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SafetySpeed SR5 Owner's Manual

Panel saw/router
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SR5U vertical panel saw/router with
optional accessories
Read and understand this manual before operating this tool. Failure to follow the safety precautions and
instructions can result in serious injury or death. Keep this manual in an accessible and safe location for
Panel Saw/Router
Owner's Manual
SR5, SR5U, SR5A, SR5UA, 3400 & TR2
Proudly made in the USA
www.SafetySpeed.com
TR2 horizontal router with optional accessories
future reference.

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  • Page 1 Panel Saw/Router Owner’s Manual SR5, SR5U, SR5A, SR5UA, 3400 & TR2 SR5U vertical panel saw/router with TR2 horizontal router with optional accessories optional accessories Proudly made in the USA www.SafetySpeed.com Read and understand this manual before operating this tool. Failure to follow the safety precautions and instructions can result in serious injury or death.

  • Page 2: Limited Warranty

    Note: The Model and Serial Number label of the SR5 variations and the 3400 can be found on the upper, left side of the frame, when facing the vertical saw/router (Fig. 1). The Model and Serial Number label of the TR2 (horizontal router) can be found on the top, front left side of the frame (Pg.

  • Page 3: Table Of Contents

    Router Carriage Components………………………………………………… 14 Installation/Set Up ..............Tools Required for Installation ..............16 Operating Environment ................16 Inventory…...…………………………………………………………………... 17 Unpacking (SR5-3400) ................17 Unpacking/Machine Assembly (TR2) ............19 Machine Assembly (SR5-3400)……………………………………………… 22 Operation ................... Capacities of the Tool ................34 Selecting a Router Bit ................

  • Page 4: Safety

    Keep this manual in an accessible and safe location for future reference. Electronic copies of this manual are available at www.safetyspeed.com. Printed copies are available by calling SSM 763-755-1600. Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 5: Safety Warning Labels Identified

    Nose Cone Adjustment (behind Carriage) DO NOT Place Hands Under Carriage or near Blade Read & Understand Manual (one behind Carriage) DO NOT Place Hands Under Horizontal Cutting Direction Carriage or near Blade DO NOT Operate in Wet Nose Cone Adjustment Conditions Horizontal Cutting Direction...

  • Page 7: Safety Procedures

    When using electric tools, always follow basic safety precautions to reduce the risk of fire, electric shock, and personal injury. READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE. Before use, be sure everyone using this machine reads and understands this manual as well as any labels packaged with or attached to the machine. 1.
  • Page 8 17. AVOID ACCIDENTAL STARTING. Be sure your tool is turned off before plugging it in. Do not use the tool if the power switch does not turn it on and off. Observe correct Lockout/Tagout procedures when performing maintenance on the tool. 18.
  • Page 9 c. SECURE WORK PROPERLY. If a piece is supported on both sides of the cut in such a way that it allows the material to bow and pinch the blade/bit, it may produce kickback. Do not cut/rout pieces smaller than the carriage.
  • Page 10 34. NEVER STAND ON THE TOOL. Serious injury could occur if the tool is tipped or if you unintentionally contact the cutting tool. 35. DIRECTION OF FEED. Always feed work into the blade or cutter against the direction of the rotation of the blade or cutter.

  • Page 11: Electrical Safety

    Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specifically designed to filter out microscopic particles. Electrical Safety Improperly connecting the grounding wire can result in the risk of electric shock.

  • Page 12: Extension Cords

    General guidelines are as follows: 120 volt: 20 amp protection. These models can include: SR5, SR5U, SR5A, SR5UA, 3400 & TR2 220 volt: 10 amp protection. These models can include: SR5, SR5U, SR5A, SR5UA, 3400 & TR2...

  • Page 13: Electrical Connections

    Reference your motor label and your local codes before installation. Electrical Connections Connect the power cord from the panel saw/router to a dedicated circuit that meets the requirement of the machine and local codes. Connect the power cord from the dust collector to a circuit that meets the requirement of the dust collector.

  • Page 14: Horizontal Router Components

    Horizontal Router Components Guide Tubes (2) Cord Keeper Dado Stop (2) ON/OFF Switch Router Nose Cone Adjustment Router Assist Lift Spring Knob (behind carriage) Carriage Lock (2) Carriage Lock (2) Carriage Router Plunge Lever Dust Collection Port Handle Rulers (2), Horizontal &...
  • Page 15 Router Base ON/OFF Switch Flip Lock Depth Adjustment Knob Carriage Lock (2) (Router Bit Depth) Router Plunge Handle Handle (2) Figure 9: SR5 and SR5A Router Carriage Installation Handle Knurled Knobs Handle Carriage Lock (2) Carriage Dust Port Router Plate...

  • Page 16: Installation/Set Up

    Your Safety Speed saw/router comes from the factory assembled and aligned. You will only have to mount the following parts before you can run these tools:  Router Motor: SR5*, SR5A*, SR5U, SR5UA, 3400 & TR2  Saw or Router Plate: SR5, SR5A, SR5U & SR5UA ...

  • Page 17: Inventory

    Each model incudes the frame, motor(s) and counterweight, except TR2. These items may be installed on the saw/router or packaged in separate boxes. The SR5 Series saws/routers include a separate box for the saw and router motor, and dust cover (Fig. 11, SR5U shown). The 3400 and TR2 include packaging for the router motors.
  • Page 18 Figure 12: Cutting back of wood crate Figure 13: Cutting along base of wood crate, do not cut through (across) base 3. Cut top of crate near saw frame, to release crate, Fig. 14. Remove back side of crate as it should be loose from saw/router and crate.

  • Page 19: Unpacking/Machine Assembly (Tr2)

    6. One or more boxes of parts are attached to the frame. The cord keeper is attached to the carriage. Remove these items for later installation. NOTE: When assembling any version of the SR5 or 3400 skip ahead to page 22 for Assembly instructions.
  • Page 20 1. With the assistance of a helper lay crate flat on floor with back (open side, Fig. 16) of crate down and cardboard side up (Fig.17). Figure 17: TR2 crate positioned flat for unpacking 2. Removing plastic sheeting, protective cardboard, and wood crating. NOTE: Uncrating methods vary by model and accessories.
  • Page 21 Make certain the router is unplugged when mounting into base, adjusting or changing bits. Observe appropriate Lockout/Tagout procedures to insure the tool cannot accidentally be powered. 8. Install router motor into base by loosening router base lock-knob (do not remove). Place router motor into base and twist to position motor until motor is seated in base but collet is not touching acrylic sub-base.

  • Page 22: Machine Assembly (Sr5-3400)

    Machine Assembly SR5, SR5U, SR5A, SR5UA & 3400 To reduce the risk of injury or damage to components, do not attempt to disassemble or repair the Counterweight without proper technical instructions from SSM. When unpacking, loosen 2 Carriage Locks (Pg. 13, Fig. 6), move Carriage to center. Remove wood support block from bottom, center of Counterweight Canister (Pg.19, Fig.15).
  • Page 23 5. Loosen carriage locks and move carriage to top of guide tubes. Alignment Pin Carriage Knurled Knob (1 of 2) Router Plate Depth Adjustment Knob (Router Bit Depth) Carriage Lock (1 of 2) Router Plunge Lever Figure 21: Mounting (Router) Plate to Carriage, SR5 shown...
  • Page 24 9. Loosen Carriage Lock and move Carriage to top of guide tubes. Mounting the Saw Plate on the Carriage Models: SR5, SR5U, SR5A & SR5UA Do not use panel saw or router motor for applications not intended. Do not use saw or router motor removed from the carriage, plate or base for any application.
  • Page 25 Alignment Pin Knurled Knob stud (1 of 2) Knurled Knob stud (2 of 2) Carriage Lock Carriage Lock Figure 22: Mounting Saw Plate to Carriage, SR5U shown 2. Mount the saw motor plate to the carriage by setting the bottom of the plate into the carriage and tipping up and back to seat plate by centering the alignment pin into the corresponding guide hole.
  • Page 26 (#12), using the included 6mm hex wrench, (supplied with the machine) from the saw motor spindle by turning it counterclockwise. Remove the outer blade flange (#13), but leave the inner blade flange (#14) on the spindle. Figure 25: Installing a Saw Blade (SR5 & SR5A)
  • Page 27 4. Install the blade with the arrow pointing counterclockwise as shown Fig. 25, #15. 5. Reinstall the outer blade flange (#13) and hand-tighten the arbor bolt (#12). To keep the spindle from turning while you tighten the bolt hold “in” the spindle lock button (#16) Use the 6mm hex wrench provided with the machine (stored in motor housing) to securely tighten the bolt clockwise.
  • Page 28 Always install the blade guard before operating the saw. The guard is shipped with two (SR5U & SR5UA, Fig. 27) or three (SR5 & SR5A, Fig. 28) torque knobs (#22) installed, depending on the model. Remove the knobs to install the guard. Be sure to leave the rubber washers on the torque knobs, as they prevent the knobs from slipping.
  • Page 29 Figure 28: Installing the Blade Guard (SR5U & SR5UA) Rip and Crosscut Rulers (Scales): SR5, SR5A, SR5U, SR5UA & 3400 The saw/router has one rip ruler mounted vertically and a second rip ruler if the Mid-Way Fence is installed. The rip ruler is set at the factory, for right-to-left cuts using a blade with a 1/8”...
  • Page 30 Figure 29: Installing the Cord Keeper Rubber Stopper Cord Keeper Figure 30: Cord keeper installed (SR5U) 2. Remove the rubber stopper from the ring in the Cord Keeper. See figure 30. Uncoil the cord, and place the plug end through the ring as shown, (Fig. 30). Connect the loose cord to the cord from the saw/router by inserting the plug and twisting to lock (if equipped with a twist-lock).
  • Page 31 NOTE: If there is too much or not enough slack in the cord, readjust if necessary. Installing the Hold-Down Clamps: All models (SR5 variations, 3400 & TR2) include two “Lower” Hold-Down Clamps and models that include the Mid-Way Fence include two “Upper” Hold-Down Clamps to be used when Vertical (cross) Routing and some crosscutting applications.
  • Page 32 “Lower” Hold-Down Clamps: Figure 33: “Lower” Hold-Down Clamp 1. Remove nut, washer and spacer from clamp. 2. Slide clamp stud into hole of faceplate and align spacer between face plate and frame (Fig. 33). 3. Attach washer and nut to stud, behind frame. 4.

  • Page 33: Operation

    4. Hand Tighten Lock Knob. 5. Remove Upper Clamps if not using Mid-Way Fence by reversing above procedure. Backer Board The Backer Board (Fig. 36) is used when crosscutting thin sheet goods such as plastics or when trimming flexible material as it gives support at the cut. It can also reduce chipping and tearing. It is standard equipment for the SR5A and SR5UA and is factory installed.

  • Page 34: Capacities Of The Tool

    Capacities of the Tool Small Work pieces Do not cut/rout pieces that are so small that your hand must be behind the carriage to hold the piece in place. Use a tool better suited to these applications, such as a table saw, radial arm saw, chop saw, band saw or router table.

  • Page 35: Selecting A Router Bit

    Bits or for help in choosing the correct router bits. SSM #763-755-1600. NOTE: The SR5 and SR5A with Milwaukee routers include a second collet for ¼” bits. All router models come equipped with the standard ½” collet, which is the best choice for large router bits.

  • Page 36: Selecting A Saw Blade

    Selecting a Saw Blade The saw blade must be carefully matched to the materials being cut. Improper blade selection can result in reduced tool life, inaccurate and poor quality cuts, and safety risks. NOTE: The following table lists some recommended blades for certain applications. If in doubt, consult with your machinery dealer, or with our customer service department (763-755-1600), to determine the best blade for your cutting needs.

  • Page 37: Basic Operating Functions/Saws

    ON/OFF Switch Handle Spindle Lock Carriage Lock Blade Guard Index Pins Carriage Lock Figure 37: Basic SAW Operating Controls and Components (SR5 & SR5A) Tension Lock Knob Dado Stop (2) (Hold Down Bar) Knurled Knob (2) ON/OFF Switch Handle Spindle Lock...

  • Page 38: Changing The Blade

    Always install the blade guard before operating the saw (Fig. 39 & 40, #21). Blade Guard Figure 39: Removing/Installing the Blade Guard (Models SR5 & SR5A) Blade Guard (smaller knob) Figure 40: Removing/Installing the Blade Guard (Models SR5U & SR5UA)
  • Page 39 3. Remove the blade guard, see “Removing and Installing the Blade Guard” and (Fig. 39 & 40, #21). 4. To keep the spindle from turning while you loosen the arbor bolt (SR5 & SR5A Fig. 41, #12) or (SR5U &...

  • Page 40: Starting And Stopping The Motors

    Figure 42: Installing a Saw Blade (SR5U & SR5UA) Starting and Stopping the Motors SR5 & SR5A Saws: Start the saw motor by lifting on the paddle switch (ON) (Pg. 37, Fig. 37), located under the saw handle. Stop the motor by pressing the switch down (OFF).
  • Page 41 Use both Carriage Locks when ploughing or cross routing. Rip and Crosscut Rulers (Scales): SR5, SR5A, SR5U, SR5UA & 3400 The saw/router has one rip ruler mounted vertically. The rip ruler is set at the factory, for right-to-left cuts using a blade with a 1/8”...

  • Page 42: General Operating Tips

    Be sure the blade is installed before following these steps: 1. Remove the blade guard (Pg. 37, Fig. 39 & 40) so the blade is exposed. 2. Loosen the carriage lock and lower the carriage to a comfortable working height, as shown in figure 43. Figure 43: Adjusting the Crosscut Rulers 3.

  • Page 43: Operating Procedure: Crosscutting

     Vertical panel saws/routers are intended for cutting large panels down to size. As the overall panel size becomes smaller and smaller consider the “Midway fence” page 68 or other types of sawing/routing tools as they become more convenient and safer to use. ...
  • Page 44 12. When making saw cuts that are less than 1” (25mm), the chatter preventer (guard) (located inside the blade guard) must be resting on the work piece, not on the cut-off piece. See page 47 & 48, Fig. 50 & 51. If it is not positioned this way, it will jam the work piece and prevent the carriage from continuing through the cut.

  • Page 45: Operating Procedure: Rip Cutting

    Figure 46: Crosscutting using optional Midway Fence Kit (work extends at least 4” (100mm) beyond saw carriage) Operating Procedure: Rip cutting A rip cut is a horizontal cut that can be done either from the left to the right or from the right to the left, as shown on page 46, Fig.
  • Page 46 6. When the motor has reached full speed, slowly and smoothly push the work piece through the saw, in the direction of the feed arrow on the saw. Warning: Avoid placing your hands, clothing, or body parts under the carriage or in the cutting path of the saw blade. Do not look directly down the line of cut because dust and debris are generated during this operation.
  • Page 47 If the saw jams, turn the saw OFF and wait for the blade to stop. Then back the saw out of the cut before continuing with the cut. Figure 50: Chatter Preventer (guard) in position for crosscutting (SR5 shown)

  • Page 48: Basic Operating Functions/Routers

    Routing is accomplished with the Router Carriage and a router bit for the proper cut. This can be accomplished using either a vertical router (e.g. SR5 or 3400) or horizontal router (e.g. TR2). The router can be pulled across stock for vertical cuts or the router can be locked in place and stock fed through for horizontal routing.
  • Page 49 1. With bit installed, (see Changing Bits page 24), set proper depth of cut. 2. Adjust bit depth by loosening motor clamp or flipping open lever clamp (depends on model). 3. Rotate depth collar or depth knob (depends on model) to extend bit past nose cone to desired depth of cut. 4.
  • Page 50 8. Tighten the Nose Cone Locking knob at the back of the Router Carriage. 9. Raise router using the Plunge Lever. 10. Move Router Carriage either to top of Guide Tubes for vertical cuts (see Vertical Routing section) or position along Guide Tubes and lock into position using both Carriage Locks and both hold-down clamps (see Horizontal Routing section).

  • Page 51: Maintenance

    Operating Procedure: Horizontal Routing Horizontal Routing is a horizontal cut (e.g. Ploughing, Grooving, V-Grooving, Rip Cutting, etc.) that must always be done from side-to-side of the work piece when using routers. 1. With router turned OFF, confirm correct bit is installed and set to the correct depth (see Routing). 2.

  • Page 52: Cleaning

    Cleaning Unplug Saw/Router before cleaning. Observe appropriate Lockout/Tagout procedures to insure the tool cannot accidentally be powered. Daily, clean all dust and debris from the vents in the motor housing. Keep the handles clean, dry and free from oil and grease. Use only mild soap and a damp cloth to clean the tool, because certain cleaning agents and solvents are harmful to plastics and other insulated parts.

  • Page 53: Service

    The machine is aligned at the factory to a tolerance of:  1/64” (.4mm), on Models SR5, SR5U, SR5A, SR5UA, 3400 & TR2 Realignment is only required if the saw/router is mishandled or abused, or if the motor or a roller is replaced.
  • Page 54 Use the 6-ft (1830mm) ruler to check rollers for square. Use the 4-ft (1220mm) ruler to check guide tubes (or rails) for square. The tool also can be used as a giant square for layouts. Step 1: Adjust the Blade Parallel to the Guides (All models except 3400 & TR2) The blade must move parallel to the guides, or tail burning may occur and the kerf will be wider than the set of the blade.
  • Page 55 (#26). Figure 57: Adjusting Blade Perpendicularity (SR5 & SR5A) shown) Step 3: Align the Guide Tubes (all models except TR2) Unplug tool before making adjustments. Observe appropriate Lockout/Tagout procedures to insure the tool cannot accidentally be powered.
  • Page 56 To align the Guide Tubes: 1. Remove set screw, which indicates original position of guide tubes. Loosen the guide tube bracket nuts (Fig. 58), but do not remove the bracket. Using a dead blow mallet, strike the bracket on the side and in the direction you wish the guides to go.
  • Page 57 If the router bit body pulls away from the square or pushes the square away as the router carriage is moved, adjustment is required. Loosen the two bolts securing the guide tube bracket to the frame (Fig. 59), do not remove. Guide Tubes Guide Tube Bracket...

  • Page 58: Accessories

    ACCESSORIES Safety Speed offers several accessories for the vertical panel saws/routers and horizontal routers. ools Required for Accessory Installation  9/16” wrench; Frame Stand, Quick Stop, Stop Bar, Hold Down Bar, Extension Tables  5/8” wrench; Fixed Stand  ¾” wrench; Frame Wheels ...

  • Page 59: Frame Stand

    Frame Stand The Frame Stand Accessory allows vertical saws/routers to be freestanding in the shop. It includes two long angle- steel supports that attach to the top of the frame, one bracket that attaches to the bottom of the frame, and U-bolts or other fasteners for mounting them.
  • Page 60 Figure 62: Fixed Stand SR5U shown from back Figure 63: Fixed Stand SR5U shown from back/bottom Table Extensions (TR2) The Table Extension accessory adds 20” (500mm) to one side of the tool frame. It includes one extension table,...
  • Page 61 two legs and fasteners. It can be mounted to either side of the TR2. Multiple Table Extensions can be added. Extensions are recommended for routing 8-ft (2440mm) or longer sheets. Figure 64: Table Extension TR2 Installation: Unplug tool before making adjustments or installing accessories. Observe appropriate Lockout/Tagout procedures to insure the tool cannot accidentally be powered.

  • Page 62: Frame Extensions

    Frame Extensions The Frame Extensions Accessory adds 20” (500mm) to each end of the tool frame. It includes two extensions and fasteners. (Except TR2). Extensions are recommended for cutting panels longer than 10 ft. (3040mm). Installation: Unplug tool before making adjustments or installing accessories. Observe appropriate Lockout/Tagout procedures to insure the tool cannot accidentally be powered.
  • Page 63 Figure 67: Dust Tube, Saws NOTE: Routers include a clear dust collection fitting (Dust Tube), which directs chips and dust into the dust collection kit and vacuum (Fig. 68). Figure 68: Dust Tube, Routers Installation: Refer to figures 67 - 70. Before beginning installation, disconnect the power supply to the motor, raise the carriage to the top of the guides, and lock the carriage in place with then carriage lock.
  • Page 64 Be sure the tool frame is securely supported and cannot be tipped over during this installation procedure. An additional person should support and stabilize the frame at all times during the installation. Hose Roller System Dust Hose Blade Guard with Dust Collecting Bonnet Dust Tube Dust Elbow...

  • Page 65: Operation

    3. Mount the hose rollers to the top of the frame. 4. Lay the 1 ” (40.6mm) black flexible vacuum hose across the rollers, with one end to the front of the frame and one end to the back of the frame. 5.

  • Page 66: Quick Stop

    Use as template to drill 7/32” (5.55mm) holes. Angle Support Stop Bar Figure 72: Installing the Stop Bar (viewed from the rear) 3. Push the stop bar housing as far toward the center of the tool as possible. 3. Working from the back of the machine, use the angle supports as templates to drill six 7/32” (5.55mm) holes (two per bracket) in the horizontal tubes of the frame.
  • Page 67 1. Attach the two mounting brackets to the long aluminum angle bar of the Quick Stop, as shown in figure 73, using the screws provided. Stop Block Mounting Bracket Figure 73: Installing the Quick Stop (viewed from rear of frame) 2.

  • Page 68: Midway Fence

    The accessory contains the components shown in figure 76. NOTE: Standard equipment on all SR5 models, optional on 3400, not available for TR2. Installation: Unplug tool before making adjustments or installing accessories.
  • Page 69 2. Set the complete right-hand fence assembly onto the tool frame as shown in figure 77. LEFT SIDE RIGHT SIDE Figure 77: Mounting the Midway Fence Fig. 78: Midway fence installed 3. Tip the top of the rear support brackets (#9 in Fig. 76) under the upper horizontal frame member (#8), raise the fence, and push the lower ends of the rear support brackets down behind the lower horizontal frame member.

  • Page 70: Fence Alignment

    Fence Alignment 1. Disconnect the power supply to the tool. 2. Remove the blade guard. 3. Slightly loosen the bolts that secure the aluminum extrusion (#5, Fig. 76) to the rear support brackets (#9), to allow the extrusion to be moved up or down by tapping it with a mallet. 4.
  • Page 71 Vertical Tube Support Bracket Spring Hold-Down Arm Tension Lock Knob Figure 79: Installing the Hold-Down Bar Hold-Down Bar (Vertical Tube) Hold-Down Arms Tension Lock Knob Figure 80: Hold-Down bar installed...

  • Page 72: Air Clamping Package

    Air Clamping Package (for routers) The Air Clamp Accessory replaces the (lower) manually operated clamps for 3400 & TR2. Not available for SR5, SR5A, SR5U or SR5UA. Installation Install as shown in figure 81. 1. Bolt air clamps in place of manual clamps 2.

  • Page 73: Accessory List

    1 HP, 100 CFM, 90” S.P. 740C MEASURE WITH ACCURACY 2.25 HP, 115 CFM, 110” S.P. 740CC QUICK STOP Automater (120 V only) AUTO1 SR5, SR5U, 3400 (8 ft.) H6460 DIGITAL QUICK STOP EXPAND CAPABILITY SR5, SR5U, 3400 H6460-DRO MIDWAY FENCE 3400...
  • Page 74 13943 LINCOLN ST. NE HAM LAKE, MN 55304 763-755-1600 Fax: 763-755-6080 sales@safetyspeed.com www.SafetySpeed.com 122116...

This manual is also suitable for:

Sr5uSr5aSr5ua3400Tr2

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