Craftsman 113299112 User Manual 10 BELT DRIVE SAW Manuals And Guides L0802709
CRAFTSMAN Saw Circular Manual L0802709 CRAFTSMAN Saw Circular Owner's Manual, CRAFTSMAN Saw Circular installation guides
User Manual: Craftsman 113299112 113299112 CRAFTSMAN 10 BELT DRIVE SAW - Manuals and Guides View the owners manual for your CRAFTSMAN 10 BELT DRIVE SAW #113299112. Home:Tool Parts:Craftsman Parts:Craftsman 10 BELT DRIVE SAW Manual
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F Save ThisManual For FutureReference MODEL NO. 113.299112 SAW WITH LEGS TWO CAST IRON TABLEEXTENSIONS MOTOR QUICK RELEASE EXACT-i-RIP FENCE SAWDUST COLLECTOR KIT MITER GAUGE AND HOLD DOWN Seria! Number Model and serial number may be found at the righthand side of the base. You should record both model and serial number in a safe place for future use. YOUR SAFETY: READ ALL INSTRUCTIONS [RRFTZMRN I 0" Deluxe Belt Drive Saw • assembly • operating • repair parts CAREFULLY J ,,... SEARS, ROEBUCK AND CO., Hoffman Estates, IL 60179 Part No. SP5802 Printed in USA FULL ONE YEAR STATES and Sears will repair it, free of charge. This warranty applies only while this product is used in the United States. If lJhisTable Saw is used for commercial or rental purposes, this warranty will apply for ninety days from the date of purchase. This warranty gives your specific legal rights, and you may also have other rights which vary from state to state. SEARS, ROEBUCK AND CO., D/817 WA Hoffman Estates, IL 60179 SAFETY iNSTRUCTiONS C: Bolt the saw to the floor if it tends to slip, walk, or slide during normal use. D. When using table extensions over 24" wide on any side of the saw, bolt the saw to the floor or prop up the outer end of the extension from the floor to keep the saw from tipping. 3. Put the saw where neither operators or bystanders must stand in line with the saw blade. Safety is a combination of common sense, staying alert and knowing how your table saw works. Read this manual to understand this saw. SAFETY SIGNAL WORDS DANGER: If the safety information is not followed, someone WILL be seriously injured or killed WARNING: If the safety information is not followed, someone COULD be seriously injured or killed. 4. GROUND THE SAW - This saw has an approved 3conductor cord and a 3-prong grounding type plug. The plug fits grounding type outlets designed for 120 volt, 15 amp circuits. The green conductor in the cord is the grounding wire. To avoid electrocution, NEVER connect the green wire to a live terminal. CAUTION: If the safety information is not followed, someone MAY be injured. Read and follow all safety informationand instructions. BEFORE USING THE SAW: 5. To avoid injury from electrical shock, make sure your fingers do not touch the plug's metal prongs when plugging in or unplugging the saw. 6. To avoid back injury, get help or use recommended caster accessories when you need to move the saw. Always get help if you need to lift the saw. Hold the saw close to your body. Bend your knees so you can lift withyour legs, not your back. 7. NEVER STAND ON TOOL. Serious injury could occur if the tool tips or you accidentally hit the cutting tool. Do not store anything above or near the tool where anyone might stand on the tool to reach them. WARNING: To avoid mistakes that could cause serious, permanent injury, do not plug the saw in until the following steps have been satisfactorily completed. 1. Assembly and alignment. (See pages 14-39) 2. Learn the use and function of the ON-OFF switch, guard, spreader, anti-kickback device, miter gauge, table insert and blade elevation and bevel controls. (See pages 39-42) BEFORE EACH USE: 3. Review and understanding of all safety instructions 1. Inspect your saw. A. To avoid injury from accidental starting, unplug the saw, turn the switch off and remove the switch key before raising or removing the Guard, changingthe cutting too!, changing the setup or adjusting anything. B. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect the way it works. If any part is missing, bent, or broken in any way, or any electrical parts don't work properly. turn the saw off and unplug the saw. C. Replace damaged, missing, or failed parts before using the saw again. D. Use the Sawblade Guard, Spreader, and AntiKickback Pawls for any thru-sawing (whenever the blade comes through the top of the workpiece} ' Make sure .the. Pawls . .work properly " Make sure the Spreader is in hne withthe sawblade. E. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking for and removing keys and and operating procedures in this manual. 4. Review of the maintenance methods for this saw. (See page 61) Read the following WARNING front of your saw. label found on the WHEN INSTALUNG OR MOVING THE SAW': 1. AVOID DANGEROUS ENV RONMENT. Use the saw n a dry place protected from rain. Keep work ................. A. _'u[ me saw on a nrm _evelsun_,uuwhere there is ij-len'" [y of room for handlin" t.j and -roDerl,, H uH y su'_'_rt I-,v_, ing the workpiece. B. Support the saw so the table is level and the saw does not rock. FOR TABLE SAW 2 adjusting wrenchesfrom tool before tuming it on. R [b avoidinjury from jams, slips or thrown pieces (kickback and throwback): 1.)USE ONLY RECOMMENDED ACCESSORIES. Follow the instructions that come with the accessories. The use of improper accessories may cause risk of injury to persons. 2,)Choose the right blade or cutting accessories for the material and the type of cutting you plan to do. 3.)Never use grinding wheels, abrasive cutoff wheels, friction wheels (metal slitting blades) wire wheels or buffing wheels. They can fly apart explosively. 4.) Choose and inspect your cutting tool carefully. Any power saw can throw foreign objects into the eyes. This can cause permanent eye damage. Wear safety goggies (not gtasses) that comply with ANSI Z87.1 (shown on package). Everyday eyeglasses have only impaot resistant lenses. They are not safety glasses. Safety goggles are available at Sears retail catalogue stores. Glasses or goggles not in compliance with ANSI Z87.1 could seriously hurt you when they break. WEAR YOUR SAFE To avoid cutting tool failure and thrown shrapnel (broken pieces of blade), use only 10" or smaller blades or other cutting tools marked for speed of 3450 rprn or higher. Always use unbroken, balanced designed to fit this saw's 5/8" arbor. blades When thru-sawing, (making cuts where the blade comes through the workpiece top) always use a 10 inch diameter blade. This keeps the spreader in closest to the blade. Do not overtighten arbor nut. Use arbor wrenches to "snug" it securely. Use only sharp blades with properly set teeth. Consult a professional blade sharpener when in doubt. Keep blades clean of gum and resin. 5.)Adjust table inserts flush with the table top. NEVER use the saw without the proper insert. 6.) Make sure all clamps and locks are tight and no parts have any excessive play. 2. Keep Work Area Clean A. Cluttered areas and benches invite accidents. Floor must not be slippery from wax or sawdust. B. To avoid burns or other fire damage, never use the saw near flammable liquids, vapors or gases. C. To avoid injury, don't do layout, assembly, or setup work on the table while the blade is spinning. It could cut or throw anything hitting the blade. Plan ahead to protect your eyes, hands, face and ears. 3, Plan your work. A. USE THE RIGHT TOOL - Don't force tool or attachment to do a job it was not designed for. B. Dress for safety: Do not wear loose clothing, gloves, neckties or jewelry (rings, wrist watches). They can get caugllt and draw you into moving parts. Wear nonshp footwear. Tie back long hair. Roll long sleeves above the elbow. Noise levels vary widely. To avoid possible qear_ngdamage, wear ear plugs or muffs when using For dusty operations, wear a dust mask along with the safety goggles. C. Inspect your workpiece. Make sure there are no nails or foreign objects in the part of the workpiece to be cut. D. Plan your cut to avoid KICKBACKS and THROWBACKS - when a part or all of the workpiece binds on the blade and is thrown violently back toward the front of the saw: Never out FREEHAND: Always use either a rip fence, miter gauge or fixture to position and guide the work, so it won't twist, bind on the blade and kickback. Make sure there is no debris between the workpiece and its supports. When cutting irregularly shaped workpieces, plan your work so it wilt not slip and pinch the blade. a. A piece of molding, for example, must lie flat or be held by a fixture or jig that wil! not let it twist, rock or slip while being cut. Use jigs, fixtures where needed to prevent workpiece shifting. b. Use a different, better suited type of tool for work that can't be made stable. Use extra caution with large, very small or awkward workpieces: a. Use extra supports (tables, saw horses, blocks, etc.) for any workpieces large enough to tip when not held down to the table top. NEVER use another person as a substitute for a table extension, or as additiona! support for a workpiece that is longer or wider than the basic saw table, or to help feed, support or pull the workpiece b. Never confine the piece being cut off. That is, the piece NOT against the Fence, Miter Gauge or fixture. Never hold it, clamp it, touch it, or use length stops against it. It must be free to move. If confined, it could get wedged against the blade and cause a kickback or throwback. Never cut more than one workpiece at a time. 4. Plan the through. way you wlll push the workplece NEVER put your fingers or hands of the sawt_ade or other cutting too!. in the path NEVER reach in back of the cutting tool with e_ther hand to hold down or support the workp_ece remove wood scraps, or for any other reason. Avoid hand pos_ons where a sudden s!ip could cau_ fingers or hand to move _nto a sawblade or oth ,_" cutt=ng tO01 DON_ OVERREACH. an_ batance. AJways Keep good footing Push the workp_ece against the rotation of the b_ade. NEVER feed materia! into the cutting tool from tt_e rear of the saw. push the workp_ece all the way past the As much as moss_bteoke_,_ your face and body to one s_de of the _wbtade out of lille with a poss_t_e kickback or throwback NEVER turn the saw "ON' before clearing the tabte of atl tools, wood scraps etc exceot the workp_ece and related fc_l or support devtce.s for me cut ptanned AVOID ACCIDENTAL, STARTING o Make sure switch is "OFF" before plu.cLqing saw in. WHENEVER WARNING: SAW IS RUNNING Don't let familiarity (gained 8. To avoid throwback of cut off p;e,ces: a. Use _ne G_4ard assemby. h. To remove Guard. pt6wsesbeneath or trappecl ms,de the Turn saw "OFFL 2 Remove switch key. 3 Unplug saw, 4. Wa_t for blade to stop before !_fl_n9 the 9_sard. Additional Instructions for RiP TYPE CUTS NEVER use the Miter Gauge when npp_ng, Use a push stick whenever the fence is 2 or more inches from the blade When thru-sawing, use an Auxiliary Fence and Push Block whenever the fence must be between 1/2 inch and 2 inches from the blade, Never thru-saw rip cuts narrower _an 1/2 inch. (See "BASIC SAW OPERATION USING THE RIP FENCE' section), Never rip anything shorter than 10" tong, When using a Push _ng end of the board or block against an push the work away Stick or must be uneven from the Push Block the trailsquare, A push stick end could slip off or fence, A FEATHERBOARD can hetp guide the workp_ece See BASIC SAW OPERATION - USING THE RiP FENCE. Always use featherboards for any non4f_ru rip type cuts. from frequent use of your table saw) cause a care_ess mistake. Always remember that a careless fraction of a second is enough to cause a severe Wa_t for all moving parts to stop. u, Check biade. Spreader a_d Fe_sce re: proper a_gnrnent before slar_ir_g, _._f_a n NEVER pull the workplece through. Start and finish _e clot from the front of the table saw. Nways c 24 _ KERFS ABOUT 5/16" APART injury. t. Baler÷ aclualiy cutting w_th the saw, watc_ it while _t runs for a short wh_ie If i! makes an unfarnihar no_se or vibrates a tot, stoo immediately. Turn the ,_w eft, Unplug the saw, Do not restart unt_t finding and fixing the problemo 2. Make sure the top of the arbor or cu11_ng tool turns toward the front of the saw. 3, Set the cutting tool as tow as possible for the cuz you're planning. 4. KEEP CHILDREN AWAY. All ws_tors should be kept a safe distance from work. MaKe sure bystanders are c4ear of the saw and workp_ece 5. Let, #_e blade reach full sp_ before cutting, & DON'T FORCE TOOL. !t wilt do the job be_er and safer at _ts designed rate. Feed the workp_ece rote the b{ade only fast enougr_ to let it cut without bogg_ng down or binding. 7. Before freeing any jammed material: a Turn switch "OFF". b Unplug the saw 9 BEFORE STARTING -[b avoid kickbacks and slips into the blade, make sure the rip fence is parallel to the sawblade. Check the anti-kickback pawls (See BASIC SAW OPERATION-USING THE RiP FENCE). The pawls must stop a kickback once it has started. Replace or sharpen Anti*Kickback pawls when points become dull. Plastic and composition (like hardboard) materials may be cut on your saw. However, since these are usually quite hard and slippery, the antikickback pawls may not stop a kickback. Therefore, be especially careful in your set-up and cutting procedures. WHILE CUTTING To avoid kickbacks and slips into the blade, always push forward on the section of the workpiece between the saw blade and the Rip Fence. Never push forward on the piece being cut off. Addi_lona! Instructions for ho_d the mi_er gauge and workp_ece keep your hands away from the b!ade CROSS CUT TYPE CUTS Before White cutting starting NEVER ar_,d heips fb avoid blade contact, aiways ho!d the miter gauge as shown in the BASIC SAW OPERA-. ]'tONS USING file M_TER GAUGE. use the rip fence wt_en crosscutting. An atJxiliary wood facing attached to the miter gauge can heip prevent workpiece twisting and throwbacks. Attach t to the i_oles provided. Make the facing tong enough and big e,qo_gh to support your work. Make sure however, it wii! not inter.. fore with the sawb_ade guard. (See "Using The Miter Gauge" section), Use jigs or fixtures to help hoid any piece too smait to extend across the futl length d the miter gauge face duriT_g 1he cu_ Th}s _ets yo_.,,properly BEFORE LEAVING THE SAW 1. Turn the saw off 2. Wait for b{ade to stop spirlnir_g 3. Make workshop child proof. Lock Discon,qeot master switches Remove switch key. Store it away from childre_ not qua;fled to use the toei. 4, Unp}ug [iqe tt-;e shop. the yel_ow and others saw, GLOSSARY OF TERMS FOR WOODWORKmNG Anti-Kickback Paw_s (AKB) Device which, when properly maintained, is desigried to stop the workpiece from be}ng kicked back at the operator during ripping operations. Arbor The shaft on which a c_Jtti,qgtoo; is mounted made across tb,e width of Dado A non-through cut which produces notch or trough in the workpiece, Featherboard A device which can help guard type operations. A devce used for rippir_g type operations a_iow use of a push stick, toe _arrow to Rabbet A notch i_ the _lge of a workpiece. a square workpieces sided Rea{n A sticky, sap base substance during rip Freehand Performing a cut without usir_ga fence, miter gauge, fix_ ture, hold down or other proper device to keep the workpiece from twisting during the cut. Gum A sticky, sap based residue from wood products. Heet Misalignment A dev,,ce used to feed the wo_kpiece throu#h the saw during r_,arrow ripping type operations which helps keep the operator's hands well away from the blade. Push BRock CrOSSCUt A cutting or shaping operation the workpiece, Push Stick that has hardened Ripping A cutting operation along the length of the workpiece. Revolutions per Minute (RPM) The number of turns completed by a spinning one minute. object in Sawblade Path The area of the workpiece or tab}e top directiy in line with tiqe part of tb.e workpiece which wi!! be, or has been cut by the blade. of the b_ade. Kerr The amount of materia_ removed by the blade in a tllrough cut or the slot produced by the bIade in a non through or partial cut. Kickback An uncontrolled grabbing and throwing of the workpiece back toward the front of the saw. Leading End The end of the workpiece which, dudng a rip type operation, is pushed into the cutting too! first. Molding A non-through cut which produces a special shape in the workpiece used for jointing or decoration. Ploughing Ploughing is grooving with the grain the long way of the workpiece, using the fence, Set The distance that the tip of the sawblade _ooth is be_t (or set) outward from the face of the b_ade Throw-Back Throwing of pieces in a manner similar to a kickback. Thru-Sawing Any cutting operation where the blade e×!ends pietety through the thickness of the workpiece. com-. Trailing End The workpiece end tast cut by the blade in a ripping operation. Workpiece The item on which the cutting operation is being done. The surfaces of a workpiece are commonly referred to as faces, ends, and edges. MOTOR SPECIFICATIONS AND ELECTRICAL MOTOR SPECIFICATIONS This saw is designed to use a 3450 RPM motor only. Do not use any motor that runs faster than 3450 RPM. The A/C motor used in this saw is a capacitor start. capacitor run, non-reversible type motor, it is wired at the factory for operation on 120v AC, 60 Hz., alternating current. It may be converted to operate on 240v AC Listed below are the motor specifications. not machine or any motor with an automatic reset They start or up washing by themI overload WARNING:protector. Do use can blower selves and you could get injured. Reference "Motor Connections" for connecting power cord to motor. CONNECTING OUTLET TO POWER SOURCE This saw must be grounded while in use to protect the operator from electrical shock. REQUIREMENTS WARNING: To avoid electrical shock, do not permit fingers to touch the terminals of the plug, when installing or removing the plug to or from the outlet. WARNING: Failure to properly ground this power tool can cause electrocution or serious shock, particularly when used in damp locations, or near metal plumbing, if shocked, your reaction coutd cause your hands to hit the cutting tool This saw is equipped with a 3-conductor cord and grounding type Dlug which has a grounding prong, approved by Underwriter's Laboratories and Canadian Standards Association. The ground conductor has a green lug and is attached to the tool housing at one end and to the ground prong in the attachment plug at the other end. GROUNDING SCREW LUG \ WARNING: Damaged power cords can cause shock or fires. If the power cord is worn, cut or damaged in any way, have it replaced immediately. WARNING: Electric shock can kill Not all outlets are properly grounded. If you are not sure that your outlet is properly grounded, have it checked by a qualified electrician. \. ADAPTER This plug requires a mating 3-conductor grounded type outlet as shown above. 3-PRONG PLUG g) \ \ x GROUNDING PRONG ALWAYS USE A PROPERLY GROUNDED OUTLET It is recommended that you nave a qualified electrician replace the TWO prong outlet w_tn a properly grounded THREE prong outlet. A temporary adapter, as shown, is available for connecting plug to 2-prong receptacles. The green grounding lug extending from the adapter must be connected to a pen_anent ground such as to a properly grounded outlet box. This adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. WARNING: Avoid electric shock, tf the outlet you are planning to use for this saw is of the two prong type, DO NOT REMOVE OR ALTER THE GROUNDING PRONG iN ANY MANNER. Use an adapter, as shown, and always connect the grounding lug to a known ground, such as to a properly grounded outlet box. Not all outlet boxes are properly grounded, if you are not sure the outlet box is properly grounded, have it checked by a qualified electrician. b. The movable links pivot on the center most screws. After links have been correctly positioned, be sure to tighten these screws to insure a good electrical connectior_. 240 VOLT CONNECTION Copper Post A Black Power CHANGING Ground Screw Spade Terminals MOTOR VOLTAGE Links in This Position White Power Lead WARNING: Electric shock can kill. To avoid shock, never connect plug to power source outlet until all assembly steps are completed. Unplug saw before making or changing any connections. 1. Connections for 120V AC Operation a. For operation on 120 volts, the black power lead is connected to spade terminal beside copper post. The white power lead is connected to spade terminal beside silver post. The two movable links must be in position shown in Figure 1. The red motor lead is connected to terminal "B". b. The movable links pivot on the center most screws, After links have been correctly positioned, be sure to tighten these screws to insure a good electrical connection, Red B Silver Post Figure 2 c. Replace the 120v power cord plug with a (3 blade) 240v 15 Amp U.L. listed plug (see illustration below). Connect the power cord white and black leads, respectively, to the two "hot" plug blades and connect the power cord grounding wire to the plug ground prong. 240V PLUG & RECEPTACLE Grounding Blade Is Longest Of 3 Blades 120 VOLT CONNECTION Copper Post A Green Black Power Lead Grounded _- Outlet Box Ground Screw Spade Terminals No Adapter Is Available For Links In This Position White Power Lead This Type Plug Red B Silver Post Figure I d. Plug your saw into a 240v, receptacle. 2. Connection for 24.0V AC Operation a. For operation on 240 volts, the black power lead is connected to spade terminal beside copper post. The white power lead is connected to spade terminal beside silver post. The two movable links must be in position shown in Figure 2. The red motor lead is connected to terminal "B". 1 5-Amp, 3-blade e. Make certain the receptacle is connected to a 240v AC power supply through a 240v branch circuit having at least a 15-amp capacity and protected by a 15-amp, time-delay fuse or circuit breaker. MOTOR THERMAL OVERLOAD PROTECTOR I CAUTION: TO avoid nr_ot--or damage, this motor shoued be blown out or vacuumed frequently to prevent sawdust buildup which will interfere I with n_ormal motor ventilation, Your saw _s equipped w_th _ mar'_uaFreset thermal over_a_ protector designed to open tr_e power line c_r. cu_ w_en me motor temperature exce6_s a safe teveL m_or $ overloaded el a low vo_ta_ cona_t_on exls'_. a. MOTOR tS OVERLOADED - Overioading can 0ccu[ if yet,; feed too rapidly or if sew is mis_ a_igr_ecL b MOTOR C_RCL_IT IS FUSED DIFFERENTLY FROM RECOMMENDATIONS - A!ways fotlow instructions for the proper fuseibreaker. Do not use a fusefbreaker of greater capacity without _msu_ting a qualified electrician. c, LOW VOLTAGE -Aithough the motor is designed fo_operation on the voitage and frequency specified on motor nameplate normal loads wilt be har_died safely on voltage not more than 10% above or below the namepiate voltage. Heavy bads, i_owever, require that voltage a[ motor teF m,inais equa!s the voltage specified on name p_ate. 4. Most _otor troubles may be traced to loose or incorreel cormect_ons, overloading, reduced input voltage (such as small size wire in the supply circuit) or to overly _ong sup_'31y circuit wire, Always check the cofinections the toad and the supply circuit whenever motor fails to perform satisfactorily. Check wire szes and ler_gthwith the Wire Size Chart below. W_RE S_ZES The use of any extension cord Will cause some !oss of power, To keep this to a minimum and to prevent overheating ar_d motor burn-out_ use the table beiow to determine ti_e minim{Kn wire size (AW, G) extension co_J Use or_y 3 w_re extension cords which have 3 prong gK._ur_dir]g type plugs and 3_pole receptacles ,,_ff,ich a_ept the toots plug t. After cooling [o a safe operahng temperature, the eve#earl protector can be c_es_ manually by push. {t_g the red button on the end of the motor, if the red buttO_ W_t not click into place immed_ate{y, the moto_ _ss£!_ too hot and must be allowed] to cool for a while _onqer. Th_._brae required for the motor to cooi may be equal _o _t_e ;ength of time the _3w was useu before t_e thermal overload protector opened, to shut off eiectri* ca_ ,'lew. An audible click wilt _nd_cate the pretec[or is CiOSed 2 As s_,_n as the re4dbutton w_!tdick _nto running posit_ the saw may be started and operated norma!ty, 3 Frequent "b_owing" of fuses breakers may result if. or tripping of c_rcu_t CAUTION: For circuits that are farther away from electrical service box, the wire size must be _ncreased proportionately in order to de_iver ample voltage tO the saw motor. Length of the Cor_ductor Wire (A_erican 120V 0-25 Feet 26 50 Feet 5i - t00 Feet Sizes Required Wire Gage Number) L_ne No. 16 No_ 14 No. 12 240V Line No. 16 No. 14 No. 12 contents WARRANTY SAFETY INSTRUCTIONS ............................... z FOR TABLE SAWS ........................... 2-5 GLOSSARY OF TERMS FOR WOODWORKIN'GI: .,.5 MOTOR SPECIFICATIONS AND ELECTRICAL REQUIREMENTS ...................................................... 6 Motor Specifications ................................................... 6 Changing Motor Voltage ............................................ 7 Wire Sizes .................................................................. 8 Motor Thermal Overload ............................................ 8 UNPACKING AND CHECKING CONTENTS ............... 9 Tools Needed ............................................................. 9 List of Loose Parts .............................................. t0-13 ASSEMBLY ................................................................... 14 Installing Handwheels ............................................... ! 4 Checking Table Insert ............................................. 14 Checking Blade Squareness to Table ......................15 Assembling Steel Legs ............................................ 15 Mounting Saw to Leg Set ......................................... 16 Installing Table Saw Dust Collector ....................... ! 7 Attaching and Assembling Table Extensions ...........t 9 Installing Table Extension Brackets .......................... 20 Installing Front Rip Fence Guide Bar ...................... 21 Installing Rear Fence Guide Bars ........................... 23 Adjusting Rip Fence Guide Bars ............................ 24 Installing Separator Channel .................................... 25 Rip Fence Alignment Adjustment ............................ 26 Rip Fence Lock Lever Adjustment .......................... 27 Installing Measuring Tapes and Indicator ................ 27 Assembling Micro Adjust and Racks ....................... 29 Mounting Switch ....................................................... 31 Installing Blade Guard .............................................. 32 Mounting the Motor .................................................. 35 Positioning Motor on Motor Mounting Base ............34 Installing Belt Guard ................................................. 36 Motor Connections ................................................... 37 Plugging in Motor ..................................................... 39 GE'I-FING TO KNOW YOUR SAW .............................. 39 On-Off Switch ........................................................... 39 Elevation Handwheel ............................................... 40 Tilt Handwheel .......................................................... 40 -I]lt Lock Handle ........................................................ 40 Rip Fence ................................................................. 40 Miter Gauge ............................................................. 40 i = =,== = ,1= = Blade Guard ............................................................. 40 Table Insert ............................................................... 40 Removing and Installing Saw Blade ........................ 41 Exact-l-Cut ................................................................ 41 Micro-Adjust Rip Fence ............................................ 42 BASIC SAW OPERATION .................................... 42 Work Feed Devices .................................................. 42 Push Stick and Push Block ...................................... 43 Auxiliary Fence/Work Support ................................ 43 SAFETY INSTRUCTIONS FOR BASIC SAW OPERATIONS .................................... 44 Using the Miter Gauge ............................................. 47 Crosscutting ............................................................. 47 Repetitive Cutting ...................................................... 48 Miter Cutting .............................................................. 49 Bevel Crosscutting ................................................... 49 Compound Miter Cutting .......................................... 49 USING THE RIP FENCE ............................................. 50 Ripping ...................................................................... 50 Bevel Ripping Narrow Work .................................... 50 Using Featherboards for Thru-Sawing .................... 51 Resawing .................................................................. 53 Cutting Panels .......................................................... 53 Using Featherboards for Non-Thru Sawing ............54 Rabbeting .................................................................. 55 Ploughing and Molding ............................................ 55 Dadoing .................................................................... 56 Molding Cutting ........................................................ 56 ADJUSTMENTS ............................................................ 57 Miter Gauge ............................................................. 57 Heeling Adjustment or Parallelism of Sawblade to Miter Gauge Groove ....................... 57 Blade Tilt, or Squareness of Blade to Table ............ 59 90 degree position .................................................... 59 45 degree position ................................................... 60 Tilt Mechanism ......................................................... 61 Maintenance ............................................................. 61 Lubrication ................................................................. 62 SEARS RECOMMENDS THE FOLLOWING ACCESSORIES ........................................................... 62 TROUBLE SHOOTING ................................................ 63 General ..................................................................... 63 Motor ................................................................... 63, 64 REPAi R PARTS ..................................................... 66 - 75 = , ==H,r unpacking and check contents COMBINATION E OLS NEEDED DRAW LIGHT LINE ON BOARD Screwdrivers mbination Square SQUARE MUST BE TRUE STRAIGHT EDGE OF BOARD 3f4" THICK THIS EDGE MUST BE PERFECTLY STRAIGHT 1) Small Flat Blade 2) Small Philltps 3) Medium Phillips ALONG THIS EDG_ SHOULD BE NO GAP OR OVERLAP HERE WHEN SQUARE IS FLIPPED OVER IN DoI-rED POSITION, _. r 2' Rafting Square J Pliers i Separate all parts from packing materials ana check each one with the illustration and the list of Loose Parts to make certain all items are accounted for. before discarding any packing material. I use gasoline, naptha or simiJar highly volatile j WARNING: To avoid fire or health hazard, never J so,vents. ' WARNING: If any parts are missing, do not J attempt to assemble the table saw or plug in the power cord or turn the switch on until the missing parts are obtained and are instaUed correctly. f Remove the protective oil that is applied to the table top and edges of the table. Use any ordinary household type grease and spot remover. Apply a coat of automobile wax to the table. Wipe all parts thoroughly with a clean, dry cloth, WARNING: For your own safety, never connect plug to power source outlet until all assembly steps are complete, and you have read and understood the safety and operational instructions. LIST OF LOOSE PARTS Identify Parts The following parts are included'. NOTE: Before beginning assembly, check that all parts are included, If you are missing any part, do not assemble the saw. Contact your Sears Service Center to get the missing part, Sometimes small parts can get lost _n packaging material. Do not throw away any packaging until saw is put together. Check _ackaging for missing parts before contacting Sears.,A corn plete parts list (Repair Parts) Is at the end of the manual. Use the list to identifythe number of the missing part. Item F Part Name A Miter Gauge Assembly .................................... 1 B Saw Guard Assembly ........................................ C Fence Assembly ................................................ 1 D Front Fence Guide Bar ...................................... 1 E Rear Fence Guide Bar ...................................... 1 F Bag of Loose Parts ............................................. * G Owners Manual .................................................. 1 H Leg ..................................................................... 4 I End Stiffener ...................................................... 2 J Side Stiffener ..................................................... 2 K Table Extension 12 x 27 .................................... 2 L Motor .................................................................. 1 M Fence Tape ........................................................ 2 N Lower End Stiffener ........................................... 2 O Lower Side Stiffener .......................................... 2 P Micro Adjust Rack .............................................. 2 Q Motor Base ........................................................ 1 • Number varies; bags can contain other smaller bags. Check both table saw and rip fence packages for bag packs, NOTE: To make assembly easier, keep contents of each bag together and separate from contents of other bags. Q M I t 10 ___d I° --q T item R S T U Part Name Qty. Door ................................................................... Saw Dust Collector ........................................... Deflector ............ Adapter Plates .................................................. 11 1 1 1 2 UST AA AB AC AD AE AC AF AG AH AZ AW AX J K M N OF PARTS iN BAG Belt Guard ........................................................... t Belt Guard Support ............................................. ! Support Bracket ................................................. 1 "S" Clip ................................................................ 3 Ty "TT' Pan Head Screw, 10-.32x 1/'2.................2 OF LOOSE PARTS AA AD Switc_'lAssembly ................................................ Hand Wheel ....................................................... Micro Adjust Knob Assembly ............................ indicator ............................................................. Pan Head Screw 8-32 x 5/16 ............................ Square Nut-8-32 ................................................ End Cap, Left Fence Head ................................ End Cap, Right Fence Head ............................. End Cap, Left, Front Guide Bar ......................... End Cap, R ght Front Guide Bar ............ 2 I 1 1 1 1 1 1 t J K M _ I! AG AF BA BB BC BD BE BF BG BH BI Truss Head Screw, 1/4-20 x 1/2"...................... 40 Lockwasher, t/4 External .............................. 42 Hex Nut 1 _4_20............................................ 42 Hex Nut, 3/8-16 .................................................. 8 Levelling Foot 3/8 .............................................. 4 Hex Head Screw. 5/16-18 x 1-1.'4".................... 4 Hex Nut. 5/16-18 ................................................ 4 Lockwasher, 5/16 External Type ....................... 6 Flatwasher. 11/32 x 11/16 x 1/16", .................... 8 CA CB CC CD CE Handle ................................................................ Rod Support ....................................................... Screw, Wing 1/4-20 x 1...................................... Washer 17/64 x 5/8 x 1/16 ................................. Miter Gauge Clamp ........................................... BE 1 ! 2 2 1 CC CA 12 CB AJ AK AL AM AN AO AP AQ AR AT Spreader RodAssembly ................................... 1 AO GuardSupport .................................................. l DrivePuley....................................................... 1 GripNotchBelt112x41....................................... 1 ArborWrench ..................................................... 1 Spreader Suppo_............................................. 1 Bracket ............................................................. 8. ThumbScrew5/!64 8x 1................................ I WireTie.............................................................. 2 BIadeGuardSupportSpacer ........................... ! AK AQ AT BC BL BN BM BQ BR BP External Lockwasher 1/4.................................... 2 Hex Nut 1/4-20 .................................................. 2 Hex Head Screw, 5/t6-18 x 1 ............................6 External Lockwasher 5/16 ............................... 20 Heavy Hex Jam Nut 5/!6-18 .......................... 20 Hex Head Screw, 1/4-20 x 5/8 ......................... 4 Carriage Bolt 5/!6-18 x 3/4 ............................... 4 Bolt, Square Head, 5/16-18 x I "........................ 8 .o oc© BL BQ _ AA AB AE BL BN BM BO BS BT BZ BW Piain Washer 13164". ......................................... 8 Washer 21/64 x 5/8 x !/16 ............................ 28 Pan Head Screw, 10-32 x 3/8 ......................... 12 Hex Head Screw, 5/16-18 x 3/4 ...................... 8 Hex Head Screw, 5/16-t8 x 1-I14 ..................... 8 Hex Head Screw, 5/16-!8 x 5/8 ...................... 3 External Lockwasher 5/16 ............................... 20 Heavy. Hex Jam Nut 5/16-18 ......................... 20 VVasher 11/32 x tlr16 x 1/16 ............................. 8 Shim Washer ................................................... 10 External Lockwasher #10 .............................. 12 Nut, Square 10-32 ....................................... 12 Bolt, Square Head. 5116-18 x 3/4". ................... 8 BR lilllt __ i p,BL BN .© os ) 8Z 13 L_t BW AB ASSEMBLY Before mounting the saw on tegs or a stand or a bench, the Table _nsert and Btade Squareness must be Choked at this time. INSTALLING HANDWHEELS 1. Stide t,_e _evation bandy, heel onto its shaft. Line up the flat spot on the shaft with the set screw in the handv,dseol. Using a hex "L_Iwrench tighten the set screw securely against the flat spot on the shaft,. Repeat this same proco-xJureto instaJl the ti_t handwheek I WARNtNG: To avoid I make sure switch t netted to power. CHECKING injury from is "OFF" and accidental ELEVATION HANDWHEEL \ start, 3732_N. plug is not con- HEX "'L"WRENCH TABLE iNSERT _nsert should be flush with tabie top Chec_ as shown Loosen flat head screw that holds insert and adjus! the four set screws as necessary [ighten flat r'_ead screw Do not tighten screw to the point where _tdeflects the inse£ CAUTION: insert TILT HANDWHEEL must be even with the table sur- face. inserts too high or low can let the workpiece "snag or catch on uneven edges. Workplece could twist and kick back. 2 To remove insert, A. Make sure saw _s OFF an(] unplugged. B Loosen Screw. C, Luft =nsert from front end, and _ull toward front of SaW. 3. To replace insert, A Make sure saw is off and unplugged. B. Place insert into insert opening m table and push toward rear of saw to engage spring clip and until keyslot =n insert will drop over screw. Tigl_ten screw. / PHILLIPS FLAT HEAD SCREW C, Do not tighten screw to the point where it will deflect the insert. 14 CHECKgNG TABLE BLADE SQUARENESS TO IMPORTANT; BLADE must be SQUARE (90 degrees) to TABLE, in order to proceed with assemblly. MAKE SURE SQUARE IS NOT TOUCHING TIP OF TOOTH 1. Make sure saw is off and unplugged, 2. Turn ELEVATION handwheel clockwise until blade is up as high as it will go, 3, Check for BLADE SQUARENESS..,if square to table, adjust it at this time, blade is not NOTE: The combination square must be "true" - see start of "Unpacking and Checking Contents" section for checking method used to check square. Refer to "BLADE TILT, OR SQUARENESS OF BLADE TO TABLE" in the "ADJUSTMENT" section of this manual for instructions on how to square blade to table. ASSEMBLING From among Hardware: STEEL LEGS the loose parts, find the following 40 Truss Head Screws, 1/4-20 x !/2 in. long Itop of screw is rounded) 40 Lockwashers, 1/4 in. External Type (approx. diG, of hole 1/4 in.) 40 He× Nuts, 1/4-20 (approx. diG. of hole 1/4 in.) 8 Hex Nuts, 3/8-16 (approx. diG. of hole 3/8 in.) 4 Leveling Feet ....... i== I,i 1/4-20 X 1/2 IN. TRUSS HEAD SCREW ___ © 1/4-20 HEX NUT . Assemble the legs as shown: 1. Insert the Truss Head Screws through the holes in the legs, then through the holes in the upper stiffeners. MAKE SURE THE SCREWS GO THROUGH THE HOLES IN THE UPPER SIDE STIFFENERS MARKED "X". 2. Install the Iockwashers. Screw on the nuts hand tight. 3. Insert the Truss Head Screws through the holes in the Legs, then through the holes in the lower stiffeners. MAKE SURE THE SCREWS GO THROUGH THE HOLES IN THE LOWER STIFFENERS MARKED 4. Install the Iockwashers, Screw on the nuts but do not tighten until completely assembled, 5. After completing the leg assembly as shown, tighten all the nuts. 6. install leveling feet. 7. Adjust leveling feet as follows: a. Move saw to desired location. b. With 9/! 6 inch wrench loosen bottom nut, c. Back offtop nut byhand. d, Raise or lower foot by adjusting bottom nut using 9/16 inch wrench. e. Snug top nut against ins;de of leg by hand. f. Tighten all four bottom nuts using 9/16 inch wrench, 1/4 IN. LOCKWASHER 15 HEX NUT MOUNTING I. From a_o_g water 4 4 4 8 SAW TO PARTS LEG SET the tcx_se pa_s, find the following Hex Head Screws, 5/16..18 x t-I/4" Hex ,_quts,5/16.18 Lockwasher, 5/16 External Type Flat Washers, !1/32 x t!/16 x 1/16 SHOWN ACTUAL S_ZE hard long 5/16-18 ;4 1-t/4 IN. HEXHEAD SCREW 5/16-18 HEX NUT WARNING: The saw is heavy. To avoid back injury, get help to lift the saw. Hold the saw close to your body; Bend your knees so you can lift with your legs, not your back. 5/16 IN. EXTERNAL FLATWASHER LOCKWASHER 2, Place saw or_ sawbase so that holes in bottom saw line up w_th holes in top of saw base. of BOLT HOLE LOCATION AT EACH OORNER 3, Locate tt_e adapter plates and position them between the _aw base and legset as illustrated. Place, the mountin¢l bolts through the adapter plates .saw houstng an(] legset as shown. Securely tigi_ten a_ nuts. The adapter plates wi!t form the mounting tr;_me for the chute. LEFT POSITION ADAPTER PLATES ON TOP OF LEG STIFFENER FRONT SIDE RIGHT SIDE LEG STIFFENER POSITION ADAPTER PLATES ON TOP OF LEG STIFFENER o _ADAPTER PLATES 16 RIGHT mNSTA.LLING TABLE SAW DUST COLLECTOR RIGHT REAR NOTCH FRONT _ NOTCH 1. From among the loose parts, find the following hardware: 2 Hex Head Screw 1/4-20 x 5/8 2 Hex Nuts 1/'4-20 2 Lockwasher, t/4 External Type 2, Look underneath the saw to locate the proper position for the chute. With the discharge opening facing the rear of the saw; slip the front and rear notches of the chute's right hand side on top of the Adapter Plates. Compress the left hand side slightly to allow easy passage on top of the left hand side of the adapter plates; release the side pressure while positioning the left hand housing notch over the adapter plates. LEFT FRONT NOTCH DISCHARGE NOZZLE TOWARD REAR 3. Slide the door up and under upper tabs on the open face of the chute. Push the bottom edge of the door towards the rear of the saw to snap it over lower tab of chute. UPPER LOWER _ TABS DOOR 17 4. Thedeflectoris mountedto the rearof thesawon theleftsideviewedfromtherear.Inserttwo1/4-20x 5/8"hexheadscrewsthroughthe outsideholesof the deflector,marked"X".andthroughthebottom frameofthesawcabinet.InstallIockwasher andnut to eachscrew.Aligndeflectorwithsawcabinet. "l]ghtennuts. REAR OF SAW BASE CABINET 5. Connectoneendof the2-1/2"x 7' hosetothe dischargeopeningandtheotherendto yourCRAFTSMANSawDustCollector SystemorWet/Dry Vac. 0 I WARNING: Blade Remove and install J door only with saw exposure. off, and unplugged, 6. To remove door, push gently down on lower tab with thumb while Dulling OUt at bottom of door with fingers. This completes the installation process and the table saw dust collector is ready to use. LEG SET LOWER TAB • Push Tab Down • Pull Out On Bottom Edge Of Door 18 X 1111111111111i!11 ATTACHmNG AND ASSEMBUNG TABLE EXTENSmONS 5/16-18 X 1-1/4 IN. HEX HEAD SCREW WARNING: Stock table extensions must be installed. They hetp support the fence rail. An unsupported rail can twist. Twisted rail can misaiign fence. A misaligned fence can cause binding or kickback. You could be hit or cut. Q 1. From among the loose parts find the following hardware: (Quantity indicated is for 2 extensions) 8 8 8 8 5/16 IN. EXTERNAL Hex Hd. Screw. 5/16-18 x 1-!/4 Flat Washer (Dia. of Hole 11/32) External Lockwasher, 5/16 Hex Nut, 5/16-18 2. Insert four (4) 5/16-18 x 1-1/4 in. long screws through holes in each EXTENSION. 3. Position an extension against table so screws extend through holes in table. 4. Install flat washer, Iockwashers, and nuts on the screws... DO NOT TIGHTEN. . CHECK WITH SQUARE AT 2 PLACES MARKED WITH "X" Line up front edge of extension with front edge of table. Link up top surface of extension with top surface of table at the locations indicated by the "X"s (see illustration). Use a combination square to line up these edges and surfaces. Slightly tighten nuts with a 9/16" wrench. WARNING: Table extensions must be installed. Front edge of table and extensions must be lined up. An uneven front edge can twist the fence rail. Twisted rail can misaiign fence. A misaligned fence can cause binding or kickback. You could be hit or cut. 6: If adjustment is necessary (tow in the center) use a "C" clamp to raise the center of the extension into position. Make sure front edge of extension is lined up with front edge of table. Then firmly tighten nuts. 7. Repeat the same procedure extension. 5/16-18 HEX NUT to insta!l the other 19 FLAT WASHER iNSTALLiNG TABLE EXTENSION BRACKETS 1. From among the loose parts find the following hardware: 4 4 4 4 4 5/16 IN, EXTERNAL 5/16 IN. Hex Head Screws. 5/16-18x 1" long Lockwashers, 5/16 External Type Flatwashers. 21/64" inside dia. Hex Nuts, 5/16-18 Brackets 21/64 IN. WASHER 2. Put one of the brackets against the right edge of the right extension so the bracket is lined up with the FIRST hole near the front of the extensior Insert a 5/16-18xl inct_ long screw through a fiat washer, through top hole in the bracket, and through the FIRST hole in the extension. Install a Iockwasher and nut on the screw. Leave the nut loose enough so you can adjust this bracket later. 3. tnstalt another bracket against the left side of left extension using the same procedure explained above. HEX NUT / / BRACKET EXTERNAL LOCKWASHER HEX HEAD SCREW 5tl 6-18 X 1 REAR OF EXTENSION 4. Put one of the brackets against the right rear edge of the right extension so the bracket is lined up with the FOURTH hole near the rear of the extension (see illustration). 4TH HOLE BRACKET WASHER 5. Insert one of the 5/16-18xl inch long screws through a fiat washer, through the bracket, and through the FOURTH hole in the extension. Install a Iockwasher and nut on the screw. Tighten the nut only slightly. 6. Install the other bracket against the left side of the left extension using the same procedure explained above. HEX NUT_/_ EXTERNAL LOCKWASHER 7. Do not tighten the bracket nuts until the front and rear rails are in place and adjusted properly. See INSTALLATION PROCEDURE for front and rear guide bar. 2O 5/16-18 X 1 HEX HEAD SCREW RNSTALLUNG FRONT RIP FENCE GUIDE BAR 1. From among the loose parts find the following hardware: 4 2 6 6 6 1 1 " SQ, HD. SCREW Sq. Head Screws, 5/16-18 x 1" long Sq. Head Screws, 5/16-18 x 3/4" long External Lockwashers, 5/16" inside diam. Flat Washers, 21/64" inside diam. Hex Nuts, 5/16-18 Front Guide Bar 70" long 5/16" EXTERNAL LOCKWASHER 21164" WASHER Slide the heads of four 5/16" x 1" SQ. head screws into the top slot of the guide bar until they are in the central area. Then slide one 5/16" x 3/4" SQ, head screw into the left and right ends of the top slot of the guide bar, , , Place guide bar on table top with top down and bolts facing toward you. Position guide bar so that right end, when facing saw, is 15" past end of right extension. This should leave 11" extending past left extension. Slide the 1" screws in slot until they line up with the four holes in the saw table. Slide the 3/4" screws until they line up with the holes in the brackets attached to the extensions, 4. . SQ. HEADSCREW Carefully lift and roll the front guide bar until screws face holes in saw table and brackets. When all six holes are in line, push front guide bar against saw tables and extensions. 3/4" SO, HD. SCREW 1" SQ, HD. SCREW WARNING: Tighten bolts in the proper order. improper tightening sequence can twist the fence rail Twisted rail can misalign fence, A misaligned fence can cause binding or kickback. You could be hit or cut. SAW TABLE 8RACKET EXTENSION SO. HEAD SCREW FRONT GUIDE BAR FLAT WASHER 511_1B HEX NUT LOCKWASHER 2! 6. Holding the guide bar in place with one hand, insert a flat washer, Iockwasher and nut on each screw starting from the center and alternating left and right. =inger tighten only until all six screws nave washers. lockwashers and nuts installed. Hand tighten 4 nuts at saw table first. With a straight edge along the right side of the saw blade, align the blade aligning mark on the top of the front rail with the right side of the saw blade. RIGHT SIDE OFSAW BLADE BLADE ALIGNING MARK FRONT RAIL ! WARNING: Blade aligning marks must be aligned I with blade. Misaligned rail could twist. Twisted rail could misalign fence. A misaligned fence could cause binding or kickback. You could be hit or cuL STRAIGHT EDGE .J TOP OF FRONT RAIL 7. Adjust the extension table brackets against the back of the guide bar and then finger tighten the nuts. 22 tNSTALU_G REAR FENCE GUIDE BAR I. From among tt_e _ooseparts find the following: 3i4" SQ, HD. SCREW 4 2 6 6 6 1 Sq. head screws, 5/16--18 x 1" long Sq. head screws, 5/16-18 x 3/4" torT,q Externat lockwashers, 5/16" I.D. Flat washers, 21/64" I.D. Hex nuts, 5/!6-18 Rear guide bar 6!" tong 2. Lay the rear guide bar on the rear of the saw table with the left end extending 6-1/2" past the le_ edge of the extension. 5/t6" EXTERNAL 2t/64 '! WASHER 5/16" HEX NUT LOCKWASHER 3, Slide the head of four 1" long screws in the siot until they line up with the four holes in the saw tabMe. Then from each end, slide in one 3,/4" screw untii it lines up with bracket slot on end of extensions, 4. Turn rear guide bar with ,,vide section up and screws facing saw. Insert screws into holes in saw table and bracket. Install flat washer, lockwasher and 5/16-t8 nuts to screws from inside of saw table and bracket. Finger tighten the nuts. With a straight edge along the right of the saw blade, align the notch on the top of the rear rail with the right side of the saw btade. Tighten nuts from center of saw tab!e first, alternate left and right. SQ HEAO SCREW 5/16- 5. Adjust the extension table brackets against the back of the guide bar and then finger tighten the nuts. 5/16-18 X 1" 6. Shims may be required between the rear guide bar and saw table. See INSTRUCTIONS FOR ADJUSTING RIP FENCE GUIDE BARS. LOCKWASHEP; FLAT WASHER SQ. HEAD SCREW 5/16-18 X 1" 23 _,,._ 511 6-! B X 3/4" SCREW HEX _T BRACKET ADJUSTING RiP FENCE GUIDE BARS VERY THIN SHIM WASHER ,,_CREW LOCATIONS VIEW' FROM TOP OF SAW 1. From among the loose parts find the following hardware: O 10 Very Thin Shim Washers 2. Loosen the 6 nuts holding the rear guide bar in place, Holding the guide bar against the saw table and extensions, note if there is any gap between the table and the inside face of the guide bar. If no gap occurs, tighten nuts. If gap a_)pears slip shim washers into gap until space is full. Stack shim washers on table nearest to screw that is affected, When all four screw locations have been checked, remove guide bar, Tnstallstacks of shim washers to appropriate screw between guide bar fence and table saw, Reinstall guide bar with fiat washer, Iockwasher and nut on inside of saw table. Finger t_ghten nuts. SCREW LOCATIONS LOCK_NASHER FLATWASHER 3. Position rip fence over right miter gauge groove, While holding up rear of rip fence engage front end of rip fence onto the front gutde bar. Now lower rip fence down onto table. _ GUIDE BAR 4. Cut up a piece of newspalDer into 16 equally sizee pieces about 4 inches square. Separate these peces into two stacks containing 8 pieces in eacn stack. Put one stack under rear end of ripfence and other stack under front end of rip fence, HEX NUT _/ SAW TABLE SCL HEAD SCREW 8 THICKNESS L< __ 5, Rip fence should c_ear saw table lust enough to allow paper stack to slide back and forth under r_p fence. If rip fence does not clear saw table, loosen n_s holding front guide bar aria adjust bar upwards, Tighten nuts when clearance is achieved, 6. Adjust rear guide bar, as noted above, if fence does not clear saw table. 7. Slide fence left and right on guide bar to ensure clearance from side to side and from front to back. If necessary readjust rip fence guide bars to get proper clearance. Tighten all nuts holding guide bars _n place, Tighten nuts to secure table extension bracket to ra S then tighten nuts to secure bracket to extens_iontable, PAPER SHC SLIDE EASILY PAPER STACK 24 INSTALUNG SEPARATOR CHANNEL [ 11IIIIIiD WARNING: Separator channel must be properly installed to help keep thin work from stipping beneath the fence and heBp keep the fence raits straight. Without the separator channel properly in pnace,work could bind or kickback. You couM be hit or cut. 5/16-18 X 3/4 HEX HEAD SCREW G G 1. From among the loose parts, find the: 4 8 12 12 12 4 1 5/16-18 X 3/4 IN. SQ. HD. SCREW Square Head Screws, 5/16-18 x 3/4" long Hex Head Screws, 5/16-18 x 3/4" long Flat Washers, 21/64" I.D. External Lockwashers, 5/!6" I.D. hex Nuts, 5/16-18 Brackets Separator Channel 5/16" EXTERNAL 21/64" WASHER 5/16" HEX NUT LOCKWASHER SEPARATOR 2. Install brackets to separator channel with 2 holes of bracket facing channel. Use hex head screws - 5/1618" x 3/4" long through bracket hole and channel. Install flat washer, Iockwasher and nut from inside channel, Finger tighten eight nuts. CHANNEL BRACK_ SEPARATOR CHANNEL 3. Slide square head screws into slot in bracket with heads outside of brackets. Install flat washer, lockwasher and nuts from inside of bracket. Finger tighten only leaving a gap between the inside of the screw head and the outer face of the bracket. 5/16-18X3/4" HEX HD. SCREWS BRACKET NUT 4, Slide the square head screws into the slots from the right end of the front and rear fence guide bars. 5/16-18 X 3/4" HEX HD. SCREWS F_rn_ SEPARATOR CHANNEL -'-------I--I_ _ _ II _S:I!_A_N-: I Ig{R _ _1 T LOCKWASHER k' IF BRACKET FLAT WASHER BRACKE 5/16-18 X 3/4" SQ. HD. SCREW (1) REAR FENCE GUIDE BAR SEPARATOR CHANNEL SQUAREHEAD SCREWS / FRONT FENCE GUIDE BAR 25 5. Slide assembly to the left until it is 4" from the extension table. Adjust the extension table brackets against the back of the front guide bar and then finger tighten the two nuts. 6. Check dimension from side of right extension to le_t side of channel at front guide bar and rear guide bar, Adjust to insure both dimensions are identical. / ii 7. Lay a framing square from the right extension to the separator channel at the frontof the saw. When lined up. tighten two front nuts. '3 8. Same procedure as above is required at the rear of the saw. 9. Slide fence to right, over separator channel. Fence channel should clear separator channel. Feeler gauge for checking clearance can be created by cutting a piece of newspaper in 16 pieces 4" square, Stack eight pieces at front of channel and eight pieces at rear of channel. Fence should have just enough clearance to slide back and forth over paper stack. Adjust to obtair proper clearance. Tighter all nuts holding the separator channel in place. Tighten nuts to secure bracket to rails then tighten nuts to secure bracket to separator channel. RiP FENCE AUGNMENT RIGHT EXTENSION FRAMING ADJUSTMENT WARNING: A misaligned fence can cause kickbacks and jams, To avoid injury, follow these instructions until the fence is properly aligned. GROOVE 1. The rip fence must be PARALLEL with the sawblade and Miter Gauge Grooves. Clean any debris off the fence rail. Move Fence until it is along side of Groove. DO NOT LOCK IT. It should be parallel to Groove. If it is not: A. Using a hex "L" wrench, loosen the four fiat head screws located to each side of the rip fence handle, B. Hold fence head tightly against from guide bar Align fence channel so that it is parallel With groove. C. Alternately tigtiten the screws. D. Recheck alignment. E. Repeat steps as needed until fence channel is aligned with miter gauge groove. FLAT HEAD SCREWS FOR ADJUSTING FENCE PARALLELISM 26 RiP FENCE LOCK LEVER ADJUSTMENT WARNING: Make sure the fence lock works in the center and at each end of the fence rail. An improperly adjusted fence could move. Movement could cause binding or kickback. You could be hit or cut. 1. The rip fence lock lever when locked down should hold the rip fence securely. It should not be difficult to push down and lock. REAR OF If lock lever does not lock fence securely... A, Raise lock lever. B, Tighten the adjusting nut at the rear of the fence channel with a 1/2" wrench, until the lever, when locked, holds the rip fence securely. ADJUSTING NUT o o o o FLAT HEAD _ SCREWS FOR ADJUSTING FENCE PARALLELISM If lock lever is difficult to push down.,. A. Raise lock lever. B. Loosen the adjusting nut until the lever is easy to push down and holds the rip fence securely. % Check fence lock across entire rail length and adjust if necessary. Recheck fence parallelism with miter slot in locked position and adjust if necessary. [ iNSTALLiNG iNDiCATOR MEASURING ] MEASURING TAPES AND 1. From among the loose parts find: RED TAPE (24" AND 30") LINE _ PAN HEAD SCREW \ 1 1 1 1 1 Right Measuring Tape 30" Long Left Measuring Tape 24" Long Plastic Indicator Pan Head Screw - 8-32 x 5/!6" Long Square Nut - 8-32 PLASTIC INDICATOR 2. tnstall the pan head screw through the hole in the plastic indicator with the red linefacing up. Install the square nut to the underside of the screw leaving a gap of 1/8"+ between the inside of the nut and the bottom face of the plastic indicator. NUT RIP FENCE HEAD / 3. Slide the indicator nut into the groove closest to the saw table in the fence head from the right end, _ __ _/r- PLASTIC INDICATOR _ _._-..r/ l I SAW I / TABLE 4. Measure in from the right end of the fence head 13/4" to the center line of the indicator. Tighten screw. t q 5. Place rip fence on saw table to the right side of the blade. TAPE 6. Using a tape rule measure two incheS out from the right side of the blade. Position the rip fence so the left side of the fence is at this two inch mark. RIP FENC GUIDE BAR i I 7. Lock the fence in this position. 27 8. Find right tape tape 9. the "0" inch mark on the end of the 30" long measuring tape. Slide this end of the measuring under the right side of the indicator and push along top surface of rip fence guide bar. O" MARK 2" MARK RED LINE i ON INDICATOR Move measuring tape under plastic indicator until two inch mark on measuring tape is straight under red line on center of indicator. DRaW/PENCIL 10. Hold measuring tape in this position and draw a pencii mark across rip fence guide bar at left end of measuring tape, MARK P FENCE HEAD l_i J I ! HERE PENCIL MARK 11, Remove rip fence from saw, 12, Install right front measunng tape as follows: A. Place measuring tape with "0" inch mark on pencil mark you drew across left end of guide bar, B. While holding measuring tape in position lift left end and peel back about six inches of protective coating to expose adhesive on underside of measunng tape, Very carefully lower left end of measuring tape back down on rip fence guide bar making sure the measuring tape is lined up properly with the pencil mark. Press left end of measuring tape down against guide bar so adhesive will hold measuring tape in place. C, Raise measuring tape and peel back another st× inch section of protective covering. Now carefully lower measuring tape agmnst guide bar so it remains lined up and then cress down so adhesive will hold it in place, D. Continue this procedure until the full length of the measuring tape is in place on the guide bar. RiP --- TAP SURtNG FRONT FENCE GUIDE BAR 13, Place rip fence on left side of blade. ! 4. Using a tape rule measure two inches out from the left side of the blade. Position rip fence so right side of fence is at this two inch mark. 15. Lock np fence in this position 16. Followthe same procedure used to install the right measuring tape except: A, The left measuring tape is 24" long. B, The pencil mark you make across the guide bar should be at the right end of the tape. C. The end of the measuring tape with "0" inch mark must be pushed under the left side of the rio fence and the left side of the indicator. D. When peeling back protective coating to expose adhesive work from the right end of the measuring tape. 17, The measuring tapes can now be used together with the rip scale indicator to provide a quick method for positioning the rip fence to produce boards of the width you desire, If you want to rip a board 4 inches wide, simply slide the rip fence along the front guide bar until the ,ed line in the center of the plastic indicator is positioned directly above the four inch line on the measuring tape. Lock the fence in this position and rip the board. NOTE: If extreme accuracy is required when ripping, you should not use this method to position the fence Instead. use a prec=sion measunng instrument to set the rip fence the exact distance away from the blade. 28 18,Alignthefence'splasticendcaptomatchtheprofile of the head.Install2 self tap 10-32pan head screwsintotheholes. NOTE:Adjustcapso it doesnot interferewithfront guidebar, The screwsare self tapping.Drivethe screwsin untilcapisseatedagainstthefencehead. ASSEMBUNG RACKS MICRO ADJUST © AND 1. From among the loose parts find the following hardware: 10 10 8 10 1 2 10-32 X 3/8" 3/16" LOCKWASHER 13/64" PLAIN WASHER Pan Head Screw - 10-32 x 3/8" long Square Nuts - 10-32 Plain Washers - 13/64" Lockwashers - 3/16" 1. Diam. Micro Adjust Assembly Racks MICRO ADJUST ASSEMBLY 2. Take rack with teeth facing down and insert 4 pan head screws 10-32 x 3/8" with 3/16" Iockwasher and 13/64" plain washer in the 4 holes. Install from the underside. Install four 10-32 square nuts on the top side of the rack onto the pan head screws. Turn the nuts until there is a 1/8"+ space between the inside of the nut & the top of the rack. Slide the nuts with the rack attached from the left end into the middle slot, until the end of the rack is 5-1/2" past the left end of the front guide bar, Tighten all screws. 10-32 SQ. NUTS \ 13/64" RACK 29 pLAIN WASHER 3/16 '= LOCKWASHER ! 0-32 S<:_. NUT 2i 3 instant theotherrackfromthe rightendina similar mannerasdescribed in #2.slidingrackagainstleft rack.Tighten attscrews. FRONT GUIDE BAR \ 4 _akemicro-adjust assembly andinserttwopanhead screws10-32x 3/8"longwithlockwashers to holes mm,,cro adjustmount.Install10-32squarenutsto screwsleaving1/8"plusbetweeninsideof nutand topofmicroadjustmenL 5. Slidemicro-adjust boltsinbottomslotofrightendof fencehead.Slideto the leftuntilcenterof microadjustassemblyis 3-3/4"fromrightendof fence head.Tighten 2 screws. 6. Toengage micro-adjust, pushinknobandturnleftor right.Gearonshaftassembly willengage withteeth on rackandmovefenceassemblyleftor rightas required. RACK SQUARE NUTS 7 fffencedoesnotmove,makethisadjustment. Using a 1/8"hex"L" wrench loosen set screw "A" (bottom of the m_cro-adjust cam), rotate micro aGjust cam until gear can be pushed underneath teeth on rack. Line up teeth on rack w_th the middle of the gear. Ho_d gear in this position and rotate micro ad ust cam until the gear is raised up and meshes with t_th on me rack. Tighten set screw "A". If you were unable to line up the teeth on the rack with the mi@ die of me gear, then another adjuslment _srequired. Push knob tn toward rear of saw and hold knob in this pos_t_on. LOCKWASHERS CRO-ADJUST PAN HEAD SCREWS Using a hex "L" wrench, loosen set screw "B" Move gear straight backward or straight forward until teeth on _e rack are positioned in the middle of the gear. (DO NOT ROTATE GEAR). While holding the gear {nthis POSrltonpush micro_adjust knob all the way _n toward the gear and tighten set screw "B". FENCE HEAD MICRoADJUST SET SCREW "B" RACK TEETH MICRO-ADJUST GEAR SET SCREW "A" I 30 CAM MOUNTING SWITCH 1. From among the loose parts find the following hardware: 1 2 2 2 6 2 Switch Assembly with Bracket Pan Head Screws 10-32 x 3/8" long Lockwashers - 3/16" I.D, Square Nuts - 10-32 Pan HD ScrewTy "T" 10-32 x3/8 Plastic End Caps EXISTING SWITCH ASSEMBLY _ PAN HEAD SCREW 2. Insert from the bottom of the bracket, at the back of the switch assembly, the 2 pan head screws with tockwashers. 3/16" LOCKWASHER END CAP SQUARENUT PAN HEAD SCREW 10-32SELFTAP [ FRONT GUIDE BAR 3. Install the 2 square nuts on the screws so that there is an 1/8"+ clearance between the inside of the nut and the top of the switch assembly bracket, 4. Slide the nuts into the lower slot of the front guide bar from the right end, with the switch facing front, 5. Slide switch assembly left until left side of switch assembly is in line with right side of saw table tighten screws. SWITCH ASSEMBI_ II' N __j_ INSTALMNG CAPS FRONT GUIDE BAR END 1. The left and right end caps for front guide bar can be installed at this time. Align the plastic end cap to match profile of rail. 2. Install 3 self tap 10-32 pan head screws holes, into the NOTE: The screws are self tapping, Drive the screws in until cap is seated against the rail, 31 SQUARE 9o ° BRACKET NUT INSTALLING B_DE © © GUARD 1. From among the loose parts, find: HEX NUT Rex Head SCrew& 1/4-20X5/8, long Hex Head Screws, 5/i6-18 x 5/8, long Hex Head Screws, 5/t6,18x 1" long Bex Nuts, 1/4_20 (approx. dia: of hole 1/4") Lockwashers; !/4" External Type (approx. dia: of hole t/4") 2 Lockwashers, 5/16" External Type (approx, dia. of hole 5/18") 1 Thumbscrew 1 Blade Guard Support 1 Spacer 1 Spreader Support SPACER 1 Spreader Rod 1/4" LOCKWASHER 5/16" LOCKWASHERS 2 3 2 2 2 SUPPORT THUMBSCREW lI!!ljtj!l ll D 1/4-20 X 5/8" HEX HD, SCREW 5t16-18 X 5/8" HEX HO. SCREW HEX HD. SCREW 2, Before installing the blade guard, you must check the heeling adjustment (parallelism of sawblade to miter gauge groove). The procedure for making this check and adjusting it are found in the "Adjustments" Section of this manual. Refer to "Heeling Adjustment or Parallelism of Saw Blade to Miter Gauge Groove." SPREADER SUPPORT BLADE GUARD SUPPORT 5/16-18X 5/8' \ HEX. HD. SCREW WARNING: The blade must be parallel to Miter Gauge Groove. Misaligned blades could bind on workpiece. Workpiece could suddenly kickback. You could be cut or hit. 3, Lower the blade. 4. Screw the MOTOR BASE CLAMP SCREWS part way into cradle. Screw the 5/! 6-18 x 5t8" Hex Hd. screw into the blade guard support. 5,'16-18 HEX HD. X 1" SCREW 5/16-18 X 5/8" MOTORBASE CLAMPSCREWS 5. Attach Blade Guard Support with 1/8" spacer between cradle and support. DO NOT TIGHTEN screws. 5/16" LOCKWASHERS 6. Insert SPREADER ROD into SPREADER SUPPORT until pin fits into notch. Insert Thumb-screw and tighten it. THUMBSCREW ROD FLAT SURFACE \ SPREADER SUPPORT U 32 (INT0 SUPPORT) Slide SPREADER ROD into BLADE GUARD SUPPORT until end of ROD is even with edge of SUPPORT,.,lqghten Hex Head Screw in support. 7. Attach SPREADER to SPREADER SUPPORT so that the edge of the spreader is even with the edge of the spreader support...tighten screws. . SQUARE Raise ANTIKICKBACK PAWL ...align spreader SQUARE to table ..,Tighten both 5/t6-18 x 1 in. HEX HEAD SCREWS. SPREADEREDGE EVEN WITH SPREADER SUPPORT EDGE 5/16-18 X 1" HEX HD. SCREW END OF ROD EVEN WITH BLADE GUARD SUPPORT __ ,irl, 10. Raise blade all the way up., ,make sure it is square with table. 11. Raise Blade Guard..Jift up both ANTIKICKBACK PAWLS..Jnsert one of the SET SCREW WRENCHES in the notches to hold the pawls out of the way. 12. Lay blade of square or other straightedge alongside of blade. 13. Loosen Hex Head Screw in BLADE GUARD SUPPORT and move spreader so that it touches blade of square...tighten screw. 14, NOTE: The spreader is now square with the table and approximately in line with the sawblade. The spreader requires further adjustment to align it PARALLEL to the blade and in the MIDDLE of the cut (KERF) made by the sawblade. 15. iMPORTANT: To work properly, the SPREADER must always be adjusted so the cut workpiece will pass on either side at the spreader without binding or skewing to the side. WOOD NOTE: The spreader is thinner than the width of the cut (KERF) made by the sawblade by approximately three thicknesses of paper on each side of the spreader. SPREADER KERF BLADE I I LOOKING DOWN ON SAW i !6. Make two folds in a small piece (6 x 6 in.) of ordinary NEWSPAPER making three thicknesses. The folded paper will be used as a "spacing gauge." 33 __ iiiii 17.PlaceRIPFENCEontable.,, CAREFULLY moveitagainstbladesothat_tisparalle!to theblade,andjustTOUCHES tipsof saw teeth...tighten RIPFENCELOCKLEVER. 18.InsertfoldedpaperbetweenSPREADER AND FENCE. 19.Usinga 7/16in. wrench._oosen the 1/4-20hex headscrewssothespreader canslidesideways. 20. Adjustandholdspreader flatagainstfoldedpaper fence...tightenscrewsusing7/16" in. wrench. Movefenceawayfromblade.Removefolded paper,He)("L" wrench, lower antikickback pawls FOLDED 7/16 WRENCH \ and lower guard. 21. To remove BLADE GUARD AND SPREADER, loosen THUMBSCREW_.DO NOT LOOSEN OTHER SCREWS. This lets you remove and replace the guard without disturbing the s_)reader alignment. THUMB SCREW POSITIONING MOTOR ON MOTOR MOUNTING BASE LOOSEN BOTH CRADLE CLAMP 1, Put the motor mounting base against the fiat surface of a workbench. SCREWS CAPACWORS t l I/"L._,-_,,_,,_%_. MOTOR 2. Position the motor so the end with terminal cover is facing you. _-];4-_, _ 3. Loosen both cradle clamp screws, 1 4. Put a square against the LEFT side of the motor and against the top of the workbench. 5. Turn the motor inside the cradle clamps until the top of both capacitors touch the square. 6. Tighten both cradle clamp screws to hold the motor in this position. k---Z- WORKBENCH ! WARNING: Failure to properly install motor may ] let werkpiece strike capacitor cover during bevet | or compound miter cuts. Workpiece could bind l and kickback. You could be cut or hit. 34 MOUNTING THE MOTOR 1. From among the loose parts find the following hardware: 4 4 4 1 CARRIAGE BO_ Carriage Bolts, 5/16-t8 x 3/4'! tong Hex Nuts, 5/16-18 (approx. dia. of hole 5/16") Lockwashers, 5/16 in, External Type (apprex, dia. of hole 5/! 6") Cast Iron Motor Pulley G 5/16" HEX NUT 5/16" EXTERNAL LOCKWASHER MOTOR PULLEY 2. Place motor on MOTOR BASE, insert bolts through holes in base...then through the motor. Install lockwashers and nuts, 3. Position motor so that edge of MOTOR MOUNTING BASE and MOTOR BASE are even, slide motor all the way to the RIGHT. 4. Loosen set screw in motor pulley using 5/32 in, Hex "L" wrench. Slide pulley on shaft with HUB away from motor. DO NOT TIGHTEN SETSCREW. 5. Install 3/16 in, square key (furnished with motor) in grooves in pulley and motor shaft. DO NOT TIGHTEN SETSCREW, CRADLE 6. Lift motor and insert the TWO PINS on motor base into HOLES in cradle, push motor in as far as it will go, MOTOR BASE 7. Lower the blade, install belt on saw pulley and motor pulley. 8, Sight along edges of both pulleys and move motor pulley so that belt is parallel to the edges of both pulleys, tighten the setscrew in the motor pulley. 9, iMPORTANT: Measure the distance from end of motor shaft to pulley, mark this dimension down; you wilt need it later when reinstalling the pulley. SLOT WASHER EDGE OF WASHER EVEN WiTH END OF SLOT 35 10.Makesurebladeis90°totable.,.raise it all the way up. 11. Lift motor until edge of washer (see illustration) is even with _nd of slot. in this position, pull motor toward you(pins will slide in the cradle) until belt is TIGHT...make sure washer is still even with end of slot...tighten the two MOTOR BASE CLAMPS SCREWS. I2. Put your hand around the belt half way between the two 0ulteys and squeeze belt until two sides of belt touch, The motor should move freely as you squeeze the belt. If motor does not move freely, belt tension must be readjusted. INSTALUNG BELT GUARD 1. From among the loose parts find the following hardware: 1 1 1 Belt Guard Support Bracket Belt Guard Support Belt Guard 2 Self Threading Screws, 10.32 x 1/2 in. tong 2. Remove the belt and motor pulley. 3. Screws furnished with guard are "self threading".,. screw them into holes in BELT GUARD SUPPORT BRACKET. then remove them. BELT GUARD SUPPORT BRACKET 4. Position BELT GUARD SUPPORT BRACKET and BELT GUARD SUPPORT as shown and install the screws...make sure motor shaft is in CENTER of hole in SUPPORT TWO HOLES CLOSEST TOGETHER 10-32 X 1/2" SELF-THREADING SCREW / BELT GUARD SUPPORT 5. Install three CLIPS (furnished with guard) 90 degrees apart starting with one clip at the end of the guard as shown...LONG END of clip must be on outside of guard pointing away from opening n guard. OPENING BELT GUARD 36 J \ LONG END CLIPS 6. Reinstall motor pulley the same way it was when you BELT aligned the belt. Tighten setscrew. MOTOR pULLE_"_'_ !! U 7, Place belt on SAW PULLEY,..insert through opening in END of guard. end of belt ._'_ 8, Slip belt over motor pulley, _ 9. Press guard onto support so that bottom of guard is approximately 3/4 in. away from belt. NOTE: To remove guard, lift up on LONG TABS of clips...pull guard outward. The clips should remain _ on the BELT GUARD SUPPORT. _'_ -_ <14! t 3_"CLEARANCE I MOTOR CONNECT|ONS | plug to power source outlet until all assembly i WARNING: For your own safety, never connect I steps are completed, !. Open motor connector box cover located on side of motor using a flat blade screwdriver. WARNING: To avoid electrocution, never connect anything but the ground wire (colored green) to the green screw. 2, Remove GREEN SCREW and insert through round metal terminal on the end of the GREEN wire of power cord. 3. Reinsert GREEN SCREW in threaded was removed from and tighten securely. hole that it GREEN WIRE TO GREEN SCREW STRAIN RELIEF GROOVE (BOI-rOM) BLACK WIRE TO SPADE TERMINAL BESIDE COPPER POST WHITE WiRE TO SPADE TERMINAL BESIDE SILVER POST 4, Insert terminal end of BLACK wire on spade terminal next to copper post on the motor. Push terminal firmly until seated. 5. Insert terminal end of WHITE wire on spade terminal next to silver post on the motor. Push terminal firmly until seated. & Close motor connector box being sure that power cord is seated in strain relief groove and tighten box cover screws. 7. Do not plug in power cable, _ i PLUGGING EXTENSION IN MOTOR REMOVED FOR PICTURE CLARITY !, From among the loose parts, find two wire ties. 2. Route motor cord along right side of cabinet and snap ties in 1/4" hole in side of cabinet. Secure two cords in wire ties. 3. Plug motor cord into outlet on switch box. iMPORTANT: During table saw cutting operations the motor must always be plugged into the switch box. Never by-pass the switch box and plug the table saw motor directly into a power supply outlet. ? 37 WIRE TIES \ MITER GAUGF.JHOLD DOWN ASSEMBLY 7 When making miter bevel or compound miter cuts, the workpiece has a tendency to shift along the head of the miter gauge. The Hold-Down Clamp securely "clamps" the work. piece to the miter gauge and when properly applied helps prevent the workpiece from shifting. This Hold-Down Clamp will fit Craftsman miter gauges which have a threaded hole (5/16"-18) in the top of the head. Check each part according to the illustration. I Remove the LOCK HANDLE from your miter gauge by unscrewing it. 2. Screw on the handle (1) received with Hold-Down. NOTE: If your Craftsman Miter Gauge has a LOCK KNOB instead of a long handle, it will be necessary to disassemble the miter gauge and install the THREADED STUD and LOCK NUT suppliec with the HoldDown. REMOVE A. Loosen the POINTER SCREW...rotate er 90 degrees. LOCK the point- EXISTING HANDLE B, Swivel the head to 60 degrees and turn the miter gauge upside down. C. Using an 1/8" setscrew wrench, loosen the setscrew and lift the head off of the pivot stud. D. Screw the THREADED STUD (2) supplied with the Hold-Down all the way into the hole in the miter gauge bar.,.make sure that t does not extend beyond the under side of the bar. E. Screw on the LOCKNUT (3) received with the Hold-Down and tighten it against the bar using a 1/2 inch wrench F. Replace the head...tighten the setscrew only enough to permit the "head to swivel freely" out yet, not move up and down_.readjust the pointer. 3. Screw the support rod (4) tightly into the hole in the miter gauge head, 4. Position the clamp assembly (5) on the handle and rod.. Jnstal_washers (6) and wing screws (7). NOTE: The small knob (8) on the clamp screw must not turn. Check nut underneath it, ..it must be tight against the knob, Use a 1/2 inch wrench to tighten it. SETSCREW WRENCH 38 GETTING TO KNOW YOUR SAW 9 10 SAWBLADE EXACT-I-CUT 7 BLADE GUARD 8 TABLE INSERT i ANTIKICKBACK PAWLS 6 MITER GAUGE RIP FENCE RIP FENCE LOCK HANDLE 4 TILT LOCK HANDLE (UNDERNEATH 11 MICRO-ADJUST 2 ELEVATION HANDWHEEL 3 TILT / HANDWHEEL SEPARATOR 1 ON-OFF SWITCH CHANNEL 1 ON-OFF SWITCH the blade guard is correctly installed and operatI CAUTION: Before turning sw!tch on, make sure ing properly. The On-Off Switch has a locking feature, THIS FEATURE IS INTENDED TO PREVENT UNAUTHORIZED AND POSSIBLE HAZARDOUS USE BY CHILDREN AND OTHERS. A. L KEY TO turn ON...stand to either side of the blade never in line with it, ..insert finger under switch lever and pull END of lever out. Do not cycle the motor switch on and off rapidly, as this may cause the sawblade to loosen. In the event this should ever occur, allow the sawblade to come to a complete stop and retighten the arbor nut normally, not excessively. Never leave the saw while the power is "ON". (YELLOW PLASTIC) B. TO turn saw OFF,..PUSH lever in. Never leave the saw dntil the cutting tool has come to a complete stop. C, TO lock switch in OFF position...hofd switch IN with one hand...REMOVE key with other hand. WARNING: For your own safety, lower blade or other cutting tool below table surface. (if blade is tilted, return it to vertical (90°) position.) Always lock the switch "OFF". When saw is not in use, remove key and keep it in a safe place. Also, in the event of a power failure (all of your lights go out) turn switch off. Lock it and remove the key. This will prevent the saw from starting up again when the power comes back on. 39 2 6 MITER GAUGE_.head ELEVATION HANDWHEEL...elevates or lowers the blade_ Turn clockwise to elevate, counterclockwise to lower. NOTE: Any t_me sawblade has been etevated to 25!8 inches or h_gher above the table _ w_Ii be necessary to _ower the btade by turn_ng me elevation handvtC_eel 5 turns counterclockwise before tilting to bevel 3 TILT HANDVtt'HEEL.,tilts the blade for bevel cut-. t_ng Turn clOCkwise to tilt toward tuft_ .counterclockwise to titt toward vertical. When the blade iS tilted to me LEFT as far as _t w_II go. _t should be at 45 degrees to the table and T.ne beve_ indicator should point 45 degrees, NOTE: There are LIMIT STOPS on the saw whsch prevent the blade from tilting the LEFT and 90 degrees "Adjustment" section "Blade B_ade to Table'1. 4 TILT LOCK HANDLE., ,locks beyond 45 degrees to to the RIGHT, (See Tilt, or Squareness of the blade in the desired tilt position. To loosen, turn counterclockwise. Push handle in and turn it to another position crosscut£ng or mitenng by t_ghtening the !ock knob. ALWAYS LOCK tT SECURELY WHEN IN USE. There are slots for the stop p_nat the 45 degree right and tuft pos_bonsfor conveniently setting the M_ter Gauge to cut m_ters NOTE: angle cuts recheck _1. make a tr_a_ cut an then NOTE: When bevel crosscusing, attach fac.[_g s ___'_;T it extends to the right of the m_ter gauge anc. use the miter gauge m the groove to tne nght of the b!ade. _.- HOLD-DOWN CLAMP !__UXILIARY ; STOP P_N ..o_,_. _ 45_SLOT FOR STOP PIN I t.,.J --_. FACING "- 7 BLADE GUARD...must atways be in place and working properly for aHthru-sawing cuts, That is, all cuts whereby the blade cuts completely through the workpiece, To remove the guard for special operation, loosen the thumbscrew and slide the guard off of the rod. DO NOT DISTURB THE SETTING OF THE ROD. When replacing the guard, make sure the PIN in the rod engages with the NOTCH in the spreader supportl Make sure thumbscrew is tightened securely. FENCE t.,4_ HOLE JI"_L' I_J-'-_z_ I* X 3 8" DEEP _ _11[WtJ;,t-, SOUARE NEAP HE×_UT";_t JJ_ BOLT _,.'.=o ' L-I 1" COUNTERBORE, WASHER 318_'DEEP 1'4"x ss*x 1;1_ ° 114= CLEARANCE ........... 34" ....... 18" HOLE THROUGH i.6-.: THE BOARD, WOODFACtNG ..................... clearance hote through the board. for example If necessary, me m_ter gauge head can men be swweied s!_ghtly to compensate ar;d men .ockea Slots are provided in the m_ter qauqe for a_achin_ ar AUXILIARY FAC!NG to make _, eas_er to cut _ong D_eces Be sure facing does ncI ffqterfere wqn the orooer operation of the sawb_ade guard Select a suitable piece of srnocu straign_ wona. dnlt two ho_es arid attach it w;th _crews r_ght. Slots are provided in the nD fence for altachmg a wood facing when uslng the da.do heac or molding head, featherboards or other l_gs and fixtures Select a piece of smooth stratght wood approx. 3/4. n. thick and the same length as the rip fence, To fasten auxiliary face to the fence use 3 eacn, t/4"-20 x 3/4" square head machine screws with nuts, Counterbore 1" dta. hole 3/8" deep into the 3/4" dimensions, CHANNEL _4-AUX.FACE The slots for the stop p_n and the graduabons are rnanufactured to very c_ose tolerances wn;cn provide accurNcy for average woodworking, in some cases where extreme accuracy _s required when making if necessary in order to tighten or loosen. IMPORTANT: Be sure handle is hanging in the "DOWfN" position before tilting blade. If it is pointing to the 1 o'clock position it may jam on underside of the table and bend the locking bolt. 5 RtP FENCE,.,Is locked in place by pushing the lock lever down until the lever rests on the stop. To move the fence, lift the lock lever and grasp the fence with one hand at the front and then push fence left or board at the designated See Fig A. Drill a 1/4" is locked _nposition for 8 TABLE INSERT...Is removable for removing or installing blades or other cutting tools. To remove table insert: .... 3/40 ........ WARNING: To avoid injury due to accidental start, turn switch "OFF" and remove plug from power source outlet before removing insert. A Lower the blade below the table surface. B. Raise blade guard. C, Loosen Screw, D. Remove table inset, ............. 18" -................ 34 ...................... ' 40 NEVER OP_]RA]E THE S,_¢d WiT_-iOUT ii-iE PROPER INS_:!R,T iN PLAC! USE! TRE SAW BLAOE NSERT WHEN SAWING. USE T?_._::CQMBiNATiOt,_ DA©O MOLDING iNS_!:RT WHEN DADOING OR MOLD NG 9 RElieVE AND _NSTALUNG BLADE GUARD NOT SHOWN FOR PICTURE CLARITY SAWBLADE. start, turn ._}witch 'OFF"iniury and due remove p_ug from WARNING: To avoid to accidental • power source outiet before removing or installing sawblade. A. Raise 'Bad<. Girard remove inserL B. To REMOVE b._de, p!ace a block of wood against f_ont of blade. PULL arbor wrench toward you to LOOSEN arbor nut. C. To TIGHTEN arbor nL,'t, p/ac;e a block of wood against rear of ,),ado, PUSH wrench away frorn you WRENCH ARBOR NUT When instailing the blade, make sure the teeth are pointing toward the front of the saw and treat the b!ade and cofiars Rre clea_, and flee from any burrs. Ti_e HOLLOW side ,_4,_, ,_.,.,. ,_.co!lar iTiiJSt be against the blade Always tighten ',_,_.,:,.r,.o. ' = " _' r nu, securely NOTE: '.,When using the Dado or Moiding Head, it is not necessas_ to instai! _he _oose coi}ar. ]b replace insert. Place insert into insert opening in table and push toward rear of savv to engage spring c!ip and untit keyslot in insert will drop over screw, Tighten screw. Do not t ghten screw to the point where it will deflect the insert, ARBOR WRENCH // ARBOR LOOSE ARBOR WARNING: To avoid injury from a thrown workpiece, blade parts, or blade contact, NEVER oper* ate saw wilhout the proper insert in ptace. Use the sawblade insert when sawing. Use the proper size Dado/Molding insert for dado blades and molding heads. COLLAR ARBOR NUT TEETH POINTING TO FRONT OF SAW ii illrl,ll 10 NUTI,i_ I/ EXACT-I-CUT BLADE Ill'H GUARD NOT SHOWN II '11 FOR PICTURE O The "yeliow" ptastic disc imbedded in the tabie in front of the ._wblade, is provided for marking the location of the 'sawcut" on the workpiece. A. Check disc...if it is above table surface place a piece of hardwood on top of it and tap it down. B. With blade 90 degrees (square to table} cut off a piece d wood. C. Pull miter gauge back until wood is over disc, Using very sharp pencil, mark a line on disc. D. With miter gauge in right hand groove, follow same procedure and mark another line on disc. E. These lines indicate the "path" of the cut (kerr) made by the sawbtade. R Wen cutting the workpiece, _ine up mark on workpiece with line on disc. Use the hold-down clamp on the miter gauge for greater accuracy. EXACT-I-CUT 4! CLARITY 11 MICRO-ADJUST RiP FENCE, .,atlows the opera_or to accurately aajust the rip fence using onw one hand. To move the fence, push in _n the microadjust knob and rotate the knob. Rotai_ng the knob c!ockwise moves the fence to the left Rotating it counterclockwise moves the fence to the rig_t. WORK FEED DEVICES Before cutting any wood on your saw. study all of the "Basic Saw Operations". As you learn new table saw WOOdworKing techniques. you'll see that many types of cuts need different support and feeding devices, known as jigs or fixtures They can help you make cuts more accurately. By helping to steady the workpiece and keep you away from the blade, they can help you safely use your saw for certain cuts. 3/4" SLIGHTLY LESS THAN THICKNESS PUSH STICK 14-3/4' Many people custom build their own jigs anc fixtures. Jigs and fixtures are often designed for a particular cut You can use your table saw to easily make many jigs and fixtures. To get you started, we've included inszructions for some simple ones, After you have made a few practice cuts. make up these jigs before starting any projects. Make the push stick first. - i I ! 3/8" THICK PLYWOOD 2-1/2" 2-1/2" Fr--7 Push Stick Make the Push Stick using a piece of 1 x 2. Push Block There are any number of ways to properly cut your workpieces to make a push block, The following s_eos describe one way you can make a push block. Making the base: Start with a piece of 3/8 inch plywood at least 5-1/8 inches wide or wider and 14-3/4 inches long or longer. Crosscut a 2-1/2 inch wide strip off the narrow end of the plywood. Put the larger piece aside for later. Cross cut a 3/8 inch wide piece off the end of the 21/2 inch wide strip. Put the 3/8 inch wide piece aside for late¢ Go back to the piece that is at least 5-1/8" wide or wider and 12 inches long or longer. Cut it to the size and shape shown, Putting it together Glue the 2-1/2 inch strip to the base, as shown: IMPORTANT: The small piece of wood 3/8 inch x 3/8 inch × 2-1/2 inch should be glued to the plywood, Do not use nails. This is to prevent dulling of the sawblade in the event you cut in to the push block. THESE EDGES MUST BE PARALLEL L_ -_ 3J8"J- I----M21t2" BASE L -12.... 3/4" THICK PLYWOOD HANDLE 42 -I 3/4" PLYWOOD WORK FEEDDKV{CKS (cor_tinued) Making the hand!e: , _ to shape and ,,I _ piece o_'o8 _'' ir_ch thick n, o C ....... ply",tvooc_ " _ SIqOWR: NOTE: The mitered corners ea_sbe any s_=zethat looks o Position! the hande in the cef_ter of tf-_e #tywood base. Fasten them together with glL_e and wood screws. _MPORTANT: Make sure, the screw heads do not stick out from ti-_ebosom of the base, they must be flush or recessed. The bottom must be fiat and smooth enough to s_ide along the au×iiiarv fence you are now ready to make 3/8" PLYWOOD ,Jo PUSH N 3/8" THICK PLYWOOD BASE Fence Making the base: - Start with a piece of 3/8 inch plywood at Jeast 5-1/2 inches wide or wider and 30 inches long or longer. 27" l_ o Cut the piece to shape and size shown: 314" THICK PLYWOOD Making the side: o Start with a piece of 3/4 inch plywood at least 2-3/8 inches wide or wider and 27 inches long or longer. , -- BLOCK 3_ Auxiliary i SIDE Cut the piece to shape and size shown: Putting it together - Put the pieces together, as shown: IMPORTANT: Make sure the screw heads do not sticl< out from the bottom of the base, they must be flush or recessed. The bottom must be flat and smooth enough to rest on the saw table without rocking. 4-1_" 3/4" PLYWOOD _ 3/8" PL._40OD _ • ,, / _ THIS FACE AHD THIS EDGE MUST ._ BE PARALLEL--I" 43 AUXiLiARY FENCE // SAFETY INSTRUCTIONS FOR BASIC SAW OPERATIONS BEFORE EACH USE: 4 Choose and inspect your cutting tool carefully. 1. Inspect your saw. a. b. To avoid injury from aCCidenta_ starting, unptug the saw, turn the switch off ana remove the sw_tcn key before raising or remowng the guara changing the cutting tool, changing the setup or adjusting anything. e. b. C. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect the way _t works. If any part is missing, bent. or broken in any way, or any electrical parts don't work properly, turn the saw off and unplug the saw. c. Replace damaged, m_ssing, using the saw again. d. a. d. or failed parts before When thru--sawing, (making cuts where the blade comes through the workpiece top) always use a 10 inch diameter blade. This keeps the spreader in closest to the blade. Do not overtighten arbor nut. Use arbor wrenches to "snug" it securely. f. Keep blades clean of gum and resin. 5. Adjust table inserts flush with the table top. NEVER use the saw without the proper insert. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking for and remowng keys and adjusting wrenches from tool before turning it on. 6. Make sure all clamps and locks are tight and no parts have any excessive play. 2 KEEP WORK AREA CLEAN slips or thrown pieces a. Cluttered areas and benches invite accidents. Floor must not be slippery from wax or sawdust. USE ONLY RECOMMENDED ACCES. SORIES - Follow the instructions that come witl_ the accessories. Using other accessories may be dangerous. b. To avoid burns or other fire damage, never use me saw near flammable liquids, vapors or gases. 2. Choose the right blade or cutting accessory for the material and the type of cutting you plan to do. 3. Always use unbroken, balanced blades designed to fit this saw's 5/8" arbor. e. Use only sharp blades with properly set teeth. Consult a professional blade sharpener when in doubt. Use the sawblade guard, spreader, and antikickback pawls for any thru-sawing (whenever the blade comes through the top of the workplace). Make sure the pawls work properly Make sure the spreader is in line with the sawbiade. f. To avoid injury from jams, (kickback and throwback): To avoid cutting too! failure and thrown shrapnel (broken pieces of blade), use only 10" or smatler blades or other cutting tools marked for speeds of 3450 rpm or higher. Never use grinding wheels, abrasive cut-off wheels, friction wheels (metal slitting blades) wire wheels or buffing wheel. They can fly apart explosively. 44 P_an ahead to protect your eyes, 3. Inspect your workpiece. Make sure there are no nails or foreign objects in the part of the workpiece to be cdt- hands_ face, ears, a To avoid injury from accidentai b!ade contact, doHt do iayout, assembly, or setup work ors the tab!e while the b_ade is spinning. It could cut or throw anything hitting the b_ade. 4. Plan your cut to avoid KICKBACKS and THROWBACKS - when a part or all of the workpiece binds on the btade and is thrown violently back toward the front of the saw. AVOID ACCIDENTAL STARTING - Make sure switch is in "OFF" position before plugging saw in. Never cut FREEHAND: Always use either a rip fence, miter gauge or fixture to position and guide the work, so it won't twist, bind on the blade and kickback. Plan your work I. USE THE RIGHT TOOL - Don't force tool or attach_ ment to do a job it was not designed for. Make sure there's no debris between the workpiece and its supports. 2. DRESS FOR SAFETY: When cutting irregularly shaped workpieces, plan your work so it will not slip and pinch the blade. Do not wear loose clothing, gloves, neckties or jewelry (rings, wrist watches). They can get caught and draw you into moving parts. A piece of molding, for example, must lie fiat or be held by a fixture or jig that will not let it twist, rock or slip while being cut. Use jigs, fixtures where needed to prevent workpiece shifting. Wear nonstip footwear. Tie back long hair. Roil long sleeves above the elbow. Use a different, better suited type of tool for work that can't be made stable. Noise levels vary widely. To avoid possibte hearing damage, wear ear plugs or muffs when using saw for tong periods of time. Use extra caution with large, very small or awkward workpieces: Any power saw can throw foreign objects into the eyes. This can cause permanent eye damage. Wear safety goggles (not glasses) that comply with ANSI Z87.1 (shown on package). Everyday eyeglasses have only impact resistant lenses. They are not safety glasses. Safety goggles are available at Sears retain catalog stores. Glasses or goggles not in compliance with ANSI Z87.1 could seriously hurt you when they break. WEAR Use extra supports (tables, saw horses, blocks, etc.) for any workpieces large enough to tip when not held down on the table top. NEVER use another person as a substitute for a table extension, or as additional support for a workpiece that is longer or wider than the basic saw table, or to help feed, support or pull the workpiece. Never confine the piece being cut off. That is, the piece NOT against the fence, miter gauge or fixture= Never hold it, clamp it, touch it, or use length stops against it. It must be free to move. If confined, it could get wedged against the blade and cause a kickback or throwback. YOUR Never cut more than one workpiece at a time. Never turn your table saw "ON" before clearing even/thing except the workpiece and related support devices off the table. For dusty operations, wear a dust mask along with the safety goggles. 45 Plan the way you will push the workpiece Make sure the,_ [co _f the ardor or cutting tool turns toward [ne front ot the sa'v', through. NEVER pull the workpiece through. Start and finish the cut from the front of the table saw. NEVER put your fingers or hands the sawblade or other cutting tool. - Set ;no cutting you're oiann_ng KEEP CHILDREN AWAY. All visitors should be kept a safe d_stance from work Make sure bystanders are c_ear of the saw and workpiece. 5, Let the b!ade reach full speed before cutting. DON'T FORCE TOOL, It will do the job better and safer at its designed rate. Feed the workpiece into the blade only fast enough to !et it cut without bogging (]own or binding, Avoid awkward operations and hand positions where a sudden slip could cause fingers or hand to move into a sawblade or other cutting tool. Always keep gooo footing 7. Before freeing any jammed material: a. Turn switch "OFF" D. Unplug the saw, c. Wait for all moving 3arts to stop, d. Check blade, spreader and fence for proper alignment before starting, again. Push the workpiece against the rotation of the blade. NEVER feed material _nto the cutting tool from the rear of the saw. Always push the workplece all the way blade, for the cut in the path of NEVER reach in back of the cutting tooJ with either hand to hold down or support the workmece, remove wood scraps, or for any other reason. DON'T OVERREACH and balance. [oo_ as tow as possible past the saw- 8 To avoid throwback As mucn as 3ossible, keep your face and Dotty to one s_de of the sawbtade out of line with a possible kickback or throwback. of cut off pieces: a. Use the guard assembly. b, To remove pieces beneath guard: NEVER turn the saw "ON" before clearing the table of all tools, wood scraps, etc., except the worKplece and related feed or support devices for the cut planned. 1 2. 3. 4. WHENEVER SAW IS RUNNING BEFORE WARNING: Don't let familiarity (gained from frequent use of your table saw) cause a careless mistake. Always remember that a careless frac. tion of a second is enough to cause a severe injury. or trapped inside the Turn saw off, Remove switch key. Unplug saw. Wait for blade to stop before lifting tile guard. LEAVING THE SAW 1. Turn saw off, 2. Wait for blade to stop splnning. 3. Mlake workshop cmld-proof. Lock the shop. Disconnect master switches. Remove the yellow sw_tch key. Store it away from children and others not qualified to use the too!, t. Before actually cutting with the saw, watch it while it runs for a short while. If it makes an unfamiliar noise or vibrates excessively, stop immediately. Turn the saw off. Unplug the saw. Do not restart until finding and correcting the problem. 4. Unplug the saw. 46 USING THE An auxiliary wood facing attached to the miter gauge can help prevent workpiece twisting and throwbacks.Attach it to the holes provided. Make the facing long enough and big enough to support your work. Make sure, however, it wit! not into€ere with the sawb}ade guard. M_TER GAUGE THE _IiTER GAUGE _8 USED WHEN CROSSOUTTING, MITER CUTT!NG, BEVEL CUTTING, COMPOUND MITER CUTT!NG, DADOING and when RABBETING AND MOLDING across the end of a narrow workpiece. Use jigs or fixtures to help hold any piece too small to extend across the full length of the miter gauge face during the cut. This lets you properly hold the miter gauge and workpiece and helps keep your hands away from the blade. WARNING: For your own safely, always observe the fo_gowing safety precautions in addition to the safety instructions on pages 2, 3, 4, 5, 44, 45 & 46. While cuffing ADDIT_!ONAL SAFETY iNSTRUCTIONS CROSS CUT TYPE CUTS FOR To avoid blade contact, always hold the miter gauge as shown in the BASIC SAW OPERATIONS - USING THE MITER GAUGE. Before starting NEVER use the rip fence when crosscutting. CROSSCUTTING Crosscut A cutting or shaping operation made across the width of the workpiece. The graduations on the miter gauge provide accuracy for average woodworking. In some cases where extreme accuracy is required, when making angle cuts, for example, make a trail cut and then recheck it with an accurate square, or protractor. If necessary, the miter gauge head can be swiveled slightly to compensate for any inaccuracy. NOTE: The space between the miter gauge bar and the groove in the table is held to a minimum during manufacturing. For maximum accuracy when using the miter gauge, always, '_favo¢'one side of the groove in the table. In other words, don't move the miter gauge from side to side while cutting, but keep one side of the bar riding against one side of the groove. The miter gauge may be used in either of the grooves in the table. Make sure it is locked. NOTE: Glue a p_ece of sanopaper to the face of the miter gauge head. This will help prevent the workpiece from "creeping" while it is being cut. i WARNING: hold the miter Togauge avoid properly. blade contact or kickback, ] The Hold-Down Clamp should be used on the miter gauge for greater accuracy. When using the miter gauge in the LEFT hand groove, hold the workpiece firmly against the miter gauge head with your left hand, and grip the lock handle with your right. When using the RIGHT hand groove, hold the WOrkpiece with your right hand and the lock handle with your left hand. 47 Whencuttinglong workpieces,invertAUXILLIARY FENCEZWQRK SUPPORT andpositionitontopofthe guidebarstosupport theworkp_eces asneartotheend aspossible,if t!_isdoesnotadequatelysupportthe workpiece, youcanmakea simplesupportbyclamping a pieceofplywood toasawhorse. \ Usethe hold-downclampon the mitergaugefor greater accuracy: REPETITIVE CUTTING REPETITIVE CUFFING is known as cutting a quantity of pieces the same length without having to mark each piece, 1 Use the Stop Rods (optional accessory) only for cutting duplicate pieces 6 in. long and longer. 2. DO NOT FEED workpiece with RIGHT hand, merely guide it. making sure that It does not binC or pinch the sawblade. When making repetitive cuts from a tong workpiece, make sure it is adequately supported. Use the hold-down greater accuracy, clamp on the miter gauge for LEFT HAND REMOVED FOR PICTURE CLARITY 48 1.NEVERUSETHERIP FENCEASA LENGTH STOPBECAUSETHECUTOFFPIECECOULD BINDBETWEEN THEFENCEANDTHEBIJkDE CAUSING A KICKBACK. 2.Whenmakingrepetitive cutsshorterthan6",clampa blockofwood2"longtothetabletoactasa length stop,Donotclampdirectlytothebottomedgeofthe tablebecause the"swivel"oftheclampwit!notgrip properly.Placea smal!blockof woodbetween the bottomedgeofthetableandthe"C"clamp. \ BLOCK CAUTION: Avoid kickback from twisting the workpiece. When clamping the block, make sure that the end of the block is wetl in front of the sawbRade. Be sure it is clamped securely, CUT OFF PIECE 3. Slide the workpiece along the miter gauge until it touches the block...hold it securely or clamp it with the Hold-Down Clamp. 4. Make tile cut...turn the saw off...remove the piece after the biade has stopped and before cutting the next piece. MITER CUTTING MITER CUTTING is known as cutting wood at an angle other than 90 ° with the edge of the wood, Follow the same procedure as you would for.cross-cutting. Adjust the miter gauge to the desired angle, and lock it. The miter gauge may be used in either of the grooves in the table. When using the miter gauge in the LEFT hand groove, hold the workpiece firmly against the miter gauge head with your left hand. and grip the lock handle with your right. When using the RIGHT hand groove, hold the work_ piece with your right hand and tie knob with your left hand. Use the Hold-Down Clamp on the miter gauge for greater accuracy, ..... = BEVEL CROSSCUTTING BEVEL CROSSCUTTING s the same as crosscutting except that the wood is also cut at an angle...other than 90 degrees with the flat side of the wood. Adjust the blade to the desired angle. Use the Miter Gauge in the groove to the RIGHT of the blade, it cannot be used in the groove to the LEFT because the blade guard will interfere. Hold the workpiece with your right hand and the Iockhandle with your left hand. Use the AUXILIARY FENCE,SNORK SUPPORT COMPOUND for MITER CUTTING COMPOUND MITER CUTTING is a combination of miter cutting and bevel crosscutting. The cut is made at an angle other than 90 degrees to both the edge and the flat side of the wood. Adjust the miter gauge and the b_ade to the desired angle...Make sure miter gauge is locked. additional support of the workpiece. Lay it across the guide bars to support the workplece as near to the end as possible. Use tie Hold-Down Clamp on the miter gauge for greater accu racy. 49 USING THE RiP FENCE A FEATHERBOARD p_ece p._ RIPPING. BEVEL RIPPING PLOUGHING. MOLDING RESAWlNG AND RABBETING are performed using the RIP FENCE together With the AUXILIARY FENCE/MJORK SUPPORT, PUSH STICK OR PUSH BLOCK. t 5/16" KERFS WARNING: For your own safety, always observe I the following safety precautions in addition to the safety instructions on pages 2, 3, 4, 5, I ADDITIONAL SAFETY INSTR UCTIONS TYPE CUTS NEVER use the miter gauge FOR RiP when ripping. Use a push stick whenever the fence is 2 or more inches from the blade. When thru-sawing, use an auxiliary fence and 3L_sh block whenever the fence must be between 1/2 inch and 2 inches from the blade. Never thru-saw rip cuts narrower than 1/2 inch. - When using a push stick or push block, the trailing end of the board must be square. A push stick or block against at uneven end could shp off or push the work away from the fence. Never rip anything shorter than !0" long. can help guide the work24- APART ABOU1 ,_ 1---_ Before starting To avoid kickbacks and slips into the blade, make sure the rip fence is parallel to the sawblade. Check the antFkickback pawls. The pawls must stop a kickback once it has started. Replace or sharpen antFkickback pawls when points become dull. Plastic and composition (like hardboard) materials may be cut on your saw. However, since these are usually quite hard and slippery, the anti-kickback pawls may not stop a kickback. Therefore, be especially careful in your set-up and cutting proceaures. Have blade extend approximately !/8 inch above top of workpiece. Additional blade exposure would increase the hazard potential. While cutting To avo=d kickbacks and slips into the blade, always push forward on the section of the workpece between the saw blade and the rip fence. Never push forward on the piece being cut off. RIPPING Ripping A cutting operation along the length Position the fence to the desired Iockin place. ALWAYS SUPPORT of the workpiece. WIDTH OF RIP and Before starting to rip, be sure. A. Rip Fence is parallel to sawblade. B. Spreader is properly aligned with sawbtade. C. Antikickback pawls are functmonlng properly. When ripping LONG BOARDS or LARGE PANELS. always use a work support. A simple one can be made by" clamping a p_ece of plywood to a sawhorse. BEVEL RIPPING NARROW WORK When bevel ripping rnateriat! 6 _n. or narrower, use fence on the right side of the blade ONLY. This wil! provide more space between the fence and the saw blade for use of a push stick, If the fence is mounted to the left, the sawblade guard may interfere with eroper use of a push stick. 50 : _il ¸ .. LONG WORKPIECES USING FEATHERBOARDS THRU-SAW_NG FOR "C"CLAMPS FEATHERBOARD WORK Featherboards are used to keep the Work with the fence kickbacks. and table as shown, and in contact to help st(_;p Add 7-1/2 inch high flat facing board to the fence, the full length of the fence. Mount featherboards to fence and table as shown, so that leading edges of featherboards will support work,piece. the edge presses only on the uncut portion (forward of the blade), it might otherwise pinch the l WARNING: sure the afeatherboatd against blade in the Make kerr and cause kickback. Before starting the operation (turn switch lower cutter below table surface): "OFF" and (a) Install featherboards so they exert pressure on the workpiece; be positive they are secure, and (b) Make sure by trial that the featherboards kickback if one should occur. , ,,,,,,, .... ==1 ¢ FEATHERBOARD Featherboards are not employed for thru sawing operations when using the miter gauge, wit stop a ,=1 WARNING: To avoid kickback push forward only on the part of the workpiece that will pass between the blade and the fence. Keep your hands out of the saw blade path and push the worKpiece forward until the trailing end is on top of the table, Stop your thumbs at the front edge of the table, Finish the cut with the appropriate work helper, a push stick or push block. 51 SUPPORT "C"CLAMPS When "WIDTH OF RIP" is 2 tn. or wiaer LJSE THE PUSH STICK to finish pushing the work past the blade. a_ the way When WIDTH OF RIP is 1/2" to 2 in., tlqe pusn st_ct< CANNOT be used because the guard will interfere USE the AUXILIARY FENCE/WORK SUPPORf and PUSH BLOCK, Attach Auxiliary Fence/Work Support to Rip Fence with two "'C" clamps Feed the workpiece by hand along the AUXILIARY FENCE until the end is approx, 1 in, past the front edge of the table. Continue to feed using the PUSH BLOCK. Hold the workpiece in position and install the PUSH BLOCK by sliding it on top of the AUXILIARY FENCE_iORK SUPPORT (this may raise guard), 52 Narrowstripsthickerthanthe AuxiliaryFence/Work Supportmay enterthe guardandstrike the baffle. CAREFULLY t'aiseguardonly enoughto clea_the workpieceUsePUSHBLOCKtocompletecut. BAFFLE WARNING: To avoid #;iury from b_ade contact, never thru saw rip cuts narrower than t/2" wide. RESAWJNG < RESAWING is known as ripping a piece of wood through its thickness. Do not attempt to resaw BOWED or WARPED material. NOTE: To RESAW a piece of Wood wider than 3-3/8 inch, it witl be necessary to remove the blade guard and use the AUXILIARY FENCENVORK SUPPORT (See "Work Helpers"). _::_:_r";: MALL'_'_ "_ _ Clamp it to the table so that the workpiece will SLIDE EASILY but not TILT or MOVE SIDEWAYS without BINDING between the two fences. 1. Do not "Back Up" (reverse feeding) while resawing because this could cause a kickback. 2. Make first pass to depth slightly more than one=half the width of the board; keep the same face of the board against fence for the second paSS_ 3, Install blade guard immediately upon completion of the resawing operation. " WARNING: Do not clamp directly to the bottom edge of the table because the "swivel" of the clamp will not grip properly. Place a small block of wood between the bottom edge of the table and the "C" clamp. • CUTTING __ = ,=rl .....S i BLOCKJ For your safety: = PANELS AUXILIARY FENCE PANEL_#ORK When cutting panels (whenever fence is positioned outside of table or channel separator surface), ALWAYS use the AUXILIARY PANEL!WORK SUPPORT. SUPPORT 1. Unlock fence and raise rear end. 2. Position AUXILIARY PANEL/WORK SUPPORT as shown and attach it with two "C" clamps. 53 USING FEATHERBOARDS NON THRU-SAWING FOR "c" Featherboaras are not employed during non tr_ru-sawing operations when using the miter gauge. FEATHERBOARD WORK SUPPORT Use featherboards for all other non "thru-sawing" operations [when sawblade guard must be removedk Featherboards are used to keep the work in contact with the fence and table as shown, ana to stop kickbacks. Add 7-4/2 inch high flat facing board to the fence the full length of the fence. Mount featherboards to fence and table as shown, so that leading edges of featherboards will support worKpiece until cut is complete, and the workpiece has been pushed completely past the cutter (sawblade. dado head. molding head, etc.) with a pushstick, as _n ripping. Before starting the operation (turn switch "OFF" and lower cutter below table surface): (a) Install featherboards so they exer_ oressure on the workpiece; be positive they are secure, and (b) Make sure by trial that the featherboards will stop a kickback ff one should occur. Replace the sawblade guard as soon as the non thrusawing operation is complete. 54 CLAMPS RABBETING RABBETING is known as cutting out a section of the corner of a piece of material, across an end or along an edge. FIRST CUT RABBET To make a RABBET requires cuts which do not go all the way through the material. Therefore the blade guard must be removed. 1. Remove blade guard. RABBETING ALONG THE EDGE 2. For rabbeting along an edge (long way of workpiece) as shown, add facing to rip fence approximately as high as the workpiece is wide. Adjust rip fence and blade to required dimensions; then make first cut with board to required dimensions; then make first cut with board flat on table as any rip (type) cut; make second cut with workpiece on edge. Follow all precautions, safety instructions, and operational instructions as for ripping, or rip type operations, including featherboards and push stick, etc. 3. For rabbeting across an end, for workpiece 101/2" and narrower make the rabbet cut with the board flat on the table. Using the miter gauge fitted with a facing, follow the same procedures and instructions for cross cutting making successive cuts across the width of cut. DO NOT use the rip fence for rabbeting across the end. I I guard immediately upon completion of rabbeting I WARNING: operation. For your own safety, install blade I RABBETING ACROSS THE END Rabbet cuts can also be made in one pass of the workpiece over the cutter using the dado head or molding head. PLOUGHING AND MOLDING MOLDING is shaping the workpiece with the grain the long way of the workpiece, using the fence. Use proper holddowns and feed devices. PLOUGHING is grooving with the grain the long way of the workpiece, using the fence. USE proper holddowns and feed devices. MOLDING PLOUGHING 55 DADOING Instructions for operating the Dado Head are contained in a booklet furnished with the Dado Head. © The arbor on the saw, is only long enough so that the widest cut that can be made is 13/16" wide. It is not necessary to install the outside loose collar before screwing on arbor nut. Make sure the arbor Rut is tight, ALWAYS USE RECOMMENDED DADO INSERT ALWAYS REPLACE THE BLADE. GUARD AND bPREADER WIlE N YOU ARE FINISHED DADOING. LOOSE COLLAR AR!O! N! SAW ARBOR When using the Dado Head, it will be necessary to remove the Blade Guard and Spreader. USE CAUTION. USE MITER GAUGE, FENCE. FEATHERBOARDS OR PUSH STICKS AS REQUIRED. REMOVE SAWSLADE AND INSTALL WARNING: For your own safety, always replace the blade guard and spreader when you are finished dadoing. SACK OF SAW MOLDING CUTTING Instructions for operating the Molding Head are contained in a booklet furnished with the Molding Head. ALWAYS USE RECOMMENDED MOLDING [NSER-[ When using the Molding Head, it will be necessary to remove the Blade Guard and Spreader. USE CAUTION. USE MITER GAUGE, FENCE, FEATHERBOARDS, OR PUSH STICKS. etc., AS REQUIRED. i or,oo. the blade guard and spreader when you are finished molding. ! 56 ADJUSTMENTS 7 WARNING: For your own safety, turn switch ] "OFF" and remove pUug from Power source out_etbefore making any adjustments, MITER GAUGE NOTE: The holes for the stop pin and the graduations are manufactured to very close tolerances which provide accuracy for average Woodworking. in some cases where extreme accuracy is required, when making angle cuts, for example, make a trial cut and then recheck it. CLAMP LOCK 5 "_ "="4 LATCH 1 iiiii! If necessary, the miter gauge head can be swiveled slightly to compensate for any inaccuracy. 1. Loosen the "handle" and pull "stop pin" OUT. 2. Swivel the head, position it at "0", push the stop pin IN, lock the handle. 3. The HEAD should be square with the Bar and the pointer should point to "0". Readjust the pointer if necessary, 4. If the head is not square with the bar, adjustments are required. A. Loosen the "handle" (1) and the "two screws" (2) B. Position the HEAD square with the BAR using a combination square. C. PUSH the STOP PIN into the hole in the head at "0"...push the pin into the hole and twist it. Lock the handle. D. Recheck with the square. If the head is stilt not square, loosen the screws (2) and readius[ the INDICATOR BLOCK. E. With the head square with the bar and the pin pushed into the hole, adjust the pointer (3) to point to "0". E The miter gauge head must rest on top of the bar without being able to move up and down_,.yet it must swivel freely. WRENCH 2 G. The swiveling movement of the he_d can be adjusted by tightening or loosening the _etscre_ (4)...using the 1/8 in. setscrew wrench. NOTE: The setscrew is _ocated inside of the ,"'a4,s..,.--,_-_ reach it, swivel the head to 60 degrees and turn th.'-_. miter gauge upside down. HEEUNG ADJUSTMENT or PARALLELISM OF SAWBLADE TO MBTER GAUGE GROOVE While cutting, the material must move in a straight line PARALLEL to the SAWBLADE. Therefore, both the Miter Gauge Groove and the Rip Fence must be PARALLEL to the Sawblade. WARNING: The blade must TOOTH be parallel to the miter gauge groove. Misaligned blades could bind on workpiece. Workpiece could suddenly kickback. You could be cut or hit. If the sawblade IS NOT parallel to the Miter Gauge groove, the blade will bind at one end of the cut. (This is known as ("HEELING'_. To check for parallelism: t. Raise blade all the way up...raise b_ade .q_rd 2. Mark an "x" on one of the teeth w_ich is SET (be "_ to the LEFT. make sure switch is ,'OF_" and plug is not connected to power source outtet. 57 3 P_ace the head of a com_r_at_on square _n the GROOVE ad_us_ blade of sqL_are so treat _I jus! toucl_es t_e _D of lb,e MARKED top,n, 4 Move sq{_are to REAR rotate blade to see MARKED tooth ag;_n toucr}es [:_ade of square. if 5. tf tooth touches square at FRONT arid REAR sawbtade is PARALLEL to MITER GAUGE GROOVE 6 - - - FRONTTRUNNION REARTRUNNION if tooth does no; touch zr_e same amount, .the mechanism underneath must be adjusted to make the biade PARALLEL to GROOVE A. Rear trunmon must be moved TOWARD the combination square if there is a space oetween marked tooth and end of square in step 4 B. Rear trunnion mus! be moved AWAY" from the square ff marked tooth pushes souare out of pos_t_on in the groove, REAR-TRUNNION 7. LOOSenall three screws that hold the rear trunnton and all three screws that hold the front trunn_orL SCREWS NOTE; All six screws can be reached through back of saw. Use a 9/16-in wrench. To reach left-hand front_ trunnion screw, tilt blade to 45 d_grees screws reposlbon blade at 90 degrees. .J After loosening / RIGHT-HAND / CENTER FT-HAND (BEHIND_ (B_,_ND HERE) _RONT-TRUNNIONSCREWS 8, Using a wood block and mallet as shown, move rear trunmon to right or left as required to realign the blade, tf necessary, shift front trunnion _n sLmilar manner: but do NOT move front trunnion unless EDGE OF TRUNNION CLAW HAMMER necessary Recheck the alignment with the square. then securely rebghten all six trunnion screws, WOOD BLOCK EDGE OF CRADLE REAR OF SAW LOOKING ON TOP OFTABLESAW 58 BLADE T_LT, OR SQUARENESS OF BLADE TO TABLE WT,:>t _Te bevel ponte is !,oi _t n9 directly to the '0' rra:k (_ _e, ,_,_,,, scae. the sawMade st ou_d make a • _ ,,0 t _,, e_., to the taHe 90' POSiTiON ;% c qec
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