Festool PI561556, PM561556, PD561556, PD561432 User Manual
TS 55 REQ
Guided Circular Saw
Guided Circular Saw
Supplemental User’s Manual
WARNING To reduce the risk of serious injury, read and understand all safety
precautions and instructions in this manual before using this tool.
Limited Warranty
1
30 Day Money Back Guarantee
Buy with condence. If you are not completely satised, return
your tool
receive a refund of either your purchase price or the lowest
retail price at which the same item has been offered since your
date of purchase. Freight charges are not refundable.
2
to the selling dealer within 30 days and you will
1+2 Limited Warranty
Festool offers a 3 year limited warranty, one of the strongest in
the industry. This warranty is valid on the pre-condition that the
tool is used and operated in compliance with the Festool operat-
ing instructions. Festool warrants that the specied tool will be
free from defects in materials and workmanship for a term of 3
years from the date of purchase.
Conditions of 1+2 Limited Warranty
All customers receive a free extended limited warranty (1 year
+ 2 years = 3 Years) on new Festool power tools purchased
from an authorized retailer. Festool is responsible for all ship-
ping costs during the rst 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. Proof of purchase may be required.
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. Operating a tool at
a voltage or frequency different from the tool’s rating will void
the warranty. This includes the usage of the tool in combination
with a transformer. Festool does not condone nor support the
use of any non-Festool engineered, designed, and manufactured accessories or consumables with Festool products. Use of
any non-Festool products may affect performance or void the
warranty. Festool is not responsible for any damages or losses
incurred and user assumes all risk and responsibility with nonFestool derived products. Also excluded are “wearing parts,”
such as carbon brushes, lamellas of air tools, rubber collars
and seals, sanding discs and pads, and Festool gear (hats and
shirts).
1 The following is an exemplar Festool limited warranty. The actual warranty that comes
with your power tool is controlling.
2 Tool must be returned in complete and whole condition as supplied to include Systainer,
cutter, blade, power cord, etc.
The obligations of Festool 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 warranty period. FESTOOL 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 specic 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. Festool makes
no other warranty, express or implied, for Festool portable
power tools. This warranty policy is only valid for tools that are
purchased in the US and Canada. Warranty policies of other
countries may vary when obtaining warranty service outside the
US and Canada. Some countries do exclude warranty for products bought outside their territory. Festool reserves the right to
reject the repair of any tool that is not part of the US/Canada
product line. No agent, representative, distributor, dealer, or
employee of Festool 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 800-554-8741 (613-363-0169 Canada)
for authorization and address details. To expedite the repair,
please ll out and enclose the Repair Order Form. Download
the form at www.festoolusa.com (www.festoolcanada.com).
No collect shipments will be accepted. No Festool hats, 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 assumes no liability
for incidental, special, or consequential damage of any kind.
Equipment specications, applications, and options are subject
to change at the sole discretion of Festool 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.
© 2013 TTS Tooltechnic Systems AG & Co. KG
All rights reserved. Printed in the United States of America and
Germany.
2 TS 55 REQ
Festool USA is a division of Tooltechnic Systems, LLC.
Festool is a trademark and service mark of TTS Tooltechnic
Systems AG & Co. KG
Plug-It and Systainer are registered trademarks of TTS
Tooltechnic Systems AG & Co. KG
www.festoolusa.com
Contents
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
Specic Safety Rules for Circular Saws ................ 5
Causes and Prevention of Kickback ..................... 5
Respiratory Exposure Safety Warnings ................ 5
Functional Description ..................................... 6
Intended Use ................................................... 7
Technical Specications ..................................... 7
Setup ............................................................... 7
Setting Up a New Saw ...................................... 7
Adjusting the Guide Rail Cams ........................... 7
Trimming the Guide Rail Splinter Guard ............... 8
Installing the Outrigger Splinter Guard ................ 8
Changing the Sawblade .................................... 9
Sawblade Selection ........................................ 10
Tooth Shape ............................................... 10
Number of Teeth and Spacing ........................ 10
Hook Angle ................................................. 10
TS 55 REQ Sawblades .................................. 10
Guide Rails .................................................... 11
Tips for Choosing Guide Rail Lengths .............. 11
Joining Rails ................................................ 11
Operation ...................................................... 12
Setting the Blade Depth .................................. 12
Setting the Bevel Angle ................................... 13
Setting the Motor Speed ................................. 13
Using the Limit Stop ....................................... 14
Using Dust Extraction ..................................... 14
Connecting the Plug-it Cord ............................. 15
Turning on the Saw ........................................ 15
Applications .................................................. 16
Straight-Lining Rough Lumber ......................... 16
Crosscutting and Trimming .............................. 17
Plunge Cutting ............................................... 18
Cutting Non-Wood Materials ............................ 19
Soft Plastics ................................................ 19
Brittle Plastics ............................................. 19
Thin Aluminum ............................................ 19
Extruded Aluminum ..................................... 19
Maintenance .................................................. 20
Routine Maintenance ...................................... 20
Replacing the Guide Rail Splinter Guard ............ 21
Changing the Motor Brushes ............................ 21
Adjustments .................................................. 22
Matching Multiple Saws to Shared Guide Rails . 22
Installing the Imperial Depth Gauge ............... 23
Troubleshooting ............................................ 24
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.
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, could result
in minor or moderate injury.
NOTICE: Indicates a potential situation which, if not avoided, can result in property
damage or damage to the tool.
Note: Indicates information, notes, or tips for improving your success using the tool.
Tool Symbols
V Volts
W Watts
Hz Hertz
~ Alternating Current (AC)
n
No-load Speed
o
Ø Diameter
Class II Double Insulated
Supplemental Owner’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, re, and/or
serious injury.
Work Area Safety
► Keep your work area clean and well lit. Cluttered or dark work
areas invite accidents.
► Do not operate power tools in explosive atmospheres, such
as in the presence of ammable liquids, gases, or dust. Power
Electrical Safety
► Power tool plugs must match the outlet. Never modify the
plug in any way. Do not use any adapter plugs with earthed
(grounded) power tools. Unmodied plugs and matching
outlets will reduce risk of electric shock.
► Avoid body contact with earthed or grounded surfaces 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, pull-
ing, 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.
Save all warnings and instructions
for future reference.
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 re 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)
<50 Ft. 14
50-100 Ft. 12
>100 Ft. Not recommended
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 inuence 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 pro-
tection. Protective equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
► 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 nger on
the switch or energizing power tools that 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 clothing 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 devices are provided for the connection of dust extrac-
tion and collection facilities, ensure these are connected and
properly used. Use of dust collection can reduce dust-related
hazards.
► Always wear safety glasses complying with ANSI Z87.1.
Ordinary glasses are not proper protection.
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, or storing the tool.
Such preventive safety measures reduce the risk of starting
the tool accidentally.
► Store idle tools out of reach of children and do not allow
persons unfamiliar with the power tool or these instructions
4 TS 55 REQ
to operate the power tool. Power tools are dangerous in the
hands of untrained users.
► 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, accessories, and tool bits etc. in accor-
dance 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.
Service
► Have your power tool serviced by a qualied repair person
using only identical replacement parts. This will ensure that
Specic Safety Rules for Circular Saws
► Keep hands away from the blade and cutting area. Keep your
second hand on the auxiliary handle. If both hands are holding the saw, they cannot be cut by the blade.
► Keep your body positioned to either side of the saw blade, but
not in line with the saw blade. Kickback could cause the saw
to jump backward. (See “Causes and Prevention of Kickback”
below.)
► Do not reach underneath the workpiece. The blade is fully
exposed under the workpiece.
► Never use a plunging circular saw that fails to return to its
unplunged position. If the saw ever fails to fully retract the
sawblade as expected, immediately stop using the saw and
have the saw serviced by an authorized service center.
► Never use a dust extraction system when making cuts that
can result in sparks, such as cutting through nails and other
ferrous materials. Sparks and hot embers can cause a re or
explosion in the dust extraction system.
► To reduce the risk of serious injury, never alter or misuse the
power tool.
the safety of the power tool is maintained.
► Never hold the piece being cut in your hands or across your
leg. It is important to support the work properly to minimize
body exposure, blade binding, or loss of control.
► Hold the saw by the insulated handles when performing an
operation in which the sawblade may contact hidden wiring or
its own cord. Contact with a “live” wire will make the exposed
metal parts of the tool “live” and shock the operator.
► When ripping, always use a rip fence or straight edge guide.
This improves the accuracy of cut and reduces the chance for
blade binding.
► Always use blades with the correct size and shape arbor
holes. Blades that do not match the mounting hardware of
the saw will run eccentrically, causing loss of control.
► Never use damaged or incorrect blade anges or bolt. The
blade anges and bolt were specially designed for your saw
for optimum performance and safety of operation.
Causes and Prevention of Kickback
Kickback is a sudden reaction to a pinched, bound, or misaligned saw blade that causes the saw to lift up and out of the
workpiece toward the operator.
Chances for kickback may be reduced by taking proper precautions as described below:
► Maintain a rm grip with both hands on the saw and position
your body and arm to allow you to resist kickback forces.
Kickback forces can be controlled by the operator if proper
precautions are taken.
► When interrupting a cut for any reason, release the trigger
and hold the saw motionless in the material until the blade
comes to a complete stop. Never attempt to remove the saw
from the work or pull the saw backward while the blade is in
motion, or kickback may occur.
► When restarting a saw in the workpiece, center the saw blade
in the kerf and check that the saw teeth are not engaging the
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
material. If the saw blade is binding during a restart, it may
climb up or kickback from the workpiece.
► Do not use a dull or damaged blade. Dull or improperly
sharpened blades cause excessive friction, blade binding, and
kickback.
► Support large panels to minimize the risk of the blade pinch-
ing and causing a kickback. Large panels tend to sag under
their own weight. Supports must be placed under the panel
on both sides, near the line of cut and near the edge of the
panel.
► The bevel adjusting knobs must be fully tightened before
making a cut. If the blade tilts during a cut, it will bind and
cause a kickback.
► Use extra caution when making a plunge cut into existing
walls or other blind areas. The protruding blade may cut
objects that can cause kickback.
dusts, especially from hardwoods, but also from some soft-
woods 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.
Supplemental Owner’s Manual 5
Functional Description
F
E
G
I
R
J
K
L
D
C
G
F
H
B
A
S
I
D
O
L
M
Q
P
O
N
Item Name or Description Ref. Page(s)
A Viewing Window 8
B Arbor Bolt 9
C Spring Loaded Riving Knife --
D Miter Release Button 13
E Dust Collection Port 14
F Plunge/Trigger Release 15
G FastFix Arbor/Plunge Lock 9
H Trigger (On/Off Switch) 15
I Auxiliary Handle --
J Blade Wrench Storage 9
6 TS 55 REQ
Item Name or Description Ref. Page(s)
K Depth Stop and Gauge 12,23
L Bevel Gauge and Lock Knob 13
M Speed Control 13
N Plug-It Power Cord Port 15
O Guide Rail Cams 7,8
P Sole Plate --
Q Outrigger Splinter Guard 8,18
R Limit Stop 14,18
S Main Handle --
Intended Use
The TS 55 REQ, hand-operated circular saw, is designed
exclusively for sawing of wood, wood-like materials, and
plastics. The saw may also be used for cutting aluminum
when a Festool aluminum-cutting sawblade is installed. The
tool should not be altered or used for any other purpose,
other than as specied in these operating instructions. Using
the tool in contravention to this manual will void your warranty and may lead to injury. The user shall be responsible
and liable for damages and accidents resulting from misuse
or abuse of this saw.
Technical Specications
Power Consumption 1200 Watts (10 amps @ 120 volts)
Speed Range 2,000 to 5,200 RPM (no load)
Blade Diameter 160 mm
Arbor Diameter 20 mm, Round
Depth of Cut (without guide rail) 55 mm (2.2”) @ 90°, 43 mm (1.7”) @ 45°
Bevel Angle 0° to 45°, plus -1° to 47°
Weight 4.5 kg (9.9 lbs)
Setup
Setting Up a New Saw
There are some simple setup procedures to follow before a
new saw can be used. Follow this sequence of inspections
and adjustments before using the saw for the rst time. It
is important that these instructions be followed sequentially
before cutting the zero-clearance splinter guards.
WARNING! Always disconnect the saw from the
power supply before making any adjustments to the
saw or installing or removing any accessory.
CAUTION! Check regularly whether the saw blade
is in good condition, and the arbor bolt is rmly
tightened. Saw blades which are cracked, damaged,
or deformed should no longer be used.
1. With the saw unplugged, inspect the blade for damage
and make sure it is properly secured to the arbor. (Refer
to “Changing the Sawblade” on page 9 for more
information).
2. Perform the guide rail gib cam adjustment procedure
described below.
3. Install the power cord into the Plug-It receptacle on the
saw (refer to page 15 for more information).
4. After completing all of the inspections and adjustments
listed above, cut the zero-clearance splinter guards as
described on page 8.
Adjusting the Guide Rail Cams
The guide rail cams tighten against the rib of the guide rail
to remove any side-play from the saw during a cut. Knobs
on the top of the cams permit easy adjustment.
1. Place the saw on the guide rail.
2. Loosen both cams by rotating the knobs
counterclockwise.
3. Working with one cam at a time, jiggle the saw side-to-
side while turning the cam clockwise until the saw ts
snugly to the rail.
4. Repeat for the second cam.
5. Make sure the cams are not over tightened by
sliding the saw down the guide rail. If the saw
does not slide easily, loosen the cams.
Supplemental Owner’s Manual 7
Notes:
► The cams do not need to be very tight for normal opera-
tions. A tiny amount of side-play will not impact the
quality of a cut.
► Over tightening the cams or operating the saw in abrasive
environments can cause premature wear of the wear
bars. Periodically inspect the wear bars for at spots, and
replace if necessary.
Replaceable
Wear Bars
Guide Rail
Cams
Trimming the Guide Rail Splinter Guard
The leading edge of the guide rail has a replaceable, rub-
ber, zero-clearance strip. The rst time the saw is used with
the guide rail, this strip is trimmed to match the sawblade.
When trimmed to size, this strip reduces chipping and
tearout during normal cutting.
Important: If you have more than one saw that
uses the same guide rail system, you want all of the
saws to have the same cutting path. Before cutting
the splinter guard, use the “Matching Multiple Saws
to Shared Guide Rails” on page 22 to match one
saw to another before completing this procedure.
1. Set the blade depth very shallow (6 to 7 mm) so that the
blade teeth penetrate the strip by about half a tooth, as
shown.
2. Set the motor speed to 6.
3. Place the guide rail on a stable surface with the strip
hanging over the edge so you don’t cut the table.
4. If necessary, adjust the guide rail cams as described on
page 7.
5. Cut the strip in a single, smooth, low-speed rip from one
end of the guide rail to the other.
Set the blade depth so
about 1/2 a tooth is
Splinter
Guard
below the splinter guard.
Installing the Outrigger Splinter Guard
The outrigger splinter guard is used to prevent chipping
on the offcut side of the sawblade. The outrigger can be
retracted away from the workpiece when not needed.
Note: The outrigger splinter guard is a consumable
item and will need to be replaced periodically when it
is no longer close to the blade.
Note: The rst time you use the outrigger splinter
guard, it will be trimmed to match the blade.
1. Remove the clear viewing window by pushing straight
down and sliding it out of the saw.
2. Remove the thumbscrew from the outrigger and slide
the outrigger on to the front edge of the blade guard as
shown.
3. Insert the thumbscrew through the outrigger, through the
height adjustment slot, and into the captive nut on the
back side of the outrigger.
4. Place the guiderail on the workpiece and the saw on the
guiderail.
5. Press down on the outrigger splinter guard so it is lightly
touching the workpiece, and tighten the thumbscrew.
Begin and end with
cams lined up with
guide rail ends
6. For longer life, remove the splinter guard and reinstall
the clear viewing window, when not in use.
8 TS 55 REQ
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