Clarke Woodworker CTS10PLM Installation and operation manual

10” TABLE SAW
10” TABLE SAW
Model: CTS10PLM
Part No. 6500741
OPERATING & MAINTENANCE
INSTRUCTIONS
0302

Thank you for purchasing your new CLARKE 10” TABLE SAW which is designed for DIY and
hobby use ONLY
Before attempting to operate this machine, please read this instruction manual thoroughly
and follow all directions carefully. In doing so you will ensure the safety of both yourself and
others around you and, at the same time you should look forward to the machine providing
long and trouble free service.
GUARANTEE
This product is guaranteed against faults in manufacture for 12 months from purchase date.
Keep your receipt as proof of puchase. This guarantee is invalid if the product has been found to have
been abused in any way or not used for the purpose for which it was intended, or to have been
tampered with in any way. The reason for return must be clearly stated. This guarantee does ot affect
your statutory rights.
CONTENTS
Specifications ................................................................................................... 3
General Safety Rules ....................................................................................... 4
Additional Safety Rules for Table Saws ......................................................... 5
Electrical Connections .................................................................................... 6
Features ...................................................................................................... 7
Glossory of Terms .............................................................................................. 8
Unpacking and Checking Contents ............................................................. 9
Assembly Instructions ..................................................................................... 10
Mounting the Saw .......................................................................................... 12
Important Checks before Starting ............................................................... 13
Operating Instructions ................................................................................... 14
Starting & Stopping .................................................................. 15
Rip Cutting ................................................................................ 15
Cross Cutting (incl. Mitre Gauge adjustments) .................... 18
Repetitive Cutting .................................................................... 19
Mitre Cutting ............................................................................. 20
Bevel Cross Cutting .................................................................. 20
Compound Mitre Cutting ....................................................... 21
Maintenance .................................................................................................. 21
Changing the Saw Blade ........................................................ 22
Saw Blade Adjustments ........................................................... 22
Trouble Shooting ....................................................................... 24
Parts Lists and Diagrams ........................................................................... 25-30
3

SPECIFICATIONS
Model No ....................................................................... CTS1OPLM
Part No ........................................................................... 6500741
Motor .............................................................................. 230V ~ 50Hz 1 ph
Power rating .................................................................. 1,525 Watts
Speed ............................................................................. 4800 rpm
Fuse rating ...................................................................... 13Amps
Saw Blade ...................................................................... 10” diameter, (255 mm)
Bore ................................................................................. 5/8”(16mm)
Maximum depth of cut ................................................ 70mm
Gross Weight .................................................................. 20.5KG
Table dimensions ........................................................... 660x446mm (26”x 17 1/2”) overall
Noise level at operating position ................................ 98dB LWA
(Cutting 50mm soft wood)
Please note that the detaiis and specifications contained herein, are correct at the time at going to print. However, CLARKE
INTERNATIONAL reserve the right to change specitications at any time without prior notice. Always check machines’ data label
Use of machine
This machine is designed to rip and cross cut wood exclusively, up to a maximum thickness of 70mm. It
is NOT designed to carry out ‘non-through cut’ operations.
For correct operation it must be fixed and operated as laid down in this manual.
This saw is intended for DIY and hobby use ONLY
Restrictions of use
This saw is NOT suitable for cutting:
•Timber greater than 70mm in thickness,
•Metal. Stone, Rubber, Plastic, Bones, Etc.
•Logs or round timber.
DO NOT use to rebate, tenon, mould or groove.
DO NOT fit any other blades or combination of blades.
DO NOT use as a free standing machine or as a hand held machine.
DO NOT modify the machine or its guards/controls in any way,
DO NOT use with any covers/guards removed.
4

GENERAL SAFETY RULES
WARNING!
As with all machinery, there are certain hazards involved with their operation and
use. Exercising respect and caution will considerably lessen the risk of personal
injury. However, if normal safety precautions are overlooked or ignored, personal
injury to the operator or damage to property may result.
1. READ AND BECOME FAMILIAR with the entire operating manual. Learn the tool’s applications and
limitations as well as the specific potential hazards peculiar to it,
2. CHECK DAMAGED PARTS. Before use of the machine, a guard or other part that may be damaged
should be checked to ensure that it will operate properly and perform its intended function.
Check for alignment of moving parts, breakage of parts, mounting, or any other conditions that
may affect its operation Any damaged part should be properly repaired or replaced.
3. ALWAYS KEEP GUARDS in place and in working order.
4. ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday
eyeglasses do not have impact resistant lenses, they are NOT safety glasses.
5
5. KEEP WORK AREA CLEAN. Cluttered areas and benches
invite accidents.
6. WEAR EAR PROTECTORS/DEFENDERS.
7. REMOVE ADJUSTING KEYS AND SPANNERS. Form habit of
checking to see that keys and spanners etc., are removed
from machine before turning it on.
8. DRUGS, ALCOHOL MEDICATION, Do not operate machine
whilst under the influence of drugs, alcohol or any medication.
9. ALWAYS FEED WORK into the blade against direction of rotation
only.
10. WEAR PROPER APPAREL. Loose clothing orjewellery may get
caught in moving parts. Wear protective hair covering to contain
long hair.
11. USE RECOMMENDED ACCESSORIES. The use of improper
accessories could be hazardous. Use ONLY those recommended
in this manual.
12. NEVER STAND ON MACHINE. Injury could occur from a fall.
13. NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn power OFF. DonÆt leave machine until it
comes to a complete stop
14. ALWAYS DISCONNECT MACHINE from electrical supply when making adjustments, changing parts
or carrying out maintenance operations.
15. DON’T FORCE THE MACHINE to do ajob for which it was not designed.
16. AVOID DANGEROUS ENVIRONMENT. Don’t use machine in damp or
wet locations or expose to rain. Keep your work area well illuminated.
DO NOT USE in explosive atmosphere (around paint, flammable liquids
etc.).
17. KEEP CHILDREN AWAY All visitors should be kept a safe distance from
work area, especially whilst operating the unit.

18. MAINTAIN TOOLS IN TOP CONDITION. Keep the blade sharp and
clean for best and safest performance. Follow instructions for
changing accessories.
19. DON’T OVERREACH. Keep your proper footing and balance at
all times. For best footing wear rubber soled footwear. Keep
floor clear of oil, scrap wood, etc.
20. MAKE WORKSHOP CHILDPROOF. Take precautions to prevent
access to the machine when it is not in use.
6
ADDITIONAL SAFETY RULES FOR TABLE SAWS
1. ALWAYS use saw Blade Guard, Riving Knife and Antikickback Pawls for every operation.
2. ALWAYS old the work firmly against the Mitre Gauge or Rip Fence.
3. USE push-stick when required. Always use a push-stick for ripping narrow stock. Refer to ripping
applications in instruction manual where push-stick is covered in detai.
4. NEVER perform any operation freehand’ which means using your hands to support or guide
the work piece. Always use either the Rip Fence or the Mitre Gauge to position and guide the
work.
5. NEVER stand, or have any part of your body, in line with the path of the saw blade. Keep your
hands out of the line of the saw blade.
6. NEVER reach behind or over the saw blade for any reason.
7. REMOVE the rip fence completely when crosscutting.
8. If off cuts of wood become jammed in the machine, switch off and disconnect from supply
before removal.
9. NEVER use the Rip Fence as a cut-off gauge when crosscutting.
10. NEVER attempt to free a stalled saw blade without first turning the saw
OFF Turn off power switch immediately to prevent motor damage.
11. PROVIDE adequate support to the rear and sides of the saw table or
wide or long workpieces.
12. AVOID KICKBACKS (work thrown back toward you) by keeping blade
sharp, keeping rip fence parallel to the saw blade, keeping riving knife
and anti kickback pawls and guard in place. Do not release work before
it is pushed all the way past the saw blade. Do not rip work that is twisted or warped or does not
have a straight edge to guide along the fence.
13. AVOID awkward operations and hand positions where a sudden slip could cause your hand to
move into the saw blade,
14. NEVER use solvents to clean plastic parts. Solvents could possibly dissolve
or otherwise damage the material. Only a soft damp cloth should be used
to clean plastic parts.
15. PERMANENTLY MOUNT your table saw before performing any cutting
operations. Refer to ‘Mounting the Saw’ on page 12
16. NEVER cut metals or materials which may make hazardous dust.
17. ALWAYS use in a well ventilated area. Remove sawdust frequently. Clean
out sawdust from the Interior of the saw to prevent a potential fire hazard.
This is particularly important if a dust extraction device is not used. Always
clean away sawdust at the end of a days’ operation.

ELECTRICAL CONNECTIONS
WARNING!
If the power cable is worn or cut, or damaged in any way, have it replaced
immediately to avoid shock or fire hazard.
Connect the mains lead to a 230 volt (50Hz) domestic electrical supply via a standard 13 amp BS 1363
plug fitted with a 13 amp fuse, or a suitably fused isolator switch.
WARNING! THIS APPLIANCE MUST BE EARTHED.
IMPORTANT: The wires in the mains lead are coloured in accordance with the following code:
Green & Yellow - Earth
Blue - Neutral
Brown - Live
As the colours of the flexible cord of this appliance may not correspond with the coloured markings
identifying terminals in your plug, proceed as follows:
Connect GREEN & YELLOW coloured cord to plug terminal marked with a letter ‘E’ or Earth symbol
“ ”, or coloured GREEN or GREEN & YELLOW.
Connect BROWN coloured cord to plug terminal marked letter ‘L’ or coloured RED.
Connect BLUE coloured cord to plug terminal marked letter ‘N’ or coloured BLACK.
We strongly recommend that this unit is connected to the mains supply via a Residual
Current Device (RCD).
I MPORTANT!
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e. non- re-
wirable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a danger of
electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct replacement
is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local dealer or most electrical stockists.
Fuse Rating
The fuse in the plug must be replaced with one of the same rating (13 amps) and this replacement
must be ASTA approved to BS1362.
Extension Cable
If an extension cable is fitted, ensure the minimum cross section of the conductor is 1 .5mm2for up to
15 metres in length, and 2.5mm2 for up to 25 metres.
7

8
1. The switch panel incorporates the ON and OFF switches.
2 Your saw also teatures an Overload Protection device, so that it the motor is overloaded (due to
feed pressure being too great, dull blade or low voltage), the Overload Relay will intervene, and
the motor will automatically cut out.
3. A Dust Extraction Outlet is provided at the rear of the machine. A vacuum extractor with a suitable
fiexible hose (58mm dia.), may be connected and used either permanently or intermiffently as
required.
4. The Table is provided with two slots, one each side ot the saw blade, running across its entire
width. These slots are tor use with the Mitre Gauge, when cross cuffing either square or mitres, and
is explained under ‘Operation’. A scale on the Mitre Gauge indicates the angle at which the
workpiece is being mitred.
5. Four holes are provided in the base so that the saw may be bolted to a workbench or stand.
Please note that the machine MUST be tirmly secured to either a workbench, or a support to
ensure its complete stability. This is explained in detail under ‘Mounting the Saw’ on page 12.
FEATURES

6. The Blade Tilt Lock Handle locks the tilt mechanism atter the blade is adjusted to its desired position.
7. The Blade Height Adjuster Wheel elevates or lowers the blade, It is also used to tilt the blade from
0oto 450o,
8. The Blade Tilt Scale shows the degree the blade is tilted.
9. The Rip Fence is for use when rip cuffing timber. It can be easily moved or locked in place by using
the rip tence locking handle - lift up to loosen, press down to lock.
10. The Blade Guard protects the operator and must ALWAYS be in place and working properly at
all times.
WARNING!
NEVER USE MACHINE WITH THE BLADE GUARD REMOVED.
11. Anti-Kickback Pawis are affached to the blade guard bracket, which, when properly maintained,
are designed to stop the workpiece tram being kicked back at the operator during operation.
12. The Riving Knife is essential in preventing kickback and in producing a good clean cut, without
binding or chaffering taking place.
13. The Table Insert is removable to tacilitate the installation or removal of the saw blade, and must
ALWAYS be in place for all cuting operations.
GLOSSARY OF TERMS
Arbour The shaft on which a cuffing tool is mounted.
Crosscut A cuffing or shaping operation made across the width of the workpiece.
Freehand Pertorming a cut without a fence, mitre gauge, fixture, hold down or otherproper
device to keep the workpiece from twisting during the cut
Heel Misalignment of the blade.
Kerf The amount of material removed by the blade.
Kickback An uncontrolled grabbing, and throwing of the workpiece back toward thefront of
the saw during a rip type operation.
Leading End The end of the workpiece which, during a rip type operation, is pushed into the
cutting tool first.
Push Stick A device used to feed the workpiece through the saw during a narrow rip type
operation and which helps keep the operator’s hands well away from the blade.
Push Block A device used for rip type operations too narrow to allow use of a push stick.
Resin A sticky, sap base substance that has hardened.
Ripping A cuffing operation along the length of the workpiece.
9

UN-PACKING AND CHECKING CONTENTS
The Table Saw is shipped complete In one carton.
Separate all parts and check to ensure that all components are accounted for, according to the
following list, before discarding any packing material.
Should any component be missing or damaged in transit, please contact your CLARKE dealer
immediately, or CLARKE Customer Service Department on 020 8988 7400.
Checking Straight
Edge with Comb
Square
2
Fig.1
Table of Loose Parts
ATable Saw Assembly.
BRip Fence (Without Handle).
CMitre Gauge Assy (With Handle).
DMitre Gauge Storage
ERip Fence Storage
FBlade Guard Assy., c/w bracket
and anti-kickback pawis
Loose parts in bags
GArbor Spanner.
HSaw Blade Securing Nut Spanner
JRip Fence Handle
KBlade Height Adjuster Wheel Handle with nut.
LSupport Block c/w Blade Guard Mounting
Bracket and 2pcs M5x12mm screws and
lockwashers
MSupport Block Mounting Bolt, lockwasher.
1 x spacer and 1 x flat washer.
N1 x Coach Bolt with lock washer and nut.
(For securing the Blade Guard Assy to Blade
Guard Mounting Bracket).
PPush Stick
Tools Needed for Assembly
1. Combination Square - Must Be True
- check as shown in diagram opposite.
2. Phillips Screwdriver
3. Medium Screwdriver
4. 10mm Spanner

ASSEMBLY
Before the machine can be used, the loose parts must first be assembled to it, and certain adjustments
carried out. Please proceed as follows:
A. Handle (to Blade Height Adjuster Handwheel - see illustration, page 7)
1. Locate the small plastic handle, (item K, Fig. 2). with the centre screw and nut, and screw the
nut in fully so that it butts up against the handle.
2. Screw the centre screw, with the handle, into
the rim of the Blade Height Adjuster handwheel
until the nut binds up against the rim. Back off
the screw slightly and hold it in that position whilst
you screw out the nut until it is tight against the
rim of the handwheel, thereby locking the
centre screw in position,
When properly assembled, the handle will rotate freely about the screw, with only a small amount
of end play.
B. The Saw Blade (If not fitted)
CAUTION!
Exercise extreme care when handling the Saw Blade,
The teeth are extremely sharp......carelessness could cause severe personal injury
1. Turn Blade height adjuster handwheel clockwise until the arbour is up as high as it will go. remove
the two table Insert screws and lift the table insert out of the recess in the table.
2. Place the open end arbour spanner on the flats on the inner flange to prevent the arbour from
rotating, and remove the blade securing nut using the spanner provided. Remove the outer
flange.
3. Manoeuvre the blade gently through the slot in the table, so as not to damage the teeth, and
mount it on the arbour, ensuring the TEETH OF THE BLADE ARE POINTING DOWN AT THE FRONT OF
THE TABLE.
4. Replace the outer flange, followed by the blade securing nut, and tighten securely.
5. Replace the table insert in the recess in the table, and secure in place - the turned over edge of
the insert faces the blade. Ensure the blade rotates truly and freely - by hand.
C. Blade Guard and Bracket Assembly
1. From among the loose parts, locate the following.
1.1 1 x Blade Guard Assembly c/w Blade
Guard and anti Kickback Pawls.
1.2 1 x Support Block and Blade Guard
Mounting Bracket (may be attached).
1.3 1 x 55mm Hex. bolt, spacer, lockwasher
and flat washer.
NOTE: The Support Black and Blade Guard Mounting
Bracket may be factory assembled,in which case,
para. 2 below does not apply
2. Remove the two M5 Screws from the Support
Block and attach the Blade Guard Mounting
Bracket in the manner shown in fig. 3, using
the same screws, and ensuring the lock
washers are in place.
Fig.3
Fig.2
2

CAUTIONI
NEVER start the machine with the Blade Guard removed.
3. Thread the 55mm bolt through the hole in the
NON RECESSED end of the Support Block. (see
fig 3), with the lock washer, followed by the flat
washer up against the bolt head.
4. Thread the spacer on to the protruding end of
the 55mm bolt, and screw the bolt into the
mounting hole at the back edge of the table.
5. Slide the slotted end of the Blade Guard
Bracket over the lug on the Blade Guard
Mounting Bracket so that the Blade Guard
Bracket sits snugly on the table, as shown in fig.
4, and secure using the single Coach Bolt, with
lock washer and nut supplied.
6. Using a straight edge, check to ensure the
Guard Bracket is correctly aligned with the saw
blade, If an adjustment is necessary, the guard
bracket can be moved left or right, by
slackening the Support Block to Mounting
Bracket screws, and adjusting accordingly.
Similarly, the Guard Bracket may be rotated by
slackening the Support Block mounting bolt.
When you are certain it is properly aligned with
the saw blade, tighten all securing bolts and
screws fully.
CAUTIONI
DO NOT force the Rip Fence Handle,,,,, if excessive force is used, the claw (see fig. 6)
willdistort. Should this occur it will be necessary to dismantle the Rip Fence assembly
and straighten the claw to ensure the Fence operates satisfactorily
3. With the handle in the vertical position, screw IN the adjuster screw (Fig.6) until you can feel
resistance. Check to ensure the fence is now securely locked to the table. This is a questionof
‘feel’ and it may be necessary to screw the adjuster screw IN (clockwise), a little more to secure
the fence, however, DO NOT overtighten the adjuster screw.
To release the fence, lift the handle up.
Fig.4
Fig.5
D. Rip Fence
1. Thread the rip fence locking handle into the cam on
the front block (see fig. 6), and tighten the locknut.
2 Place the fence on the table, and with the claw
securely located on the back edge (of the table),
press the fence locking handle down to the vertical
position. If force is required, do not continue to push
down, but slacken the adjuster screw (shown in fig.
6) a few turns until the handle can be moved easily.
Fig.6
2

4. When sefting the rip fence for ripping a piece of wood, you must always check to ensure that it
is parallel to the mitre gauge slot, If there is a small discrepancy, it may be possible to release the
locking handle and reposition the fence so that it is exactly parallel.
If the discrepancy cannot be rectified in this manner, it will be necessary to slacken the two
screws on top of the fence and move the body of the fence so that it is parallel to the mitre
gauge slot. When satisfied, tighten the two screws on top of the fence once again.
Your Table Saw is now fully assembled. However, before it can be used, you must ensure that it is
securely and correctly mounted, and checks MUST be made to ensure that all necessary adjustments
are correct, and that parts are properly aligned.
These details are covered in the following paragraphs.
MOUNTING THE SAW
IMPORTANT
If the saw is to be a permanent fixture, ensure it is sited in an area with adequate illumination and
power supply
DO NOT place it where you will be working in your own light, or where extension cables are required
- these are hazardous in a workshop environment,
If the table saw is to be used in a permanent location, it should be fastened securely to a firm supporting
surtace such as a stand or workbench, using the four mounting holes in the base.
A Floor Stand is available from your CLARKE dealer,
An ideal accessory, giving complete stability together with portability of the machine,
Model No. CLK2: Part No, 6500711
Holes should be drilled through the supporting surtace of the workbench, using the dimensions illustrated,
and the machine should be bolted down firmly, but not so tight as to cause the body to distort.
If a VACUUM DUST EXTRACTION device is NOT to be used,
an opening MUST also be made in the workbench, the same
size as the opening in the boftom of the saw. This is in order
to allow the saw dust to drop through.
Dimensions of the opening are illustrated opposite,
IMPORTANT
Ensure the Bottom Grid is in place when bolting the
machine to the workbench.
1. Each of the four mounting holes should be bolted
securely using 8mm bolts (not included).
2. Locate and mark where the saw is to be mounted.
3. Drill four (4) 10mm diameter holes through workbench,
4. Place table saw on workbench aligning the holes in the base with the holes drilled in the workbench.
5. The exsisting nuts and bolts which secure the boftom plate to the body of the machine should be
replaced with 8mm bolts (not supplied). and tightened taking care not to distort the casing.
Fig.7
2

Mounting to Plywood
An alternative method of securing your table saw is to fasten the saw base to a mounting board, with
a minimum size of 600x600mm. This is to prevent the saw from tipping whilst in use. A good grade of
plywood with a minimum thickness of 19mm is recommended.
1. Follow the instructions for mounting to a workbench, substituting a ‘plywood board’, and using
8mm countersunk screws, with lock washers and hex nuts (not included). Screw length must be at
least 12mm more than the thickness of the mounting board.
NOTE: For proper stability holes must be countersunk on bottom side of plywood so screw heads are
flush with the bottom surface of the mounting board.
2. Securely clamp the board to a workbench
using two or more ‘G’ clamps, as illustrated
in fig. 8.
The supporting surface, where the saw is to
be mounted, should be examined carefully
after mounting to ensure that no movement
can occur during use. If any tipping or
creeping is noted, it should be investigated
and rectified.
The mounting surface must be flat and even.
NOTE: To prevent damage to the body always use
flat washers at the mounting holes.
IMPORTANT CHECKS - BEFORE STARTING
IMPORTANT:
Before attempting to use the machine, it is necessary to ensure the various
components are correctly adjusted, and checked for security
1. The Blade Guard Bracket
Check with a straight edge to ensure the Blade
Guard Bracket is completely in line with the
sawblade as illustrated in fig. 9. Adjustments are
carried out as described on page 11, para 6.
2. The Riving Knife
The Riving Knife is essential in preventing kickback
and in producing a good clean cut without
chattering or binding taking place. It must be
completely in line with the saw blade and must
ALWAYS be checked before starting your machine,
To adjust the riving knife remove the rear cover to
give access to the two riving knife securing bolts.
Slacken them off and adjust the knife so that it is
completely in line with the blade.
Additionally, a clearance of NOT GREATER than
12mm should be evident between the knife and
The blade, around the entire length of the knife,
as shown in Fig. 10. Should the gap exceed 12mm,
the saw blade MUST be renewed.
Fig.8
Fig.10
Fig.9
2

Push Block
Should the Riving Knife subsequently become out of shape or misaligned, it must be gently eased
back into line, or if the damage is more severe, it must be removed and bent back into shape
accordingly or replaced.
3. The Saw Blade
Check to ensure the blade is sound. If teeth are chipped, or cracks are apparent, it must be renewed.
4. The Blade Guard
Ensure the Blade Guard is in place, pivots freely, and falls under its own weight. (DO NOT overtighten
the mounting bolt).
No further adjustments should be necessary, but before you proceed to use the machine, it is
recommended that you apply a coat of paste wax to the table to reduce friction when pushing the
workpiece. Wipe the table thoroughly with a clean dry cloth.
Fig.11
Push Block
Make the Push Block using pieces of 10mm
plywood and 19mm hardwood as shown opposite.
The small piece of wood 10x10x64mm should be
GLUED to the plywood. DO NOT USE NAILS,This is
to prevent damaging the saw blade in the event
you mistakenly cut into the push block. Position
the handle in the centre of the plywood and fasten
together with glue and wood screws.
Auxiliary Fence
Make one using pieces of 10mm plywood
and19mm hardwood. Fasten together with glue
and wood screws, illustrated opposite.
NOTE:
Since the Push Black is used with the
AuxiliaryFence, the 140mm dimensions (A), must
be held identical on both the pieces,
HELPFUL HINTS
Work Helpers
Before cutting any wood on your saw, study all of the Basic Saw Operations.
Notice that in order to make some of the cuts, it is necessary to use certain devices. ‘Work Helpers’,
such as a Push Block or an Auxilliary Fence, both of which you can make yourself.
After you have made a few practice cuts, make up these ‘helpers’ before starting any projects.
Fig.12
2

OPERATION
1. Starting and Stopping the Machine
The ON and OFF switches are located on the front left of the machine.The left hand, GREEN switch is
the ON switch and is marked with an ‘I’ symbol.
The right hand RED switch is the OFF switch. It is raised and marked with the symbol ‘0’
For additional safety, the ON switch is a ‘NO VOLT RELEASE’ type. This means that if the power is
interrupted for whatever reason whilst the machine is switched ON, the no volt release will automatically
trip, setting the machine to the OFF position, thereby preventing it from starting again when the power
is restored. The machine may then be restarted by pressing the ON switch.
Your machine also features an OVERLOAD CUTOUT device, so that if the machine is overloaded (due
to feed pressure being too great, a dull blade or low voltage etc.), the overload relay will intervene
and the motor will automatically cut out, In this event:
a. Press the OFF bufton and disconnect from the mains supply,
b. Allow the motor to cool for three to five minutes.
b. Plug the machine back into the mains supply, and switch the saw back on.
2. Ripping or Rip Cutting
This is the term used for cutting timber in the same direction as the grain, i.e usually lengthwise.
First ensure the blade is set to 90Oas indicated by the pointer showing 0Oon the scale on the front of
the machine. If absolute accuracy is required, check the blade angle with a square or protractor and
adjust if necessary by slackening the blade tilt locking handle, moving the blade until it is at 90Oand
retightening the tilt locking handle. At this point, you should also zero the pointer.
To assist in producing a straight, true cut, a RIP FENCE is used, This is positioned to the right of the saw
blade, and may be adjusted to suit the width of cut required. It should be firmly clamped in place.
ensuring it is parallel to the blade, by pushing the rip fence handle down. DO NOT force the handle. If
The handle adjustment is not correct, and too much force is applied, the fence will tend to ride up on
the table and become misaligned. Adjustment should be carried out in accordance with the instructions
given on page 11.
Additionally, when positioning the fence for maximum rip, make sure it is fully clamped, and does not
extend beyond the edge of the table. Do not rip cut with the fence beyond this position, because it
cannot be clamped.
When the width of rip is 150mm (6”) and wider,
use your RIGHT HAND to FEED the workpiece and
your LEFT HAND to GUIDE the workpiece as
sholwn in Fig. 13.
DO NOT feed the workpiece with your left hand.
Fig.13
2

When width of rip is 50 - 150mm (2” - 6”) wide
use a push stick to feed the work. (Fig. 14).
When width of rip is narrower than 50mm (2”),
the push stick cannot be used because the
guard will interfere. Use the auxiliary fence, and
push block as shown in Fig. 14.
The auxiliary fence is secured to the rip
fencewith two ‘G’ clamps as shown in Fig. 15.
Feed the workpiece by hand until the end is
approximately 1” from the front edge of
thetable. Continue to feed using the push
block on top of auxiliary fence (as shown in
Fig. 16), until the cut is complete.
When ripping, you should ALWAYS
abide by the following rules:
✔ ALWAYS clamp the rip fence securely
before use, .
✔ ALWAYS remove the mitre gauge from
table during any operations which utilise
the rip fence.
✔ ALWAYS make sure the blade guard is
installed for ALL sawing.
✔ ALWAYS set the blade height to the
thickness of the workpiece plus 2-3mm.
Additional blade exposure would increase
the hazard potential.
✔ ALWAYS keep your hands clear and out
of the path of the blade.
✔ ALWAYS switch the machine OFF and
disconnect from the mains supply If the
blade stalls or stops whilst cutting,and
BEFORE attempting to free the blade.
✔ FREQUENTLY check the action of the
Anti-kickback pawls by passing the
workpiece alongside the blade guard
bracket whilst the saw is OFF.
Pull the workpiece toward you. If The
pawls do not dig into the workpiece and
hold it, the pawls must be resharpened or
replaced.
Fig.16
Fig.15
Fig.14
✔ ALWAYS place the concave side down if the workpiece is warped. This will prevent it from rocking
whilst it is being ripped.
✔ ALWAYS use a push stick when the end of the work approaches the blade, or for short work or
work less than 6” wide,
✔ ALWAYS ensure, before starting to rip.......
A. The Rip Fence is parallel to the saw blade.
B. The Riving Knife and Blade Guard Bkt are properly aligned with the saw blade.
C. The Anti-kickback Pawis are functioning properly.
✔ ALWAYS use a work support when ripping LONG BOARDS or LARGE PANELS. A simple one can be
made by clamping a piece of plywood to a sawhorse (or see p19, ‘Crosscutting’).
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Fig.17
✘ NEVER make these cuts FREEHAND (without using the rip fence or auxiliary devices when required)
because the blade could bind in the cut and cause a KICKBACK.
✘ NEVER stand directly in front of the blade in case of a kickback. Stand to either side.
✘ NEVER reach over or behind the blade to pull the workpiece through the cut, to support long or
heavy workpieces, to remove small cut-off pieces of material or for any other reason.
✘ NEVER pick up small pieces of cut-off material from the table. Remove them by pushing them off
the table with a long stick,
✘ NEVER remove small pieces of cut-off material that may have have become trappedinside
the blade guard while the saw is running. This could endanger your hands or cause a kickback.
Turn the saw off. After the blade has stopped turning, lift the guard and remove the piece.
✘ NEVER force the work - a gentle pressure is all that is required.
The feed force should always be applied between the saw blade and the fence and down on to
the table, NOT on the section that will become the cut-off piece,
3. Rip Cutting a Bevel.
By tilting the saw blade (by up to 45O), it is possible to rip cut a bevel in your work. To do this, set the
blade angle by slackening off the Blade Tilt Locking Handle, (refer to illustration on page 8) and position
the blade using the angle gauge and pointer mounted on the front of the machine.
(if absolute accuracy is required, check the blade angle with a protractor).
You will note that the Blade Tilt Locking Handle is spring loaded.. to operate, pull the handle out
against the spring so that the handle may be turned clockwise to any desired position. Releasing the
handle locks it back on to the shaft so that the shaft may be turned anticiockwlse, thus slackening off
the blade mechanism. Repeat the procedure until the blade mechanism is completely free.
To secure the blade mechanism, once the blade angle has been correctly set.. repeat the procedure,.
turning the handle in the opposite direction. i.e. pull the handle out against the spring and turn it
anticlockwise before releasing it, then turn the handle as far as possible clockwise to lock the mechanism.
NOTE: Your saw is equipped with positive stops for fast and accurate positioning of the saw
blade at 90 and 45 degrees to the table. Should these stops become out of alignment, they
may be readjusted according to the instructions given under ‘Maintenance’
When bevel ripping material 150mm (6") or narrower, use
the fence on the RIGHT SIDE of the blade ONLY. This will
provide more space between the fence and the saw
blade for the use of a push stick.
If the fence is mounted to the left as shown in Fig. 17, the
saw blade guard may interfere with the proper use of a
push stick, as illustrated,
CAUTIONI
To prevent personal injury always disconnect plug from power source when making
adjustments.
2

4. Crosscutting.
Crosscutting is the term used to describe cuts
made in timber across the grain. This type of cut
requires the use of the MITRE GAUGE. This includes
bevel cutting, mitre cutting and compound mitre
cutting (described later in this chapter).
To perform a cross cutting operation, the work is
firmly held against the mitre gauge head, as
shown in Fig. 18, with the mitre gauge bar located
in either the left or right hand groove in the table.
With the timber carefully lined up with the saw
blade, the mitre gauge is gently moved along
the groove, past the saw blade, producing the
desired cut.
Long workpieces should be supported. A simple
arrangement is to clamp a piece of plywood to
a sawhorse or support, as shown in Fig. 18.
For maximum accuracy when using the mitre gauge, always favour one side of the groove In the
table. In other words, don’t move the mitre gauge from side to side while cutting but keep one side of
the bar riding against one side of the groove.
When using the left hand groove, hold the workplece firmly against gauge head with your left hand,
and grip the lock knob and push with your right hand. When using the right hand groove, hold the
work piece with the right hand and grip the lock knob with the left.
The graduations on the mitre gauge provide accuracy for average woodworking. In some cases
where extreme accuracy is required, when making angle cuts for example, make a trial cut and then
recheck it with an accurate square or protractor.
REMEMBER: ALWAYS remove the rip fence before attempting to cross cut.
Fig.18
Mitre Gauge Adjustment
To produce an accurate cut at 90Oyou should check the gauge
as follows:
1. Loosen the lock knob and, using a square as shown in Fig.
19, set the bar at 90Oto the body.
Tighten the lock knob and re-check with the square to
ensure no movement has taken place during the tightening
process.
If necessary readjust.
2. Slacken off the pointer securing screw and zero the pointer.
Fig.19
Auxiliary facing
Notches are provided in the mitre gauge body for
attaching an AUXILIARY FACING, to make it easier
to cut longer pieces. Ensurethe facing does not
extend so far as to interfere with the proper operation
of the saw blade guard.
Select a suitable piece of smooth straight wood, drill
two holes through it and attach it with screws.
HINT : Glue a piece of sandpaper to the face of the
mitre gauge head or auxiliary facing. This will help
prevent the workpiece from creeping while it Is being
cut.
Fig.20
19

When crosscutting, you should ALWAYS abide by the following rules:
✔ ALWAYS lock the mitre gauge securely.
✔ ALWAYS remove the rip fence from table during any operations which utilise the mitre gauge.
✔ ALWAYS make sure the blade guard is installed (for ALL sawing operations).
✔ ALWAYS set the saw blade height to the thickness of the wood plus 2-3mm. Additional blade
exposure would increase the hazard potential.
✔ NEVER stand directly In front of the blade in case of a throwback (small cut-off piece caught by
the back of the blade and thrown toward the operator). Always stand to one side of the blade.
✔ ALWAYS keep your hands clear, and out of the path of the blade.
✔ ALWAYS switch the machine OFF and disconnect from the mains supply if the blade stalls or stops
whilst cutting, and before attempting to free it.
✔ ALWAYS place the concave side down if workpiece Is warped. This will prevent it from rocking
whilst it is being cut.
✘ NEVER crosscut freehand (without using the mitre gauge or other auxiliary device) because
the blade could bind in the cut and cause a kickback or cause your fingers or hand to slip into the
blade.
✘ NEVER reach over or behind the blade to pull the workpiece through the cut, to support long or
heavy workpieces, to remove cut-off pieces of material, or for any other reason.
✘ NEVER pick up small pieces of cut-off material from the table. Remove them by pushing them off
the table with a long stick. Otherwise they could be thrown back at you by the rear of the blade.
✘ NEVER remove small pieces of cut-off material that may have become trapped inside the blade
guard while the saw is running. This could endanger your hands or cause a kickback. Turn the saw
off. After the blade has stopped turning, lift the guard and remove the piece.
5. Repetitive Cutting
Repetitive cutting is the term used when cutting a quantity of pieces of the same length without
having to mark each piece.
When making repetitive cuts from a long workpiece, make sure it is supported.
1. When making repetitive cuts, clamp a block of wood 75mm (3”) long to the table at the desired
length to act as a length stop.
NOTE: When clamping the block, make sure
that the end of the block is well in front of
the saw blade. Be sure it is clamped
securely.
2. Slide the workpiece along the mitre gauge
until it touches the block, then, holding it
securely in that position to the mitre gauge,
push it gently through the blade
3. Pull the workpiece back and push the cut-
off piece off the table with a long push stick.
DO NOT ATTEMPT TO PICK IT UP AS THIS COULD
ENDANGER YOUR HANDS.
NOTE: When cutting long workpieces, make
sure the free end is supported - from the
floor.
Fig.21
2

CAUTION!
NEVER use the rip fence as a length stop because the cut-off piece could bind
between the fence and the blade causing a kickback.
6. Mitre Cutting
Mitre cutting is the term used for cutting at an
angle other than 90Oto the edge of the wood.
Follow the same procedure as you would for
crosscutting.
Adjust the mitre gauge to the desired angle,
and lock it.
The mitre gauge may be used in either of the
grooves in the table.
When using the mitre gauge in the LEFT hand
groove, hold the workpiece firmly against the
mitre gauge head with your LEFT HAND, and
grip the lock knob with your right.
When using the RIGHT hand groove, hold the
workpiece with your RIGHT HAND and the lock
knob with your left hand,
8. Compound Mitre Cutting
Compound mitre cutting is a combination of mitre cutting and bevel crosscutting. The cut is made at
an angle other than 90Oto both the edge and the broad side of the wood.
Adjust the mitre gauge and the blade to the desired angle, and ensure the mitre gauge body is
locked.
CAUTION!
When Mitre cutting, an area of blade is exposed.
Great care must be taken when using the machine for this operation.
Fig.22
Fig.23
7. Bevel Crosscutting
Bevel crosscutting is the same as crosscutting
except that the wood is also cut at an angle,
other than 90Owith the broad side of the wood.
Adjust the blade to the desired angle.
Use the Mitre Gauge in the groove to the RIGHT
of the blade. It cannot be used in the groove
on the LEFT because the blade guard will
interfere. Hold the workplece with your right
hand and the lock knob with your left hand.
2