Delta Sidekick 36-235 Instruction Manual

INSTRUCTION MANUAL

Sidekick

TM

12 Compound Miter Saw

(Model 36-235)

REVISED 6-30-00 PA R T NO. 1349865

'Delta International Machinery Corp. 1999

2

TABLE OF CONTENTS

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ADDITIONAL SAFETY RULES FOR COMPOUNDMITER S AW S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

UNPACKING AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Moving Cuttinghead To The Up Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Moving Table To The 90 Degree Cut-Off Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Assembling Extension Table And Fence Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembling W ork Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Assembling Dust Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

FASTENING MACHINE TO SUPPORTING SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

EXTENSION CORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CONNECTING SAW TO POWERSOURCE

Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

OPERATING CONTROLS AND ADJUSTMENTS

Starting And Stopping Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Locking Switch In The OFF Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rotating Table For Miter Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Adjusting Clamping Action Of Table Locking Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Adjusting Sliding Fit Between Movable Table And Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adjusting Fence 90 Degrees To Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table Hazard Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

W ork Clamp Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

T ilting Cuttinghead For Bevel Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Adjusting Sliding Fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Adjusting Chip Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Adjusting 90 And 45 Degree Bevel Positive Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Adjusting Sliding Fit Between Trunnion And Bevel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Adjusting Tension Of Cuttinghead Return S pring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Adjusting Sliding Fit Between Cuttinghead Arm And Trunnion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Adjusting Downward Travel Of Saw Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Tool Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Adjusting Blade Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

TYPICAL OPERATIONS A N D HELPFUL HINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Auxiliary Wood Fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cutting Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cutting Bowed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Constructing Work Support Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cutting Crown Moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

MAINTENANCE

Changing The Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Brush Inspection And R eplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

W ARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3

SAFETY RULES

W oodworking can be dangerous if safe and proper operating procedures are not followed. As with all machinery, there are cert ain
hazards involved with the operation of the product. Using the machine with respect and caution will considerably lessen the possi ­bility of personal injury . However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result.
Safety equipment such as guards, push sticks, hold-downs, featherboards, goggles, dust masks and hearing protection can reduce
your potential for injury . But even the best guard won t make up for poor judgment, carelessness or inattention. Always use common
sense and exercise caution in the workshop. If a procedure feels dangerous, don t try it. Figure out an alternative procedure that feels
safer . REMEMBER: Your personal safety is your responsibility.

This machine was designed for cert ain applications only . Delt a Machinery strongly recommends that this machine not be modified
and/or used for any application other than that for which it was designed. If you have any questions relative to a p articular applica ­tion, DO N O T use the machine until you have first cont acted Delt a to determine if it can or should be performed on the product.

Technical Service Manager
Delt a International Machinery Corp.
4825 Highway 45 North
P.O. Box 2468
Jackson, TN 38302-2468

(IN CANADA: 505 SOUTHGATE DRIVE, GUELPH, ONTARIO N1H 6M7)

W ARNING: FAILURE TO FOLLOW THESE RULES

M AY RESULT IN SERIOUS PERSONAL INJURY

1. FORYOURO W N SAFETY, READ INSTRUCTION MANUAL
BEFORE OPERATING T H E TO O L. Learn the tool s application and
limit ations as well as the specific hazards peculiar to it.

2. KEEP GUARDSIN PLACE and in working order.

3. ALW AYS WEAREYEPROTECTION.

4. GROUND ALL TOOLS. If tool is equipped with three-prong
plug, it should be plugged into a three-hole electrical recept acle. If
an adapter is used to accommodate a two-prong recept acle, the
adapter lug must be att ached to a known ground. Never remove the
third prong.

5. REMOVE ADJUSTING KEYS A ND WRENCHES. Form habit
of checking to see that keys and adjusting wrenches are removed
from tool before turning it on.

6. KEEP WORKAREACLEAN. Cluttered areas and benches
invite accident s.

7. DON T USE IN DANGEROUS ENVIRONMENT. Don t use
power tools in damp or wet locations, or expose them to rain. Keep
work area well-lighted.

8. KEEP CHILDREN AND VISITO R S A W A Y . All children and
visitors should be kept a safe dist ance from work area.

9. MAKE WORKSHOP CHILDPROOF with p adlocks, master
switches, or by removing st arter keys.

10. D O N T F O R C E T O O L . It will do the job better and be safer at
the rate for which it was designed.

11. USE RIGHT TOO L. Don t force tool or att achment to do a job
for which it was not designed.

12. WEAR PROPER APPAREL. No loose clothing, gloves, neck ­ties, rings, bracelet s, or other jewelry to get caught in moving p arts.
Nonslip footwear is recommended. Wear protective hair covering to
cont ain long hair .

13. ALW AYS USE SAFETY GLASSES.W ear safety glasses.
Everyday eyeglasses only have impact resist ant lenses; they are not
safety glasses. Also use face or dust mask if cutting operation is dusty.

14. SECURE WORK. Use clamp s or a vise to hold work when
practical. It s safer than using your hand and frees both hands to
operate tool.

15. DON T OVERREACH. Keep proper footing and balance at all
times.

16. MAINTAIN TOOLSIN TO P CONDITION. Keep tools sharp
and clean for best and safest performance. Follow instructions for
lubricating and changing accessories.

17. DISCONNECT TOOLS before servicing and when changing
accessories such as blades, bit s, cutters, etc.

18. USERECOMMENDEDACCESSORIES. The use of acces ­sories and att achments not recommended by Delt a may cause
hazards or risk of injury to persons.

19. REDUCETHE RISK O F UNINTENTIONAL STARTING. Make
sure switch is in OFF position before plugging in power cord.

20. NEVER STAN D O N TOOL. Serious injury could occur if the
tool is tipped or if the cutting tool is accident ally cont acted.

21. CHECK DAMAGEDPARTS. Before further use of the tool, a
guard or other p art that is damaged should be carefully checked to
ensure that it will operate properly and perform it s intended function

check for alignment of moving p art s, binding of moving p arts,
breakage of p art s, mounting, and any other conditions that may
affect it s operation. A guard or other p art that is damaged should be
properly rep aired or replaced.

22. DIRECTION O F FEED. Feed work into a blade or cutter
against the direction of rot ation of the blade or cutter only .

23. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN
POWEROFF. Dont leave tool until it comes to a complete stop.

24. DRUGS, ALCOHOL, MEDICATION. Do not operate tool while
under the influence of drugs, alcohol or any medication.

25. MAKE SURE TOOL IS DISCONNECTED FROM POWER
SUPPLY while motor is being mounted, connected or reconnected.

26. W ARNING: The dust generated by certain woods and wood
product s can be injurious to your health. Always operate machinery
in well ventilated areas and provide for proper dust removal. U s e
wood dust collection systems whenever possible.

27. W ARNING: SOME DUST CREATED BY POWER SANDING,
SAWING, GRINDING, DRILLING, AND OTHER CONSTRUCTION
ACTIVITIES cont ains chemicals known to cause cancer, birth
defect s or other reproductive harm. Some examples of these chem ­icals are: lead from lead-based p aint s; cryst alline silica from bricks
and cement and other masonry products, and arsenic and chromi ­um from chemically-treated lumber. Y our risk from these exposures
varies, depending on how of ten you do this type of work. T o 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 p articles.

SAVE THESE INSTRUCTIONS.

4

ADDITIONAL SAFETY RULES FOR

COMPOUND MITER S AW S

1. W ARNING: U S E O NLY CROSS-CUTTING SAW
BLADES. D O NOT USE BLADES WITH DEEP GUL­LETS A S THEY CAN DEFLECT AN D CONTACT
GUARD.

2. W ARNING: Do not operate the miter saw until it is
completely assembled and inst alled according to the
instructions.

3.IF Y O U A R E N O T thoroughly familiar with the oper ­ation of compound miter saws, obt ain advice from your
supervisor, instructor or other qualified person.

4. A LW A Y S hold the work firmly against the fence and
table. D O N O T perform any operation freehand.

5. W ARNING: ALW AY S keep hands out of p ath of saw
blade. If the workpiece you are cutting would cause your
hand to be inside the t able hazard area (see section

TABLE HAZARD AREA ), the workpiece should be

clamped in place before making cut.

6. B E SUREblade is sharp, runs freely and is free of
vibration.

7. ALLOW the motor to come up to full speed before
st arting cut.

8. KEEP motor air slot s clean and free of chip s.

9. ALWAYSMAKE SURE rot ating t able is tight before
cutting, even if the t able is positioned in one of the
positive stop s.

10. BE SURE blade and flanges are clean and that arbor
screw is tightened securely.

11. U S E only blade flanges specified for your saw .

12. NEVER use blades larger or smaller in diameter than
recommended. Recommended size of blade is 12 in
diameter.

13. NEVER apply lubricant s to the blade when it is running.

14. A L W A Y S check the blade for cracks or damage
before operation. Replace cracked or damaged blade
immediately.

15. NEVER use blades recommended for operation at
less than 4800 RPM.

16. U S E the blade guard at all times.

17. A L W A Y S keep the lower blade guard in place and
operating properly.

18. NEVER reach around or behind saw blade.

19. MAKE SURE blade is not cont acting workpiece be­fore switch is turned on.

20. NEVER lock the switch in the ON position.

21. IMPORTAN T:Af ter completing cut, release power
switch and wait for coasting blade to stop before return ­ing saw to raised position.

22. TURN OFF S AW and M A K E SURE blade has come
to a complete stop before removing or securing work ­piece, changing workpiece angle or changing the angle
of the blade.

23. D O N O T remove jammed or cut-off pieces until
blade has stopped.

24. NEVER cut ferrous met als or masonry.

25. NEVER recut small pieces.

26. PROVIDE adequate support to the sides of the saw
table for long workpieces.

27. NEVER use the miter saw in an area with flammable
liquids or gases.

28. NEVER use solvent s to clean plastic p art s. Solvent s
could possibly dissolve or otherwise damage the material .
Only a sof t, damp cloth should be used to clean plastic
parts.

29. DISCONNECT saw from power source before ser ­vicing or changing blades.

30. DISCONNECT saw from power source and clean
the machine before leaving it.

31. MAKE SURE the work area is cleaned before leaving
the machine.

32. SHOULD any part of your miter saw be missing,
damaged or fail in any way, or any electrical component
fail to perform properly , shut of f switch and remove plug
from power supply outlet. Replace missing, damaged or
failed p art s before resuming operation.

33. ADDITIONAL INFORMATION regarding the safe
and proper operation of this product is available from the
National Safety Council, 1121 Spring Lake Drive, It asca,
IL 60143-3201, in the Accident Prevention Manual for
Industrial Operation and also in the Safety Dat a Sheet s
provided by the NSC. Please also refer to the American
National Standard Institute ANSI 01.1 Safety Require­m e n t s for W oodworking Machinery and the U.S. Dep art­ment of Labor OSHA 1910.213 Regulations.

34. S AVE THESE INSTRUCTIONS. Refer to them fre ­quently and use them to instruct others.

5

UNPACKING A ND CLEANING

Fig. 2

Your new compound miter saw is shipped complete in
one carton. Carefully unp ack the machine and all loose
items from the carton. IMPORTANT:D O NO T LIFT T H E
MITER S AW B Y TH E SWITCH HANDLE O R TABLE
CONTROL HANDLE AS THIS M AY CAUSE MIS­ALIGNMENT. A LW A Y S LIFT T H E MACHINE B Y THE
BASE. Remove the protective coating from all unp ainted
parts. This coating may be removed with a sof t cloth
moistened with kerosene (do not use acetone, gasoline,
or lacquer thinner for this purpose). Figure 2 illustrates
the saw removed from the carton. Note that the machine
is shipped with the cuttinghead locked in the down
position and the t able rot ated to the 45 degree lef t miter
position. Figure 3 illustrates the loose items supplied with
your machine.

1 -Extension t able

2 -Fence slide

3 -Fence slide support

4 -Dust bag

5 - W ork clamp

6 -Arbor and fence wrench

7 -1/8 hex wrench

8 -5/32 hex wrench

9 -Open end wrench

10 -Lock knobs for work clamp (2)

11 - Lock handle for slide fence

12 -1/4 flat washer

Fig. 3

13 -5/16 flat washer (2)

14 -5/16 lock washer (2)

15 -5/16-18 x 1/2 long hex head screw (2)

16 -5/16 flat washer (2)

17 -5/16 lock washer (2)

18 - 5/16-18 x 1-1/4 long hex head screws (2)

17

16

18

13

14

15

12

9

11

10

8

7

6

5

3

2

1

4

6

ASSEMBLY INSTRUCTIONS

W ARNING: F O R YOUR O W N SAFETY, DO NOT CONNECT THE MITER S AW TO THE
POWER SOURCE UNTIL THE MACHIN E IS COMPLETELY ASSEMBLED AN D YOU
HAVE READAND UNDERSTO O D THE ENTIRE OWNERSMANUAL.

Fig. 4

Fig. 5

Fig. 6

MOVING CUTTINGHEAD
TO THE UP POSITION

1. Pull out cuttinghead lockpin (A) Fig. 4, and move the
cuttinghead (B) to the up position.

2. Fig. 5, illustrates the lockpin (A) pulled out and the
cuttinghead (B) in the up position.

MOVING TABLE TO
THE 90 DEGREE
C U T-OFF POSITION

1. Depress table lock lever (A) Fig. 6, and rot ate t able (B)
to the 90 degree straight cut-of f position. Then release
lock lever (A).

B

A

B

A

B

A

7

Fig. 7

Fig. 7A

Fig. 7B

Fig. 7C

2. Fig. 7, illustrates the t able (B) in the 90 degree
straight cut-of f position. NOTE: Table lock lever (A) must
be depressed when rotating t able. When lock lever (A) is
not depressed, the t able is in the locked position and
cannot be moved.

3. For proper operation and adjustment of the t able, refer
to sections, R O T A TING TABLE FOR MITER CUTTING,

ADJUSTING CLAMPING ACTION O F TABLE LOCKING
MECHANISM and ADJUSTING SLIDING FIT BETWEEN
M O VABLE TABLE AND BASE.

ASSEMBLING EXTENSION
TABLE AND FENCE SLIDE

1. Place 5/16 lockwasher and 5/16 flat washer on
each 1/2 long hex head screw (A) Fig. 7A, and thread
the two screws (A) into the two threaded holes on lef t
side of saw t able, as shown. NOTE: Only thread the
screws a few threads into the holes at this time.

2. Assemble the table extension (B) Figs. 7A and 7B, to
lef t side of saw t able making sure groove of table exten ­sion (B) is inside flat washers as shown in Fig. 7B.

3. Using a straight edge (C) Fig. 7C, make cert ain
extension t able (B) is level with saw t able (D) as shown,
and tighten the two screws (A) Fig. 7B.

B

A

B

A

B

A

B

C

D

8

4. Assemble the fence slide support (E) Fig. 7D, to the
extension t able (B) using the two 1-1/4 long hex head
screws, 5/16 lockwashers and 5/16 flat washers (F).
Bring screws up through the two holes (G) in t able exten ­sion and thread them into the two threaded holes (H) on
bottom of fence slide support. NOTE: Do not completely
tighten screws at this time.

Fig. 7D

Fig. 7E

Fig. 7F

Fig. 7HFig. 7G

5. Using a straight edge (C) Fig. 7E, make cert ain
fence slide support (E) is level with saw fence (J) as
shown, and tighten the two screws that were assembled
in STEP 4.

6. Position the fence slide (K) Fig. 7F , in position on top
of saw fence (J) and fence slide support (E). Slide fence
slide (K) back and forth several times to check alignment
of fence slide support (E) and make final adjustment to
fence slide support if necessary.

7. Remove screw and spring (L) Fig. 7G, and lock
handle (M) from locking stud (N) as shown.

8. Place 1/4 flat washer (O) Fig. 7G, onto locking stud
(N) and insert locking stud (N) Fig. 7H, through slot in
fence slide and thread locking stud into threaded hole in
fence slide support (E) as shown.

H

F

B

G

E

H

J

E

J

E

K

O

N

M

L

N

E

9

Fig. 7J

Fig. 8

Fig. 9

Fig. 10

9. Position lock handle (M) Fig. 7J, on locking stud and
replace screw and spring (L) that were removed in STEP 7.
NOTE: Lock handle (M) is spring-loaded and can be re­positioned by lif ting up on handle and repositioning it on
stud located underneath handle.

ASSEMBLING WORK CLAMP

1. The st andard equipment work clamp can be assembled
to any one of the three holes (A) Fig. 8, provided on the
base of the machine, as follows:

2. Thread lock knob (B) Fig. 9, into threaded hole on
side of hole to be used and insert post (C) of work clamp
down through hole as far as possible. Then tighten lock
knob (B). An additional lock knob (B) is supplied and can
be threaded into one of the other three holes. W e sugges t
having the two lock knobs, one of which is shown at (B),
threaded into the two most commonly used holes where
the work clamp will be used.

3. For proper operation and adjustment of the work
clamp, refer to section WORKCLAMP OPERATION .

ASSEMBLING DUST BAG

1. Depress spring clip s (A) Fig. 10, of dust bag (B) and clip
dust bag (B) onto end of dust chute, as shown.

L

M

A

A

C

B

A

B