Festool PD561438, PN561438 User Manual
TS 55 EQ
Circular Saw Instruction Manual
Important: Read and understand all
instructions before using this tool.
Warranty
Conditions of 1+2 Warranty
You are entitled to a free extended warranty (1 year + 2
years = 3 years) for your Festool power tool. Festool shall be
responsible for all shipping costs during the first year of the
warranty. During the second and third year of the warranty
Festool Limited Warranty
This warranty is valid on the pre-condition that the tool is
used and operated in compliance with the Festool operating
instructions. Festool warrants, only to the original consumer
purchaser, that the specified tool will be free from defects in
materials and workmanship for a term of one year from the
date of procurement. Festool makes no other warranty,
express or implied, for Festool portable power tools. No
agent, representative, distributor, dealer or employee of
Festool has the authority to increase or otherwise change the
obligations or limitations of this warranty. The obligations of
Festool in its sole discretion under this warranty shall be
limited to the repair or replacement of any Festool portable
power tool that is found to be defective as packaged with the
User Manual.
Excluded from 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, and batteries.
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.
Festool portable power tools requiring replacement or repair
are to be returned with the receipt of purchase to Festool
(call 800-554-8741 for address details).
IN NO EVENT SHALL FESTOOL BE LIABLE FOR ANY
CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR
BREACH OF THIS OR ANY OTHER WARRANTY,
EXPRESSED OR IMPLIED WHATSOEVER. ALL
WARRANTIES IMPLIED BY STATE LAW, INCLUDING
THE IMPLIED WARRANTIES OF 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. With the
exception of any warranties implied by state or province law
as hereby limited, the foregoing express limited warranty is
exclusive and in lieu of all other warranties, guarantees,
agreements and similar obligations of Festool. This warranty
gives you specific legal rights and you may also have other
rights which vary from state to state in the U.S., and
province to province in Canada.
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 specifications, 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.
© 2006 TTS Tooltechnic Systems AG & Co. KG
All rights reserved. Printed in the United States of America and Germany.
Festool is a trademark and service mark of TTS Tooltechnic Systems AG & Co. KG
www.festoolusa.com
2 TS 55 EQ Circular Saw
Contents
Warranty ..............................................................................2
Conditions of 1+2 Warranty .........................................2
Festool Limited Warranty .............................................2
Liability Statement .........................................................2
Proprietary Notice..........................................................2
General Safety Rules...........................................................4
Work Area Safety .......................................................4
Electrical Safety ..........................................................4
Extension Cords .........................................................4
Personal Safety ...........................................................4
Tool Use and Care......................................................4
Service..........................................................................5
Specific Safety Rules for Circular Saws.......................5
Causes and Prevention of Kickback ........................5
Respiratory Exposure Warning................................5
Tool Description..................................................................6
Technical Specifications.................................................6
Intended Use ...................................................................7
Single-Point Entry ..........................................................7
Setup and Adjustments......................................................7
Setting up a New Saw....................................................7
Adjusting the Guide Rail Gib Cams ............................8
Trimming the Guide Rail Splinter Guard ...................8
Trimming the Outrigger Splinter Guard ....................9
Replacing and Adjusting the Riving Knife.................9
Changing the Sawblade...............................................10
Setting the Blade Perpendicular to the Sole Plate....11
Adjusting the 45º Bevel Stop.......................................12
Matching the TS 55 to an Existing Guide Rail..........12
Operation ...........................................................................13
Setting the Blade Depth...............................................13
Setting the Motor Speed ..............................................13
Turning On the Saw.....................................................14
Using the Outrigger Splinter Guard..........................14
Setting the Bevel Angle ...............................................15
Using the Guide Stop...................................................15
Using Dust Extraction..................................................16
Applications ......................................................................17
Straight-Lining Rough Lumber.................................. 17
Crosscutting and Trimming........................................18
Plunge Cutting.............................................................. 19
Cutting Non-Wood Materials..................................... 20
Soft Plastics ...............................................................20
Brittle Plastics ...........................................................20
Thin Aluminum........................................................20
Extruded Aluminum ...............................................20
Accessories.........................................................................21
Sawblades......................................................................21
Guide Rails ....................................................................22
Dust Cover ....................................................................22
Guide Rail Accessory Kit.............................................22
Rip Fence (Parallel Guide) ..........................................22
Systainer (System Container) .....................................23
Troubleshooting................................................................24
Maintenance ......................................................................25
Routine Maintenance................................................... 25
Replacing the Guide Rail Gib Cams ..........................26
Replacing the Guide Rail Splinter Guard .................26
Changing the Motor Brushes...................................... 27
Instruction Manual 3
General Safety Rules
WARNING: Read and understand all instructions listed below.
Failure to heed instructions may result in personal injury,
electrocution, or fire hazard.
Work Area Safety
► Keep your work area clean and well lit. Cluttered benches and
dark areas invite accidents.
► Do not operate power tools in explosive atmospheres, such as
in the presence of flammable liquids, gases, or dust. Power
tools create sparks which may ignite the dust or fumes.
Electrical Safety
► Double insulated tools are equipped with a polarized plug
(one blade is wider than the other). This plug will fit in a
polarized outlet only one way. If the plug does not fit fully into
the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install a polarized outlet. Do not change
the plug in any way. Double insulation eliminates the need for
the three wire grounded power cord.
Extension Cords
All due care should be practiced while using extension cords with
this tool.
► When operating a power tool outside, use an outdoor extension
cord marked “W-A” or “W”. These cords are rated for outdoor
use and reduce the risk of electric shock.
► Never use an extension cord that is damaged, such as cuts,
exposed wires, or bent/missing prongs.
► Use only extension cords rated for the purpose.
Personal Safety
► Stay alert, watch what you are doing, and use common sense
when operating a power tool. Do not use 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.
► Dress properly. Do not wear loose clothing or jewelry. Contain
long hair. Keep your hair, clothing, and gloves away from
moving parts. Loose clothes, jewelry, or long hair can be caught
in moving parts.
► Avoid accidental starting. Be sure the switch is off before
plugging in the power cord. Carrying tools with your finger on
Tool Use and Care
► Use clamps or other practical way to secure and support the
workpiece to a stable platform. Holding the work by hand or
against your body is unstable and may lead to loss of control.
► Do not force the tool. Use the correct tool for your application.
The correct tool will do the job better and safer at the rate for
which it is designed.
► Do not use the tool if the switch does not turn it on or off. Any
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.
Save These Instructions
► Keep bystanders, children, and visitors away while operating a
power tool. Distractions can cause you to lose control.
► Avoid body contact with grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of
electric shock if your body is 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 to carry the tools or
pull the plug from an outlet. Keep cord away from heat, oil,
sharp edges or moving parts. Replace damaged cords
immediately. Damaged cords increase the risk of electric shock.
► 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 router to lose power and damage the tool.
Extension Cord Ratings
Cord Length Size (AWG)
<50 Ft. 14
50-100 Ft. 12
100-150 Ft. 10
>150 Ft. Not recommended
the switch or plugging in tools that have the switch on invites
accidents.
► Remove adjusting keys or wrenches before turning the 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.
Proper footing and balance enables better control of the tool in
unexpected situations.
► Use safety equipment. Always wear eye protection. Dust mask,
non-skid safety shoes, hard hat, or hearing protection must be
used for appropriate conditions. (Ordinary glasses are NOT
proper eye protection.)
► Store idle tools out of reach of children and other untrained
persons. Tools are dangerous in the hands of untrained users.
► Maintain tools with care. Keep cutting tools sharp and clean.
Properly maintained tools with sharp cutting edges are less likely
to bind and are easier to control.
► Check for misalignment or binding of moving parts, breakage
of parts, and any other condition that may affect the tool's
operation. If damaged, have the tool serviced before using.
Many accidents are caused by poorly maintained tools.
► Use only accessories that are recommended by the
manufacturer for your model. Accessories that may be suitable
for one tool may become hazardous when used on another tool.
4 TS 55 EQ Circular Saw
Service
► Tool service must be performed only by qualified repair
personnel. Service or maintenance performed by unqualified
personnel could result in a risk of injury.
► When servicing a tool, use only identical replacement parts.
Specific Safety Rules for Circular Saws
!WARNING: Risk of personal injury.
► 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 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 fire or explosion in
the dust extraction system.
Causes and Prevention of Kickback
Kickback is a sudden reaction to a pinched, bound, or misaligned saw
blade that causes an uncontrolled saw to lift up and out of the workpiece
toward the operator.
When the blade is pinched or bound tightly by the kerf closing down, the
blade stalls and the motor reaction drives the unit rapidly back toward
the operator.
If the blade becomes twisted or misaligned in the cut, the teeth at the
back edge of the blade can dig into the top surface of the wood, causing
the blade to climb out of the kerf and jump back toward the operator.
Kickback is the result of incorrect operating procedures or conditions
and can be avoided by taking proper precautions as described below:
► Never hold the piece being cut in your hands or across your
► Hold the saw by the insulated handles when performing an
► When ripping, always use a rip fence or straight edge guide.
► Always use blades with the correct size and shape arbor holes.
► Never use damaged or incorrect blade flanges or bolt. The blade
Use of unauthorized parts or failure to follow maintenance
instructions may create a risk of electric shock or injury.
leg. It is important to support the work properly to minimize
body exposure, blade binding, or loss of control.
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.
This improves the accuracy of cut and reduces the chance for
blade binding.
Blades that do not match the mounting hardware of the saw will
run eccentrically, causing loss of control.
flanges and bolt were specially designed for your saw for
optimum performance and safety of operation.
Supports must be placed under the panel on both sides,
near the line of cut and near the edge of the panel as
shown.
► 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.
► Maintain a firm 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.
► If the blade is binding or 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. Investigate and take corrective actions to
eliminate the cause of blade binding.
► When restarting a saw in the workpiece, center the saw blade in the
kerf and check that the saw teeth are not engaging the 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 pinching and
causing a kickback. Large panels tend to sag under their own weight.
Respiratory Exposure Warning
Various dust created by power sanding, sawing, grinding, drilling
and other construction activities contains chemicals known (to the
State of California) to cause cancer, birth defects or other
reproductive harm. Some examples of these chemicals are:
► lead from lead-based paints,
► crystalline silica from bricks, cement, and other masonry
products,
► arsenic and chromium from chemically-treated lumber.
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 work with approved safety
equipment, such as dust masks that are specially designed to filter
out microscopic particles.
Instruction Manual 5
Tool Description
Figures 1a and 1b
a. Dust Collection Port.
b. Spring Loaded Riving Knife.
c. Arbor Bolt.
d. Outrigger Splinter Guard.
e. Depth Stop and Gauge.
f. Blade Wrench Storage.
g. FastFix Arbor/Plunge Lock.
h. Auxiliary Handle.
Technical Specifications
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)
Bevel Angle 0º to 45º
Weight 4.5 kg (9.9 lbs)
Certifications UL745, CSA C22.2/745
i. Bevel Gauge and Lock Knob.
j. Guide Rail Gib Cams.
k. Sole Plate.
l. Plug-it Power Cord Port.
m. Speed Control.
n. Main Handle.
o. Trigger (On/Off Switch).
p. Plunge Release and Trigger Safety Release.
55 mm (2.2") @ 90º/43 mm (1.7") @ 45º
All metric dimensions are binding. Sawblade dimensions are critical for safe
operation, and are presented in metric units only.
The TS 55 has several features to protect the motor from
misuse.
► The TS 55 has thermal overload protection. If the motor
overheats from extended heavy use, the electronic
controller will shut down the motor until it cools down.
This is to protect the motor from permanent damage.
Once the thermal overload has activated, simply wait a
few minutes for the motor to cool down before resuming
operation. The thermal overload resets automatically
when the temperature returns to normal.
► The TS 55 also has over-current protection. If the electrical
current to the motor exceeds the safe limit (such as what
happens with a pinched blade), the motor is temporarily
disabled to protect itself. The motor is automatically reset
when the power trigger is released.
6 TS 55 EQ Circular Saw
Intended Use
The TS 55 EQ, 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 specified in these operating instructions. Using the tool in
contravention to this manual will void your warrantee and may lead to injury. The user shall be responsible and liable for
damages and accidents resulting from misuse or abuse of this saw.
Single-Point Entry
Single point entry means that the sawblade
always enters the cut at the same location
regardless what the bevel angle is set to. The
pivot point of the bevel adjustment is
located at the bottom edge of the splinter
guard. This means that the cut will always
be along the splinter guard for any bevel
setting.
(Note that this is applicable only when the
guide rail is used. When the guide rail is not
under the saw, the bevel cut will move
slightly outward, away from the main body
of the saw.)
Setup and Adjustments
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 first 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!
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 10 for more
information).
!WARNING: Check regularly whether the saw blade is in
good condition. Saw blades which are cracked,
damaged, or deformed should no longer be used.
2. The riving knife is installed and adjusted at the factory,
however, you should verify that it is properly secured
and adjusted (refer to page 9 for more information).
!CAUTION: The riving knife is a safety feature of the saw to
prevent binding in the cut. All saw work should be
carried out only with the riving knife installed and
correctly set!
3. Install the power cord into the [Plug It] receptacle on the
saw (refer to page 14 for more information).
4. Perform the guide rail gib cam adjustment procedure
described on page 8.
5. After completing all of the inspections and adjustments
listed above, cut the zero-clearance splinter guards as
described on page 8.
Instruction Manual 7
Adjusting the Guide Rail Gib Cams
The guide rail gib cams tighten against the rib of the guide
rail to remove any side-play from the saw during a cut.
Thumbwheels on the top of the cams permit easy
adjustment.
1. Place the saw on the guide rail.
2. Loosen both cams by rotating the
thumbwheels counterclockwise.
3. Working with one cam at a time, jiggle
the saw side-to-side while turning the
cam clockwise until the saw fits
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.
Notes:
► The cams do not need to be very tight for normal
operations. A tiny amount of side-play will not impact the
quality of a cut.
Trimming the Guide Rail Splinter Guard
The leading edge of the guide rail has a replaceable,
rubber, zero-clearance strip. The first 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.
If you have more than one saw that uses the same
guide rail system, you want all of the tools to have
the same cutting path. Before cutting the splinter
guard, use the "Matching the TS 55 to an Existin
Guide Rail" procedure desc
match one tool to another.
1. at
Set the blade depth very shallow (6 to 7 mm) so th
the blade teeth pen
tooth, as shown.
etrate the strip by about half a
ribed on page 12 to
g
► The cam action of the gibs allows for a large force to be
applied to the gibs from a small amount of turning of the
thumbwheel.
► Over tightening the cams or operating the saw in abrasive
environments can cause premature wear. Periodically
inspect the cams for flat spots, and replace if necessary.
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 gib cams as described on
page 8.
5. Cut the strip in a single, smooth, low-speed rip from one
end of the guide rail to the other.
2. Set the motor speed to its lowest setting (setting 1).
8 TS 55 EQ Circular Saw
Trimming 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.
Before the outrigger splinter guard is used for the first
time, it needs to be trimmed to fit the sawblade.
1. Remove the thumbscrew from the outrigger and
slide the outrigger on to the front edge of the blade
guard as shown.
2. Insert the thumbscrew through the outrigger,
through the height adjustment slot, and into the
captive nut on the back side of the outrigger.
3. Raise the outrigger to its top position and tighten
the thumbscrew.
4. Place the saw on a stable surface so that the blade
can be plunged down without cutting the surface
(or use a piece of scrap wood).
5. Set the motor speed to its lowest setting (setting 1).
6. Start the saw and slowly plunge the blade to full
depth.
Replacing and Adjusting the Riving Knife
Periodically inspect the riving knife to ensure it is not bent and
has proper clearance away from the blade. Replace if bent.
1. Unplug the saw for safety.
2. Raise the FastFix latch lever and plunge the saw until it locks
into position (see page 10 for more information on the
FastFix lever).
3. Using the arbor wrench (stored in the auxiliary handle)
loosen the riving knife mounting screw.
4. If the riving knife needs replacement, slide it out of its
mounting, and slide a new knife back in.
5. Raise or lower the riving knife so there is a 2 to 4 mm (3/32
to 5/32 inch) clearance between the knife and the blade.
6. Retighten the mounting screw.
Instruction Manual 9
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