RYOBI 10 IN (254 MM) TABLE SAW

MODEL NO. BT3100-1

REPAIR SHEET
RYOBI 10 in. (254 mm) TABLE SAW - MODEL NO. BT3100-1
FOR MITER TABLE ASSEMBLY, REFER TO FIGURE B FOR BLADE GUARD ASSEMBLY, REFER TO FIGURE E FOR RIP FENCE ASSEMBLY, REFER TO FIGURE C FOR MOTOR ASSEMBLY, REFER TO FIGURE D

96, 72

122 91

114 115

FIGURE A

PARTS LIST - FIGURE A

The model number will be found on the data plate attached to the right side panel of the cabinet, next to the saw's on board receptacle. Always mention the model number in all correspondence regarding your TABLE SAW or when ordering repair parts.

KEY PART NO. NO.

DESCRIPTION
KEY PART QTY. NO. NO. 44 615570-615570-968705-009
969214-969226-001 0181010111-94 0181010350-94 0181010328-94 0181010327-94 0181010329-661694-A181010802 969113-001 623924-002 662481-607406-0181011805 969251-002 663144-001 969122-002 969123-001 969124-001 969125-002 969126-001 969127-001 969128-001 969129-002 998292-002 607406-006 661796-001 969130-001 A181014002 969222-001 969221-001 706382-359 706382-360 706382-346
MOTOR ASSEMBLY.. 1 SHIM.. 2 HEX NUT (5/8-18).. 1 SAW TABLE.. 1 FRONT CABINET PANEL.. 1 REAR CABINET PANEL. 1 RIGHT CABINET PANEL. 1 LEFT CABINET PANEL. 1 LOCKER BRACKET. 1 CLAMPER BRACKET.. 1 DUST COVER.. 1 MITER TABLE ASSEMBLY. 1 CLAMP PLATE.. 2 NEEDLE ROLLER (1/4 in. X 3/4 in.). 2 CLAMP.. 1 SHIM.. 5 HEX NUT (5/16-18). 2 FRONT RAIL. 1 REAR RAIL.. 1 RAIL HOLDER NUT (5/16). 4 RAIL LOCKING CLAMP. 4 BEVEL GEAR.. 2 SHAFT... 1 GEAR SHAFT.. 1 HANDLE SHAFT.. 1 GEAR RACK. 1 TILTING GEAR.. 1 CLUTCH.. 1 CAM.. 1 SCREW (8-32 X 1-3/16 in. FIL. HD.). 1 HEX NUT (3/4-16).. 1 WASHER.. 1 BEVEL LOCKING LEVER. 1 BLADE ADJUSTING HANDLE. 1 SPRING.. 1 SPRING.. 1 WASHER.. 1 WASHER.. 3 WASHER.. 4
HEX BOLT (5/16-18 X 1-1/8 in.). 2 HEX BOLT (5/16-18 X 3/4 in.). 4 SCREW (10-24 X 5/8 in. PAN HD.).. 662493-002 SCREW (10-24 X 5/8 in. PAN HD.).. 968703-005 SCREW (8-32 X 3/8 in. PAN HD.).. 607406-005 NYLON HEX NUT (3/8-16). 969218-001 SET SCREW (1/4-20 X 3/8 in.). 941401-018 ROLL PIN. 941401-831 ROLL PIN. 9181015330102 NAME PLATE.. 9181015330301 SCALE LABEL.. 969137-001 OUTLET (15 AMP SINGLE POLE). 969138-001 CORD... 989001-001 CABLE CLAMP.. 969140-001 BEVEL INDICATOR. 642149-001 WIRE NUT.. 643128-001 LOCK NUT (8-32 HEX).. 969142-001 CONE DISC SPRING.. 9181015332202 DATA PLATE.. 615570-012 BOLT (1/4-20 X 1 in. HEX). 615570-011 BOLT (1/4-20 X 2 in. HEX). 622171-053 HEX NUT (1/4-20).. 968705-004 SCREW (10-24 X 5/16 in. PAN HD.). 969230-001 PLUG SOCKET BOX (A). 969229-001 PLUG SOCKET BOX (B). 968702-011 SCREW (8-16 X 3/4 in. PAN HD.). 664087-001 LOCKER SUPPORT. 0181010923 RIVET... 662079-001 SET SCREW (10-24 X 3/8 in.). 410151710 CAP SCREW.. 968705-040 SCREW (10-24 X 1/2 in. PAN HD.). 0181010342 THROAT PLATE.. 969220-002 CAP SCREW.. 663181-001 LABEL... 0181010110 GUIDE HOLDER. 1

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PARTS LIST - FIGURE A (CONT'D)
KEY PART NO. NO. 662329-001 662062-001 662062-002 969205-001 614658-007
KEY PART NO. NO. 0181010102-94 969174-004 969175-002 969216-001 623111-001 644585-002 706382-343 661853-001 663339-001 661992-662080-984407-984407-001

QTY. 4 1

V BELT.. 2 1/4 in. SPACER.. 1 1/2 in. SPACER.. 1 BLADE WASHER.. 2 SCREW (8-32 X 3/4 in. PAN HD.). 3 969600-001 SHIM.. 2 968705-015 SCREW (10-24 X 1 in. PAN HD.). END PLUG F1 (FRONT LEFT). END PLUG F2 (FRONT RIGHT) END PLUG R1 (RIGHT REAR). END PLUG R2 (LEFT REAR). 1 A181010901 RIP FENCE ASSEMBLY. 1 969165-001 BLADE GUARD ASSEMBLY. 1 A181012002 * ACCESSORY TABLE ASSEMBLY. GROUNDING LABEL. SCREW (FLAT HD.). 1
ACCESSORY TABLE. HANDLE SHAFT.. HANDLE. SPRING PLATE. RETAINING EXTENSION. HEX NUT (1/4-20). WASHER.. SPACER. HANG TAG.. BACK-UP PLATE.. SCREW (10-24 X 3/4 in. FLAT HD.). BOLT HOLDER.. REAR SWITCH COVER. SWITCH KEY.. SCREW.. SWITCH (INC. KEY NO. 115).

* Item 96 includes parts 42, 78, 100 through 106, and 111.

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FIGURE B: SLIDING MITER TABLE ASSEMBLY
KEY PART NO. NO. 0181010101-94 969188-001 661811-001 969190-001 969191-002 969192-001 615570-010 706382-357 662285-001 968702-009 969227-001 969225-001 969228-003 664137-001 969916-006 968705-QTY. 32 KEY PART NO. NO. 34 607617-003 621721-010 969502-001 969500-001 969501-002 621721-001 703477-006 661844-001 703477-059 621032-002 661845-001 969218-005 969915-002 941401-308 661706-001 662306-001 968705-007
MITER TABLE TOP. MITER FENCE.. PIVOT... SAW GAGE.. MITER INDICATOR. MITER FENCE HOLDER. BOLT (5/16-18 X 3-1/4 in. HEX HD.). WASHER. ADJUSTING CLAMP. SCREW (8-16 X 5/8 in. PAN HD.). SPRING PLATE.. MITER SLIDE LOCK. MITER BASE.. GUIDE BAR.. HOLDER PLATE. SCREW (10-24 X 15/32 in. PAN HD.).
O-RING.. 4 WASHER.. 1 ECCENTRIC SCREW (10-24).. 3 QUICK STOP. 1 ECCENTRIC SCREW (8-32). 1 WASHER.. 1 HEX NUT (ELASTIC STOP). 1 SLIDE (A).. 4 HEX NUT (ELASTIC STOP). 4 LOCK WASHER. 12 SLIDE (B).. 4 SET SCREW (10-24 X 1/4 in. HEX SOCKET). 4 MITER LOCKING CLAMP. 4 ROLL PIN.. 4 GUIDE PLATE.. 2 NON-ECCENTRIC SCREW (10-24)... 1 SCREW (10-24 X 1/2 in. PAN HD.). 1

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FIGURE C: RIP FENCE ASSEMBLY
23 KEY PART NO. NO. 13 969144-001 968704-006 969155-001 941401-309 607067-007 969254-001 969154-002 969114-001 969253-001 941401-833 969156-001 610878-003 706382-358 DESCRIPTION QTY. 2 KEY PART NO. NO. 26 706404-969240-001 968703-969146-623019-004 969252-001 969147-002 968703-005 969150-001 0181010115-58 DESCRIPTION

QTY. 1

RIP FENCE.. SCREW (10-14 X 1/2 in. PAN HD.). FENCE ROLLER. ROLL PIN.. SCREW (10-24 X 1 in. PAN HD.).. CLAMPER - B. ROLLER HOLDER. DOWEL PIN (1/4 in. X 3/4 in.).. COMPRESSION SPRING. ROLL PIN.. ROD... SCREW (1/4-20 X 5/8 IN. BUTTON HD.). WASHER..
HEX NUT (8-32).. SCALE INDICATOR. SLIDE.. SCREW (8-32 X 1/2 in. PAN HD.). SCREW. ECCENTRIC ROLLER. LOCKING HANDLE.. RUBBER PLUG.. CLAMPER - A. PIN.. SCREW AND WASHER.. PLATE.. FRONT BLOCK..

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FIGURE D: MOTOR ASSEMBLY 8

KEY NO. 13

PART NO. 969209-001 616452-010 969235-003 969203-001 969210-002 622167-068 969235-004 969235-4750011 4130268

KEY NO. 24

PART NO. 4560026
ARBOR.. 1 WOODRUFF KEY (3/16 in.). 1 BALL BEARING (6003). 1 BEARING PLATE. 1 ARBOR PULLEY.. 1 RETAINING RING. 1 BALL BEARING (6002). 1 BALL BEARING (6200ZZ). 1 MOTOR BRACKET.. 1 MOTOR PULLEY.. 1 ARMATURE ASSEMBLY. 1 BEARING BUSHING. 1 SCREW AND WASHER (FIELD PAN HD.).. 2

FIELD ASSEMBLY. 1 MOTOR HOUSING. 1 BRUSH COVER.. 2 BRUSH ASSEMBLY.. 2 BRUSH HOLDER ASSY. 2 SCREW AND WASHER (PAN HD.).. 4 SET SCREW (HEX).. 2 STRAIN RELIEF BUSHING.. 1 CABLE CLAMP.. 1 POWER CORD.. 1 CONNECTOR.. 2

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FIGURE F: BLADE GUARD ASSEMBLY
10 KEY NO. PART NO. 968700-004 969169-001 662002-001 969608-001 969233-010 969170-DESCRIPTION QTY. KEY PART NO. NO. 969610-002 969612-001 969170-002 969168-9181015330202 DESCRIPTION QTY. 5
SCREW AND WASHER. 2 ANTI-KICKBACK FINGERS.. 2 SPACER CAP.. 2 TORSION SPRING. 1 PUSH NUT. 4 DOWEL PIN.. 1
ARM.. 1 COVER.. 1 DOWEL PIN.. 1 RIVING KNIFE ASSEMBLY. 1 WARNING LABEL. 1 HAND WARNING LABEL. 1
FIGURE F: REPLACEMENT PARTS

504 506

503 505

KEY NO. 502 503

PART NO. 820193-004 820193-005 820193-006 820193-007

KEY NO. 506

PART NO. 969244-003 969244-004 969196-001
3/32 IN. HEX KEY.. 1 1/8 IN. HEX KEY.. 1 5/32 IN. HEX KEY.. 1 3/16 IN. HEX KEY.. 1
LARGE WRENCH.. 1 SMALL WRENCH.. 1 SAW BLADE.. 1

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RYOBI 10 in. (254 mm) TABLE SAW MODEL NO. BT3100-1
The model number will be found on the data plate attached to the right side panel of the cabinet, next to the saws on board receptacle. Always mention the model number in all correspondence regarding your TABLE SAW or when ordering repair parts.

Page 9

FIGURE G

PARTS LIST FOR FIGURE G

KEY NO. 13 PART NO. 0181010338-94 0181010335-411011707 0181010336-94 0181010337-A181011501 983000-232 4-03 DESCRIPTION QTY.
LEVELING FOOT..... 4 HEX NUT..... 32 WASHER..... 32 CARRIAGE BOLT.... 24 LEG..... 4 UPPER BRACE.... 2 SCREW..... 4 HEX NUT.... 8 UPPER SIDE BRACE..... 2 LOWER BRACE..... 4 STORAGE BRACKET.... 4 WASHER..... 12 BOLT..... 4 STAND FASTENER ASSEMBLY... 1 OPERATORS MANUAL

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READ ALL INSTRUCTIONS

s KNOW YOUR POWER TOOL. Read the operator's manual carefully. Learn the saw's applications and limitations as well as the specific potential hazards related to this tool. s GUARD AGAINST ELECTRICAL SHOCK BY PREVENTING BODY CONTACT WITH GROUNDED SURFACES. For example; pipes, radiators, ranges, refrigerator enclosures. s KEEP GUARDS IN PLACE and in working order. Never operate the tool with any guard or cover removed. Make sure all guards are operating properly before each use. s REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on. s KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. DO NOT leave tools or pieces of wood on the saw while it is in operation. s AVOID DANGEROUS ENVIRONMENT. Don't use power tools in damp or wet locations or expose to rain. Keep work area well lit. s KEEP CHILDREN AND VISITORS AWAY. All visitors should wear safety glasses and be kept a safe distance from work area. Do not let visitors contact tool or extension cord while operating. s MAKE WORKSHOP CHILDPROOF with padlocks or master switches, or by removing starter keys. s DON'T FORCE TOOL. It will do the job better and safer at the feed rate for which it was designed. s USE RIGHT TOOL. Don't force tool or attachment to do a job it was not designed for. Don't use it for a purpose not intended. s MAKE SURE YOUR EXTENSION CORD IS IN GOOD CONDITION. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A wire gage size (A.W.G.) of at least 14 is recommended for an extension cord 25 feet or less in length. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord. s DRESS PROPERLY. Do not wear loose clothing, gloves, neckties, or jewelry. They can get caught and draw you into moving parts. Rubber gloves and nonskid footwear are recommended when working outdoors. Also wear protective hair covering to contain long hair. s ALWAYS WEAR SAFETY GLASSES WITH SIDE SHIELDS. Everyday eyeglasses have only impactresistant lenses; they are NOT safety glasses.

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s BLADES COAST AFTER TURN OFF. s NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal sparking of the motor could ignite fumes. s INSPECT TOOL CORDS PERIODICALLY. If damaged, have repaired by a qualified service technician at an authorized service facility. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Repair or replace a damaged or worn cord immediately. Stay constantly aware of cord location and keep it well away from the rotating blade. s INSPECT EXTENSION CORDS PERIODICALLY and replace if damaged. s KEEP TOOL DRY, CLEAN, AND FREE FROM OIL AND GREASE. Always use a clean cloth when cleaning. Never use brake fluids, gasoline, petroleum-based products, or any solvents to clean tool. s STAY ALERT AND EXERCISE CONTROL. Watch what you are doing and use common sense. Do not operate tool when you are tired. Do not rush. s DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switches replaced by an authorized service center. s GUARD AGAINST KICKBACK. Kickback occurs when the blade stalls rapidly and workpiece is driven back towards the operator. It can pull your hand into the blade resulting in serious personal injury. Stay out of blade path and turn switch off immediately if blade binds or stalls. s USE RIP FENCE. Always use a fence or straight edge guide when ripping. s SUPPORT LARGE PANELS. To minimize risk of blade pinching and kickback, always support large panels. s BEFORE MAKING A CUT, ADJUSTMENTS ARE SECURE. BE SURE ALL s WHEN SERVICING use only identical Ryobi replacement parts. Use of any other parts may create a hazard or cause product damage. s REMOVE ALL FENCES AND AUXILIARY TABLES before transporting saw. Failure to do so can result in an accident causing possible serious personal injury. s ALWAYS USE BLADE GUARD, RIVING KNIFE, AND ANTI-KICKBACK PAWLS on all "through-sawing" operations. Through-sawing operations are those in which the blade cuts completely through the workpiece as in ripping or crosscutting. Keep the blade guard down, the anti-kickback pawls down, and the riving knife in place over the blade. s ALWAYS SECURE WORK firmly against rip fence or miter fence. s ALWAYS USE A PUSH STICK FOR RIPPING NARROW STOCK. A push stick is a device used to push a workpiece through the blade instead of using your hands. Size and shape can vary but the push stick must always be narrower than the workpiece to prevent the push stick from contacting the saw blade. When ripping narrow stock, always use a push stick, so your hand does not come close to the saw blade. Use a featherboard and push blocks for non-through cuts. s NEVER perform any operation "freehand" which means using only your hands to support or guide the workpiece. Always use either the rip fence or miter fence to position and guide the work. s NEVER stand or have any part of your body in line with the path of the saw blade. s NEVER reach behind, over, or within three inches of the blade or cutter with either hand for any reason. s MOVE THE RIP FENCE out of the way when crosscutting. s NEVER use rip fence as cutoff gage when crosscutting. s NEVER attempt to free a stalled saw blade without first turning the saw OFF and disconnecting the saw from the power source. s PROVIDE ADEQUATE SUPPORT to the rear and sides of the saw table for wide or long work pieces. Use a sturdy "outrigger" support if a table extension more than 24 inches long is attached to the saw. s AVOID KICKBACKS (work thrown back toward you) by: A. Keeping blade sharp. B. Keeping rip fence parallel to the saw blade. C. Keeping riving knife, anti-kickback pawls, and blade guard in place and operating. D. Not releasing the work before it is pushed all the way past the saw blade using a push stick. E. Not ripping work that is twisted or warped or does not have a straight edge to guide along the fence. s AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause your hand to move into the cutting tool.

s USE ONLY CORRECT BLADES. Do not use blades with incorrect size holes. Never use blade washers or bolts that are defective or incorrect. The maximum blade capacity of your saw is 10 in. (254 mm). s AVOID CUTTING NAILS. Inspect for and remove all nails from lumber before cutting. s NEVER TOUCH BLADE or other moving parts during use. s NEVER START A TOOL WHEN ANY ROTATING COMPONENT IS IN CONTACT WITH THE WORKPIECE. s DO NOT OPERATE THIS TOOL WHILE UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR ANY MEDICATION. s GROUND ALL TOOLS. If tool is equipped with threeprong plug, it should be plugged into a three-hole electrical receptacle.

Page 5

s CHECK WITH A QUALIFIED ELECTRICIAN or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the tool is properly grounded. s USE ONLY CORRECT ELECTRICAL DEVICES: 3-wire extension cords that have 3-prong grounding plugs and 3pole receptacles that accept the tool's plug. s DO NOT MODIFY the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician. s USE ONLY RECOMMENDED ACCESSORIES listed in this manual or addendums. Blades must be rated for at least 5,500 rpm. Use of accessories that are not listed may cause the risk of personal injury. Instructions for safe use of accessories are included with the accessory. s DOUBLE CHECK ALL SETUPS. Make sure blade is tight and not making contact with saw or workpiece before connecting to power supply. s SECURE THE SAW TO THE LEG STAND OR A WORKBENCH capable of supporting the load of the saw plus any workpiece. This is necessary to avoid any risk of the saw tipping over. s MAKE SURE THE WORK AREA HAS AMPLE LIGHTING to see the work and that no obstructions will interfere with safe operation BEFORE performing any work using the table saw. s ALWAYS TURN OFF SAW before disconnecting it, to avoid accidental starting when reconnecting to power supply. s SAVE THESE INSTRUCTIONS. Refer to them frequently and use to instruct other users. If you loan someone this tool, loan them these instructions also.

Before attempting to use your table saw, familiarize yourself with all operating features and safety requirements.

GETTING TO KNOW YOUR SAW

BLADE GUARD ASSEMBLY ANTI-KICKBACK SLIDING PAWLS MITER TABLE THROAT PLATE ADJUSTING CLAMP RIVING KNIFE SAW BLADE RIP FENCE ACCESSORY TABLE REAR RAIL SCALE INDICATOR SCALE
FRONT RAIL MITER FENCE QUICK-STOP MITER FENCE HOLDER RIP FENCE LOCKING HANDLE SWITCH
END PLUG (4) MITER SCALE MITER LOCKING CLAMPS MITER SLIDE LOCK MITER TABLE BASE
BLADE ADJUSTING HANDLE BEVEL LOCKING LEVER BEVEL INDICATOR BEVEL SCALE LEVELING FOOT LEG STAND Fig. 5 Page 12

STORAGE BRACKETS

Although some of the illustrations in this manual are shown with the blade guard removed for clarity, do not operate the saw without the blade guard unless specifically instructed to do so. TO TURN YOUR SAW OFF: 1. Press the switch button down to turn off ( ). TO LOCK YOUR SAW : 1. Press the switch button down. 2. Remove the switch key from the switch and store in a safe, secure location.

OPERATING COMPONENTS

The upper portion of the blade projects up through the table, surrounded by an insert called the throat plate. To cut wood at a bevel, the blade must be tilted, using the blade adjustment handle, scale, and bevel indicator found on the front of the cabinet. Inside the cabinet, adjustable positive stops are provided for 0 and 45. The sliding miter table assembly is used for all crosscutting operations. The miter fence is easily adjusted to cut wood at an angle by loosening the adjusting clamp, setting the fence to the miter scale, and retightening the clamp. The sliding miter table, which rests on a base mounted on the rails, can be repositioned along the rails for wide work. It can be reversed so the projecting base is in the back. It can also be moved from the right side to the left side as needed. With the miter fence removed the miter table offers additional support for other operations such as ripping. Your saw includes a rip fence and an accessory table. The accessory table can be moved from the right side of the saw to the left side as needed. The rip fence is used to position work that will be cut lengthwise. A scale on the front rail shows the distance between the rip fence and the blade. The riving knife is a metal device directly behind and above the blade. It is used to help keep the cut wood from binding together and causing possible kickback. It is very important to use the riving knife for all through-sawing operations. The anti-kickback pawls are toothed plates mounted on the riving knife. Their teeth point away from the work in case the work should be pulled back, toward the operator. Then the teeth dig into the wood to help prevent or reduce the possibility of kickback. Your Ryobi BT3100-1 table saw features a receptacle on the right side of the cabinet that permits use of accessories. Use only accessories that are listed for use with this tool. When using a listed accessory, unplug the saw motor cord and use the receptacle and BT3100-1 main power switch to operate the accessory.

ASSEMBLING LEG STAND

See Figures 8 and 9. s Take the following hardware from the leg stand hardware bag: 24 carriage bolts (5/16-18 x 3/4 in.) 4 leveling feet 32 flat washers (5/16 in.) 32 hex nuts (5/16-18) Note: Remaining hardware from this bag is used for mounting leg stand on the table saw base and mounting storage brackets to upper brace. s Take 4 legs and 8 braces from loose parts. s Place an upper side brace inside two of the legs, with the legs wide end up. (Upper side braces have two large holes in each end.) Make sure the two posts on the leg align with the small holes on the brace.

UPPER BRACE

s Align the two large holes on the brace and the legs. Insert the carriage bolts. Add flat washers and hex nuts and hand tighten. Repeat for the other upper brace. These are the front and back sets. s For the side sets, install a upper brace on two legs. Add hardware and finger tighten. Repeat for the other upper brace. s Use the same steps to install the lower braces. Tighten all hex nuts with a wrench. s Place a hex nut and flat washer on each leveling foot. Install the leveling feet from the bottom of each leg with the bolts pointing up. Cap with the remaining flat washers and hex nuts but do not tighten. s Move the leg set to desired location. Adjust the leveling feet with a wrench, then tighten the top hex nut.

HEX NUT WASHER

CARRIAGE BOLT

UPPER SIDE BRACE HEX NUT

WASHER

HEX NUT HEX NUT

SCREW STORAGE BRACKET(S) LOWER BRACE WASHER HEX NUT LEVELING FOOT Page 15 Fig. 8
ASSEMBLING STORAGE BRACKETS
See Figure 9. s Take storage brackets from loose parts. s Take the following hardware from the leg stand hardware bag: 4 screws (1/4-20 x 1/2 in. Pan Hd.) 4 hex nuts (1/4-20) 4 washers (1/4 in.) s Secure storage brackets to upper braces of leg stand as shown in figures 8 and 9.
STORAGE BRACKET(S) UPPER BRACE
MOUNTING THE LEG STAND ON THE TABLE SAW BASE
See Figure 10. s Take the following from a small hardware bag: 4 hex bolts (1/4-20 x 3/4 in.) 4 hex nuts (1/4-20) 8 flat washers (1/4 in.) Note: This hardware was in the bag with hardware for assembling the leg stand and leveling feet.

s The kerf (the cut made by the blade in the wood) will be wider than the blade to avoid overheating or binding. Make allowance for the kerf when measuring wood. s Make sure the kerf is made on the waste side of the measuring line. s Cut the wood with the finish side up. s Knock out any loose knots with a hammer before making the cut. s Always provide proper support for the wood as it comes out of the saw.

Cross Cut

TYPES OF CUTS
See Figure 22. There are six basic cuts: 1) the cross cut, 2) the rip cut, 3) the miter cut, 4) the bevel cross cut, 5) the bevel rip cut, and 6) the compound (bevel) miter cut. All other cuts are combinations of these basic six. Operating procedures for making each kind of cut are given later in this section.

Rip Cut

Always make sure the blade guard and anti-kickback pawls are in place and working properly when making these cuts to avoid possible injury. Cross cuts are straight 90 cuts made across the grain of the workpiece. The wood is fed into the cut at a 90 angle to the blade, and the blade is vertical. Rip cuts are made with the grain of the wood. To avoid kickback while making a rip cut, make sure one side of the wood rides firmly against the rip fence. Miter cuts are made with the wood at any angle to the blade other than 90. The blade is vertical. Miter cuts tend to creep away from the miter fence during cutting. This can be controlled by holding the workpiece securely against the miter fence.

Miter Cut

Bevel Cross Cut
Always use a pushstick with small pieces of wood, and also to finish the cut when ripping a long narrow piece of wood, to prevent your hands from getting close to the blade. Bevel cuts are made with an angled blade. Bevel cross cuts are across the wood grain, and bevel rip cuts are with the grain. The rip fence must always be on the left side of the blade for bevel rip cuts. Compound (or bevel) miter cuts are made with an angled blade on wood that is angled to the blade. Be thoroughly familiar with making cross cuts, rip cuts, bevel cuts, and miter cuts before trying a compound miter cut.

Bevel Rip Cut

Compound (Bevel) Miter Cut Fig. 22
All blades and cutting accessories must be rated for at least 5,500 rpm to prevent possible injury.

Page 22

FEATHERBOARD
A featherboard is a device used to help control the workpiece by guiding it securely against the table or fence. Featherboards are especially useful when ripping small workpieces and for completing non-through cuts. The end is angled, with a number of short kerfs to give a friction hold on the workpiece. Lock it in place on the table with a C-clamp. Test that it could resist kickback. in the featherboard. Positioning the featherboard will depend on the placement of the bolt and the position of the sliding miter table on the rails. Place the washer on the bolt and attach the adjusting clamp knob, loosely. Position the featherboard with the hex head of the bolt in the miter table slot but do not tighten. Completely lower the saw blade. Position the rip fence to the desired adjustment for the cut to be performed and lock. Place the workpiece against the fence and over the saw blade area. Adjust the featherboard to apply resistance to the workpiece just forward of the blade. Securely tighten the adjusting clamp knob to secure the featherboard in place. Attach a C-clamp to further secure the featherboard to the edge of the Sliding Miter Table.

BEVEL LOCKING LEVER

BLADE ADJUSTING HANDLE Fig. 25
NOTE: PLACE BLADE BETWEEN INNER AND OUTER BLADE WASHER SMALL HEX LARGE HEX WRENCH WRENCH SMALL SPACER TO LOOSEN
ARBOR LARGE SPACER INNER BLADE WASHER OUTER BLADE WASHER Fig. 26 TO LOWER BLADE, PUSH BEVEL LOCKING LEVER LEFT AND ROTATE BLADE ADJUSTING HANDLE COUNTERCLOCKWISE
TO LOCK BLADE ANGLE, PUSH BEVEL LOCKING LEVER LEFT.
TO RAISE BLADE, PUSH BEVEL LOCKING LEVER LEFT AND ROTATE BLADE ADJUSTING HANDLE CLOCKWISE. Fig. 27

Page 24

TO CHECK, REPLACE OR ADJUST THE RIVING KNIFE AND BLADE GUARD ASSEMBLY
The riving knife is mounted between several shims that can be relocated as needed to center the knife behind the blade. It is held in place by two bolts and hex nuts at its base. The bolts are set in slots that permit front-to-back adjustment.
Failure to turn the table saw off, remove the switch key, and unplug the saw before servicing or working on it could result in accidental starting causing possible serious injury. s Lower the blade. s Remove the throat plate. s Raise the saw blade by pushing the bevel locking lever to the left and rotating the blade adjustment handle clockwise. s With blade guard up, make sure the riving knife is placed at least 1/8 in. from the outer points of the blade. See Figure 29. Then make sure it is centered within the width of the blade. See Figure 30. If either placement is wrong, adjust with the following steps. s Put the saw in angle mode by moving the bevel locking lever to the right. Slowly turn the blade adjusting handle until the bevel indicator is at a 30 angle. Lock the angle by holding the blade adjusting handle with one hand and returning the bevel locking lever to the left with the other. s With the box end of the small hex key, remove the two nuts at the base of the riving knife. Remove the riving knife/guard assembly. s Rearrange the riving knife between the shims to achieve the correct centering. BLADE GUARD

RIVING KNIFE

THROAT PLATE Fig. 28
RIVING KNIFE BLADE 1/8 INCH

Fig. 29

Properly align riving knife. Improperly aligned riving knife can cause blade to bind which will increase risk of kickback. s Adjust the riving knife on the bolts front-to-back as needed to place the riving knife approximately 1/8 in. from the blades outer points. Put the nuts back on and tighten. s Bring the blade back to the desired angle and height. Lower the blade, insert the throat plate, then securely tighten the throat plate screw.

Make sure the blade guard assembly is installed and working properly to avoid serious personal injury. s Remove the rip fence by lifting the locking handle. s Loosen the adjusting clamp to set the desired angle of the miter fence. Place the miter indicator on the miter fence to the desired angle on the miter table. Retighten the clamp. s Place a support (the same height as saw table) behind the saw for the cut work. s Make sure the miter fence will not contact the blade while feeding the wood. Make a trial pass of the miter table. The miter fence should not contact the blade. Loosen the adjusting clamp to move it away from the blade if needed. s Make sure the wood is clear of the blade before turning on the saw. s Let the blade build up to full speed before moving the workpiece into the blade. s Hold the work firmly against the miter fence with both hands, keeping well clear of the blade, and push the miter table to feed the work into the blade.
TO MAKE A STRAIGHT RIP CUT
See Figure 38. It is recommended you make a test cut on scrap wood.

MITER TABLE

REAR RAIL RIP FENCE PUSH STICK
Make sure the blade guard assembly is installed and working properly to avoid serious personal injury. s Remove the miter fence. Position accessory table and sliding miter table to provide the support necessary for the cut being performed. Securely lock the rip fence with the locking handle. s Don't leave one side of saw unsupported. s Position the rip fence the desired distance from the blade for the cut and securely lock the handle. Adjust the scale to zero at the cutting edge of the blade. Page 28

FRONT RAIL

LOCKING HANDLE Fig. 38
TO MAKE A BEVEL CROSS CUT
See Figure 39. It is recommended that you place the piece to be saved on the left side of the blade and that you make a test cut on scrap wood.
QUICK STOP MITER FENCE ADJUSTING CLAMP
Make sure the blade guard assembly is installed and working properly to avoid serious personal injury. s Remove the rip fence by lifting the locking handle. s Move the bevel locking lever to the right for Angle mode. Turn the blade adjustment handle until the bevel indicator is at the desired angle. Push the bevel locking lever securely to the left to lock the angle. s Set the blade to the correct depth for the workpiece. s Loosen the adjusting clamp on the miter fence. Set the miter fence to 90 with either the quick-stop or the miter scale. s Make sure the miter fence will not contact the blade as the wood feeds into the blade. Make a trial pass of the miter table. The end of the miter fence should not contact the blade. Loosen the adjusting clamp to move it away from the blade if needed. s Place a support (the same height as saw table) behind the saw for the cut work. s Make sure the wood is clear of the blade before turning on the saw. s Let the blade build up to full speed before moving the miter table to feed the workpiece into the blade. s Hold the work with both hands and push the miter table to feed the work into the blade. s When the cut is made, turn the saw off ( ). Wait for the blade to come to a complete stop before removing the workpiece.

MITER LOCKING CLAMPS Fig. 41
TO MAKE A LARGE PANEL CUT
See Figure 41. Make sure the saw is properly secured to a work surface so it will not tip over under the weight of a large panel.
Make sure the blade guard assembly is installed and working properly to avoid serious personal injury. s Raise the locking handle on the rip fence to allow the rails to move freely. s Lift off the sliding miter table assembly by raising the miter locking clamps to release the grippers. s Remove the accessory table by swinging out the lever and lifting the table up and out. s Rotate the front rail clamps (under the front rail) to the left and slide the front rail to the side where the panel will rest. Lock the rail clamps after positioning the front rail. s Rotate the rear rail clamps (under the rear rail) to the left and position the rear rail to support the panel. Align the rear rail with the front rail. Lock the rail clamps after positioning the rear rail.
s Place the accessory table onto the rails far enough from the blade to help support the panel and lock securely. s Place the sliding miter table assembly onto the rails and lock securely. The miter table can be rotated 180 so the projecting base is at the back of the work surface so you won't run into it as you feed the panel into the blade. (Tables can be placed on either side of blade.) s Position the rip fence the desired distance from the blade for the cut and securely lock the handle. s Place a support behind the saw for the cut work. s Make sure the panel is clear of the blade before turning on the saw. s Let the blade build up to full speed before feeding the workpiece into the blade.

Page 30

TO MAKE NON-THROUGH CUTS
Non-through cuts can be made with the grain (ripping) or across the grain (crosscut). The use of a non-through cut is essential to cutting grooves, rabbets, and dadoes. This is the only type cut that is made without the blade guard installed. Make sure the blade guard assembly is reinstalled upon completion of this type of cut. Read the appropriate section which describes the type of cut in addition to this section on non-through or dado cuts. For example, if your non-through cut is a straight cross cut, read and understand the section on straight cross cuts before proceeding. FEATHERBOARD
Unplug the saw to avoid possible injury. s Remove the screw holding the throat plate in place. Remove the throat plate. s Raise the saw blade. s Put the saw in angle mode by pushing the bevel locking lever to the right. Turn the blade adjusting handle until the blade indicator shows a 30 angle. Push the bevel locking lever securely to the left to lock the angle. s With the box end of the small hex wrench, loosen the two hex nuts at the base of the riving knife. Do not remove hex nuts. Remove the riving knife/guard assembly. Retighten the two hex nuts on the base. Insert the throat plate. s Lower the blade and insert the throat plate, then securely tighten the throat plate screw. s Bring the blade back to 90. s Raise the blade to the correct height by turning the blade adjusting handle counterclockwise. s Feed the workpiece into the blade.

Page 32

MAINTENANCE

GENERAL MAINTENANCE

s To maintain the table surfaces, fence, and rails, periodically apply paste wax to them and buff to provide smooth functioning. To prevent work from slipping during cutting operation, DO NOT wax the working face of the miter fence. s Protect the blade by cleaning out sawdust from underneath the table and in the blade teeth. Use a resin solvent on the blade teeth. s Clean plastic parts only with a soft damp cloth. DO NOT use any aerosol or petroleum solvents.
Always begin by disconnecting the power supply. s Periodically check all clamps, nuts, bolts, screws, and belts for tightness and condition. Make sure the throat plate is in good condition and in position. s Check the blade guard assembly.

LUBRICATION

This saw has been lubricated at the factory prior to shipment. Following extended use, you should inspect and lubricate the following areas to assure smooth operation.
ELEVATING SHAFT THREADED HOLE

LOCKER BRACKET ASSEMBLY

See Figure 43. s Add dry lube between both bevel gears, the backup washers and the locker bracket. s Add dry lube between threaded hole in motor casting and threaded elevating shaft. Recommended Lubricants: Dry Silicone or Teflon Lubricant

BEVEL GEAR

TILT / ELEVATING MECHANISM
See Figure 44. s Add dry lube between the handle shaft and the bore of the clamping bolt. s Add dry lube between the face of the clamping bolt and the face of the handle shaft. s Add dry lube on the inner surfaces of the bevel locking lever which contacts the cam.

LOCKER BRACKET

BACKUP WASHER Fig. 43
CLAMPING BOLT CAM SURFACE

SPRING HANDLE SHAFT

BLADE ADJUSTING HANDLE

CAM Fig. 44 Page 33

Before performing any adjustment, make sure the tool is unplugged from the power supply and the switch is in the off ( ) position. Failure to head this warning could result in serious personal injury. 0 BOLT

TO SET BLADE AT 0 OR 45

The bevel locking lever may work loose and require adjusting. To adjust it, use the following steps. s Push the lever full left to the locked position. s Remove the screw on the blade adjusting handle. You will need a 3/16 in. hex key for this procedure. s Remove the blade adjusting handle and cam. Pull out the cam. s Remove the set screw on the bevel locking lever. s Remove the bevel locking lever from hex nut. s Relocate bevel locking lever on the hex nut. s Replace set screw and tighten securely. s Replace the cam so that the lobe is against the tab as shown in Figure 47. Make sure the cam is seated in the lever. s Reassemble the handle to the shaft and cam. Check whether the lever is now in the desired position. Tighten screw securely. SOCKET HEAD SCREW

HEX NUT

TAB CAM SPRING BEVEL LOCKING LEVER Fig. 47

SET SCREW

TO ALIGN THE MITER LOCKING CLAMPS

See Figure 48.

Before performing any adjustment, make sure the tool is unplugged from the power supply and the switch is in the off ( ) position. Failure to head this warning could result in serious personal injury. The miter locking clamps are preset at the factory but may require adjusting after extended use or if damage occurs in shipping. Adjust them with the following steps: s s s s Loosen the set screw behind each locking clamp. Loosen the screw on top of each locking clamp. Lift the locking clamp to the Up position. Push the clamp forward tight against the front rail to bring the clamp into alignment. s When the clamps are correctly positioned, retighten the screws and the set screws. s Push both front and rear miter locking clamps down to secure the sliding miter table. Page 35 MITER LOCKING CLAMP Fig. 48
TO ADJUST THE FRONT AND REAR RAIL CLAMPS
See Figure 49. The rail clamps are located below the rails and ensure tight attachment of the rail. Following extended use, the rail holder nut inside the rails may need adjusting. s Remove the miter table and accessory table. s Remove the front and rear rails by loosening the rail clamps and sliding the rails off. s Rotate each rail clamp to the left until it hits or comes in contact with the bottom of the saw table. s Tighten rail holder nut until it is snug. s Loosen rail holder nut one-fourth (1/4) turn. s Replace the rails and check the rail clamps.

RAIL HOLDER NUT

HEX MOUNTING BOLT
RAIL CLAMP Fig. 49 ACCESSORY TABLE CAP SCREW LEVER WASHER
TO ADJUST THE ACCESSORY TABLE

See Figure 50.

After extended use, the accessory table may work loose causing the accessory table to be loose on the rails. Follow the steps below, when adjustments are required: s Remove the hex nut on the lever using a 3/8 in. nut driver. s Remove the backup plate and spring plate. Rotate the spring plate 180 and reinstall on the handle shaft. s Reassemble all parts and tighten hex nut securely. Note: The spring plate offers two ends for use before requiring replacement.

TO ADJUST THE SLIDING MITER TABLE ASSEMBLY
The sliding miter table assembly has been preset at the factory to be parallel to the blade. However, misalignment during shipping or requirements for very precise and accurate cuts may require realignment. The square relationship between the blade and the miter fence as it travels the entire distance from the front to the rear of the miter table base during a cut is very important for making precise and accurate cuts. To avoid unnecessary setups and adjustments, we suggest that you check these setups carefully with a framing square and make practice cuts in scrap wood before making finish cuts in good workpieces. Note: Follow the general rule of measuring twice and cutting once. Do not loosen any screws for the following adjustments until you have made checks and are sure adjustments are needed. Once screws have been loosened, these settings must be reset. Two basic checks should be made to determine if adjustments are necessary: s The miter base must be parallel to the blade as the table slides from the front to the rear of the miter table assembly.
HANDLE SHAFT BACKUP PLATE
RETAINING RING SPRING PLATE HEX NUT Fig. 50
s The miter fence must be square to the blade when set at exactly zero (0) on the miter table scale. This is necessary in order to be able to use the scale on the miter table. The miter table has adjustment screws for squaring miter fence to blade and maintaining 0 scale settings when miter base adjustments are required. Note: These checks and adjustments are being explained in step by step procedures, however, you should be aware that they depend upon each other.

Page 36

CHECKING SLIDING MITER TABLE ASSEMBLY
To Check Miter Base Parallelism:
Begin by unplugging your saw. Failure to unplug saw could result in accidental starting causing possible serious injury. s Set saw up as if you were preparing to make a cut. Tighten rail clamps, miter locking clamps, adjusting clamp, etc. s Slide miter table (A) to the front of miter base (B) as far as it will go. Place a reference mark (C) near the end of the miter table as shown in figure 51. Note: Front of miter base is on infeed side of saw. s Place a reference mark on one of the blade teeth (D) and rotate the blade (E) so that the reference mark on the blade is at the front of the throat plate (F). s Place a framing square (G) against the blade and align with reference mark on miter table. Measure the distance between the blade and the edge of miter table. Note: Place framing square between carbide teeth and measure from blade. This step will insure framing square is square against blade from the front to back of blade. s Remove framing square and slide miter table to the rear of miter base as far as it will go. See Figure 52. s Rotate the blade so the reference mark on the blade is at the rear of the throat plate. Measuring from the same mark on the blade at the rear will eliminate the effect of blade wobble. s Place framing square against the blade and align with the same reference mark on the miter table. Measure the distance between the blade and the edge of the miter table at the rear. s Compare whether the front and rear measurements are the same. If they are the same, proceed with checking the miter fence alignment. If not, this indicates the miter base needs aligning. Miter base must then be adjusted before checking miter fence alignment. See TO ADJUST THE MITER BASE section that follows. D G C D F B Fig. 51 E F

B Fig. 52

Page 37
To Check Miter Fence Alignment
See Figure 53. The miter fence must be perpendicular to the blade when set at zero degrees.
Begin by unplugging your saw. Failure to unplug saw could result in accidental starting causing possible serious injury. s Set the miter fence (H) at 0 as shown in figure 53. Miter indicator (I) should be set precisely on 0 and secured in place with adjusting clamp (J). Note: The quick-stop is not necessary for this checking procedure. However, you may want to check and adjust it to 0 at this time. See Quick-Stop section that follows. s Place a framing square (G) firmly against the miter fence (H) with the other side against the blade (E). s Check whether the miter fence and blade are square with each other. With the framing square against the miter fence there should be no gap from the front to the rear of the blade. s If a gap exists, the miter fence may be out of square. s Rotate the blade and recheck. If there is a consistent gap between the front and rear of the blade, the miter table needs aligning. Follow the adjustment procedures that follow.

Fig. 53

MAKING ADJUSTMENTS TO SLIDING MITER TABLE ASSEMBLY

To Adjust the Miter Base

See Figure 54. REMEMBER: Check all settings before loosening screws for the following procedures. Once screws have been loosened, these settings must be reset.
Eight screws are visible on the miter base (B). s Four screws (K) are on the holder plates and secure these plates to the rails. It is not necessary to loosen or adjust these screws for this adjustment procedure. s Another pair of screws (L) is in the base, at the rear. Loosen these two screws (L) and the rear miter locking clamps (M). s The last pair of screws is located on the infeed side of the base. Loosen the left screw (N) only. s The right screw (O) will be used as a pivot point. Note: The front two miter locking clamps (P) and rail clamps should remain locked. s Follow the steps in TO CHECK MITER BASE PARALLELISM, adjust the miter base so that it is parallel to the blade. s Retighten the left front screw (N). s Clamp the rear miter locking clamps (M). s Retighten the two rear screws (L). Page 38