a piece of scrap, or anything else that is in or near the cutting path of the blade. n AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the blade. ALWAYS make sure you have good balance. NEVER operate the miter saw on the floor or in a crouched position. n NEVER stand or have any part of the body in line with the path of the saw blade. n ALWAYS release the power switch and allow the saw blade to stop rotating before raising it out of the workpiece. n DO NOT TURN THE MOTOR SWITCH ON AND OFF RAPIDLY. This could cause the saw blade to loosen and could create a hazard. Should this ever occur, stand clear and allow the saw blade to come to a complete stop. Disconnect your saw from the power supply and securely retighten the blade bolt. n IF ANY PART OF THIS MITER SAW IS MISSING or should break, bend, or fail in any way, or should any electrical component fail to perform properly, shut off the power switch, remove the miter saw plug from the power source and have damaged, missing, or failed parts replaced before resuming operation. n ALWAYS STAY ALERT! Do not allow familiarity (gained from frequent use of the saw) to cause a careless mistake. ALWAYS REMEMBER that a careless fraction of a second is sufficient to inflict severe injury. n IF THE POWER SUPPLY CORD IS DAMAGED, it must be replaced only by the manufacturer or by an authorized service center to avoid risk. 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 saw. n ALWAYS TURN OFF THE SAW before disconnecting it to avoid accidental starting when reconnecting to power supply. NEVER leave the saw unattended while connected to a power source. n TURN OFF TOOL and wait for saw blade to come to a complete stop before moving workpiece or changing settings. n THIS TOOL should have the following markings: a) b) c) d) e) f) g) h) Wear eye protection. Keep hands out of path of saw blade Do not operate saw without guards in place. Do not perform any operation freehand. Never reach around saw blade. Turn off tool and wait for saw blade to stop before moving workpiece or changing settings. Disconnect power (or unplug tool as applicable) before changing blade or servicing. No load speed. n ALWAYS carry the tool only by the carrying handle. n AVOID direct eye exposure when using the laser guide. n SAVE THESE INSTRUCTIONS. Refer to them frequently and use to instruct other users. If you loan 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 NAME Voltage Current DESIGNATION/EXPLANATION 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, or 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 Alternating Current Direct Current no No Load Speed Class II Construction .../min Per Minute Wet Conditions Alert 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 your 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 or 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 DOUBLE INSULATION Double insulation is a concept in safety in electric power tools, which eliminates the need for the usual threewire 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 data plate) 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. NOTE: 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 the nearest authorized service center for repair. Always use original factory replacement parts when servicing. 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 -- ELECTRICAL CONNECTION This tool 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. NOTE: AWG = American Wire Gauge 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. 8 GLOSSARY OF TERMS Anti-Kickback Pawls (radial arm and table saws) A devise 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. Crosscut A cutting or shaping operation made across the grain or the width of the workpiece. Cutter Head (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 workpiece 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 Arbor .............................................................. 5/8 in. Blade Diameter.......................................................... 10 in. No Load Speed ................................................. 5,000/min. Input ................................120 V, 60 Hz, AC only, 15 Amps Net Weight............................................................ 34.9 lbs. Cutting Capacity with Miter at 0°/Bevel 0°: Maximum nominal lumber sizes:.................... 2 x 6, 4 x 4 Cutting Capacity with Miter at 45°/Bevel 0°: Maximum nominal lumber sizes:..............................2 x 4 Cutting Capacity with Miter at 0°/Bevel 45°: Maximum nominal lumber sizes:..............................2 x 6 Cutting Capacity with Miter at 45°/Bevel 45°: Maximum nominal lumber sizes:..............................2 x 4 SAW ARM UPPER BLADE GUARD DUST GUIDE SWITCH TRIGGER LOWER BLADE GUARD BEVEL SCALE BEVEL LOCK KNOB SLIDING MITER FENCE "NO HANDS ZONE" "NO HANDS ZONE" BOUNDARY LINE LABEL SUPPORT FOOT BLADE WRENCH MITER SCALE THROAT PLATE STOP BLOCK MITER TABLE BASE POSITIVE STOP(S) CONTROL ARM MITER LOCK HANDLE MITER LOCK PLATE TABLE EXTENSIONS Fig. 1 10 FEATURES KNOW YOUR COMPOUND MITER SAW See Figure 1. Before attempting to use this product, familiarize yourself with all operating features and safety rules. CARRYING HANDLE 15 AMP MOTOR The saw has a powerful 15 amp motor with sufficient power to handle tough cutting jobs. It is made with all ball bearings, and has externally accessible brushes for ease of servicing. SAW ARM 10 in. BLADE A 10 in. blade is included with the compound miter saw. It will cut materials up to 2 in. thick or 6 in. wide, depending upon the angle at which the cut is being made. LOCK PIN BLADE WRENCH STORAGE See Figure 1. A blade wrench is packed with the saw. One end of the wrench is a phillips screwdriver and the other end is a hex key. Use the hex key end when installing or removing blade and the phillips end when removing or loosening screws. A storage area for the blade wrench is located in the saw's base. MITER LOCK HANDLE SAW ARM LOCKED IN DOWN POSITION SPINDLE LOCK BUTTON SWITCH TRIGGER Fig. 2 CARRYING HANDLE See Figure 2. For convenience when carrying or transporting the miter saw from one place to another, a carrying handle has been provided on top of the saw arm. To transport, turn off and unplug the saw, then lower the saw arm and lock it in the down position. Lock saw arm by depressing the lock pin. MITER LOCK HANDLE See Figure 2. The miter lock handle securely locks the saw at desired miter angles. SPINDLE LOCK BUTTON See Figure 3. The spindle lock button locks the spindle stopping the blade from rotating. Depress and hold the lock button while installing, changing, or removing blade. Fig. 3 SWITCH TRIGGER PADLOCK SWITCH TRIGGER See Figure 4. To prevent unauthorized use of the compound miter saw, disconnect it from the power supply and lock the switch in the off position. To lock the switch, install a padlock (not included) through the hole in the switch trigger. A lock with a long shackle up to 9/32 in. diameter may be used. When the lock is installed and locked, the switch is inoperable. Store the padlock key in another location. Fig. 4 11 FEATURES POSITIVE STOPS ON MITER TABLE Positive stops have been provided at 0 , 15 , 22-1/2 , 30 , and 45°. The 22-1/2° and 45° positive stops have been provided on both the left and right side of the miter table. ° ° ° ° SLIDING MITER FENCE The miter fence on the compound miter saw has been provided to hold your workpiece securely against when making all cuts. The left side is larger providing additional support. It has a sliding feature for clearance of the saw arm when making bevel or compound cuts. Loosen the fence screw before attempting to slide the miter fence. Once the desired position of the miter fence is determined, tighten the fence screw to secure the sliding fence. BEVEL LOCK KNOB The bevel lock knob securely locks your compound miter saw at desired bevel angles. Positive stop adjustment screws have been provided on each side of the saw arm. These adjustment screws are for making fine adjustments at 0° and 45°. SELF-RETRACTING LOWER BLADE GUARD The lower blade guard is made of shock-resistant, seethrough plastic that provides protection from each side of the blade. It retracts over the upper blade guard as the saw is lowered into the workpiece. ELECTRIC BRAKE An electric brake has been provided to quickly stop blade rotation after the switch is released. LASER GUIDE For more accurate cuts, a laser guide is included with the miter saw. When used properly, the laser guide makes accurate, precision cutting simple and easy. SUPPORT FOOT A swingout support foot has been added to provide additional stability for the miter saw. TOOLS NEEDED The following tools (not included) are needed for making adjustments or installing the blade: COMBINATION WRENCH (2) (10 mm, 12 mm) HEX KEY (6 mm) FRAMING SQUARE COMBINATION SQUARE Fig. 5 12 LOOSE PARTS LIST The following items are included with your Compound Miter Saw: n Miter Lock Handle n Work Clamp n Dust Bag n Blade Wrench n Dust Guide n Hex Key (5 mm) n Stop Block n Blade Washer n Small Wing Screw n Hex Key Bolt n Clamp Brackets (2) n Operator's Manual n Clamp Bracket Screws (2) n Warranty Registration Card (not shown) n Table Extensions (2) DUST BAG DUST GUIDE BLADE WASHER MITER LOCK HANDLE 5 mm HEX KEY HEX KEY BOLT BLADE WRENCH SMALL WING SCREW TABLE EXTENSIONS CLAMP BRACKET SCREWS CLAMP BRACKETS WORK CLAMP STOP BLOCK Fig. 6 WARNING: The use of attachments or accessories not listed might be hazardous and could cause serious personal injury. 13 ASSEMBLY UNPACKING This product requires assembly. n Carefully lift saw from the carton by the carrying handle and the saw base, and place it on a level work surface. NOTE: This tool is heavy. To avoid back injury, lift with your legs, not your back, and get help when needed. n This saw has been shipped with the saw arm secured in the down position. To release the saw arm, push down on the top of the saw arm, cut the tie-wrap, and pull out on the lock pin. n Lift the saw arm by the handle. Hand pressure should remain on the saw arm to prevent sudden rise upon release of the tie wrap. 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 and satisfactorily operated the tool. n 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 this manual. n If any parts are damaged or missing, please call 1-800-525-2579 for assistance. 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: Do not start the compound miter saw without checking for interference between the blade and the miter fence. Damage could result to the blade if it strikes the miter fence during operation of the saw. MOUNTING HOLES See Figure 7. WARNING: Always make sure the compound miter saw is securely mounted to a workbench or an approved workstand. Failure to heed this warning can result in serious personal injury. The compound miter saw should be mounted to a firm supporting surface such as a workbench. Four bolt holes have been provided in the saw 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. The hole pattern for mounting to a workbench is shown in figure 7. 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. 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. TRACE HOLES AT THESE LOCATIONS FOR HOLE PATTERN TRACE HOLES AT THESE LOCATIONS FOR HOLE PATTERN SAW BASE 14 MOUNTING SURFACE Fig. 7 ASSEMBLY MITER LOCK HANDLE See Figure 8. To install the miter lock handle, place the threaded stud on the end of the miter lock handle into the threaded hole in the control arm under miter table. Turn clockwise to tighten. CONTROL ARM DUST GUIDE See Figure 9. To install the dust guide, place the end over the exhaust port in the upper blade guard. Turn the guide so that the open end is facing down. TO TIGHTEN MITER LOCK HANDLE MITER TABLE UPPER BLADE GUARD EXHAUST PORT TO LOOSEN Fig. 8 DUST BAG See Figure 10. A dust bag is provided for use on this miter saw. It fits over the exhaust port on the upper blade guard. To install it, remove dust guide from exhaust port. Then, squeeze the two metal clips to open the mouth of the bag and slide it on the exhaust port. Release the clips. The metal ring in the bag should lock in between the grooves on the exhaust port. To remove the dust bag for emptying, simply reverse the above procedure. DUST GUIDE WORK CLAMP See Figure 11. The work clamp provides greater control by clamping the workpiece to the fence or the saw table. It also prevents the workpiece from creeping toward the saw blade. This is very helpful when cutting compound miters. Depending on the cutting operation and the size of the workpiece, it may be necessary to use a C-clamp instead of the work clamp to secure the workpiece prior to making the cut. Fig. 9 EXHAUST PORT WARNING: In some operations, the work clamp assembly may interfere with the operation of the blade guard assembly. Always make sure there is no interference with the blade guard prior to beginning any cutting operation to reduce the risk of serious personal injury. To install the work clamp: n Place the shaft of the work clamp in either hole on the saw table base. n Rotate the knob on the work clamp to move it in or out as needed. DUST BAG Fig. 10 WARNING: When using any clamp with the stop block, install the clamp on the same side as the stop block. This will eliminate the possibility of trapping the workpiece, resulting in the saw blade and workpiece kicking up. Failure to heed this warning can result in serious personal injury. 15 BASE WORK CLAMP Fig. 11 ASSEMBLY TABLE EXTENSIONS See Figures 12 - 14. To use the stop block, slide the stop block on the back arm of the desired table extension first. To install table extensions, insert the ends of extensions into the holes in the sides of the base. See Figures 13 - 14. Adjust the extensions to the desired length. Secure extensions in place by positioning a clamp bracket under each table extension beneath the miter table. Orient each clamp bracket as shown in figure 14. Secure each clamp bracket in place with a clamp bracket screw. The clamp bracket screw threads through the clamp bracket and tightens against bracket support on bottom of miter table, securing clamp bracket against table extension. MITER SAW BASE Fig. 13 SAW VIEWED FROM BOTTOM MITER SAW BASE BRACKET SUPPORT TABLE EXTENSION STOP BLOCK See Figures 12 and 15. The stop block is included with the table extensions and is useful as a stop for making repetitive cuts to the same length. It can be installed on either side of the saw base: n Slide the stop block on the back arm of either table extension, then insert the table extensions into the saw base. n Use the small wing screw to secure the stop block to the table extensions. n Loosen the small wing screw and adjust the stop block the desired distance from the blade for the cut to be made. For accurate placement of the stop block, measure the distance from the teeth set on the blade to the stop block. n Tighten wing screw securely. n Plug the saw in. n Make a test cut in scrap material and measure the length of the workpiece. n Make any necessary adjustments. TABLE EXTENSION CLAMP BRACKET ASSEMBLED CLAMP BRACKET CLAMP BRACKET SCREW Fig. 14 STOP BLOCK SMALL WING SCREW TABLE EXTENSION BASE Fig. 12 16 Fig. 15 STOP BLOCK ASSEMBLY TO INSTALL / REPLACE THE BLADE See Figures 16 - 17. SPINDLE LOCK BUTTON WARNING: A 10 in. blade is the maximum blade capacity of the saw. Never use a blade that is too thick to allow outer blade washer to engage with the flats on the spindle. Larger blades will come in contact with the blade guards, while thicker blades will prevent the blade bolt from securing the blade on the spindle. Either of these situations could result in a serious accident and can cause serious personal injury. n Unplug the saw. n Raise saw arm. n Rotate lower blade guard up and remove screw. Rotate blade bolt cover up and back to expose the blade bolt. n Depress the spindle lock button and rotate the blade bolt until the spindle locks. n Using the wrench provided, loosen and remove the blade bolt. NOTE: The blade bolt has left hand threads. Turn blade bolt clockwise to loosen. n Remove outer blade washer (or laser guide). Do not remove inner blade washer. n Wipe a drop of oil onto inner blade washer (or laser guide) and outer blade washer where they contact the blade. Fig. 16 LOWER BLADE GUARD SHOULDER SCREW SCREW BLADE BOLT COVER WARNING: If inner blade washer has been removed, replace it before placing blade on spindle. Failure to do so could cause an accident since blade will not tighten properly. n Fit saw blade inside lower blade guard and onto spindle. The blade teeth point downward at the front of saw as shown in figure 17. n Replace outer blade washer (or laser guide). Double "D" flats on blade washers align with flats on spindle. n Depress spindle lock button and replace blade bolt. NOTE: The blade bolt has left hand threads. Turn blade bolt counterclockwise to tighten. TO LOOSEN CAUTION: Always install the blade with the blade teeth and the arrow printed on the side of the blade pointing down at the front of the saw. The direction of blade rotation is also stamped with an arrow on the upper blade guard. n Tighten blade bolt securely. n Replace the lower blade guard and blade bolt cover. n Replace screw and tighten securely. TO TIGHTEN BLADE OUTER BLADE WASHER WITH DOUBLE "D" FLATS INNER BLADE WASHER WITH DOUBLE "D" FLATS BLADE BOLT 17 FLAT(S) ON SPINDLE Fig. 17 ASSEMBLY WARNING: Make sure the spindle lock button is not engaged before reconnecting saw into power source. Never engage spindle lock button when blade is rotating. Follow the directions below for using the laser guide. Removing Your Mark: Position the laser line near the left edge of your mark on the work surface in order to remove the mark. To Cut Your Mark: Position the laser line near or over your mark on the work surface in order to cut the mark. To Leave Your Mark: Position the laser line near the right edge of your mark on the work surface in order to leave the mark. After you have become familiar with using the laser guide, you will be able to remove, cut, or leave your mark on the work surface. Practice will teach you the correct position for aligning the laser line with your mark. MOUNTING THE LASER GUIDE See Figure 18. n Unplug the saw. n Make sure inner blade washer is in place before positioning saw blade on the spindle of the saw. NOTE: The laser guide replaces the outer blade washer. n Place the laser guide onto the spindle, aligning the double "D" flats in the laser guide with the flats on the spindle. n Position flat surface of laser guide against the blade. Warning labels are visible when laser guide is mounted properly. n Depress spindle lock button and secure laser guide using only the special hex key bolt provided. NOTE: The hex key bolt has left hand threads. Turn bolt counterclockwise to tighten. n Using the hex key provided with the saw, tighten bolt securely. n Remove the hex key and store it in a safe place for future use. n Replace the lower blade guard and blade bolt cover. n Retighten phillips screw securing blade bolt cover. Tighten screw securely. BLADE LASER GUIDE HEX KEY BOLT INNER BLADE WASHER DANGER: Laser radiation. Avoid direct eye contact with light source. HEX KEY SPINDLE Fig. 18 ALIGNING THE LASER GUIDE LINE See Figure 19. The laser guide will generate a red colored line on the work surface when the blade is spinning. The red laser line will appear as a broken line on the workpiece when the blade assembly is in the uppermost position and the motor switch is activated. This broken line will let you see your mark and the laser guide line at the same time, and will assist you in lining up the mark for more accurate cutting of the workpiece. Align the laser line and the mark with the blade at the uppermost position. Once both lines are in alignment, do not move the workpiece until after you have finished cutting. As the blade assembly is lowered toward the workpiece, the broken line will become solid. Make several practice cuts on different styles and thickness of material. Fig. 19 18 BROKEN RED LINE ASSEMBLY NOTE: Many of the illustrations in this manual show only portions of the compound miter saw. This is intentional so that we can clearly show points being made in the illustrations. Never operate the saw without all guards securely in place and in good operating condition. FRAMING SQUARE SLIDING MITER FENCE MITER TABLE SQUARING THE MITER TABLE TO THE FENCE See Figures 20 - 23. n Unplug the saw. n Push down on the saw arm and pull out the lock pin to release the saw arm. n Raise saw arm to its full raised position. n Loosen the miter lock handle approximately one-half turn. n Depress the miter lock plate and rotate the miter table until the pointer on the control arm is positioned at 0°. n Release the miter lock plate and securely tighten the miter lock handle. n Lay a framing square flat on the miter table. Place one leg of the square against the fence. Place the other leg of the square beside the throat plate in the miter table. The edge of the square and the throat plate in the miter table should be parallel as shown in figure 20. n If the edge of the framing square and the throat plate in the miter table are not parallel as shown in figures 21 and 22, adjustments are needed. n Using the blade wrench provided, loosen the socket head screws securing the fence. Adjust the fence left or right until the framing square and throat plate are parallel. n Retighten the screws securely and recheck the fence-totable alignment. MITER LOCK PLATE MITER LOCK HANDLE THROAT PLATE VIEW OF MITER TABLE SQUARE WITH FENCE SLIDING MITER FENCE Fig. 20 MITER TABLE FRAMING SQUARE THROAT PLATE VIEW OF MITER TABLE NOT SQUARE WITH FENCE, ADJUSTMENTS ARE REQUIRED SLIDING MITER FENCE Fig. 21 MITER TABLE FRAMING SQUARE THROAT PLATE VIEW OF MITER TABLE NOT SQUARE WITH FENCE, ADJUSTMENTS ARE REQUIRED Fig. 22 19 ASSEMBLY SQUARING THE BLADE TO THE FENCE See Figures 24 - 26. n Unplug the saw. n Pull the saw arm all the way down and engage the lock pin to hold the saw arm in transport position. n Loosen the miter lock handle approximately one-half turn. n Depress the miter lock plate and rotate the miter table until the pointer on the control arm is positioned at 0°. n Release the miter lock plate and securely tighten the miter lock handle. n Lay a framing square flat on the miter table. Place one leg of the square against the fence. Slide the other leg of the square against the flat part of saw blade. NOTE: Make sure that the square contacts the flat part of the saw blade, not the blade teeth. n The edge of the square and the saw blade should be parallel as shown in figure 24. n If the front or back edge of the saw blade angles away from the square as shown in figures 25 - 26, adjustments are needed. n Loosen the socket head screws that secure the miter fence to the miter table. n Rotate the miter fence left or right until the saw blade is parallel with the square. n Retighten the screws securely and recheck the blade-tofence alignment. The saw has two scale indicators, one on the bevel scale and one on the miter scale. After squaring adjustments have been made, it may be necessary to loosen the indicators screws and reset them to zero. SOCKET HEAD SCREW(S) SOCKET HEAD SCREW(S) SLIDING MITER FENCE BLADE MITER LOCK PLATE FRAMING SQUARE MITER TABLE MITER LOCK HANDLE Fig. 24 VIEW OF BLADE SQUARE WITH FENCE SLIDING MITER FENCE BLADE MITER TABLE FRAMING SQUARE VIEW OF BLADE NOT SQUARE WITH FENCE, ADJUSTMENTS ARE REQUIRED Fig. 25 SLIDING MITER FENCE BLADE FENCE Fig. 23 MITER TABLE FRAMING SQUARE VIEW OF BLADE NOT SQUARE WITH FENCE, ADJUSTMENTS ARE REQUIRED 20 Fig. 26