Black & Decker 606404-00, BT2500 User Manual

INSTRUCTION MANUAL

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GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA DE GARANTIA. ADVERTENCIA: LEASE ESTE INSTRUCTIVO ANTES DE USAR EL PRODUCTO. SI TIENE DUDAS, POR FAVOR LLAME.

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PRODUCT FOR ANY

REASON PLEASE CALL

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WITH YOUR BLACK &DECKER PRODUCT,

CALL 1-800-54-HOW-TO (544-6986)

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A VAILABLE, CA TALOG No., TYPE No., AND DATE CODE (e.g.

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SENT ATIVE CAN RESOL VE YOUR PROBLEM OVER THE

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US ACALL. YOUR FEEDBACK IS VITALTO BLACK & DECKER.

TABLE OF CONTENTS

• Table Of Contents......................................................................2

• Rules For Safe Operation..........................................................3

• Electrical....................................................................................3

• Important Safety Instructions ....................................................3

• Saw Blade Guard And Spreader ..............................................4

• Kickbacks ..................................................................................4

• Making A Push Stick..................................................................4

• Specifications ............................................................................4

• Necessary Hardware ................................................................5

• Unpacking ................................................................................6

• Tools Included ..........................................................................7

• Tools You Will Need To Supply ..................................................7

• Assembly ..................................................................................7

Install The Four Legs ..............................................................7

Clean The Tabletop ................................................................7

Handwheel Assembly..............................................................7

Attaching Right Front Rail ......................................................7

Attaching Left Front Rail..........................................................7

Aligning And Leveling Front Rail Assembly ............................8

Attaching Right And Left Table Extensions..............................8

Leveling Table Extensions To Tabletop ..................................8

Attaching Rear Rails ................................................................9

Attaching Right Side Table Brace............................................9

Installing The Guard And Spreader Assembly ........................9

•

Adjustments ..............................................................................9

Checking The Throat plate......................................................9

Adjusting The Bevel Stops....................................................10

Bevel Pointer Adjustment......................................................10

Adjustment of Miter Gauge....................................................10

Rip Fence Operation And Adjustment ..................................10

• Micro Knob Adjustment............................................................10

• Replacing The Blade ..............................................................10

• Leveling The Saw....................................................................11

• On - Off Switch........................................................................11

•

Saw Blades..............................................................................11

• Operation ................................................................................11

Operating Instructions ..........................................................11

Ripping ..................................................................................11

Bevel Ripping........................................................................12

Ripping Small Pieces ............................................................12

Crosscutting ..........................................................................12

Bevel Crosscutting ................................................................12

Mitering..................................................................................12

Compound Mitering ..............................................................12

Dado Cutting ........................................................................12

Dust Collection......................................................................12

• Maintenance............................................................................13

Care Of Tabletop ..................................................................13

Lubrication ............................................................................13

Maintaining Fence System....................................................13

• Accessories ............................................................................13

• Service Information..................................................................13

•

Warranty..................................................................................13

• Push Stick Pattern ..................................................................14

IMPORTANT SAFETY INSTRUCTIONS

• KEEP GUARDS IN PLACE and in working order.

• 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 injuries.

• DON’T USE IN DANGEROUS ENVIRONMENT .Don’t use power tools in damp or wet loca-

tions, or expose them to rain. Keep work area well lighted.

• KEEP CHILDREN AWAY. All visitors should be kept safe distance from work area.

• MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter

keys.

• DON’T FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

• USE RIGHT TOOL. Don’t force tool or attachment to do a job for which it was not designed.

• USE PROPER EXTENSION CORD. 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. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

• WEAR PROPER APP AREL.Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.

• ALW AYS USE SAFETY GLASSES.Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are not safety glasses.

• DON’T OVERREACH. Keep proper footing and balance at all times.

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest perform-

ance. Follow instructions for lubricating and changing accessories.

• DISCONNECT TOOLS before servicing; when changing accessories, such as blades, bits, cutters, and the like.

• REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off position before plugging in. If power is interrupted to tool, turn off switch before restoring power.

• USE RECOMMENDED ACCESSORIES. Consult the instruction manual for recommended accessories. The use of improper accessories may cause risk of injury to persons.

• NEVER STAND ON T OOL. Serious injury could occur if the tool is tipped over 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

WARNING: FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL

BEFORE OPERATING SAW

• ALWAYS WEAR EYE PROTECTION

• DO NOT WEAR GLOVES, NECKTIES, JEWELRY OR LOOSE CLOTHING

• CONTAIN LONG HAIR

• KEEP HANDS AND FINGERS OUT OF THE SAW BLADE PATH — USE EXTRA CAU-

TION WHEN BEVELING

• AL WAYS USE BLADE GUARD AND SPREADER FOR EVERYOPERATION FOR WHICH IT CAN BE USED, INCLUDING THROUGH SAWING

• USE A“PUSH STICK” WHEN REQUIRED

• KNOW HOW TO AVOID KICKBACKS — SEE MANUAL

• ALWAYS SUPPORT WORK WITH TABLE AND FENCE OR MITER GAUGE

• NEVER USE FENCE AND MITER GAUGE TOGETHER

• NEVER REACH AROUND OR OVER SAW BLADE

• SECURELY MOUNT SAW BLADE BEFORE OPERATING

• NEVER REMOVE JAMMED OR CUT-OFF PIECES UNTILPOWER IS OFF AND BLADE

HAS STOPPED

• DO NOT EXPOSE TO RAIN OR USE IN DAMP LOCATIONS

• DO NOT OPERATE THIS MACHINE WHILE UNDER THE INFLUENCE OF ALCOHOL

OR DRUGS

• FAILURE TO COMPLY WITH THESE WARNINGS MAY RESULT IN SERIOUS PERSONAL INJURY.

WARNING: When using electric tools, basic safety precautions should always be followed to reduce risk of fire, electric shock, and personal injury, including the following:

GROUNDING INSTRUCTIONS

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify plug provided — if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.

REPAIR OR REPLACE DAMAGED OR WORN CORDS IMMEDIATELY. Grounded tools intended for use on a supply circuit having a nominal rating less than 150

volts: This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in Figure A. The tool has a grounding plug that looks like the plug illustrated in Figure A. A temporary adapter, which looks like the adapter illustrated in Figures B and C, may be used to connect this plug to a 2-pole receptacle as shown in Figure B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. The green-colored rigid ear, lug, and the like, extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box. The adapter (C) is not for use in Canada.

B CD

GROUNDED

OUTLET

BOX

GROUNDING

MEANS

GROUNDING PIN

ADAPTER

Minimum Gauge for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150 240V 0-50 51-100 101-200 201-300

Ampere Rating

More Not more AWG Than Than 0-6 18 16 16 14 6 - 10 18 16 14 12 10 - 12 16 16 14 12 12 - 16 14 12 Not Recommended

GROUNDING PIN

of parts, mounting, and any other conditions that may affect its operation. Aguard or other part that is damaged should be properly repaired or replaced.

• DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the

blade or cutter only.

• NEVER LEAVE T OOLRUNNING UNATTENDED. TURN POWER OFF .Don’t leave tool until

it comes to a complete stop.

ADDITIONAL SAFETY RULES FOR TABLE SAWS

• Wear eye protection.

• Use saw-blade guard and spreader for every operation for which it can be used, including

all through sawing.

• Keep hands out of line of saw blade.

• Use a push-stick when required.

• Know how to reduce risk of kickback.

• Do not perform any operation freehand.

• Never reach in back of or over saw blade.

• USE A DUST MASK and safety glasses when sawing. This saw is capable of generating

large amounts of sawdust.

• Do not use lubricants or cleaners (particularly spray or aerosol) in the vicinity of the plastic

guard. The polycarbonate material used in the guard is subject to attack by certain chemicals.

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 (CCA).

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.

SAW BLADE GUARD AND SPREADER

Your table saw is equipped with a blade guard and spreader assembly (Figure A part A and Figure 22 part C) that covers the blade and prevents accidental contact. The spreader is a flat plate that fits into the cut made by the saw blade and effectively fights kickback by lessening the tendency of the blade to bind in the cut. The spreader can only be used when making through cuts that sever the wood. When making dadoes, rabbits and other cuts that make less than through cuts, the blade guard and spreader assembly must be removed from the saw.

NOTE: Be sure to re-install guard and spreader after these cuts. Two anti-kickback pawls are located on the sides of the spreader that allow the wood to pass

through the blade in the cutting direction but lock it if it tries to move backwards toward the operator.

TERMS: The following terms will be used throughout the manual and you should become famil-

iar with them.

• Through-Sawing refers to any cut that completely severs the workpiece.

• Push-Stick refers to a wooden stick, usually home-made, that is used to push small workpieces

through the saw and keeps the operator’s hands clear of the blade.

• Kickback occurs when the saw blade binds in the cut and violently thrusts the workpiece back

toward the operator.

• Freehand refers to cutting without the use of a miter gauge or rip fence or any other means of

guiding or holding the workpiece other than the operator’s hand.

KICKBACKS - HOW TO AVOID THEM AND PROTECT

YOURSELF FROM POSSIBLE INJURY:

Kickback is a dangerous condition! It is caused by the workpiece binding against the blade. The result is that the workpiece can move rapidly in a direction opposite to the feed direction. During kickback, the workpiece could be thrown back at the operator. It can also drag the operator’s hand back into the blade if the operator’s hand is in the wrong place.

1.)Always use the guard and make certain it is in good working order. The guard’s splitter helps prevent binding and the anti-kickback pawls on each side of the splitter minimize the possibility of kickback. Use extra caution until the workpiece is through the splitter and has engaged anti-kickback pawls.

2.)Do not saw warped, bowed or cupped wood. The workpiece must have one straight, smooth side to go against the rip fence or miter gauge. The workpiece must sit flat on the table without rocking.

3.)Do not cut “freehand”. Always use either the rip fence or the miter gauge. Never use both.

4.)Use extra care when the guard assembly cannot be used (during dadoing or molding).

5.)Support large workpieces carefully. Allowing them to sag or droop can cause kickback.

6.)Be certain that the rip fence is parallel to the saw blade.

7.)Do not rip by applying the feed force to the section of the workpiece that will become the cut-off (free) piece. Feed force when ripping should always be applied between the saw blade and the fence; use a push stick for short work, 6” (152mm) wide or less. For less than 2" (51mm) wide, you must use a special fixture.

8.) Keep saw blade guard, splitter and anti-kickback pawls in place and operating properly. Keep pawls sharp. If pawls are not operational, return your unit to the nearest Black & Decker Service Center for repair. The splitter must be in alignment with the saw blade and the pawls must stop a kickback once it has started. Check their action before ripping.

9.) Plastic and composition (like hardboard) materials may be cut on your saw. However, since these are usually quite hard and slippery, the anti-kickback pawls may not stop a kickback. Therefore, be especially attentive to following proper set up and cutting procedures for ripping.

10.) Use saw blade guard and spreader for every operation for which it can be used, including all through sawing.

MAKING A PUSH STICK (BACK PAGE)

• In order to operate your table saw safely you must use a push-stick whenever the size or shape of the workpiece would cause your hands to be within 6 inches of the saw blade or other cutter.

• No special wood is needed to make a push-stick as long as it’s sturdy and long enough. A length of 12 inches is recommended with a notch that fits against the edge of the workpiece to prevent slipping. It’s a good idea to have several push sticks of the same length (12 inches) with different size notches for different workpiece thicknesses.

• See the inside back cover for a picture of a push stick. The shape can vary to suit your own needs as long as it performs its intended function of keeping your hands away from the blade.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

SPECIFICATIONS

Table Size 23 1/2" x 40 1/2" Miter Angle 60° L&R Bevel Angle 2° Right to 47° Left Blade Size 10" (254mm)

Max. Cut Depth 0° Bevel ..............3-3/8" (79mm)

Max. Cut Depth 45° Bevel ............2-1/4" (54mm)

RPM, no load 4800

Necessary Hardware

There are five hardware bags which contain all the necessary nuts, bolts and washers to assemble the components included with the BT2500. The bags are organized as follows:

WRENCH BAG Contents

2 - Blade wrenches 1 - Combination wrench 1 - Allen wrench

LEG STAND HARDWARE Contents

10 - Hex nuts 10 - Washers 10 - Pan head phillips screws

FRONT & REAR RAIL HARDWARE Contents

4 - Hex nuts 4 - Lockwashers 4 - Square head bolt 4 - Cap screws w/lockwashers

EXTENSION TABLE HARDWARE Contents

4 - Hex nuts 4 - Lockwashers 2 - Cap screws 2 - Square head bolts 6 - Cap screws w/lockwashers

FENCE & MITER GAUGE Contents STORAGE HARDWARE 8 - Hex nuts

8 - Lockwashers 2 - Cap screws 4 - Carriage bolts 2 - Square head bolts 2 - Miter gauge hangers 2 - Fence hangers

UNPACKING & ASSEMBLY- FIG.A

Carefully unpack the table saw and all loose items from the carton. Examine all parts to make sure that parts have not been damaged during shipping. If any parts are missing or damaged, contact your dealer to replace them before attempting to assemble the tool.Illustrated below are all the loose items (excluding the hardware bags) packed with the saw.

Fig. A

A. Blade guard assembly

B. Rip fence assembly

C. Rip fence handle

D. Miter gauge assembly

E. Feet (4)

F. Legs (4)

G. Front rails (2)

H. Rear rails (2)

I. Table extensions (2)

J. Handwheel

K. Sleeve

L. Handwheel lockknob

M. Table brace

N. Rip fence storage bracket (2)

O. Miter gauge storage bracket (2)

STEP 4. Clean the table top.

Before proceeding with the assembly of your saw, it is recommended that you clean the tabletop to remove the rust preventive coating. Clean the top with mineral spirits or denatured alcohol.

STEP 5. Handwheel assembly (Figures 4,5)

Bevel Adjustment Wheel (Right side of saw) Attach the sleeve (part K packed in styrofoam) to the shaft that extends from the side of the table saw as shown in Figure 4. Align the flat portion on the inside of the handwheel (part J) with the flat portion on the shaft. Thread on the handwheel lock knob (part L) but do not tighten at this time. NOTE: Lock knobs are for locking height and bevel settings once they are established.

STEP 6. Attach the right front rail (long section) to tabletop (Figure 6)

Insert two of the square head bolts from the front and rear rail hardware bag shown to the left, into the channel of the front rail as shown in Figure 6. Align the two bolts with the two holes on the right side of the tabletop. Push the bolts through the holes and loosely attach a lockwasher and hex nut onto the bolts. Slide the front rail to the right far enough to expose the two holes on the left side of the tabletop.

STEP 7. Attach the left front rail to tabletop (Figures 7,8)

Insert two of the square head bolts into the channel of the left front rail as shown in Figure

7. Align the two bolts with the two holes on the left side of the tabletop. Push the bolts through the holes and loosely attach a lockwasher and hex nut onto the bolts. Slide both sections of the front rails together and insert the black coupler on the left rail into the right rail as shown in Figure 8. At this time, move the front rail assembly so that the section where the two rails meet is approximately in line with the saw blade.

Assembly for BT2500

PLEASE READ ENTIRE ASSEMBLY SECTION

BEFORE PROCEEDING.

TOOLS INCLUDED

To aid you with assembly of your new saw, we have included the following tools.

• 6mm Allen Wrench

• 12mm/10mm Combination Wrench

• (2) Blade Wrenches

TOOLS YOU WILL NEED TO SUPPLY

• Phillips screwdriver

• Combination Square

You will also need:

• Mild solvent cleaner such as mineral spirits, paint thinner or denatured alcohol.

STEP 1. Remove parts bags and all component parts from the carton and check the contents

against the parts illustrated on pages 5 and 6.

STEP 2. Remove the saw from the box and leave it in an upside down position. Y ou may need

help. The combined weight of the table top and motor assembly is approximately 100 lbs.

STEP 3. Install the four legs. (Figures 1,2,3)

With the saw assembly upside down, attach the legs using the 10 bolts in the leg stand hardware bag shown to the left. Insert the bolt through the hole in the leg as shown in Figure 1. (NOTE: All four legs are the same. The front legs use 3 bolts each and the back legs use 2 bolts each.) With the bolt inserted through the leg, insure that the curved portion of the plastic positioner is aligned with the curve of the leg as shown in Figure 2. Using the supplied hex wrench and the supplied 12mm wrench, attach the legs as shown in Figure 3.

NOTE: DO NOT OVERTIGHTEN. THE LEGS ARE HOLLOW AND WILL INDENT IF EXCESSIVE FORCE IS USED. Place the 4 rubber feet on the ends of the legs and have

someone help you turn the assembly right side up.

STEP 8. Aligning and leveling the front rail assembly (Figures 9,10)

Loosen the lock knob in the center of the front hand crank and turn the crank handle clockwise to raise the blade so that it is approximately two inches above the tabletop. Thread the orange rip fence locking handle (part C) into the front of the rip fence (part B). Place the rip fence on the front rail to the right side of the blade as shown in Figure 9. Slightly push against the side of the rip fence and slide it over until it comes in contact with the blade. With the rip fence in position, tap the appropriate end of the front rail until the 0 marking on the scale aligns with the line in the window on the right side of the rip fence. (The left side will not line up until fence is on left side of blade.) Carefully lift off the rip fence without changing the rail position. Now that the front rail is in position, it is important to level it with the tabletop before tightening it down. To level the front rail, use the longer section of the rear rail (part H) as a straightedge and place it against the tabletop and against the front rail as shown in the insert in Figure 10. Pressing down on the straightedge (Figure

10) where the two rails meet will level the rails. Keeping the front rail firmly pressed down, tighten the hex nuts with the 12mm wrench supplied. Now place the fence on the left side of the blade to see if the pointer lines up. If not, loosen the phillips head screw and slide the plastic piece to align the red mark. NOTE: Remaining four capscrews will be used in step 11 to attach rear rail.

STEP 9. Attach the right and left table extensions (Figures 11,12,13)

Insert a square head bolt from the extension table hardware bag shown to the left, into the channel opening at the end of the front rail as shown in Figure 11. Push the table extension onto the bolt in the rail (Figure 12). Place a lockwasher and nut on the bolt and tighten snug but not tight. Insert three capscrews with lockwashers into the edge of the extension and into the tabletop and tighten snug but not tight (Figure 13). Repeat for opposite side extension. NOTE: Re-

maining hardware will be used to attach rear of extension to rear rail in step 11.

STEP 10. Leveling table extensions to tabletop (Figures 14,15).

Slide extension from the rear until it stops against the front rail (Figure 14). Lay a rear rail, as a straightedge, across the back edge of the tabletop and extension and lift up on the extension until it is flush with straightedge as shown in Figure 15. Tighten the rear most capscrew of the extension with the supplied hex wrench. Lay the straightedge across the front of the tabletop and extension and repeat the process of pulling up on the extension until it is level with the tabletop. Tighten the remaining two capscrews. With the straightedge still in place, level the outside portion of the extension and tighten the square head bolt in the front rail. Repeat this process for the left side table extension.

guard clamp nuts (D) which changes the location where the spreader mounts. Make sure the spreader is centered and parallel to the blade by lining up the parts with a straightedge. Also make sure there is some clearance between the spreader and the blade and that the blade spins freely. Using one hand to keep the spreader straight up and down as shown in Figure 23, tighten nuts (A) with 10mm wrench supplied, lower blade and replace throat plate. If the spreader is not parallel to the blade up and down, simply bend it left or right until it is aligned with the blade at the top and bottom when the blade is at the full upright position. IMPORTANT: THE GUARD SHOULD BE IN PLACE FOR ALLPOSSIBLE CUTS. When making non-through cuts, the guard can be easily removed by slightly loosening the outer guard nuts (A). The guard can easily be replaced without having to readjust the inner nuts.

Adjustments

PERFORM ALLADJUSTMENTS WITH THE TABLE SAW UNPLUGGED. NOTE: Your table saw is fully and accurately adjusted at the factory at the time of manufac-

ture. If readjustment due to shipping and handling or any other reason is required, follow the steps below to adjust your saw.

Once made, these adjustments should remain accurate.

STEP 1. Checking the throat plate

To change the height of the throat plate, loosen the phillips head screw in the front of the throat plate and adjust the four setscrews on the throat plate with a 2.5mm hex wrench. When properly adjusted, the front of the throat plate should be flush or slightly below the surface of the table top, and the rear of the throat plate should be flush or slightly above the table top.

CAUTION: The table insert must be in place and securely fastened at all times.

STEP 11. Attaching rear rails (Figures 16,17)

From the rear of the saw attach the longer rear rail to the left side of the tabletop (Figure

16) using three capscrews with lockwashers. NOTE: The capscrew that attaches to the table extensions will also require a hex nut (from table extension hardware bag). Using the miter gauge as a straightedge (Figure 17), level the outside edge of the table extension and tighten the two outside capscrews on the left side rear rail. Repeat the process for the other side extension. Level the two rear rails where they meet and tighten the two capscrews in the center of the tabletop.

STEP 12. Attach right side table brace (Figures 18,19)

The table brace fits between the rear rail and the front rail as shown in Figure 18. It also serves as a convenient place to hold the miter gauge and rip fence when not in use. Assemble the brackets to the brace as shown in Figure 19 before attaching it to the rails. Use four round head carriage bolts, lockwashers and hex nuts from the fence and miter gauge storage hardware bag shown to the left. Insert two square head bolts into the channel of the front rail and attach the brace to the rail using two lockwashers and hex nuts. Use capscrews to attach the rear end of the brace. NOTE: The large brackets are for rip fence storage and are located on the outside edge of the brace.

STEP 13. Install the guard and spreader assembly (Figures 20,21,22,23)

Remove the throat plate as shown in Figure 20. Lower the blade to tabletop height by turning the blade height adjustment wheel (front of saw) counterclockwise (Figure 21). Loosen the outer guard retaining nuts (A), shown in Figure 22, enough so that the spreader will fit between the two guard retaining plates (B). Raise the blade to its highest setting. Install the spreader (C) and ensure that it is aligned with the blade and that the back edge of the spreader is 90 degrees to the tabletop. If not, the position is adjusted by moving the inner

18 19

STEP 2. Adjust the bevel stops

CAUTION: Turn off and unplug saw.

1. Loosen the bevel lock handle and turn the bevel angle handwheel clockwise until it stops.

2. Raise the blade to its highest position and lift the blade guard.

3. Check blade angle with a combination square from left side of the blade, keeping the square against the flat part of the blade and not touching the teeth or table insert.

4. If blade angle is wrong, turn the 90° stop screw (located to the left of the blade looking from the front) 1 time counterclockwise with a 4mm hex wrench.

5. Turn handwheel until blade is 90° to the tabletop as indicated with a square.

6. Turn 90° stop screw (left of blade) clockwise till slight resistance is felt.

NOTE: DO NOT OVERTIGHTEN.

7. Check the 45° setting. Tilt the blade with the bevel handwheel as far as it will go to the left. Place square against the blade (be sure the square is not against one of the saw teeth). If the blade is not at 45°, unscrew the 45° stop screw (right of blade) turn handwheel 1 turn clockwise, then crank wheel counterclockwise to bring blade to 45° setting and tighten the screw. Recheck and repeat if necessary.

STEP 3. Bevel Pointer Adjustment

If bevel pointer does not point to “0”, when blade is at 90° to the table top, loosen the pointer screw with a phillips screwdriver. (The screw is accessible through the handwheel and the curved slot in front of the saw.) Set the pointer to “0” and retighten the pointer screw.

STEP 4. Adjustment of Miter Gauge (Figure 24).

Your miter gauge features adjustable stops at 90° and 45° left and right. To adjust these stops, loosen the lock nuts (A) and tighten or loosen the three adjusting screws (B). Check the gauge with a combination square and tighten the three adjusting nuts. To set the miter gauge past the 45 degree stops, pull out on the stop pin (C) and continue to the required angle.

STEP 5. Rip Fence Operation and Adjustments (Figure 25)

CAUTION: The rip fence must be aligned parallel to the blade to minimize the danger of

kickback.

For convenience sake, we will align the rip fence parallel to the saw blade. Your rip fence has two adjustment procedures. The first, “Fence Parallel to Saw Blade,” is performed as follows:

1. Turn off and unplug table saw.

2. Raise blade to its full upright position at 90° to the table top.

3. Align the edge of the rip fence to the saw blade. Push the fence body firmly against the table top rail to ensure proper fit.

4. Push down the cam lock lever to lock the fence in place.

5. If the fence no longer aligns with the saw blade, an adjustment is necessary. To adjust, release cam lock lever and loosen (counterclockwise) the two 5mm alignment hex head bolts on the top of the fence near the front, as shown in Figure 25.

6. With the two alignment bolts loosened, push on the fence body and move the rear of the fence side to side as necessary to realign it with the blade. Re-tighten the two alignment bolts and check alignment. Repeat as necessary.

The procedure for making the other adjustment, “Fence Clamping Tension,” is performed as follows:

If you are experiencing problems with the fence slipping:

1. Turn off and unplug table saw.

2. Release the cam lock lever.

3. To increase the clamping force of the rip fence, slowly tighten the tensioning nut (clockwise). This requires a 10mm socket at the back end of the fence.

4. When a reasonable amount of force is applied against the fence and it remains clamped stationary, proper adjustment has been achieved.

NOTE: DO NOT TIGHTEN the tensioning nut to the point where the fence does not slide easily on the table top.

IMPORTANT: To always obtain the best alignment of the rip fence, develop the habit of holding the front block on the fence against the table top rail while tightening the cam lock lever. Tighten the lock lever securely to prevent fence movement while sawing.

HINT: The rip scale pointer will need to be readjusted whenever a thicker or thinner blade is installed. To readjust the pointer, loosen the phillips head screw and slide the plastic piece to align the red mark. When making critical cuts, make a trial cut on scrap wood rather than relying on the rip, bevel or miter scales or stops.

MICRO ADJUSTMENT KNOB (FIGURE 25)

The micro adjustment knob is especially helpful when moving the rip fence left or right in small increments. Push in on the knob and turn to move the rip fence to desired location.

REPLACING THE BLADE (FIGURE 26).

CAUTION: Turn off and unplug saw.

1. Raise the saw blade approximately one inch above the table top by turning the blade height adjustment wheel (front of saw) clockwise.

2. Remove the throat plate by loosening the phillips head screw in the front of the plate and lifting the plate out.

3. Place one blade wrench provided with your saw, onto the flats on the blade arbor. Place the other blade wrench onto the arbor nut. Remove the arbor nut and flange from the saw arbor by turning counterclockwise (Figure 26). Place saw blade to its highest position and remove old blade.

4. Ensure the spindle and washers are free from dust and debris. Place the new saw blade on to the spindle making sure the teeth of the blade point down at the front of the table. Assemble the washer and arbor nut to the spindle and tighten arbor nut as far as possible by hand, making sure that the saw blade is against the inner flange and the large washer diameter is against the blade.

5. Lower the blade and place one blade wrench onto the flats on the blade arbor. Place the other blade wrench onto the arbor nut. Tighten the arbor nut by turning clockwise.

Adjustment Screws

Micro Adjustment Knob

6. NOTE: Different types of blades make different kerfs (width of cuts). Therefore, it is necessary to check adjustment of rip fence pointer and blade guard splitter when changing blades.

LEVELING THE SAW

The saw can be leveled by loosening the bolts on the back legs and sliding the leg up or down slightly and retightening the bolts.

If the saw becomes unstable when cutting oversize or overweight workpieces, stop and secure the saw to the floor. To do this, remove the rubber feet and mount angle brackets to each leg after drilling 5/16” (8mm) diameter holes in each leg 1/4” (6.3mm) minimum from the end. “Angle brackets and mounting hardware to be obtained locally.” Secure brackets to floor using the appropriate wood screws or concrete anchors as required.

ON-OFF SWITCH

Pull out the switch paddle to turn your saw ON and push it in to turn your saw OFF. A hole is provided in the switch for insertion of a padlock to lock the saw off as shown in Figure 27.

WARNING: Be sure switch is in the OFF position before plugging machine in.

SAW BLADES

THIS SAW IS INTENDED FOR THE USE WITH SAW BLADES 10” IN DIAMETER OR SMALLER.

1. The saw blade furnished with your new saw is a 10" (254mm) carbide tipped blade, used for cross cutting (across the grain) and ripping (with the grain). The center hole to fit on the arbor is 5/8" (16mm) diameter (.625").

2. There are many types of blades available to do specific and special jobs such as cross cut only, rip only, hollow ground, thin plywood, paneling, etc. These blades produce finer finish work, are more efficient and are easier on your saw. You will want to avail yourself of some of these as you become proficient with your projects.

3. Use only saw blades designed for maximum safe operating speeds of 6,000 RPM or greater.

4. Saw blades should always be kept sharp. It is recommended that you locate a reputable sharpening service to sharpen your blades when needed.

5. Never stack blades on top of one another to store. Place material such as cardboard between them to keep the blades from coming in contact with one another.

CAUTION: Abrasive wheels should not be used on this saw.

Operation

Plain sawing includes ripping and cross cutting, plus a few other standard operations of fundamental nature. The following methods feature safety. As with all power tools respecting the tool, using caution and following safe practices will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or completely ignored, personal injury to the operator can result. Read and follow all warnings indicated on the saw. Observe the safety rules included in this manual.

THIS SAW IS NOT INTENDED FOR CUTTING METALLIC WORK PIECES.

Operating Instructions

There are two basic types of cuts: ripping and crosscutting. In general, cutting with the grain is ripping and across the grain is crosscutting. However, with man made materials this distinction is somewhat difficult to make. Therefore, cutting a piece of wood to a different width is ripping and cutting across the short dimension is crosscutting. Neither ripping or crosscut- ting may be done safely freehand! Ripping requires the use of the rip fence and crosscutting uses the miter gauge.

CAUTION: Before using the saw each and every time verify the following:

1. Blade is tight.

2. Bevel angle and height lock knobs are tight.

3. If ripping, ensure fence lock lever is tight and fence is parallel to the blade.

4. If crosscutting, miter gauge knob is tight.

5. Safety glasses are being worn.

6. The blade guard is properly attached and the anti-kickback teeth are functioning.

Failure to adhere to these common safety rules can greatly increase the likelihood of injury.

RIPPING

1. Lock the rip fence by pressing the fence lock lever down. Remove the miter gauge.

2. Raise the blade so it is about 1/8" (3.2mm) higher than the top of the workpiece.

3. Hold the workpiece flat on the table and against the fence. Keep the workpiece about 1" (25.4mm) away from the blade.

CAUTION: The workpiece must have a straight edge against the fence and must not be warped, twisted or bowed. Keep both hands away from the blade and away from the path of the blade.

4. Turn the saw on and allow the blade to come up to speed. Both hands can be used in starting the cut. When there is approximately twelve (12) inches (305mm) left to be ripped, use only one hand, with your thumb pushing the material, your index and second finger holding the material down and your other fingers hooked over the fence. Always keep your thumb along side your first two fingers and near the fence.

5. Keeping the workpiece against the table and fence, slowly feed the workpiece rearward all the way through the saw blade. Continue pushing the workpiece until it is clear of the guard and it falls off the rear of the table. Do not overload the motor.

6. NEVER try to pull the workpiece back with the blade turning. Turn the switch off, allow the blade to stop, raise the anti-kickback teeth on each side of the splitter if necessary and slide the workpiece out.

7. When sawing a long piece of material or a panel, always use a work support. Asawhorse, rollers, or out feed assembly provides adequate support for this purpose. The work support must be

at the same height as the saw table.

CAUTION: Never push or hold onto the “free” or “cut off” side of the workpiece.

BEVEL RIPPING

This operation is the same as ripping except the bevel angle is set to an angle other than zero degrees.

WARNING: Before connecting the table saw to the power source or operating the saw, always inspect the guard and splitter for proper alignment and clearance with saw blade. Check alignment after each change of bevel angle.

RIPPING SMALL PIECES

It is unsafe to rip small pieces. It is not safe to put your hands close to the blade. Instead, rip a larger piece to obtain the desired piece. When a small width is to be ripped and the hand cannot be safely put between the blade and the rip fence, use one or more push sticks. Apattern is included on the back cover to make push sticks. Use them to hold the workpiece against the table and fence, and push the workpiece fully past the blade. See Figure 28.

CROSSCUTTING

1. Remove the rip fence and place the miter gauge in the appropriate slot.

2. Adjust the blade height so that the blade is about 1/8" (3.2mm) higher than the top of the workpiece.

3. Hold the workpiece firmly against the miter gauge with the path of the blade in line with the desired cut location. Keep the workpiece an inch or so in front of the blade. KEEP BOTH HANDS AWAY FROM THE BLADE AND THE PATH OF THE BLADE.

4. Start the saw motor and allow the blade to come up to speed.

5. While using both hands to keep the workpiece against the face of the miter gauge, and holding the workpiece flat against the table, slowly push the workpiece through the blade. See Figure 29.

6. Never try to pull the workpiece with the blade turning. Turn the switch off, allow the blade to stop, and carefully slide with workpiece out.

CAUTION: Never touch or hold onto the “free” or “cut off” end of the workpiece.

BEVEL CROSSCUTTING

This operation is the same as crosscutting except that the bevel angle is set to an angle other than 0°.

WARNING: Before connecting the table saw to a power source or operating the saw,

always inspect the guard and splitter for proper alignment and clearance with saw blade. Check alignment after each change of bevel angle.

MITERING

This operation is the same as crosscutting except the miter gauge is locked at an angle other than 0°. Hold the workpiece FIRMLY against the miter gauge and feed the workpiece slowly into the blade (to prevent the workpiece from moving). See Figure 30.

COMPOUND MITERING

This is a combination of bevel crosscutting and mitering. It is infrequently used. Follow the instruction for both bevel crosscutting and mitering.

DADO CUTTING

CAUTION: Do not attempt to stack dado blades thicker than 13/16" (20.6mm). For any

dado stack greater than 1/2” (12.7mm), remove the outer washer and do not use. Place the dado stack on the spindle and tighten the arbor nut with the blade wrench. Do not use dado blades larger than 8" (203mm) diameter.

NOTE: Dado cuts require a special dado insert catalog number BT510 sold separately.

Since Dado cuts are not through cuts, the cuts must be performed with the blade guard removed. To remove the guard/spreader assembly, loosen the two nuts (A) in Figure 22 and remove the guard assembly.

Anytime a cut is required that is considerably wider than the saw kerf, a dado is used. Adado cut is commonly used to add support and line up a shelf for a cabinet, bookcase or some such project. When using the dado, the guard must be removed. Use EXTREME care when using the dado without the guard. If a deep cut is required . . .use several successive passes rather than attempting to make it with one pass. Maximum dado width on this saw is 13/16" (20.6mm). DO NOT USE WIDER COMBINATIONS.

CAUTION: Always check dado blade clearance before plugging in the saw.

Be sure to place the guard back in position and check adjustments when the dado cuts are complete.

DUST COLLECTION

Y our table saw is equipped with a dust shroud with a 2-1/2” (63.5mm) dust collection port. For best results, connect a vacuum to the port at the rear of the saw.

If the saw is operated without a vacuum attached, most of the dust will be blown out the dust collection port. After extended use, the saw’s dust collection system may become clogged. To clear the dust collection system:

a) Unplug the saw. b) Use a paint stick or long screwdriver to loosen debris and cut-offs and pass it out through

the port. When cutting wet wood without a vacuum, making long narrow cut-offs or when cutting with

a dado blade, clean the dust collection port each time.

Maintenance

Use only mild soap and damp cloth to clean the tool. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

IMPORTANT: To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by authorized service centers or other qualified service organizations, always using identical replacement parts

CARE OF THE TABLE TOP

Protect your investment. Keep your table saw clean. If you notice signs of rust, steel wool the areas, clean with mineral spirits or denatured alcohol and apply paste wax.

MAINTAINING FENCE SYSTEM

Y our fence should always slide freely. If it seems to require excessive force to slide or if it feels rough, wipe the rails and fence head gliding surface with a cloth or paper towel. Check the movement again. If it still feels rough, clean the fence head with a mild solvent such as denatured alcohol or mineral spirits. Re-coat the rail with a heavy coat of paste wax or a light oil. Slide the fence head back and forth several times to coat the rail and fence. Wipe off any excess wax or oil from the rail. If fence still does not move freely, refer to rip fence adjustment section.

LUBRICATION

First clean off any accumulated sawdust from the gears and the worms with a stiff brush. Next, remove any pitch or resin which has built up. You may need to use a solvent such as mineral spirits to remove it. Next, re-apply grease to the gears marked with arrows in Figure

30. Y ou can also apply paste wax to the gears if you find that the grease is attracting too much sawdust. NOTE: Keep all spray lubricants away from upper guard.

Over time, the lubricants used in the mechanism of your table saw may need to be replenished.

ACCESSORIES

Recommended accessories for use with your tool are available from your local dealer or authorized service center. If you need assistance regarding accessories, please call:

1-800-54-HOW-TO. (800-544-6986).

WARNING: The use of any accessory not recommended for use with this tool could be

hazardous.

SERVICE INFORMATION

Black & Decker offers a full network of company-owned and authorized service locations throughout North America. All Black & Decker Service Centers are staffed with trained personnel to provide customers with efficient and reliable power tool service.

Whether you need technical advice, repair, or genuine factory replacement parts, contact the Black & Decker location nearest you.

To find your local service location, refer to the yellow page directory under “Tools—Electric” or call: 1-800-54-HOW-TO (800-544-6986).

FULL TWO-YEAR HOME USE WARRANTY

Black & Decker (U.S.) Inc. warrants this product for two years against any defects in material or workmanship. The defective product will be replaced or repaired at no charge in either of two ways.

The first, which will result in exchanges only, is to return the product to the retailer from whom it was purchased (provided that the store is a participating retailer). Returns should be made within the time period of the retailer’s policy for exchanges (usually 30 to 90 days after the sale). Proof of purchase may be required. Please check with the retailer for their specific return policy regarding returns that are beyond the time set for exchanges.

The second option is to take or send the product (prepaid) to a Black & Decker owned or authorized Service Center for repair or replacement at our option. Proof of purchase may be required. Black & Decker owned and authorized Service Centers are listed under “ToolsElectric” in the yellow pages of the phone directory.

This warranty does not apply to accessories. This warranty gives you specific legal rights and you may have other rights which vary from state to state and province to province. Should you have any questions, contact the manager of your nearest Black & Decker Service Center. This product is not intended for commercial use.

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