Charnwood W625 Operator's Manual

TABLE SAW

OPERATORS MANUAL

MODEL: W625

Charnwood, Cedar Court, Walker Road,

Hilltop Industrial Estate, Bardon Hill, Leicestershire, LE67 1TU

Tel. [phone] Fax. [phone]

email: [e-mail] website: www.charnwood.net

GENERAL SAFETY RULES

WARNING: Do not attempt to operate the machine until you have read thoroughly and understood

completely all instructions, rules, etc. contained in this manual. Failure to comply may result in
accidents involving fire, electric shock, or serious personal injury. Keep this owner's manual and
review frequently for continuous safe operation.

1. Know your machine. For your own safety, read the owner's manual carefully.
Learn its application and limitations, as well as specific potential hazards
pertinent to this machine.

2. Make sure all tools are properly earthed.

3. Keep guards in place and in working order. If a guard must be removed for
maintenance or cleaning, make sure it is properly replaced before using the
machine again.

4. Remove adjusting keys and spanners. Form a habit of checking to see that
the keys and adjusting spanners are removed from the machine before
switched it on.

5. Keep your work area clean. Cluttered areas and workbenches increase the
chance of an accident.'

6. Do not use in dangerous environments. Do not use power tools in damp or
wet locations, or expose them to rain. Keep work areas well illuminated.

7. Keep children away. All visitors should be kept a safe distance

8. from the work area.

9. Make workshop childproof. Use padlocks, master switches and
remove starter keys.

10. Do not force the machine. It will do the job better and be safer at the rate
for which it is designed.

11. Use the right tools. Do not force the machine or attachments to do a job for
which they are not designed. Contact the manufacturer or distributor if there is
any question about the machine's suitability for a particular task.

12. Wear proper apparel. Avoid loose clothing, gloves, ties, rings, bracelets, and
jewellery which could get caught in moving parts. Non-slip footwear is
recommended. Wear protective hair covering to contain long hair.

13. Always use safety glasses. Normal spectacles only have impact resistant lenses.
They are not safety glasses.

14. Do not over-reach. Keep proper footing and balance at all times.

15. Maintain the machine in good condition. Keep the machine clean for best and safest
performance. Follow instructions for lubrication and changing accessories.

16. Disconnect the machine from power source before servicing and when
changing the blade.

17. Never leave the machine running unattended. Turn the power off. Do not leave the
machine until it comes to a complete stop.

18. Do not use any power tools while under the effects of drugs, alcohol or medication.

19. Always wear a face or dust mask if operation creates a lot of dust and/or chips.
Always operate the tool in a well ventilated area and provide for proper dust removal.
Use a suitable dust extractor.

ADDITIONAL RULES FOR CIRCULAR SAWS

1. Ensure that the saw table is clear of off-cuts, tools or anything else that might foul the
work-piece.

2. If your saw has a dust extractor hose connected to the crown guard, ensure that it is
held clear of the table and will not foul the work-piece as it passes over the table.

3. When cutting large sheets of material or long boards use one or more roller stand(s)
to support the work or have a competent helper to support it as it feeds off the rear of
the table.

4. Never use the saw without the riving knife and check that it is in line with the blade
before using the saw.

5. Always use a brush to clear the table of dust or debris. NEVER use your hands,
especially when the machine is running.

6. ALWAYS USE A PUSH STICK WHEN IT IS NECESSARY TO PUSH ANY PIECE
OF MATERIAL OF SUCH SIZE THAT IT WOULD BRING YOUR HANDS WITHIN 30
CM OF THE BLADE.

7. Do not cut material that is badly warped or which has screws or nails in it

8. Be extra vigilant when cutting stock which has loose knots in it as these may fly out
of the saw.

9. NEVER remove the table insert when the saw is running.

10. To avoid exposure to hazardous dust, do not use this saw without connecting it to a
suitable dust extractor.

11. Always work with a sharp saw blade and feed the work at a rate suited to the
thickness and hardness of the material.

Note: This table saw has been designed and built solely as a woodworking machine.

Do not modify it in any way or use for anything other than its designated purpose. Neither the
manufactures nor the supplies are liable for any damage or injury caused by incorrect
assembly, operation or electrical connection of this machine.

Specification

Table size

550(w) x 1600(d)mm

Table size with optional table extension
Table height

950(w) x 1600(d)mm

800mm

Motor (carbon brush) 1600W, 240v single phase

Blade diameter and bore 300mm (12”) 30mm

Blade rotation speed (no load)

3000 rpm

Maximum depth of cut at 90

o

60mm

Maximum depth of cut at 45

o

40mm

Maximum cutting width

290mm (12”)

Cutting width with optional table extension

690 mm (27”)

Dust extractor hose connection
Dimensions (WxDxH)

100mm

600mm x 1690mm x 1050mm

Weight

60 kg

Rating

Trade

(Note: Imperial measurements approximate)

Risk of Injury! Wear Eye Wear Ear
Never reach into Protection Protection
the running saw blade.

Rating Description

Trade: Suitable for daily use by professional woodworkers.
Continuously rated, high power and a heavy duty construction. Typically used by several different

operators in a small or medium sized business. Will be used up to the machines maximum limit with
some long work periods. Expected maximum use of 1000 hours annually.

Unpacking

This saw is best unpacked on the floor as it is quite
heavy.

Open the carton, carefully unpack all of the contents
and lift the body of the saw onto a bench, leaving it
inverted.

Familiarise yourself with the parts and take the time to
sort out the various types of nuts and bolts.

Assembly

Leave all bolts finger tight until assembly of the legs is
completed.

Locate the leg with the square hole cut out for the NVR
switch and place it on the table as shown, inside the
turned down edges of the table.

Secure the leg with 4 bolts. M6 x 16mm long bolts with
washes and nuts.

Repeat for the other 3 legs

Next, bolt on the four braces which fit half way down each
leg. There are 2 long rails and 2 short rails.

Bolt the four rails together as shown, using three M6 x
16mm bolts with washers and nuts in each corner.
It does not matter which pair, the long or the short are on
top but please keep this symmetrical.

Place the four black rubber feet on the legs.
True up the assembly and tighten all the bolts.

Locate the rear extension table.

Attach the two support braces, using four M6 x 16mm
bolts with washers and nuts. Noting that they fit inside the
table and on top of the floor stand rail.

Locate the ripping fence guide rail and bolt it onto the front
of the table. Use an M6 x 16mm bolt with washer and nut.

At the other end of the fence guide rail, use a longer bolt
M6 x 20mm. Note how there is a cut out in the guide rail
which fits over a bolt head.

Offer up the NVR switch and fix it in place with the two
self tapping screws provided.

Bolt on the dust extractor port noting that the side entry
faces away from the motor.
Use four M3 x10mm long bolts.

Fit the wheels using four M6 x 16mm bolts with washers
and nuts.
Adjust them, so that the wheels are just clear of the
ground when all four feet are supporting the saw.

The wheels will make contact with the floor and take the
weight of the saw when it is lifted by means of the
handles, which will be fitted later.

Raise the blade by turning the handle at the front of the
saw (See Using the Table Saw on page 13)

Locate the crown guard, loosen the bolt near the dust port
and fit the guard to the riving knife. The bolt will slide into
the slot at the top of the knife. When it is fully seated,
retighten the bolt.

Loosen the two bolts at the right, rear of the table and slot
in the dust hose support. Retighten the bolts.

Fit one end of the dust collection hose to the spigot on the
back of the crown guard, fit the other end to the side inlet
of the dust extractor port and clip the middle into the
support bracket you have just fitted.

Bolt on the two lifting handles, using two M6 x 16mm
bolts, washers and nuts for each one.

Fit the hook to the front right leg, which is used to hang
the push stick.

Locate the fence carrier assembly and the L shaped
fence. Assemble the fence by sliding two square head
bolts into the T-slot in the extrusion, passing them through
the vertical face of the mitre fence base, securing them
with a washer and yellow knob.

The black handle is used to lock the fence along the guide
rail. When the handle is lifted the fence assembly will slide
smoothly along the rail, when the handle is fully
depressed the fence is locked in position.

This is how the completed fence should look. With it
mounted on the front rail and the adjustable mitre gauge
set to 0° it can be used as a rip fence.

When mounted on the left hand side rail, the mitre angle
can be set for crosscutting, up to 60 degrees each way.

Rip fence

Mitre fence

Optional Side Extension Table

If you have purchased the optional right hand extension
table;

Bolt the two support braces to the right hand side floor
stand rail. This gives support to the table while you are
attaching it.

Push a bolt through each of the two holes adjacent to the
legs. Place a washer and nut on the back end. Leave
them loose and with a good length of the bolt protruding
on the outside of the table.

Slot the table over the two protruding bolts and support
the outer edge by guiding the braces so that they sit
inside the turned down edge of the extension table, as
shown. Level the extension table to the main table and
tighten all the bolts.

Optional Sliding Carriage

Note: If installed, remove the mitre fence guiderail which is bolted to the left hand side of the table.

Unpack the components and familiarise yourself with
them.

Identify the front and rear guide rail carriers. Fit one to
each end of the left hand side of the table, as shown.

Note that the front and rear are different.
To install the carrier, remove two of the bolts which

secure the leg to the table. Refit them with the carrier on
the outside of the table.

Next, bolt on the two support brackets, using three bolts,
with washers and nuts, as shown.

Use the larger M8 bolt here.

Slide the carriage table assembly onto the guide rail, as
shown. There are 6 bearings which sit in contact with the
guide rail. They are a tight fit so you may need to push
to get it started.

The lower pair of bearings can be adjusted to get a tight
fit against the guide rail as necessary.

Fix the guide rail to the carriers with the four hex socket
head bolts provided. Note that the front end of the guide
rail, will project about 110mm in front of the main table.

Fit the remaining two cap head bolts through the ends of
the rail. These will act as travel limit stops for the
carriage and prevent the table from coming off the end
of the rail.

Setting The Sliding Table
Firstly set the height:

These holes are slotted so that the carrier may be
adjusted up or down to bring the sliding carriage to the
correct height. Ideally it will be just proud of the table
(0.5mm to 1mm) to allow the work piece to easily slide
over the main table.

Next set the level:
Use this bolt to level the carriage. Turning the bolt
clockwise, will lift the left hand side of the table. Once a
good level has been achieved tighten the nut up against
the face of the guide rail carrier to lock it.

Use a straight edge (or the fence carrier that you have
removed) to check the level of the sliding table. Here
you see a carriage that needs adjusting. Keep adjusting
the bolts until the sliding table and the main table are
correctly aligned.

Take the pivot bolt, M10 x 65mm, place an M10 steel
washer over the bolt and then pass the bolt through the
fence support. Next place a black plastic washer onto
the bolt and then screw the bolt into the threaded hole in
the sliding table. The plastic washer sits between the
fence support and the sliding table.
Tighten the bolt securely but check the fence can still
pivot freely around this point.

Take the locking handle, place a steel washer over the
bolt and then pass the bolt through the fence support.
Next place a black plastic washer onto the bolt and then
pass the bolt through the hole in the sliding table.
Secure the bolt with a steel washer and nyloc nut. The
plastic washer sits between the fence support and the
sliding table.
Use a spanner to adjust the nyloc nut so that when the
locking handle is pressed down the fence will not pivot.
When the handle is lifted the fence should swing around
pivot point.

Slide the heads of the two bolts, M6 x 45mm, into the T­slot of the mitre fence extrusion, pass them through the
fence support and secure them with washers and the
two black plastic wing nuts.

There is an adjustable, flip-over length stop on the
fence, to speed up repetitive work.

Use a set square to set the mitre fence extrusion at 90
degrees to the blade.
The mitre scale has two fixing screws which can be
loosened to make an adjustment to the scale if
necessary.
Next set the 90 degree return stop. The round silver
stop, has a fixing bolt drilled off centre. With the fence
still locked at the 90 degree position, loosen the fixing
bolt and rotate the stop until it touches the back of the
fence support. Tighten the fixing bolt.

Using The Table Saw

Start / Stop Switch
Blade Angle Scale
Blade Angle Locking Knob
Blade Height Scale
Blade Height Adjustment Handle

On/Off Switch

To turn the saw on, press the green button. Wait for the blade to reach its maximum speed
of rotation before commencing with the cut.
To turn the machine off again, press the red button.
The machine is fitted with an NVR (No Voltage Release) switch. This type of switch is
designed so that if the machine is disconnected from the mains whilst running and then
reconnected, the motor will not automatically restart.

Cutting Depth

Adjustments to the cutting depth should be made only when the saw is not running.
Turn the crank handle to set the blade to the required depth. Turn anticlockwise to lower the
blade, turn clockwise to raise the blade. The blade height should always be set so that only
the carbide tips of the blade (approx. 5mm) projects above the wood.

Angle of Cut

Adjustments to the angle of cut should be made only when the saw is not running.

To tilt the blade for making bevel cuts, there are 2 locking knobs. Loosen both of the yellow knobs,
located at the front and the rear of the machine. Push the bottom blade housing around to the required
angle, a scale is provided for guidance. Lock the angle by tightening both of the yellow knobs.

Cutting Width

The rip fence is used to make longitudinal (with the grain) cuts. Set the fence to the required
dimension by measuring with a rule between the fence and the blade. Clamp the fence in
place by firmly pressing down the locking lever.

To avoid kickback, the far end of the fence extrusion should be set correctly.
The fence extrusion should be set so that the end is level with the centre of the saw blade.
This allows the timber space to expand into, after the cut has been made.
When cutting wider pieces the fence extrusion can be moved further towards the back of the
blade, in a line projecting at roughly at 45 degrees out from the centre of the blade.

Mitre Fence

To cut across the grain, use the sliding mitre fence. To set 90 degrees or any other angle,
undo the locking handle and rotate the quadrant to the desired angle. Lock the angle setting
with the plastic handle. The fence extrusion can then be adjusted so thet the end is close to
the blade, giving better support to the work piece. When setting the fence, take care to
ensure the fence will not contact the blade.

Making a cut

Ensure there is enough space around the table for the work piece before starting the cut.
Position your feet in a stable and balanced stance.
When feeding the timber, place your hands on the section of timber being kept. Never hold
the waste part of the timber.
Never force timber through the saw, always let it cut at its own speed.
When cutting narrow pieces - use the push stick.

Blade Removal and Replacement

Always switch off and unplug the saw before removing or replacing the blade.

The table insert panel surrounding the blade is
removable to allow access to the interior of the saw.

Remove the crown guard and then remove the four
screws using a cross head screw driver and lift out the
panel.

The saw is supplied with 2 spanners. Use the peg
spanner to lock into the saw blade flange and hold the
blade stationary. Use the 13mm spanner to undo the
locking bolt.
Please Note: The bolt is Left Hand Thread
Turn it clockwise to undo it.
Refit the blade, flange and bolt in the same way.

Troubleshooting

Saw vibrates

Check all nuts and bolts for tightness and
check that blade is not damaged.

Cuts are slow, wood is blackened

Examine the blade. If any Tungsten tips are
missing or broken the blade should be
replaced. If the tips are blunt, the saw blade
may be professionally sharpened.

Saw stalls

Feed rate too high, slow down.

Rip fence is not parallel to blade

Lower saw guard fills with dust

When pressing start, nothing happens

Bring the fence up to the blade and re-align
the fence so it is parallel, using the large
locking know on the mitre fence base.

It is essential to use a vacuum extractor or
chip collector with this machine. If one is
being used, check for blockages in the hose.

Check power supply, fuse in plug and switch.

Declaration of Conformity for CE Marking

Charnwood Declare that Woodworking Circular Saw, Model W625
Conforms with the following Directives: Machinery Directive 2006/42/EC

Low Voltage Directive 2006/95/EC
EMC Directive 2004/108/EC

And further conforms to the machinery example for which the EC type examination
Certificate No. BM 50163884, AN 50232926 and AE 50221146 have been issued by TUV
Rheinland LGA Products GmbH, Tillystrasse 2, 90431, Nurnberg.

I hereby declare that equipment named above has been tested and found to comply with the
relevant sections of the above referenced specifications. The machinery complies with all
essential requirements of the directive.

Signed: Dated: 11/11/2009 Location: Leicestershire
Richard Cook, Director

Charnwood W625 Exploded Diagram

W625 Parts List

Item

Part

QTY

Item

Part

QTY

01

Table

1

55

Motor, Induction 240v, 1600w

1

02

Leg 4 56

NVR switch

1

03

Rail - long

2

57

Depth of cut adjustment handle

1

04

Rail - short

2

58

Tilt locking knob

1

05

Rear extension table

1

59

Hinge

2

06

Brace for extension table

2

60

Pivot bolt (M6 x 8mm special)

1

07

Saw blade

1

61

Plastic Nut

2

08

Locating plate

1

62

Pointer

1

09

Spacer

2

63

Dust extractor hose (not shown)

1

10

Riving knife support

1

64

Cam

1

11

Pressure plate

1

65

Cap head bolt M6 x 20mm

6

12

Riving knife

1

66

Nut M6

6

13

Crown guard - right

1

67

Washer M6

58

14

Crown guard - left

1

68

Spring washer M6

10

15

Rise and fall handle

1.

69

Hex. head bolt M6 x 16mm

45

16

Guide block

1

70

Self tapping screw 14mm

4

17

Connection block

1

71

Coach bolt

2

18

Motor bracket

1

72

Coach bolt

1

19

Blade housing box

1

73

Pan head screw M6 x 25mm

1

20

Blade assy. support - front

1

74

Coach bolt M6 x 20mm

2

21

Blade assy. support - rear

1

75

Hex. Nut

1

22

Blade arbour

1

76

Hex. head bolt M8 x 45mm

2

23

Blade flange - inner

1

77

Hex. head bolt

2

24

Blade flange - outer

1

78

Hex. head bolt

1

25

Blade housing plate

1

79

Hex. head bolt

1

26

Protective cap

1

80

Hex. head bolt M6 x 16mm

45

27

Pointer

1

81

Hex. head bolt

4

28

Mitre fence base

1

82

Hex. head bolt

4

29

Fence Extrusion

1

83

Hex. head bolt

4

30

Fence guide rail

2

84

Hex. Nut

1

31

Roundhead Screw M3 x 40mm

2

85

Locking handle

1

32

Circlip 6mm Diameter

1

86

Hex. Nut

1

33

Spring

1

87

Hex. Nut M10

1

34

Washer M6

58

88

Hex. Nut

2

35

Locking plate

1

89

Self locking nut

3

36

Mitre fence locking knob

1

90

Self locking nut M6

4

37

Pin 1 91

Coach bolt

2

38

Table insert

1

92

Screw

2

39

Dust extraction port

1

93

Round head bolt M3 x 10mm

11

40

Scale

1

94

Screw

5

41

Angle indicator

1

95

Hex Head Bolt M3 x 10mm

11

42

n/a 96

Mitre gauge support plate

1

43

Wheel

2

97

Bolt M3 x 16mm

4

44

Wheel bracket - left

1

98

Self tapping screw M2 x 24mm

5

45

Wheel bracket - right

1

99

Lock washer M3

7

46

Axle

1

100

Lock washer

1

47

Push Stick

1

101

Self locking nut M8

12

48

Handle lift limiter

2

102

Circlip 12mm Diameter

1

49

Handle attachment bracket

2

103

Large washer M6 x 18mm

9

50

Lifting Handle

2

104

Large washer

4

51

Dust hose support

1

105

Self locking nut M10

1

52

Blade Changing Spanner

106

Rubber foot

4

53

Depth of cut scale

1

107

Circlip

1

54

Push Stick hanger

108

Hex. nut

2

Charnwood W625SC Exploded Diagram - Sliding Carriage Assembly

W625SC Parts List

Item

Part

QTY

Item

Part

QTY

01

Cap head bolt M6 x 16mm

2

19

Cap head bolt

1

02

Guide rail carrier – rear

1

20

Self tapping screw

2

03

End cap

2

21

End cap

1

04

Wing nut M6

8

22

Mitre fence extrusion

1

05

Hex head bolt M6 x 16mm

2

23

Pivot bolt M10 x 65mm

1

06

Support bracket – rear

1

24

Plastic Washer M10

1

07

Hex. head bolt M6 x 16mm

4

25

End cap

2

08

Washer M6

4

26

Fence Support

1

09

Spring washer M6

2

27

Washer M10

2

10

Nut M6

2

28

Sliding Table

1

11

End cap

1

29

Wing nut M6

2

12

Washer M6

16

30

Cap head bolt M6 x 16mm

4

13

Spring washer M6

4

31

Support bracket – front

1

14

Nut M6

8

32

Guide rail carrier – front

1

15

Bolt (M6 x 45mm special)

2

33

Bearing bracket

1

16

Flip-over stop

1

34

Guide rail

1

17

Locking handle

1

35

Hex. head bolt M6 x 16mm

8

18

Stop bracket

1