Black & Decker BDTS200, 90528116 User Manual

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INSTRUCTION MANUAL

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TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ADDITIONAL SPECIFIC SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

CARTON CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

SPANISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

FRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

SERVICE CENTER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .back cover

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol indicates potentially hazardous situation which, if not avoided, may result

in property damage.

It is important for you to read and understand this manual. The information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS. The symbols below are used to help you recognize this information.

SAFETY GUIDELINES - DEFINITIONS

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.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away

from face and body. Wear appropriate hearing protection during use. Under some conditions and duration of use, noise from this product

may contribute to hearing loss.

SAVE THESE INSTRUCTIONS!

CALIFORNIA PROPOSITION 65

GENERAL SAFETY RULES

WARNING: READ ALL INSTRUCTIONS BEFORE OPERATING PRODUCT. FAILURE TO FOLLOW ALL

INSTRUCTIONS LISTED BELOW MAY RESULT IN ELECTRIC SHOCK, FIRE AND OR SERIOUS INJURY.

IMPORTANT SAFETY INSTRUCTIONS

1. FOR YOUR OWN SAFETY, READ THE INSTRUCTION MANUAL BEFORE OPERATING THE MACHINE.

Learning the machine’s application, limitations, and specific hazards will greatly minimize the possibility of accidents and injury.

2. WEAR EYE AND HEARING PROTECTION. ALWAYS USE SAFETY GLASSES. Everyday eyeglasses are NOT safety glasses. USE CERTIFIED SAFETY EQUIPMENT. Eye protection equipment should comply with ANSI Z87.1 standards. Hearing equipment should comply with ANSI S3.19 standards.

3. WEAR PROPER APPAREL. 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.

4. DO NOT USE THE MACHINE IN A DANGEROUS ENVIRONMENT. The use of power tools in damp or wet locations or in rain can cause shock or electrocution. Keep your work area well-lit to prevent tripping or placing arms, hands, and fingers in danger.

5. MAINTAIN ALL TOOLS AND MACHINES IN PEAK CONDITION. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. Poorly maintained tools and machines can further damage the tool or machine and/or cause injury.

6. CHECK FOR DAMAGED PARTS. Before using the machine, check for any damaged parts. Check for alignment of moving parts, binding of moving parts, breakage of parts, and any other conditions that may affect its operation. A guard or any other part that is damaged should be properly repaired or replaced. Damaged parts can cause further damage to the machine and/or injury.

7. KEEP THE WORK AREA CLEAN. Cluttered areas and benches invite accidents.

8. KEEP CHILDREN AND VISITORS AWAY. Your shop is a potentially dangerous environment. Children and visitors can be injured.

9. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure that the switch is in the “OFF” position before plugging in the power cord. In the event of a power failure, move the switch to the “OFF” position. An accidental start-up can cause injury.

10.

USE THE GUARDS. Check to see that all guards are in place, secured, and working correctly to reduce the risk of injury.

11. REMOVE ADJUSTING KEYS AND WRENCHES BEFORE STARTING THE MACHINE. Tools, scrap pieces, and other debris can be thrown at high speed, causing injury.

12. USE THE RIGHT MACHINE. Don’t force a machine or an attachment to do a job for which it was not designed. Damage to the machine and/or injury may result.

13. USE RECOMMENDED ACCESSORIES. The use of accessories and attachments not recommended may cause damage to the machine or injury to the user.

14. USE THE 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. See the Extension Cord Chart for the correct size depending on the cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

15. SECURE THE WORKPIECE. Use clamps or a vise to

hold the workpiece when practical. Loss of control of a workpiece can cause injury.

16. FEED THE WORKPIECE AGAINST THE DIRECTION OF

THE ROTATION OF THE BLADE, CUTTER, OR ABRASIVE SURFACE. Feeding it from the other

direction will cause the workpiece to be thrown out at high speed.

17. DON’T FORCE THE WORKPIECE ON THE MACHINE.

Damage to the machine and/or injury may result.

18. DON’T OVERREACH. Loss of balance can make you

fall into a working machine, causing injury.

19. NEVER STAND ON THE MACHINE. Injury could occur if the

tool tips, or if you accidentally contact the cutting tool.

20. NEVER LEAVE THE MACHINE RUNNING UNATTENDED. TURN THE POWER OFF. Don’t leave the machine until it comes to a complete stop. Achild or visitor could be injured.

21. TURN THE MACHINE “OFF”, AND DISCONNECT THE MACHINE FROM THE POWER SOURCE before installing or removing accessories, before adjusting or changing set-ups, or when making repairs. An accidental start-up can cause injury.

22. MAKE YOUR WORKSHOP CHILDPROOF WITH

PADLOCKS, MASTER SWITCHES, OR BY REMOVING STARTER KEYS. The accidental start-up

of a machine by a child or visitor could cause injury.

23. STAY ALERT, WATCH WHAT YOU ARE DOING, AND

USE COMMON SENSE. DO NOT USE THE MACHINE WHEN YOU ARE TIRED OR UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR MEDICATION. A

moment of inattention while operating power tools may result in injury.

24. WARNING: USE OF THIS TOOL CAN

GENERATE AND DISBURSE DUST OR OTHER AIRBORNE PARTICLES, INCLUDING WOOD DUST, CRYSTALLINE SILICA DUST AND ASBESTOS DUST. Direct particles away from face and body.

Always operate tool in well ventilated area and provide for proper dust removal. Use dust collection system wherever possible. Exposure to the dust may cause serious and permanent respiratory or other injury, including silicosis (a serious lung disease), cancer, and death. Avoid breathing the dust, and avoid prolonged contact with dust. Allowing dust to get into your mouth or eyes, or lay on your skin may promote absorption of harmful material. Always use properly fitting NIOSH/OSHA approved respiratory protection appropriate for the dust exposure, and wash exposed areas with soap and water.

SAVE THESE INSTRUCTIONS.

Refer to them often

and use them to instruct others.

1. DO NOT OPERATE THIS MACHINE until it is assembled and installed according to the

instructions.

2. OBTAIN ADVICE FROM YOUR SUPERVISOR, instructor, or another qualified person if you are not familiar with the operation of this machine.

3. FOLLOW ALL WIRING CODES and recommended electrical connections.

4. USE THE GUARDS WHENEVER POSSIBLE. Check to see that they are in place, secured, and working correctly.

5. KICKBACK IS THE NATURAL TENDENCY OF THE

WORKPIECE TO BE THROWN BACK AT THE OPERATOR when the workpiece initially contacts the

blade or if the workpiece pinches the blade. Kickback is dangerous and can result in serious injury.

AVOID KICKBACK by:

A. keeping blade sharp and free of rust and pitch. B. keeping rip fence parallel to the saw blade. C. using saw blade guard and spreader for every

possible operation, including all through sawing.

D. pushing the workpiece past the saw blade prior to

release.

E. never ripping a workpiece that is twisted or

warped, or does not have a straight edge to guide along the fence.

F. using featherboards when the anti-kickback device

cannot be used.

G. never sawing a large workpiece that cannot be

controlled.

H. never using the fence as a guide when

crosscutting.

I. never sawing a workpiece with loose knots or

other flaws.

6. ALWAYS USE GUARDS, SPLITTER, AND ANTI-KICKBACK FINGERS whenever possible.

7. REMOVE CUT-OFF PIECES AND SCRAPS from the table before starting the saw. The vibration of the machine may cause them to move into the saw blade and be thrown out. After cutting, turn the machine off. After the blade has come to a complete stop,

remove all debris.

8. NEVER START THE MACHINE with the workpiece against the blade.

9. NEVER run the workpiece between the fence and a moulding cutterhead.

10. CUTTING THE WORKPIECE WITHOUT THE USE

OF A FENCE OR MITER GAUGE IS KNOWN AS “FREEHAND” CUTTING. NEVER perform “free-hand”

operations. Use either the fence or miter gauge to position and guide the workpiece.

11. HOLD THE WORKPIECE FIRMLY against the miter

gauge or fence.

12. CUTTING COMPLETELY THROUGH THE WORK-

PIECE IS KNOWN AS “THROUGH-SAWING”.

Ripping and cross-cutting are through-sawing operations. Cutting with the grain (or down the length of the workpiece) is ripping. Cutting across the grain (or across the workpiece) is cross-cutting. Use a fence or fence system for ripping. DO NOT use a fence or fence system for cross-cutting. Instead, use a miter gauge. USE PUSH STICK(S) for ripping a narrow workpiece.

13. AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause a hand to move into the blade.

14. KEEP ARMS, HANDS, AND FINGERS away from the blade.

15. NEVER have any part of your body in line with the path of the saw blade.

16. NEVER REACH AROUND or over the saw blade.

17. NEVER attempt to free a stalled saw blade without first turning the machine “OFF”.

18. PROPERLY SUPPORT LONG OR WIDE workpieces.

19. NEVER PERFORM LAYOUT, assembly or set-up work on the table/work area when the machine is running.

20. TURN THE MACHINE “OFF” AND DISCONNECT THE MACHINE from the power source before installing or removing accessories, before adjusting or changing set-ups, or when making repairs.

21. TURN THE MACHINE “OFF”, disconnect the machine from the power source, and clean the table/work area before leaving the machine. LOCK THE SWITCH IN THE “OFF” POSITION to prevent unauthorized use.

22. ADDITIONAL INFORMATION regarding the safe and proper operation of power tools (i.e. a safety video) is available from the Power Tool Institute, 1300 Sumner Avenue, Cleveland, OH 44115-2851 (www.powertoolinstitute.com). Information is also available from the National Safety Council, 1121 Spring Lake Drive, Itasca, IL 60143-3201. Please refer to the American National Standards Institute ANSI

01.1 Safety Requirements for Woodworking Machines and the U.S. Department of Labor OSHA 1910.213 Regulations.

ADDITIONAL SPECIFIC SAFETY RULES

WARNING: READ ALL INSTRUCTIONS BEFORE OPERATING PRODUCT. FAILURE TO FOLLOW ALL INSTRUCTIONS

LISTED BELOW MAY RESULT IN ELECTRIC SHOCK, FIRE AND OR SERIOUS INJURY.

Fig. A Fig. B

GROUNDED OUTLET BOX

CURRENT

CARRYING

PRONGS

GROUNDING BLADE IS LONGEST OF THE 3 BLADES

GROUNDED OUTLET BOX

GROUNDING

MEANS

ADAPTER

2. Grounded, cord-connected machines intended for use on a supply circuit having a nominal rating less than 150 volts:

If the machine is intended for use on a circuit that has an outlet that looks like the one illustrated in Fig. A, the machine will have a grounding plug that looks like the plug illustrated in Fig. A. A temporary adapter, which looks like the adapter illustrated in Fig. B, may be used to connect this plug to a matching 2-conductor receptacle as shown in Fig. 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. Whenever the adapter is used, it must be held in place with a metal screw.

NOTE: In Canada, the use of a temporary adapter is not permitted by the Canadian Electric Code.

WARNING: SHOCK HAZARD. IN ALL CASES,

MAKE CERTAIN THE RECEPTACLE IN QUESTION IS PROPERLY GROUNDED. IF YOU ARE NOT SURE HAVE A QUALIFIED ELECTRICIAN CHECK THE RECEPTACLE.

1. All grounded, cord-connected machines:

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 machine is equipped with an electric cord having an equipmentgrounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Do not modify the plug provided - if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Improper connection of the equipment-grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipmentgrounding 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 machine is properly grounded.

Use only 3-wire extension cords that have 3-prong grounding type plugs and matching 3-conductor receptacles that accept the machine’s plug, as shown in Fig. A.

Repair or replace damaged or worn cord immediately.

A separate electrical circuit should be used for your machines. This circuit should not be less than #12 wire and should be protected with a 20 Amp time lag fuse. If an extension cord is used, use only 3-wire extension cords which have 3-prong grounding type plugs and matching receptacle which will accept the machine’s plug. Before connecting the machine to the power line, make sure the switch (s) is in the “OFF” position and be sure that the electric current is of the same characteristics as indicated on the machine. All line connections should make good contact. Running on low voltage will damage the machine.

WARNING: SHOCK HAZARD. DO NOT EXPOSE THE MACHINE TO RAIN OR OPERATE THE MACHINE IN

DAMP LOCATIONS.

POWER CONNECTIONS

Your machine is wired for 120 Volt, 60 HZ alternating current. Before connecting the machine to the power source, make sure the switch is in the “OFF” position.

GROUNDING INSTRUCTIONS

WARNING: SHOCK HAZARD. THIS MACHINE MUST BE GROUNDED WHILE IN USE TO PROTECT THE

OPERATOR FROM ELECTRIC SHOCK.

FUNCTIONAL DESCRIPTION

NOTICE: THE PHOTO ON THE MANUAL COVER ILLUSTRATES THE CURRENT PRODUCTION MODEL. ALL OTHER ILLUSTRATIONS CONTAINED IN THE MANUAL ARE REPRESENTATIVE ONLY AND MAY NOT DEPICT THE ACTUAL COLOR, LABELING OR ACCESSORIES AND ARE INTENDED TO ILLUSTRATE TECHNIQUE ONLY.

FOREWORD

Model BDTS200 is a 10 inch Table Saw designed to give high quality performance with depth of cut capacity up to 3 inches (76mm) at 90° and 2 inches (51mm) at 45° for clean cutting of standard stock sizes.

EXTENSION CORDS

WARNING: Use proper extension cords. Make sure

your extension cord is in good condition and is a 3-wire extension cord which has a 3-prong grounding type plug and matching receptacle which will accept the machine’s plug. When using an extension cord, be sure to use one heavy enough to carry the current of the machine. An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. Fig. C shows the correct gauge to use depending on the cord length. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Fig. C

MINIMUM GAUGE EXTENSION CORD

RECOMMENDED SIZES FOR USE WITH STATIONARY ELECTRIC MACHINES

Ampere Total Length Gauge of

Rating Volts of Cord in Feet Extension Cord

0-6 120

up to

25 18 AWG 0-6 120 25-50 16 AWG 0-6 120 50-100 16 AWG 0-6 120 100-150 14 AWG

6-10 120

up to

25 18 AWG 6-10 120 25-50 16 AWG 6-10 120 50-100 14 AWG 6-10 120 100-150 12 AWG

10-12 120

up to

25 16 AWG 10-12 120 25-50 16 AWG 10-12 120 50-100 14 AWG 10-12 120 100-150 12 AWG

12-16 120

up to

25 14 AWG 12-16 120 25-50 12 AWG 12-16 120

GREATER THAN 50 FEET NOT RECOMMENDED

MOTORIZED BENCH SAW PARTS

Fig. 1 illustrates the saw removed from the container. Figs. 2 and Fig. 3 illustrate the loose items packed with the saw. Fig. 4 illustrates the loose items packed for the stand.

Fig. 1

CARTON CONTENTS

1. Leg (4) (2 with holes at base for attaching wheel bracket and brace)

2. 3/8 inchFlat Washer for Mounting Saw to Stand & for Assembling Stand (24)

3. Foot (4)

4. M8x1.25 Hex Nut for Mounting Saw to Stand & for Assembling Stand (20)

5. M8x1.25x45mm Hex Screw for Mounting Saw to Stand (4)

6. M8x1.25x20mm Carriage Head Bolts for Assembling Stand (16)

7. 18-1/2 inchTop Front and Rear Brackets (2)

8. 17 inch Top Side Brackets (2)

9. 22 inch Bottom Front and Rear Brackets (2)

10. 20-3/8 inch Bottom Side Brackets (2)

11. Wheel Assembly (2)

12. 25 inch Brace (1)

Fig. 4 Stand Hardware

Fig. 2

Fig. 3

Fig. 2 Parts

1. Rip Fence

2. Splitter and Guard Assembly

3. Lock Handle for Rip Fence

4. Blade Raising and Lowering Handwheel

5. Miter Gage

6. Splitter Support Bracket

7. Splitter Bracket

8. Handle for Blade Raising and Lowering Handwheel

9. Miter Gage Holder

10. Spring Clip for Miter Gage Holder

11. Blade Wrench

Fig. 3 Hardware

1. M6x1x55mm Pan Head Screw (1)

2. 1/4-20x2 inch Hex Head Screw (1)

3. M6x1x20mm Hex Head Screw (1)

4. 1/4-20x1/2 inch Hex Head Screw (2)

5. M6x1x12mm Flat Head Screw (1)

6. M4x.7x10mm Pan Head Screw (1)

7. M4x.2x10mm Pan Head Screw (4)

8. M8x1.25 Hex Nut (1)

9. M6x1 Wing Nut (1)

10. M4.7 Hex Nut (1)

11. M6.4 Flat Washer (3)

12. 1/4 inch Internal Tooth Lockwasher (1)

13. 1/4 inch External Tooth Lockwasher (5)

14. 3/16 inch Flat Washer (4)

15. 3/16 inch External Tooth Flat Washer (1)

Fig. 4

ASSEMBLY

ASSEMBLY TOOLS REQUIRED

(None supplied)

* Phillips head screw driver

* 13mm wrench for stand bolts * 10mm wrench for splitter assembly bolts * Straight edge and/or framing square for adjustments

ASSEMBLY TIME ESTIMATE - 1 hour

WARNING: THE SAW MUST BE PROPERLY SECURED TO A SUPPORTING SURFACE. ALSO, FAILURE TO

PROVIDE A SAWDUST FALL-THROUGH AND REMOVAL HOLE WILL ALLOW SAWDUST TO BUILD UP AROUND THE MOTOR, CAUSING A POSSIBLE FIRE HAZARD AND/OR MOTOR DAMAGE.

Fig. 4A

ELEVATING AND SUPPORTING SURFACES FOR A SAW WITH NO STAND

The saw must be elevated enough for sawdust to fall through the bottom of the saw and not build up around the motor. Position the four mounting holes located on the base of the saw cabinet (two of which are shown at (A) Fig. 4A) over whatever proper support you are using. Then securely fasten the saw to the supports. The saw can be secured by fastening the stand through the mounting holes with suitable hardware (not supplied).

WARNING: THE SAW SUPPORT MUST BE STABLE

AND ABLE TO SUPPORT 300 POUNDS.

You can also construct a simple elevated support, as shown in Fig. 4B.

WARNING: USE A GOOD GRADE OF PLYWOOD

WITH A MINIMUM 3/4 INCH THICKNESS. DO NOT MAKE THE MOUNTING BOARD FROM PARTICLE BOARD SINCE PARTICLE BOARD BREAKS EASILY.

WARNING: A HOLE MUST BE PROVIDED IN THIS

SUPPORT TO ALLOW SAWDUST TO FALL THROUGH.

Square the saw on the supporting surface and mark the location for four 5/16 inch holes to be drilled (Fig. 4B).

WARNING: MAKE SURE THERE IS AT LEAST 3

INCH ON ALL FOUR SIDES OF THE

BASE.

Set the saw aside and then drill holes in these marks. Locate and mark an 11 inch or 12 inch square centered between the four mounting holes. Cut out and remove the square (Fig. 4B). To elevate the supporting surface, measure two 2x4s (A) Fig. 4B to the width of two opposite sides of the supporting surface. Attach the supporting surface to the narrow edges of the 2X4s (as shown in Fig. 4B) using wood screws (not provided) in at least three spots (B) Fig. 4B on each side. Fasten the saw to the surface by inserting suitable hardware (not supplied) through the mounting holes on the saw and into the previously drilled holes. While using the saw, periodically remove the sawdust buildup from below the saw.

5/16" PILOT

HOLES

11" OR 12"

SQUARE

CUTOUT

SAW PLACEMENT

MARKS

3" MINIMUM

Fig. 4B

WARNING: DISCONNECT MACHINE FROM POWER SOURCE.

ATTACHING MITER GAUGE HOLDER

WARNING: DISCONNECT MACHINE FROM POWER SOURCE.

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

1. Attach the spring clip (E) Fig. 5 to the miter gauge holder (A) using an M4x.7x10mm pan head screw (F), 3/16 inch external tooth lockwasher, (B) and M4x.7 hex nut.

NOTE: The hex nut (G) Fig. 6 will fit into the recess at the back of the miter gauge holder (A) Fig. 5 to keep the spring clip (E) secured to the miter gauge holder.

2. Attach the miter gauge holder (A) Fig. 7 to the left side of the saw cabinet using the four M4x.2x10mm screws (B) Fig. 8, and 3/16 inch flat washers (C) from inside of the saw cabinet.

3. Fig. 9 illustrates the miter gauge (D) inserted into the holder.

Fig. 10

MITER GAUGE

The miter gauge is shipped assembled and is supplied with a T-slot bar (A) Fig. 10 that is inserted into either one of the two T-slotted miter gauge grooves (B) located in the table top. The T-slot prevents the miter gauge from falling when it is extended beyond the front of the table when cross-cutting extra wide workpieces.

ASSEMBLING STAND

1. Attach the rubber feet (H) Fig. 11 to the bottom of each leg (F). Locate the two legs (F) which have holes at the bottom for attaching the wheel brackets (G) and brace (E). (Make sure wheels and brackets are properly oriented. See inset Figure 12). To attach the brackets, remove the nuts from the bolts and insert the bolts through the holes in the bottom of the two legs and into the holes in brace (E). Thread the nuts back on the bolts and tighten. Assemble the stand as shown in Fig. 11, using 16 M8x1.25x20mm carriage head bolts, 3/8 inch flat washers and M8x1.25 hex nuts. Align the holes in the stand legs (F) with the holes in the brackets. Insert the carriage head bolt through the hole in the leg and the hole in the bracket, place a flat washer on the carriage head bolt and thread a hex nut onto the carriage head bolt. Repeat this process for the 15 remaining holes in the legs and brackets.

NOTE: Loosely tighten the hardware for further adjustment.

Letters are on the stand brackets to ease assembly:

A - Top front and rear brackets B - Top side brackets C - Bottom side brackets D - Bottom front and rear brackets E - Bottom brace

NOTE: Each rubber foot is provided with holes for mounting the stand to the floor surface if required.

Fig. 11

Fig. 13

SAW TO STAND

1. Turn saw table face down on a piece of cardboard to protect the table surface. Place stand upside down onto saw and align the four holes in the stand with the mounting holes in the saw.

2. Place a 3/8 inch flat washer on a M8x1.25x45mm hex head screw. Insert the hex head screw through the mounting hole in the saw and the mounting hole in the stand. Place another 3/8 inch flat washer on the hex head screw and thread a M8x1.25 hex nut on the screw and loosely tighten. Complete this process for the other three holes.

3. Stand the saw upright, as shown in Fig. 13 (Saw is shown fully assembled here).

4. Push down on top of the saw so that the legs of the stand adjust to the surface of the floor. Tighten all hardware securely.

Fig. 12

Wheel

Fig. 14

Fig. 15

Fig. 16

ATTACHING BLADE HEIGHT ADJUSTING HANDWHEEL

1. Insert an M6x1x55mm pan head screw (D) Fig. 14 through the handle (E). Attach the handle (E) to the handwheel (A) by threading the screw (D) clockwise into the handwheel.

2. Attach the handwheel (A) Fig. 15 to the shaft (B). Align the flat on the inside of the handwheel to the flat on the shaft.

3. Fasten the handwheel (A) Fig. 16 to the shaft using an M6x1x12mm flat head screw (C)

WARNING: DISCONNECT MACHINE FROM

POWER SOURCE.

WARNING: PROPERLY ALIGN THE BLADE

GUARD AND SPLITTER ASSEMBLY WITH THE SAW BLADE TO PREVENT KICKBACK.

1. Position the blade 90 degrees to the table and lock in place.

2. Fasten the splitter support bracket (A) Fig. 17 to the splitter bracket (B) using two 1/4-20x1/2 inch hex head screws (C) and two 1/4 inch external tooth lockwashers (D).

NOTE: Loosely tighten the screws for further adjustment.

Fig. 17

ATTACHING BLADE GUARD AND SPLITTER ASSEMBLY

Fig. 22

Fig. 18

Fig. 21Fig. 20

Fig. 19

3. Locate the 1/4-20x2 inch hex head screw (G) Fig. 18. Place the 1/4 inch internal tooth lockwasher (O) M6.4 flat washer (P) and the 1/4 inch external tooth lockwasher (R) on the screw (G).

4. Position the recessed end (E) Fig. 19 of the splitter bracket (B) against the end of the pivot rod (F), and fasten using the assembly in STEP 3. NOTE: Do not completely tighten screw (G) at this time. Assembly shown in

Fig. 20.

NOTE: Loosely tighten the hardware for further adjustment.

5. Position the splitter (H) Fig. 21 against the splitter support bracket, making certain the two protrusions (K) on the splitter support bracket are inside the slot of splitter (H).

6. Attach the splitter (H) Fig. 22 to the splitter support bracket (B). Place a 1/4 inch external tooth lockwasher and an M6.4 flat washer on an M6x1x20mm hex head screw (L).

7. Insert the screw (L) Fig. 22 through the splitter support bracket (C) and the splitter (H). Place an M6.4 flat washer and a 1/4 inch external tooth lock washer on the screw (L). Thread an M6x1 wing nut (M) Fig. 23 on the screw (L) Fig. 23.

Fig. 26

Fig. 28Fig. 27

ASSEMBLING RIP FENCE

1. Thread the M8x1.25 hex nut (A) Fig. 26, approximately halfway on the stud of the handle (B).

2. Thread the handle (B) Fig. 26 into the tapped hole (C) in the fence cam (D). Tighten the hex nut (A) Fig. 27 against the cam (D).

3. The rip fence is usually set up on the right hand side of the saw table. Lift the lock handle (B) Fig. 28 and position the fence on the table. Push down on the handle (B) Fig. 28 to lock the fence in place.

Fig. 25Fig. 24

Fig. 23

NOTE: Before tightening the wing nut (M) Fig. 23, make certain a gap of at least 1/8 inch is between the bottom edge of the splitter (N) and the top surface of the table (P) and that the protrusions (K) are inside the slot of the splitter assembly (H).

8. Use a straight edge to see if the splitter (H) Fig. 24 is aligned with the saw blade (R). If an adjustment is necessary, the splitter (H) can be moved left or right and rotated.

9. When the splitter is properly aligned with the saw blade, tighten the screws (C) and (G) Fig. 25.

MOVING THE SAW

To move the saw, grasp the side of the table opposite of the wheels. Lift the saw so that it is slightly off the floor and pull the table to the desired location as shown.

CAUTION: Not all floors are perfectly smooth, check both wheels each time you move the saw

to ensure that they are not engaging the floor when the saw is at rest. Make sure all bolts are securely fastened.

BLADE HEIGHT ADJUSTMENT

To adjust the height of the saw blade, turn the handwheel (A) Fig. 31. Turning the handwheel clockwise lowers the blade and turning the handwheel counter-clockwise raises the blade.

Fig. 31

Fig. 30

Fig. 29

OPERATION

STARTING AND STOPPING SAW

The on/off switch (A) Fig. 29 is located on the front of the saw cabinet. To turn the saw “ON”, move the switch (A) up to the “ON” position. To turn the saw “OFF”, move the switch (A) down to the “OFF” position.

WARNING: Make sure that the switch is in the “OFF” position before plugging in the power cord. In the event of a

power failure, move the switch to the “OFF” position. An accidental start-up can cause injury.

LOCKING SWITCH IN THE “OFF” POSITION

IMPORTANT: When the tool is not in use, the switch should be locked in the “OFF” position to prevent unauthorized use. To lock the tool, grasp the switch toggle (B) and pull it out of the switch (Fig. 30). With the switch

toggle (B) removed, the switch will not operate. However, should the switch toggle be removed while the saw is running, the machine can be turned “OFF,” but cannot be restarted without re-inserting the switch toggle (B).

OPERATIONAL CONTROLS AND ADJUSTMENTS

Fig. 32

BLADE TILT ADJUSTMENT

To tilt the saw blade, loosen the lock handle (A) Fig. 32 and move the handwheel (B) until the blade is at the desired angle. Tighten the lock handle (A).

NOTE: The lock handle (A) is spring-loaded. Pull out on the handle (A) and reposition it on the serrated stud located underneath the handle.

WARNING: THE BLADE TILTING LOCK HANDLE

(A) MUST BE LOCKED DURING ALL CUTTING OPERATIONS.

TO ADJUST POSITIVE STOP AT 90 DEGREES

1. Raise the saw blade to its maximum height.

2. Loosen the blade tilting lock handle (A) Fig. 32, move the blade tilting mechanism (B) as far as possible to the left, and tighten the blade tilting lock handle (A).

3. Place a square (A) Fig. 33 on the table with one end of the square against the blade, and check to see if the blade is 90 degrees to the table. If not, loosen the screw (B) Fig. 33 a few turns and move the blade tilting mechanism until the blade is 90 degrees to the table. Tighten the blade tilting lock handle (A) Fig. 32, and tighten the screw (B) Fig. 33 until it stops.

Fig. 33

90 AND 45 DEGREE POSITIVE STOP ADJUSTMENTS

Your saw is equipped with positive stops for rapid and accurate positioning of the saw blade at 90 and 45 degrees to the table.

WARNING: DISCONNECT MACHINE FROM POWER SOURCE.

Fig. 34

TO ADJUST POSITIVE STOP AT 45 DEGREES

1. Raise the saw blade to its maximum height.

2. Loosen the blade tilting lock handle (A) Fig. 32, move the blade tilting mechanism (B) as far as possible to the right, and tighten the blade tilting lock handle (A).

3. Place a square (A) Fig. 34 on the table with one end of the square against the blade, and see if the blade is 45 degrees to the table. If not, loosen the screw (C) Fig. 34 a few turns and move the blade tilting mechanism (B) Fig. 32, until the blade is 45 degrees to the table. Tighten the blade tilting lock handle (A) Fig. 32, and tighten the screw (C) Fig. 34 until it stops.

RIP FENCE OPERATION AND ADJUSTMENTS

1. To move the rip fence (A) Fig. 35 along the table, lift up the fence locking lever (B), slide the fence to the desired location on the table, and push down the fence locking lever (B).

2. The pointer indicates the distance from the fence to the saw blade. If an adjustment is required, loosen the screw (C) Fig. 35 and adjust.

IMPORTANT: The rip fence must be properly aligned to the miter gauge slot to prevent kickback when ripping.

3. The saw blade is set parallel to the miter gauge slot at the factory. The fence must be parallel to the miter gauge slot to do accurate work and to prevent kickback when ripping. To check the alignment:

4. Position the fence next to the miter gauge slot (Fig.

35). Clamp the fence to the table by pushing the locking lever (B) down . The edge of the fence should be parallel to the miter gauge slot.

Fig. 35

TABLE INSERT ADJUSTMENT

WARNING: DISCONNECT MACHINE FROM

POWER SOURCE.

1. Make sure that the table insert (A) Fig. 36, is flush with, or slightly below, the surface of the table (B).

2. If the table insert is above the surface of the table, tighten the two table insert screws (C) Fig. 36 to lower the insert.

Fig. 36

5. If an adjustment is necessary, loosen the two screws (D) Fig. 35, and lift the locking lever (B). While holding the fence bracket (F) firmly toward the front of the saw, move the rear of the fence (A) until it is parallel with the miter gage slot. Tighten two screws (D) and push locking lever down (B).

6. Adjust the clamping action of the fence (A) Fig. 35 by lifting the locking lever (B) and turning the screw (E) clockwise to increase, or counterclockwise to decrease the clamping action of the fence.

MITER GAUGE OPERATION AND ADJUSTMENTS

For cross-cutting (blade set 90 degrees to the table), the miter gauge can be used in either table slot. For bevel cross-cutting (with the blade tilted), use the miter gauge in the right table slot only so that the blade will be tilted away from the miter gauge and your hands.

To operate the miter gauge, loosen the lock knob (E) Fig. 37, and rotate the miter gauge to the desired angle.

Fig. 37

ADJUSTING BLADE PARALLEL TO MITER GAUGE SLOTS

The blade was adjusted parallel to the miter gauge slots at the factory. In order to ensure accurate cuts and help prevent kickback, check this adjustment.

To adjust:

WARNING: DISCONNECT MACHINE FROM POWER SOURCE.

1. Raise the blade to its highest position and adjust the blade so that it is 90 degrees to the table.

2. Select a tooth on the saw blade that is set to the left. Mark this tooth with a pencil or marker.

3. Use a combination square (A) Fig. 38 against the miter gauge slot and adjust the blade (B) of the square until it touches the marked tooth.

4. Rotate the blade and check the same marked blade tooth at the rear of the saw table (Fig. 39).

Fig. 38

Fig. 39

Fig. 40

5. If the front and back measurements (Figs. 38 and

39) are not identical, you can adjust the blade. Start by loosening the nuts below the four screws (C) Fig. 40 on the table. Then loosen the screws (C). Carefully move the saw blade until the blade is parallel to the miter gauge slot. When done, tighten four nuts under the table and the four screws (C) Fig. 40 securely.

NOTE: If sufficient adjustment cannot be achieved by loosening the screws (C) Fig. 40, loosen the screw (D) Fig. 40 necessary to make the adjustment.

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