Ryobi PTS01 - BRUSHLESS 6-1/2 in. TRACK SAW Manual

GENERAL POWER TOOL SAFETY WARNINGS

To reduce the risk of injury, the user must read and understand the operator's manual before using this product.
SAVE THIS MANUAL FOR FUTURE REFERENCE

Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mainsoperated (corded) power tool or battery-operated (cordless) power tool.

WORK AREA SAFETY

• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
• When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
• If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.
• Use this product only with batteries and chargers listed in tool/appliance/battery pack/charger correlation supplement 987000-432.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, nonskid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
• If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
• Do not wear loose clothing or jewelry. Contain long hair. Loose clothes, jewelry, or long hair can be drawn into air vents.
• Do not use on a ladder or unstable support. Stable footing on a solid surface enables better control of the power tool in unexpected situations.

POWER TOOL USE AND CARE

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
• Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/ or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
• Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

BATTERY TOOL USE AND CARE

• Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
• Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
• When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
• Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
• Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265°F may cause explosion.
• Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

SERVICE

• Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
• Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

TRACK SAW SAFETY WARNINGS

CUTTING PROCEDURES

Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.

• Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
• Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.
• Never hold the workpiece in your hands or across your leg while cutting. Secure the workpiece to a stable platform. It is important to support the work properly to minimise body exposure, blade binding, or loss of control.
• Hold the power tool by insulated gripping surfaces, when performing an operation where the cutting tool may contact hidden wiring. Contact with a "live" wire will also make exposed metal parts of the power tool "live" and could give the operator an electric shock.
• When ripping, always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding.
• Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades that do not match the mounting hardware of the saw will run off-centre, causing loss of control.
• Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation.

KICKBACK CAUSES AND RELATED WARNINGS

• Kickback is a sudden reaction to a pinched, jammed or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator;
• When the blade is pinched or jammed tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator;
• If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.

Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

• Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.
• When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding.
• When restarting a saw in the workpiece, centre the saw blade in the kerf so that the saw teeth are not engaged into the material. If a saw blade binds, it may walk up or kickback from the workpiece as the saw is restarted.
• Support large panels to minimise the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.
• Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
• Blade depth and bevel adjusting locking levers must be tight and secure before making the cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
• Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

GUARD FUNCTION

• Check the guard for proper closing before each use. Do not operate the saw if the guard does not move freely and enclose the blade instantly. Never clamp or tie the guard so that the blade is exposed. If the saw is accidentally dropped, the guard may be bent. Check to make sure that the guard moves freely and does not touch the blade or any other part, in all angles and depths of cut.
• Check the operation and condition of the guard return spring. If the guard and the spring are not operating properly, they must be serviced before use. The guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
• Assure that the base plate of the saw will not shift while performing a "plunge cut". Blade shifting sideways will cause binding and likely kick back.
• Always observe that the guard is covering the blade before placing the saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after the switch is released.
• Do not use abrasive wheels with this saw.
• Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control.

RIVING KNIFE FUNCTION

• Use the appropriate saw blade for the riving knife. For the riving knife to function, the body of the blade must be thinner than the riving knife and the cutting width of the blade must be wider than the thickness of the riving knife.
• Adjust the riving knife as described in this instruction manual. Incorrect spacing, positioning and alignment can make the riving knife ineffective in preventing kickback.
• Always use the riving knife, except when plunge cutting. The riving knife must be replaced after plunge cutting. The riving knife causes interference during plunge cutting and can create kickback.
• For the riving knife to work, it must be engaged in the workpiece. The riving knife is ineffective in preventing kickback during short cuts.
• Do not operate the saw if the riving knife is bent. Even a light interference can slow the closing rate of a guard.
• Use the appropriate saw blade for the riving knife. For the riving knife to function properly, the body of the saw blade must be thicker than 1.0 mm and the cutting width of the saw blade must be wider than 1.4 mm.

SYMBOLS

The following signal words and meanings are intended to explain the levels of risk associated with this product.

SYMBOL	SIGNAL	MEANING
	DANGER:	Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.
	WARNING:	Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.
	CAUTION:	Indicates a hazardous situation, that, if not avoided, may result in minor or moderate injury.
	NOTICE:	(Without Safety Alert Symbol) Indicates information considered important, but not related to a potential injury (e.g. messages relating to property damage).

Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the product better and safer.

SYMBOL	NAME	DESIGNATION/EXPLANATION
	Safety Alert	Indicates a potential personal injury hazard.
	Read Operator's Manual	To reduce the risk of injury, user must read and understand operator's manual before using this product.
	Eye Protection	Always wear eye protection with side shields marked to comply with ANSI Z87.1.
	Wet Conditions Alert	Do not expose to rain or use in damp locations.
	No Hands Symbol	Failure to keep your hands away from the blade will result in serious personal injury.
	Recycle Symbol	This product uses lithium-ion (Li-ion) batteries. Local, state or federal laws may prohibit disposal of batteries in ordinary trash. Consult your local waste authority for information regarding available recycling and/ or disposal options.
	Direct Current	Type or a characteristic of current
n o	No Load Speed	Rotational speed, at no load
.../min	Per Minute	Revolutions, strokes, surface speed, orbits etc., per minute
V	Volts	Voltage
min	Minutes	Time

FEATURES

PRODUCT SPECIFICATIONS
Motor: 18 V DC
Blade Diameter: 6-1/2 in.
Blade Arbor: 5/8 in.
Track Size: 27.5 in. each
Bevel Capacity: -1˚ to 48˚
Cutting Depth at 0º
with track: 1-15/16 in.
without track: 2-1/8 in.
Cutting Depth at 45º
No Load Speed: 4,300/min (RPM)
with track: 1-7/16 in.
without track: 1-9/16 in.

OVERVIEW

1. Dust exhaust port
2. Blade wrench storage area
3. Depth lock knob
4. Lock-off button
5. Switch trigger
6. Spindle lock
7. Bevel scale
8. Bevel lock knob
9. Bevel bypass lever
10. Negative bypass tab
11. Track adjustment tab
12. Anti-tip knob
13. Plunge depth control lever
14. Depth of cut scale
15. Track clamp
16. Connector
17. Track
18. Cutting blade
19. Riving knife
20. Front handle

ASSEMBLY

UNPACKING
This product requires assembly.

• Carefully remove the product and any accessories from the box. All items listed in the Includes section must be included at the time of purchase.

Items in this Assembly section are not assembled to the product by the manufacturer and require customer installation. Use of a product that may have been improperly assembled could result in serious personal injury.

• This saw has been shipped with a tie-wrap securing it in the plunge position. To release the saw, push down on the top of the front handle, cut the tie-wrap, and slowly allow the saw to raise to its fully raised position.

The saw's body is spring loaded. Hold the front handle down to prevent it from snapping up when cutting the tie-wrap. Failure to do so could result in possible serious injury.

• Inspect the product carefully to make sure no breakage or damage occurred during shipping.
• Do not discard the packing material until you have carefully inspected and satisfactorily operated the product.
• If any parts are damaged or missing, please call 1-800-525-2579 for assistance.

If any parts are damaged or missing do not operate this product until the parts are replaced. Use of this product with damaged or missing parts could result in serious personal injury.

Do not attempt to modify this product or create accessories not recommended for use with this product. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury.

To prevent accidental starting that could cause serious personal injury, always remove the battery pack from the product when assembling parts.

INSTALLING THE BLADE

1. Blade change position
2. Lock-off button
3. Spindle lock
4. Plunge depth control lever
5. Depth lock knob

1. Lock-off button

1. Blade screw

1. Spindle lock
2. Blade wrench
3. Blade screw
4. Outer blade washer
5. Spindle
6. Inner blade washer
7. Cutting blade
8. To loosen
9. To tighten

A 6-1/2 in. blade is the maximum blade capacity of the saw. Never use a blade that is too thick to allow outer blade washer to engage with the flats on the spindle. Larger blades will come in contact with the blade guard, while thicker blades will prevent blade screw from securing blade on spindle. Either of these situations could result in a serious accident.

• Remove the battery pack from the saw.
• Remove the blade wrench from the storage area.
  NOTE: Two wrenches are included with the saw, a small one for the track and a large one for the blade.
• Place the plunge depth control lever in the blade change position.
• Depress the lock-off button.
• Grasp the front handle and apply downward pressure to lower and expose the blade screw. Continue pressing down to lower the saw to its fully lowered position.
• Slowly allow the front handle to rise until the saw locks in the blade change position. In this position, the saw cannot be lowered or raised.
• Place the saw on its side with the spindle facing up.
• Depress and hold the spindle lock button and remove the blade screw and outer blade washer.
  NOTE: Turn the blade screw counterclockwise to remove.

NOTICE: To prevent damage to the spindle or spindle lock, always allow motor to come to a complete stop before engaging spindle lock.
NOTE: Do not run the saw with spindle lock engaged.

• Wipe a drop of oil onto the inner blade washer and outer blade washer where they contact the blade.

If inner blade washer has been removed, replace it before placing blade on spindle. Failure to do so could cause an accident since blade will not tighten properly.

• Fit the blade inside the slot in the base and onto the spindle.
• Replace the outer blade washer.
• Depress and hold the spindle lock button, then replace the blade screw. Tighten the blade screw securely by turning it clockwise.
• Return the blade wrench to the storage area.
• Place the saw in the upright position and move the plunge depth control lever to the scoring or plunge cut position before attempting a cut.
  NOTE: Never use a blade that is too thick to allow the outer blade washer to engage with the flats on the spindle.

REMOVING THE BLADE
See Figures 1-4

• Remove the battery pack from the saw.
• Remove the blade wrench from the storage area.
  NOTE: Two wrenches are included with the saw, a small one for the track and a large one for the blade.
• Place the plunge depth control lever in the blade change position.
• Lock the saw in the blade change position as previously described.
  NOTE: When the saw is lowered into the blade change position, a portion of the blade and riving knife extend beyond the base. Ensure the saw is positioned to provide adequate clearance before putting it in the blade change position.
• Position the saw on its side as shown, depress the spindle lock button, and remove the blade screw by turning it counterclockwise.
• Remove the outer blade washer.
• Carefully push the back of the blade up and off of the spindle.
• n Remove the blade by sliding it out of the slot in the base.

INSTALL/REMOVE THE RIVING KNIFE

1. Hole
2. Blade wrench
3. Riving knife
4. Slot
5. Studs

Only remove the riving knife for non-through cuts and pocket cuts. Removing the riving knife for any other cuts may result in kickback and possible serious personal injury.

• Remove the battery pack from the saw.
• Remove the blade wrench from the storage area.
  NOTE: Two wrenches are included with the saw, a small one for the track and a large one for the blade.
• Place the plunge depth control lever in the blade change position.
• Lock the saw in the blade change position as previously described.
• Locate the screw inside the hole at the back of the blade cover.
• Insert the blade wrench into the hole and loosen several turns but do not remove the screw by turning it in a counterclockwise direction.
• Slide the riving knive inside the guard and carefully align the slot in the knife with the stud inside the blade guard.
  NOTE: Insert the riving knive completely into the guard until it stops to make sure it is securely in position.
  NOTE: When correctly installed, the riving knife should be 5 mm from the blade. If necessary, loosen the screw and reposition the riving knife.
• Tighten the screw securely by turning it clockwise.
• Return the blade wrench to the storage area.
• Place the saw in the upright position and move the plunge depth control lever to the scoring or plunge cut position before attempting a cut.

To remove the riving knife:

• Remove the battery pack from the saw.
• Remove the blade wrench from the storage area.
• Loosen but do not remove the screw by turning it in a counterclockwise direction.
• Remove the riving knife.
• Tighten the screw securely by turning it clockwise.

Each track has a rubber cut strip running along the edge. Before cutting a workpiece using the track, the rubber cut strip must be trimmed away. Refer to "Using the Track" in the Operations section.

OPERATION

Do not allow familiarity with products to make you careless. Remember that a careless fraction of a second is sufficient to inflict serious injury.

Always remove battery pack from the tool when you are assembling parts, making adjustments, cleaning, or when not in use. Removing battery pack will prevent accidental starting that could cause serious personal injury.

Always wear eye protection with side shields marked to comply with ANSI Z87.1. Failure to do so could result in objects being thrown into your eyes and other possible serious injuries.

Do not use any attachments or accessories not recommended by the manufacturer of this product. The use of attachments or accessories not recommended can result in serious personal injury.

APPLICATIONS
You may use this product for the purposes listed below:

• Cutting all types of wood products (lumber, plywood, paneling, composition board, and hard wood)

Never use abrasive cut-off wheels of any kind with this saw. Use of non wood cutting blades can result in property damage or serious personal injury.

INSTALLING/REMOVING BATTERY PACK

1. Depress latches to remove battery pack
2. Battery pack

• Insert the battery pack into the product as shown.
• Make sure the latches on each side of the battery pack snap in place and that battery pack is secured in the product before beginning operation.
• Depress the latches to remove the battery pack.

For complete charging instructions, see the operator's manuals for your battery pack and charger.

Battery tools are always in operating condition. Lock the switch when not in use or carrying at your side, when installing or removing the battery pack, and when installing or removing blades and accessories.

KICKBACK

Kickback occurs when the blade stalls rapidly and the saw is driven back towards you. Blade stalling is caused by any action which pinches the blade in the wood.

Release switch immediately if blade binds or saw stalls. Kickback could cause you to lose control of the saw. Loss of control can lead to serious injury.

To guard against kickback, avoid dangerous practices such as the following:

• Setting blade depth incorrectly.
• Sawing into knots or nails in workpiece.
• Twisting the blade while making a cut.
• Making a cut with a dull, gummed up, or improperly set blade.
• Supporting the workpiece incorrectly.
• Forcing a cut.
• Cutting warped or wet lumber.
• Operating the tool incorrectly or misusing the tool.
• Rapidly plunging the blade into the workpiece.

To lessen the chance of kickback, follow these safety practices:

• Keep the blade at the correct depth setting. The depth setting should not exceed 1/4 in. below the material being cut.
• Inspect the workpiece for knots or nails before cutting. Never saw into a knot or nail.
• Make straight cuts. Always use a straight edge guide when rip cutting. This helps prevent twisting the blade.
• Use clean, sharp, and properly set blades. Never make cuts with dull blades.
• Support the workpiece properly before beginning a cut.
• Use steady, even pressure when making a cut. Never force a cut.
• Do not cut warped or wet lumber.
• Hold the saw firmly with both hands and keep your body in a balanced position so as to resist the forces if kickback should occur.
• When performing pocket cuts, allow the blade to reach full speed then apply slow, even downward pressure to guide the blade into the workpiece.

When using the saw, always stay alert and exercise control. Do not remove the saw from the workpiece while the blade is moving.

PLUNGE DEPTH CONTROL LEVER

1. Plunge depth control lever

1. Scoring position
2. Plunge cut position
3. Blade change position

The saw is equipped with a plunge depth control lever that limits the downward movement of the saw for different operations. The lever has three settings. One for changing the blade, one for scoring material, and one for making plunge cuts.

Blade change position
Placing the lever in this position will allow you to lock the saw in a lowered position with the blade screw visible through the window in the guard.

Scoring position:
With the lever in the scoring position, the downward travel of the blade is limited to approximately 1/4 in. depth of cut. Perform a cut with the blade at this depth to score the workpiece.
NOTE: The riving knife must be removed for this cut.
NOTE: To reduce the risk of splintering, always make a score cut before cutting through laminated or veneer faced plywood or composite materials.

Plunge cut position:
Move the lever to the plunge cut position to make deep cuts and through cuts. When the lever is in this position, the blade can be lowered to the full depth of cut.
NOTE: When the lever is in the plunge cut position, use the depth lock knob to control blade depth. The correct blade depth setting for all cuts should not exceed 1/4 in. below the material being cut.

ATTACHING THE SAW TO A VACUUM

1. Front handle
2. Lock-off button
3. Window in guard
4. Cutting blade (lowered)
5. Riving knife
6. Dust exhaust port

When cutting for an extended period of time, you can easily attach a vacuum hose to the dust exhaust port of the saw.

• Remove the battery.
• Attach the vacuum hose to the dust exhaust port on the saw.
  NOTE: The vacuum hose will fit inside or outside the dust exhaust port. The saw will accept a standard 1-7/8 in. and 1-1/4 in. vacuum connection.
• Reinstall the battery pack.

LOWERING AND RAISING THE BLADE AND RIVING KNIFE
See Figure 16

To lower the blade:

• Depress the lock-off button.
• Grasp the front handle and apply downward pressure to lower and expose the blade and riving knife (if installed).
  NOTE: Maintain downward pressure to keep the blade in a lowered position.

To raise the cutting blade:

• Slowly allow the front handle to rise until the blade and riving knife (if installed) are completely inside of the guard and the saw is in the locked position.

USING THE DEPTH LOCK KNOB

1. Depth lock knob
2. Depth of cut scale
3. Depth indicator

Always keep correct blade depth setting. The correct blade depth setting for all cuts should not exceed 1/4 in. below the material being cut. More blade depth will increase the chance of kickback and cause the cut to be rough. For more depth of cut accuracy, a scale is located on the guard.

• Remove the battery pack.
• Loosen the depth lock knob.
• Determine the desired depth of cut.
• Move the depth lock knob up or down to align the depth of cut indicator with the desired depth setting.
• Tighten the depth lock knob.

SAW BLADES
The best of saw blades will not cut efficiently if they are not kept clean, sharp, and properly set. Using a dull blade will place a heavy load on the saw and increase the danger of kickback. Keep extra blades on hand, so that sharp blades are always available.
Gum and wood pitch hardened on blades will slow the saw down. Remove saw blade from the saw and use gum and pitch remover, hot water, or kerosene to remove these accumulations. DO NOT USE GASOLINE.

STARTING/STOPPING THE SAW

1. Lock-off button
2. Switch trigger

Always check that the spindle lock button is fully released before switching on the tool.

To start the saw:

• Install the battery pack.
• Depress the lock-off button.
• Depress the switch trigger.
  Always let the blade reach full speed, then guide the saw into the workpiece.

The blade coming in contact with the workpiece before it reaches full speed or plunging the saw too quickly into the workpiece could cause the saw to "kickback" towards you resulting in serious injury. Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces.
To stop the saw: release the switch trigger.
After you release the switch trigger, allow the blade to come to a complete stop. Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position. Do not remove the saw from the workpiece while the blade is moving.

LOCK-OFF BUTTON
See Figure 18

The lock-off button reduces the possibility of accidental starting. The lock-off button is located on the handle above the switch trigger. The lock-off button must be depressed before you pull the switch trigger. The lock resets each time the trigger is released.
When the saw is raised to its uppermost position it will be locked in that position. Depress the lock-off button to unlock the saw.

USING THE TRACK

1. Track clamp
2. Track
3. Scrap material
4. Support

1. Slot
2. Raised tab

1. Track
2. Base

1. Lock knob
2. Track adjustment tab

1. Scoring position
2. Track

1. Rubber cut strip

1. Workpiece
2. Track
3. Track clamp

1. Workpiece
2. Track
3. Track clamp

The saw can be used with or without a track. To use the saw with a track, secure the track to a workpiece then attach the saw to the track. If you are using multiple tracks, assemble and secure the tracks together as described in the Assembly section.

When cutting along multiple tracks, always ensure the tracks are properly aligned and assembled. Cutting along incorrectly assembled or misaligned tracks could cause the saw to move in unexpected ways which may result in serious injuries or property damage.

To trim the rubber cut strip on the tracks:

• Remove the battery pack and riving knife from the saw.
  NOTE: Always remove the riving knife when making nonthrough cuts and pocket cuts.
• Place scrap material onto a workbench, table or other suitable support. The material should be as long or longer than the tracks being prepared for use.
  NOTE: Each track is 27.5 inches long.
• Place the track on the scrap material.
• Use the track clamp to secure the track and scrap material to the support.
• Hold the saw above the track with the blade facing the rubber cut strip.
• Align the slot in the saw's base with the raised tab on the track. Then, lower the saw onto the track.
• Check for play at the front and back of the saw and ensure the saw glides along the track smoothly.
• If necessary, loosen the lock knobs securing the track adjustment tabs. Rotate the tabs until all play (left and right) is eliminated and the saw moves freely (forward and back). Tighten the lock knobs.
• Place the plunge depth control lever in the scoring position.
• Reinstall the battery pack.
• Slide the saw to the starting end track and ensure the blade is positioned to cut all the rubber.
• Start the saw and let the blade reach full speed.
• Carefully lower the blade until it contacts the workpiece.
• Guide the saw in a forward direction along the track to trim the rubber cut strip.
  NOTE: After the rubber cut strip is trimmed, it can be used to accurately indicate the blade cut line.
• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position.
• Remove the battery pack from the saw.
• Remove the saw from the track and reinstall the riving knife.
  NOTE: When correctly installed, the riving knife should be 5 mm from the blade. If necessary, loosen the screw and reposition the riving knife.
• Loosen and remove the track clamp.
• Discard the scrap material.

To make cuts along the track:

• Secure workpiece to a workbench, table or other suitable support.
• Place the track on the workpiece and position the rubber cut strip along your desired line of cut.
• Using the track clamp, loosely secure the track to the workpiece.
• Slide the track to the end of the workpiece and continue sliding until a portion of track is hanging off the edge of the workpiece.
• Tighten the track clamp completely
• Place the saw on the track and make adjustments if needed.
• Perform one of the cutting operations described later in this section.
• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position.
• Remove the battery pack from the saw.

OPERATING THE SAW

It is important to understand the correct method for operating the saw. Refer to the figures in this section to learn the correct and incorrect ways for handling the saw.

To make sawing easier and safer, always maintain proper control of the saw by holding the saw firmly with both hands. Loss of control could cause an accident resulting in possible serious injury.
To make the best possible cut, follow these helpful hints.

• Hold the saw firmly with both hands.
• Avoid placing your hand on the workpiece while making a cut.
• Support the workpiece so that the cut (kerf) is always to your side.
• Support the workpiece near the cut.
• Use clamps or other practical ways to secure the workpiece so that the workpiece will not move during the cut.
• Always place the saw and the track on the workpiece that is supported, not the "cut off" piece.
• If possible, place the workpiece with the "good" side down.
• To reduce the risk of splintering, always make a score cut before cutting through laminated or veneer faced plywood or composite materials.
• When cutting without a track, draw a guideline along the desired line of cut before beginning your cut.
• When cutting along a track, use the rubber cut strip to indicate the blade cut line.
• When cutting along a track, apply downward pressure and gently move the saw forward. Don't force the saw and NEVER pull the saw toward you when the saw is running (turned on).

NOTICE:
All of the cutting operations described in this manual can be performed with or without a track.

CROSS CUTTING/RIP CUTTING

Ensure the riving knife is installed and working properly when making these cuts to avoid possible serious injury.
Cuts can be made across the grain of the wood (cross cuts) or with the grain of the wood (rip cuts).
Inspect the wood before making any cuts. There should be no nails or foreign objects in the workpiece.
When making a cross cut or rip cut along a track, align the line of cut with the rubber cut strip on the track.

RIP CUTTING ALONG A TRACK

• Remove the battery pack and install the riving knife.
  NOTE: Always install the riving knife when making through cuts (except pocket cuts).
• Secure workpiece to a workbench, table or other suitable support.
• Place the plunge depth control lever in the plunge cut position.
• Set the blade to the correct blade depth setting.
• Install vacuum hose (not included) if desired.
• Place the track on the workpiece and position the rubber cut strip along your desired line of cut.
• Clamp the track to the workpiece as previously described.
• Place the saw on the track and make adjustments if needed.
• Reinstall the battery pack.
• Slide the saw to the starting end of the track and ensure the blade is positioned to cut all the workpiece.
• Start the saw and let the blade reach full speed.
• Carefully lower the blade until it contacts the workpiece.
• Guide the saw in a forward direction along the track to achieve a straight rip cut.
  NOTE: Use caution to prevent the blade from binding in the cut.
  NOTE: To reduce the risk of splintering, always make a score cut before cutting through laminated or veneer faced plywood or composite materials.
• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position.
• Remove the battery pack from the saw.

RIP CUTTING WITHOUT A TRACK

• Remove the battery pack and install the riving knife.
  NOTE: Always install the riving knife when making through cuts (except pocket cuts).
• Secure workpiece to a workbench, table or other suitable support.
• Place the plunge depth control lever in the plunge cut position.
• Set the blade to the correct blade depth setting.
  Install vacuum hose (not included) if desired.
• Clamp a straight edge to the workpiece using C-clamps.
• Reinstall the battery pack.
• Place the front of the base flat on the workpiece.
• Start the saw and let the blade reach full speed.
• Carefully lower the blade until it contacts the workpiece.
• Saw along the straight edge in a forward direction to achieve a straight rip cut.
  NOTE: Use caution to prevent the blade from binding in the cut.
  NOTE: To reduce the risk of splintering, always make a score cut before cutting through laminated or veneer faced plywood or composite materials.
• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position.
• Remove the battery pack from the saw.

BEVEL CUTTING

1. Anti-tip knob
2. To extend plate
3. To retract plate
4. Lock plate

1. Bevel lock knob
2. Bevel scale
3. Bevel indicator

A bevel cut is made by cutting the workpiece with the blade at an angle.

BEVEL CUTTING ALONG A TRACK
NOTE: Always use the anti-tip feature when bevel cutting along a track to prevent the saw from tipping or becoming unbalanced.

• Remove the battery pack and install the riving knife.
  NOTE: Always install the riving knife when making through cuts (except pocket cuts).
• Secure workpiece to a workbench, table or other suitable support.
• Place the plunge depth control lever in the plunge cut position.
• Set the blade to the correct blade depth setting.
• Install vacuum hose (not included) if desired.
• Place the track on the workpiece and position the rubber cut strip along your desired line of cut.
• Clamp the track to the workpiece as previously described.
• Loosen the anti-tip knob and swing it inwards to extend the lock plate.
• Tighten the anti-tip knob.
• Hold the saw at an angle and guide the lock plate underneath the lip of the track
• Place the rest of the saw on the track and make adjustments if needed.
  NOTE: To remove the saw from the track, loosen the anti-tip knob and swing it outwards to retract the lock plate and pull the saw up and away from the track.
• Loosen the bevel lock knobs and move the saw to the desired bevel angle.
• Bevel angles can be set from -1° to 48°.
  NOTE: Use the bevel bypass lever to achieve bevel angles between 45 and 48°. Use the negative bypass tab to achieve a bevel angle of -1°. Refer to Extended Bevel Settings later in this section.
• Tighten the bevel lock knobs.

Attempting a bevel cut without having the bevel lock knobs securely tightened can result in serious injury.

• Reinstall the battery pack.
• Slide the saw to the starting end of the track and ensure the blade is positioned to cut all the workpiece.
• Start the saw and let the blade reach full speed.
• Carefully lower the blade until it contacts the workpiece.
• Guide the saw in a forward direction along the track to achieve a bevel cut.
  NOTE: Use caution to prevent the blade from binding in the cut.
  NOTE: To reduce the risk of splintering, always make a score cut before cutting through laminated or veneer faced plywood or composite materials.
• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position.
• Remove the battery pack from the saw.

BEVEL CUTTING WITHOUT A TRACK

• Remove the battery pack and install the riving knife.
  NOTE: Always install the riving knife when making through cuts (except pocket cuts).
• Secure workpiece to a workbench, table or other suitable support.
• Place the plunge depth control lever in the plunge cut position.
• Set the blade to the correct blade depth setting.
• Install vacuum hose (not included) if desired.
• Loosen the bevel lock knobs and move the saw to the desired bevel angle.
  Bevel angles can be set from -1° to 48°.
  NOTE: Use the bevel bypass lever to achieve bevel angles between 45 and 48°. Use the negative bypass tab to achieve a bevel angle of -1°. Refer to Extended Bevel Settings later in this section.
• Tighten the bevel lock knobs.

Attempting a bevel cut without having the bevel lock knobs securely tightened can result in serious injury.

• Reinstall the battery pack.
• Place the front of the base flat on the workpiece.
• Start the saw and let the blade reach full speed.
• Carefully lower the blade until it contacts the workpiece.
• Guide the blade into and through the workpiece.
  NOTE: Use caution to prevent the blade from binding in the cut.
• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position..
• Remove the battery pack from the saw.

EXTENDED BEVEL SETTINGS

1. Bevel lock knob
2. Bevel indicator
3. For 45º bevel limit
4. For 48º bevel limit
5. Bevel bypass lever

1. Negative bypass tab

The extended bevel capacity of the saw allows you to make bevel cuts from -1° to 48°.
NOTE: Always use the anti-tip feature when bevel cutting along a track to prevent the saw from tipping or becoming unbalanced.

To achieve bevel angles between 45 and 48°:

• Remove the battery pack.
• Rotate the bevel bypass lever fully clockwise to change the upper bevel limit from 45° to 48°.
  NOTE: Rotate the lever fully counterclockwise to change the upper bevel limit back to 45°.
• Loosen the bevel lock knobs and move the saw to the desired bevel angle.
• Tighten the bevel lock knobs.

To achieve a bevel angle of -1°:

• Remove the battery pack.
• Rotate the negative bypass tab near the rear of the saw fully couterclockwise.
• Rotate the negative bypass tab near the front of the saw fully clockwise.
• Loosen the bevel lock knobs and move the saw to the desired bevel angle.
  NOTE: Slight pressure may be needed to move the saw from 0° to -1°.
• Tighten the bevel lock knobs.

POCKET CUTTING

Always adjust bevel setting to zero before making a pocket cut. Attempting a pocket cut at any other setting can result in loss of control of the saw possibly causing serious injury.

• Remove the battery pack and riving knife from the saw.
  NOTE: Always remove the riving knife when making nonthrough cuts and pocket cuts.
• Secure workpiece to a workbench, table or other suitable support.
• Place the plunge depth control lever in the plunge cut position.
• Set the blade to the correct blade depth setting.
• If desired, secure the track to the workpiece and place the saw on the track.
• Install vacuum hose (not included) if desired.
• Reinstall the battery pack.
  Move the saw into position.
• Rest the base flat against the workpiece.
• Start the saw and let the blade reach full speed.
• Slowly lower the blade into the workpiece and make the first line of cut. If you are cutting along a track, lower the blade into the workpiece and guide the saw in the forward direction along the track to the desired length of cut.
  NOTE: To reduce the risk of splintering, always make a score cut before cutting through laminated or veneer faced plywood or composite materials.

Always cut in a forward direction when pocket cutting. Cutting in the reverse direction could cause the saw to climb up on the workpiece and back toward you.

• Release the trigger and allow the blade to come to a complete stop.
• Slowly allow the front handle to rise until the blade is completely inside of the guard and the saw is in the locked position.
• Reposition the saw and track (if applicable) and repeat the above steps for the remaining lines of cut.
• Clear corners out with a hand saw, sabre saw, or chisel.

To prevent accidental starting that could cause serious personal injury, always remove the battery pack from the product when making adjustments.

ADJUSTING THE BASE PARALLEL TO THE BLADE

1. Screw
2. Washer
3. Hole in base
4. Opening
5. Compression spring
6. Spring cone
7. Bracket

1. Base
2. Screws
3. Ruler
4. Cutting blade
5. Measure from this edge to blade

• Remove battery pack.
• Place the saw in an upside down position on a workbench. n Remove the bolt and washer near the center of the base.
  NOTE: The washer is located between the base and the guard.
• Turn the saw right side up.
• Slide the spring cone away from the bracket in the base.
• Remove the compression spring from the cone.
• Slide the compression spring down and away from the opening in the saw housing.
• Place the plunge depth control lever in the plunge cut position.
• Lower the blade completely.
• Turn the saw upside down.
• Mark beside one of the blade teeth at the front of the blade. Using a ruler, measure the distance from the blade tooth to the edge of the saw base indicated in figure 41. n Turn the blade so the marked tooth is at the back.
• Move the ruler to the rear and again measure the distance from the blade tooth to the edge of the saw base. If the distances are the same, the blade and the base are parallel.
• Reassemble the spring, spring cone, washer and screw.

If the distances are different:

• Remove battery pack.
• Remove the screw near the center of the base, washer, compression spring and cone.
• Place the plunge depth control lever in the plunge cut position.
• Lower the blade completely.
• Turn the saw upside down.
• Loosen but do not remove the screws near the front and back of the base.
• Adjust the base until it is parallel with the saw blade.
• Tighten the screws. Check again for squareness and continue to adjust if needed.
• Reassemble the spring, spring cone, washer and screw.

TO SET THE BLADE AT 0° AND 45°

1. Adjustment screw
2. Hex nut
3. Square
4. Cutting blade

1. Bevel indicator
2. Screw

1. Square
2. Base
3. Set screw

The angle settings of the saw have been set at the factory and, unless damaged in shipping, should not require setting during assembly. After extensive use, they may need to be checked. n Remove battery pack.

• Remove the screw near the center of the base, washer, compression spring and cone.
• Place the plunge depth control lever in the plunge cut position.

To check for squareness, 0˚ bevel:

• Loosen the bevel lock knobs and tilt the saw to 0°.
• Tighten the bevel lock knobs.
• Lower the blade completely.
• Place the saw in an upside down position on a workbench.
• Check the squareness of the saw blade to the base of the saw using a carpenter's square.

If the blade is not an exact 90° (0° bevel):

• Loosen hex nuts securing adjusting screws.
• Turn adjusting screws and adjust base until square with saw blade.
• Tighten hex nuts and bevel lock knobs securely.

Once blade is square to the base (0° bevel):

• Check bevel indicator.
• If indicator is not pointing to the 0º mark on the bevel scale, loosen the indicator adjusting screw and adjust indicator.
  NOTE: Tilt the saw to 45° and recheck indicator.
• Retighten screw.

To check for squareness, 45˚ bevel:

• Loosen the bevel lock knobs and tilt the saw to 45°.
• Tighten the bevel lock knobs.
• Lower the blade completely.
• Place the saw in an upside down position on a workbench.
• Check the squareness of the saw blade to the base of the saw using a carpenter's square.

If the blade is not an exact 45°:

• Turn the 45° stop screw 1/4 turn in the clockwise or counterclockwise direction until the blade is square.
• Tighten the bevel lock knobs.

Once blade is 45° to the base:

• Check bevel indicator.
• If indicator is not pointing to the 45º mark on the bevel scale, loosen the indicator adjusting screw and adjust indicator.
  NOTE: Tilt the saw to 0° and recheck indicator.
• Retighten screw.

When all adjustments are complete:

• Reassemble the spring, spring cone, washer and screw.

ACCESSORIES

Look for these accessories where you purchased this product or call 1-800-525-2579:

• 27.5 in. Track Assembly (incl. two connectors, set screws, and rubber cut strips): 089240074701
• 55 in. Track Assembly (incl. two connectors, set screws, and rubber cut strips): 089240074710
• Track Connector Assembly (incl. two connectors and set screws): 089240074711
• Riving Knife: 089240074115
• 27.5 in. Rubber Cut Strip: 089240074117
• 55 in. Rubber Cut Strip: 089240074116
• Track Adjustment Tabs: 089240074118 (front) and 089240074119 (back)
• 6-1/2 in. Blade: 089240074110
• Track Clamp Assembly: 089240074712

Current attachments and accessories available for use with this product are listed above. Do not use any attachments or accessories not recommended by the manufacturer of this product. The use of attachments or accessories not recommended can result in serious personal injury.

MAINTENANCE

REPLACING THE TRACK ADJUSTMENT TAB

1. Lock knob
2. Washer
3. Track adjustment tab
4. Hole in base

After extended use, the track adjustment tab may wear and need replacing.
To replace the tab:

• Remove the battery pack from the saw.
• Remove the saw from the track.
• Loosen and remove the lock knob.
• Remove the washer and the track adjustment tab.
• Place the new track adjustment tab over the hole in the base.
  NOTE: There are track adjustment tabs in the front and back of the saw. These tabs are not interchangeable. Always use identical replacement parts.
• Secure the tab in place using the washer and lock knob.
• Place the saw onto the track and adjust the tabs as necessary.