Festool Kapex KS 120 User Manual

Kapex® KS 120

Miter Saw

Sliding Dual Compound Miter Saw
Supplemental User’s Manual

WARNING To reduce the risk of serious or fatal injury, read and understand

all safety precautions and instructions in this manual before using this tool.

Limited Warranty

30 Day Money Back Guarantee

We are so confident that you will thoroughly enjoy our tools, that
we offer a 30 day money back guarantee. If you are not

1+2 Limited Warranty

Festool USA offers a 3-year limited warranty, one of the longest
in the industry. This warranty is valid on the pre-condition that
the tool is used and operated in compliance with the Festool

Conditions of 1+2 Limited Warranty

You are entitled to a free extended limited warranty (1 year + 2
years = 3 Years) for your Festool power tool. Festool USA is
responsible for all shipping costs during the first year of the
warranty. During the second and third year of the warranty, the
customer is responsible for shipping the tool to Festool. Festool
will pay for return shipping to the customer using UPS Ground
Service. All warranty service is valid 3 years from the date of
purchase on your receipt or invoice.

Excluded from the coverage under this warranty are: normal
wear and tear, damages caused by misuse, abuse, or neglect;
damage caused by anything other than defects in material and
workmanship. This warranty does not apply to accessory items
such as circular saw blades, drill bits, router bits, jigsaw blades,
sanding belts, and grinding wheels. Also excluded are "wearing
parts," such as carbon brushes, lamellas of air tools, rubber
collars and seals, sanding discs and pads, batteries, and Festool
gear (hats and t shirts).

The obligations of Festool USA in its sole discretion under this
warranty shall be limited to repair or replacement or a refund of
the purchase price for any Festool portable power tool that is
found to have a defect in materials or workmanship during the

completely satisfied, your full purchase price will be refunded,
excluding all freight charges.

operating instructions. Festool USA warrants that the specified
tool will be free from defects in materials and workmanship for a
term of 3 years from the date of purchase.

warranty period. FESTOOL USA SHALL NOT BE LIABLE FOR ANY
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES
REGARDLESS OF THE THEORY OF LAW ON WHICH THE CLAIM IS
BASED. ALL WARRANTIES IMPLIED BY STATE LAW, INCLUDING
THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE ARE HEREBY LIMITED TO THE
DURATION OF THREE YEARS.

Some states in the U.S. and some Canadian provinces do not
allow the limitations on how long an implied warranty lasts, so
the above limitation may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights that
vary from state to state in the U.S. and from province to province
in Canada.

With the exception of any warranties implied by state or province
law as limited above, the foregoing express limited warranty is
exclusive and in lieu of all other warranties, guarantees,
agreements, and similar obligations of Festool USA. Festool USA
makes no other warranty, express or implied, for Festool portable
power tools. No agent, representative, distributor, dealer, or
employee of Festool USA has the authority to increase or
otherwise change the obligations or limitations of this warranty.

Repairs

If your Festool power tools require repair, you must contact our
Service Department at [phone] for authorization and
address details. No collect shipments will be accepted. No Festool

hats, t-shirts or other wearables may be returned. Also contact
our Service Department at the telephone number listed above if
you have any questions about warranty claim procedures.

Returns

If you need to return your Festool tools for any reason, please return it to the dealer from which you originally bought the tool.

Liability Statement

This product has been built to the high standards of Festool.
Please do not attempt to operate or repair this equipment without
adequate training. Any use, operation, or repair in contravention
of this document is at your own risk. By acceptance of this
system you hereby assume all liability consequent to your use or

misuse of this equipment. Festool USA assumes no liability for
incidental, special, or consequential damage of any kind.
Equipment specifications, applications, and options are subject to
change at the sole discretion of Festool USA without notice.

Proprietary Notice

All drawings and information herein are the property of Festool,
TTS Tooltechnic Systems AG & Co. KG. All unauthorized use and
reproduction is prohibited.

Written and Illustrated by Rick Christopherson.
© 2008 TTS Tooltechnic Systems AG & Co. KG
All rights reserved. Printed in the United States of America and

Germany.

2 Kapex KS120 Miter Saw

Festool USA is a division of Tooltechnic Systems, LLC.
Festool is a trademark and service mark of TTS Tooltechnic

Systems AG & Co. KG
Kapex and FastFix are registered trademarks of TTS Tooltechnic

Systems AG & Co. KG
MiterFast is a trademark of TTS Tooltechnic Systems AG & Co. KG

www.festoolusa.com

Contents

Limited Warranty .............................................2

30 Day Money Back Guarantee......................... 2

1+2 Limited Warranty..................................... 2

Conditions of 1+2 Limited Warranty.................. 2

Repairs ......................................................... 2

Returns......................................................... 2

Liability Statement ......................................... 2

Proprietary Notice........................................... 2

About This Manual............................................3

Tool Symbols................................................. 3

General Power Tool Safety Warnings ...............4

Work Area Safety........................................ 4

Electrical Safety.......................................... 4

Personal Safety........................................... 4

Power Tool Use and Care.............................. 4

Service...................................................... 5

Specific Safety Rules for Miter Saws.................. 5

Respiratory Exposure Safety Warnings .............. 5

Tool Description ...............................................5

Technical Specifications................................... 5

Intended Use................................................. 6

Functional Description..................................... 6

Setup................................................................8

Setting Up a New Miter Saw............................. 8

Changing Sawblades....................................... 9

Transporting the Saw.....................................10

Dust Extraction .............................................10

Basic Operation..............................................11

Setting the Motor Speed.................................11

Using the Laser Guides...................................11

Power Trigger and Plunge Release................... 11

Using the Hold Down Clamp ........................... 12

Setting the Miter Angle.................................. 12

Setting the Bevel Angle ................................. 13

Using the Auxiliary Fence............................... 13

Setting the Depth Limit.................................. 14

Using the Tall Miter Latch............................... 14

Using the MiterFast Tool ................................ 15

Using the Bed Extensions and Crown Stops ...... 16

Cutting Techniques ........................................17

Miter Cuts.................................................... 18

Bevel Cuts................................................... 18

Depth Limited (Dado/Half-Lap) Cuts................ 19

Compound Miter Cuts.................................... 20

Calculating Compound Angles...................... 21

Compound Angle Calculator ........................ 21

Crown Moulding............................................ 22

Adding Auxiliary Fence Faces.......................... 23

Making a Zero-Clearance Insert...................... 23

Calibration and Adjustment............................24

Calibrating the Miter Angle............................. 24

Calibrating the Bevel Angle ............................ 26

Calibrating the Lasers.................................... 28

Troubleshooting.............................................29

Optional Accessories......................................30

Sawblades................................................... 30

MFT/3-Kapex Table....................................... 31

Bolt Down (Clamping) Kit............................... 31

Crown Stop.................................................. 31

About This Manual

Save These Instructions

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.

Indicates a potentially hazardous

WARNING!

CAUTION!

Laser
Radiation

NOTICE:

Note:

situation which, if not avoided, could
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.

This symbol is used on the machine and
in this manual to signify the possibility of
laser radiation.

Indicates a potential situation which, if
not avoided, can result in property
damage or damage to the tool.

Indicates information, notes, or tips for
improving your success using the tool.

Tool Symbols

V Volts
W Watts
Hz Hertz
~ Alternating Current (AC)
no No-load Speed
Ø Diameter

Class II Double Insulated

Designated Danger Zone.
Avoid positioning hands,
fingers, or arms in the area
designated by this symbol.

Supplemental User’s Manual 3

General Power Tool Safety Warnings

WARNING! Read all safety warnings and
instructions. Failure to follow the warnings and

instructions may result in electric shock, fire, and
serious or fatal injury.

Work Area Safety

► Keep your work area clean and well lit. Cluttered or

dark work areas invite accidents.

► Do not operate power tools i n expl osi ve atmospheres,

such as in the presence of flammable liquids, gases,

Electrical Safety

► Power tool plugs must match the outlet. Never modify

the plug in any way. Do not use any adapter plugs
with power tools. Unmodified plugs and matching outlets

will reduce risk of electric shock.

► Avoid body contac t wi th earthed or grounded surfac es

such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body is
earthed or grounded.

► Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of electric
shock.

► Do not abuse the cord. Never use the cord for

carrying, pulling, or unplugging the power tool. Keep
cord away from heat, oil, sharp edges or moving
parts. Damaged or entangled cords increase the risk of

electric shock.

► When operating a power tool outdoors, use an

extension cord suitable for outdoor use. Use of a cord
for outdoor use reduces the risk of electric shock.

Personal Safety

► Stay alert, watch what you are doing, and use

common sense when operating a power tool. Do not
use a power tool while tired or under the influence of
drugs, alcohol, or medication. A moment of inattention

while operating power tools may result in serious personal
injury.

► Use personal protective equipment. Always wear eye

protection. Protective equipment such as dust mask, non­skid safety shoes, hard hat, or hearing protection used for
appropriate conditions will reduce the risk of personal
injuries. (Eye protection must comply with ANSI Z87.1)

► Prevent unintentional starting. Ensure the switch is in

the off-position before connecting to power source,
picking up, or carrying the tool. Carrying power tools

with your finger on the switch or energizing power tools that

Power Tool Use and Care

► Do not force the power tool. Use the correct power

tool for your application. The correct power tool will do
the job better and safer at the rate for which it is designed.

► Do not use the power tool if the switch does not turn

it on and off. Any power tool that cannot be controlled with
the switch is dangerous and must be repaired.

► Disconnect the plug from the power source before

making any adjustments, changing accessories,
transporting, or storing the tool. Such preventive safety

measures reduce the risk of starting the tool accidentally.

► Stor e i dl e t ools out of reach of children and do not

allow persons unfamiliar with the power tool or these
instructions to operate the power tool. Power tools are

dangerous in the hands of untrained users.

CAUTION! Laser Radiation. This product contains a
Class II laser. Do not look directly into the laser beam.
Power ≤ 1mW, Wavelength: 640 to 660 nm

Save all warnings and instructions for future reference.

or dust. Power tools create sparks which may ignite the

dust or fumes.

► Keep children and bystanders away while operating a

power tool. Distractions can cause you to lose control.

► If operating a power tool in a damp location is

unavoidable, use a ground fault circuit interrupter
(GFCI) protected supply. Use of a GFCI reduces the risk

of electric shock.

► Never use an extension cord that is damaged,

including cuts, exposed wires, or bent/missing
prongs. Damaged extension cords increase the risk of fire
or electric shock.

► Use only extension cords rated for the purpose.
► Use only extension cords rated for the amperage of

this tool and the length of the cord. Using too small of
an extension cord can cause the cord to overheat.

Extension Cord Ratings

Cord Length Size (AWG)

<25 Ft. 14

25-50 Ft. 12

50-100 Ft. 10

>100 Ft. Not recommended

have the switch on invites accidents.

► Remove adjusting key or wrench before turning the

power tool on. A wrench or a key that is left attached to a
rotating part of the tool may result in personal injury.

► Do not overreach. Keep proper footing and balance at

all times. This enables better control of the tool in
unexpected situations.

► Dress properly. Do not wear loose clothi ng or jewelry.

Keep your hair, clothing, and gloves away from
moving parts. Loose clothes, jewelry, or long hair can be

caught in moving parts.

► If devi c es are provi ded for the c onnect ion of dust

extraction and collection facilities, ensure these are
connected and properly used. Use of dust collection can

reduce dust-related hazards.

► Maintain power tools. Check for misalignment or

binding of moving parts, breakage of parts and any
other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired
before use. Many accidents are caused by poorly

maintained power tools.

► Keep cutting tools sharp and clean. Properly maintained

tools with sharp cutting edges are less likely to bind and are
easier to control.

► Use the power tool, ac c essori es, and tool bits etc. in

accordance with these instructions, taking into
account the working conditions and the work to be
performed. Use of the power tool for operations different

from those intended could result in a hazardous situation.

4 Kapex KS120 Miter Saw

Service

► To reduce the risk of serious or fatal injury, never

open the motor housing. Have your power tool
serviced only by a qualified repair person using only
identical replacement parts.

Specific Safety Rules for Miter Saws

► To reduce the risk of serious or fatal injury, never alter

or misuse the power tool.

► Be certain the miter saw is mounted or securely placed

on a level, firm work surface before using. A level and
firm work surface reduces the risk of the miter saw becoming
unstable or tipping.

► Make sure all controls and clamping handles are

secured before starting any operation. Unsecured
clamps or adjustment handles can cause the saw and/or
workpiece to move unexpectedly.

► Always unplug the saw before servicing or changing

the sawblade.

► Never remove or disable the blade guard. Inspect the

blade guard before use. Repair or replace a damaged or
improperly functioning blade guard before further use.

► Keep hands out of the path of the sawblade. Never

cross your hand over intended line of cutting.
Supporting the workpiece “cross handed” e.g. holding the left
side of the workpiece with your right hand, is very
dangerous.

► Do not reach in back of the moving saw blade with

either hand to remove wood scraps, hold down or
support the workpiece, or for any other reason. The

proximity of the spinning saw blade to your hand may not be
obvious and you may be seriously injured.

► Use clamps to support workpiece whenever possible.

Do not use this saw to cut pieces that are too small to
be securely clamped.

► Clamp the offcut side of the workpiece when using a

length stop. An unsecured offcut can bind between the
length stop and the saw blade.

► If securing the workpiece by hand, you must always

keep hands outside of “No Hand” area as marked with
a symbol on the base. Your hand, if placed inside the “No

Hands” region, can easily slip or be pulled into the blade.

► Support long workpiec es to prevent them from tipping.

► Any repairs to the laser must be carried out by the

laser manufacturer or by an authorized agent of the
laser manufacturer. Never attempt to replace the laser on

this tool with a different type of laser.

A tipping workpiece can lift up and contact the spinning
sawblade, or bring the operator’s hand upward into the
blade.

► For proper control, never “pull” the saw through the

cut, always chop or push cut. See page 17 of this manual.

► Cut only one workpiece at a time. Multiple workpieces

cannot be adequately clamped or braced and may bind on
the blade or shift during cutting.

► Keep workpieces firmly against the rear fence when

cutting. Never cut workpieces that do not lay flat or
are curved in any way. A curved workpiece can be grabbed
by the blade and propelled back against the fence.

► Inspect workpieces for nails or foreign objects. Make

sure there are no tools or foreign objects on the saw.

► Do not cut round stock unless it is clamped in such a

way as to prevent rotation. Round stock will tend to roll
while it is being cut.

► Use only sawblades recommended by the

manufacturer and designed for use with the saw, with
a 30mm arbor bore, a 260mm diameter, and a
maximum thickness of 2mm. Be sure that the speed
marked on the saw blade is at least equal to the speed
marked on the saw. Do not use high speed steel saw
blades.

► Select the correct saw blade for the material to be cut.

Do not use the saw to cut materials other than those
recommended by the manufacturer. Never force the tool
or attachment to do a job for which it was not designed.

► Never use this saw for cutting ferrous metals.
► Never use saw blades that are damaged or deformed.

Never use a dull sawblade. A dull sawblade places undue
stress on the saw and the workpiece and can increase the
risk of kickback.

► Make sure the sawblade is securely installed and is not

backward. The arrow on the blade should match the
direction of the arrow marked on the tool.

Respiratory Exposure Safety Warnings

Substantial or repeated inhalation of dust and other airborne
contaminants, in particular those with a smaller particle size,
may cause respiratory or other illnesses. Various dusts
created by power sanding, sawing, grinding, drilling and other
construction activities contain chemicals or substances known
(to the State of California and others) to cause cancer, birth
defects or other reproductive harm. Some examples of these
chemicals/substances are:

► lead from lead-based paints;
► crystalline silica from bricks, cement, and other masonry

products;

► arsenic and chromium from chemically-treated lumber; and
► some wood dusts, especially from hardwoods, but also from

some softwoods such as Western Red Cedar.

The 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 use a properly
functioning dust extraction system. When the inhalation of
dust cannot be substantially controlled, i.e., kept at or near
the ambient (background) level, the operator and any
bystanders should wear a respirator approved by NIOSH for
the type of dust encountered.

Tool Description

Technical Specifications

Power Consumption 1600 Watts (13 amps @ 120 volts) Max. Depth (tall) 120 mm (4.75”) at 60 mm (2.3”)
Motor Speed 1400 - 3400 RPM (no load) Max. Depth at 45° Bevel 55mm (2.2”)
Arbor Diameter 30 mm Max. Width at 90° Miter 305mm (12”)
Max. Blade Size 260 mm (10.25”) dia., 2mm (5/64”) thick Max. Width at 45° Miter 210mm (8.25”)
Max. Depth (std.) 88 mm (3.46”) Weight 21.5 kg (47.3 lbs)

All metric dimensions are controlling. The arbor diameter is critical for safe operation, and is presented in metric only.

Supplemental User’s Manual 5

Intended Use

The Kapex miter saw is intended to cut wood, plastic,
aluminum, and similar materials. All applications beyond
this are regarded as improper use. The tool should not be
altered or used for any other purpose other than as
specified in these operating instructions. Using the tool in

Functional Description

contravention to this manual may lead to injury and will
void your warranty. The user shall be responsible and
liable for accidents, injuries, and property damage
resulting from misuse or abuse of this tool.

Item Name or Description Ref. Page(s)

A Bevel Gauge and Pointer (both sides) 12, 18
B Power Cord Storage 10
C Tall Miter Latch 14, 22
D Tall Miter Release 14, 22
E Bevel Lock 12, 18
F Bevel Range Selector 12, 18
G Dust Extraction Port 10
H FastFix® Arbor Lock 9

I Trigger Lock 11

Item Name or Description Ref. Page(s)

J Power Switch/Trigger 9, 10, 11
K Main Handle 11, 17
L Laser Dust Lens 28

M Blade Guard 9
N Miter Stop Release Lever 12, 15, 18, 20
O Miter Lock Lever 12, 15, 18, 20

P Miter Gauge and Pointer 12, 15,

Q MiterFast™ Angle Tool and Storage 15

6 Kapex KS120 Miter Saw

Functional Description (continued)

Item Name or Description Ref. Page(s)

A Bevel Gauge and Pointer (both sides) 12, 18

I Trigger Lock 9, 10, 11

J Power Switch/Trigger 9, 10, 11
K Main Handle 11, 17
L Laser Dust Lens 28

M Blade Guard 9
N Miter Stop Release Lever 12, 15, 18, 20
O Miter Lock Lever 12, 15, 18, 20

R Bevel Adjustment Knob 12, 18

Item Name or Description Ref. Page(s)

S Speed Control Dial (see inset) 11
T Laser On/Off Button (see inset) 11

U Depth Limit Adjustment Knob 13

V Slide Lock Knob 10

W Head Lock Knob 10

X Auxiliary Fence 13
Y Main Fence 13, 23
Z Table Inserts 23

Supplemental User’s Manual 7

Setup

Setting Up a New Miter Saw

Congratulations on your purchase of a new Kapex Sliding
Dual Compound Miter Saw. Before using your new miter
saw, make sure you fully read and understand all of the
instructions, precautions, and safety information presented
in this manual.

WARNING! To avoid tipping the miter saw during
use, the miter saw must be placed on a stable
surface.

Note: There is a 2.5 mm hex key needed for
making adjustments located in the Styrofoam
packing material. Take care not to lose it.

Note: You may want to save the original box and
packing material in case you ever need to send in
the saw for service.

The KS120 miter saw is ready to use right out of the box,
but there are several placement options available,
depending on the intended use. These options include:

► For truly portable use, the KS120 may be used directly

on a jobsite floor. The height of the cutting bed was
specifically designed to coincide with the height of a
Festool #1 Systainer, which can be used as an outfeed
support.

► For a more permanent installation, the Kapex saw is

equipped with 4 bolt holes, to be used with ¼-20 (M6)
bolts to securely bolt the saw to a work table.

► The Kapex saw was specif ically designed to be

compatible for operation on a Festool Multi-Function
Table (MFT). The four feet under the saw coincide with
the hole spacing of an MFT tabletop to keep the saw
firmly in position, and the optional bolt kit permits quick
mounting.

► The KS120 can also be used on a level and stable jobsite

work table. The saw must be securely clamped to the
table to help prevent it from tipping or falling off.

Note: When clamping or bolting the Kapex to a
work table, take care not to over tighten the
clamps or bolts, as this may distort the saw base.

8 Kapex KS120 Miter Saw

Changing Sawblades

WARNING! To reduce the risk of injury from

contact with a moving part, always unplug the
saw before changing blades.

1. Push in and rotate the FastFix

This prevents the arbor from turning and also disables
the motor.

2. Loosen the clamping screw on the arbor bolt guard,

and rotate the guard away from the arbor bolt. (The
combination hex key is stored on the back of the saw
by the power cord.)

®

arbor lock clockwise.

4. Without pushing down on the trigger lock, pull up on

the trigger to release the blade guard.

5. Raise the blade guard out of the way and remove the

outboard arbor flange and sawblade from the arbor.

6. Inspect the friction lining on the two arbor flanges. If

the lining is damaged, replace the flanges, as this can
cause the sawblade to wobble.

Note: The friction lining on the arbor flanges
grips the blade, but also permits the blade to slip
slightly, in the event of a binding condition.

WARNING! When installing a new blade, make
sure the arbor bolt is properly tightened and the
rotation direction of the sawblade matches the
rotation direction indicated on the saw (see image
below).

7. Make sure the blade is oriented correctly and install

the blade onto the inboard arbor flange.

8. Replace the outboard arbor flange, tighten the arbor

bolt, and then unlock the FastFix arbor lock.

3. Unscrew the arbor bolt by turning it clockwise. The

arbor bolt is a left-hand thread and turns the
opposite of a standard screw.

Supplemental User’s Manual 9

Transporting the Saw

When The Kapex miter saw is collapsed for transport, it is
very well balanced and easily carried using the integrated
carrying handles.

1. Unplug the saw and coil the power cord on the reel at

the rear of the saw.

4. Set the miter angle to 60° and push down on the miter

lock lever.

5. Pick up the saw from the rear by grasping the two

handle points as shown below.

WARNING! To reduce the risk of unexpectedly
starting the saw, make sure the saw is
unplugged.

2. Pull the power trigger (without depressing the trigger

lock) and lower the motor head down. When the head
is in the down position, push in on the Head Lock Knob
(see the picture to the upper right).

3. Push the motor head all the way to the rear of the saw

and tighten the Slide Lock Knob.

Dust Extraction

The Kapex saw can be connected to a dust extractor to
substantially reduce dust during operation. The dust port
swivels to either side, and accepts either a 27 or 36 mm
Festool hose. The 27 mm hose fits inside the dust port, or
the 36 mm hose fits over the outside of the dust port.

Note: For optimal dust extraction performance,
Festool recommends using a 36 mm hose.

10 Kapex KS120 Miter Saw