HTC Outfeed Rollers HOR-1038U User manual

TM
Operators Manual
FOR MODELS:
HOR-1038U
Covered by U.S. Patent No. 4,640,326

Thank You and Congratulations!
 ThankyouforyourrecentpurchaseofHTC OutfeedRollers.Thisproduct
ismanufacturedbycraftsmendedicatedtomakinghighquality,reliable
products.AllHTCproductsarebackedbyourLimitedLifetimeWarranty*
andaresponsive,dedicatedcustomerservicedepartment.Wewould
appreciatehearingyourcommentsorsuggestions.Pleasefeelfreetocall
orwriteanytime.Wewelcomecorrespondencefromeveryonewhohasever
purchasedorusedoneofourfineproducts.
A Word About Your New Outfeed Rollers
 AuniquepatentedHTC exclusive!Aworksupportthat’salwaysinplace
andreadytouse.OutfeedRollerssupporttheworkpieceto4'pasttheblade.
That’safull48"tohelpbalanceafull8'panel.HTCOutfeedRollersare
compatiblewithmostfencesystemsonthemarketandhaveapatentedcam
actionadjustmentthatlowerstheOutfeedRollers3/8"forpropersupport
ofslidingcross-cutandmiterslotfixtures.Foldsdowneasilyforcompact
storageandswingsintoplacewithouttheuseoftools.Whenyouworkwith
full4'x8'panelsandextralongboards,HTC OutfeedRollersletyouripand
cross-cuteasily,accurately...butmostimportantlysaferbyyourself.
General Product Safety Warning
 Aswithallproductstherearecertainhazardsinvolvedwiththeir
operationanduse.Usinganyproductwithrespect,caution,andcommon
sensewillconsiderablylessenthepossibilityofpersonalinjury.Safetyisa
combinationofstayingalert,knowinghowtheproductworks,andknowing
howtoproperlyusetheproduct.Touseanyproductsafelyyoushouldplan
aheadandpracticetheproperstepspriortoactuallyusingtheproduct.If
safetyrulesandinstructionsareoverlookedorignored,personalinjuryto
theoperatororotherpeopleintheareamayresult.Safeoperationofany
productrequiresthatyoureadandunderstandtheproductinstructionsand
alllabelsaffixedtotheproduct.
Always read and follow all instructions and safety rules carefully.
 Thisproductisdesignedforcertainusesonly.Thisproductoranyofits
partsshallNOTbealtered,changed,ormodifiedinanywayand/orused
foranyotherusethanit’sdesignedfor.Ifyouhaveanyquestionsaboutits
propercareoruseDO NOTusetheproductuntilyouhavewrittenHTCand
wehaveadvisedyouinwriting.
HTC Products
1161RankinDr.
Troy,MI48083
800-624-2027
www.htcproductsinc.com
8:00AMto5:00PMEST/EDTMonday– Friday
2
*SeebackcoverforcompleteWarrantyinformation.
TM

General Safety Rules
Thefollowinggeneralsafetyrulesaresuppliedasanaidforthesafeuseofmanyproducts.ThisisNOTacompletelistof
allpossiblesafetyrules.SafeuseofaproductincludesbutshouldNOT belimitedtothefollowingsafetyrules.
1. For your own safety, read instruction manual
before operating the tool. Know the tool.Readand
understandtheowner’smanualandlabelsaffixedtothe
tool.
2. Keep work area clean.Clutteredareasandbenches
inviteaccidentsandcreatefirehazards.
3. Wear proper apparel.Donotwearlooseclothing,
gloves,neckties,bracelets,drawstrings,necklaces,
ornaments,rings,wristwatches,orjewelryofanykind.
Theycangetcaughtandpullyouintomovingparts.
4. Avoid dangerous environment.Keepalerttopotential
hazardsintheworkingenvironment.Donotusetool
insituationssuchasdamporwetlocationsorinthe
presenceofhighlycombustiblematerials,dust,and
flammableliquids,fumes,vaporsorgasses.
5. Keep children and visitors away.Allvisitorsshouldbe
keptasafedistancefromworkarea.
6. Wear safety goggles.Wearsafetygoggles(not
glasses)atalltimes.Alleyeprotectionmustcomply
withtheANSIZ87.1standardforeyeprotection.
Everydayeyeglassesonlyhaveimpactresistantlenses,
theyareNOTsafetyglasses.
7. Drugs, alcohol, medication.Stayalert.Watchwhat
youaredoing.Usecommonsense.Donotoperate
toolwhenyouaretired,upset,ill,orwhileunderthe
influenceofdrugs,alcohol,ormedication.
8. First aid.Haveatleastonepersonwithfirstaidtraining
andfirstaidkitsapprovedbyAmericanNationalRed
Crossavailableatalltimes.
9. Fire extinguisher. Familiarizeyourselfintheuseof
portablefireextinguishers.Postthetelephonenumber
ofthelocalfiredepartment.Alsodevelopandknow
emergencyproceduresincaseoffire.
10. Smoke Detector. Toincreaseprotectionagainstfire,
installsmokedetectors.Forproperselectionand
installationguidelinescontactyourlocalfiredepartment.
11. Use right tool. Don’tforcetoolorattachmenttodoa
jobitwasnotdesignedfor.Don’tusetoolforpurpose
notintended–forexample–donotusecircularsawfor
cuttingtreelimbsorlogsordonotusealawnmowerto
trimbushesorhedges.
12. Don’t force tool.Itwilldothejobbetterandsaferat
therateforwhichitwasdesigned.
13. Secure work.Keephandswellawayfrommoving
parts,sawblades,andothercuttingtools.Useapush
stickorpushblocktoholdorguidetheworkwhen
workingclosetocuttingtool.Usejigs,fixtures,miter
gauge,clampsorvisestoholdworkwhenpractical.
Useafeatherboardwhenanapplicableguardcannot
beusedorforaddedsafety.Looseworkpiecesarea
hazard.
14. Never leave tool running unattended. Turnpoweroff.
Don’tleavetooluntilitcomestoacompletestop.
15. Keep guards in place.Besurethatguards,hold-
downs,andantikickbackdevicesareinworkingorder,
andpositionedproperly,andareinproperadjustment
andalignment.
16. Remove adjusting keys and wrenches.Formthe
habitofcheckingtoseethatkeysandadjusting
wrenchesareremovedfromthetoolbeforeturningthe
toolon.
17. Cutting tool exposure.Adjustthetoolforminimum
exposureofcuttingtoolnecessarytoperformthe
operation.
18. Direction of feed.Feedworkintoabladeorcutting
toolagainstthedirectionofrotationofthebladeor
cuttingtoolonly.
19. Don’t overreach.Keepproperfootingandbalanceat
alltimes.
20. Never stand on tool.Seriousinjurycouldoccurif
thetoolistippedorifthecuttingtoolisaccidentally
contacted.
21. Avoid accidental starting.Makesureswitchisinthe
“OFF”positionbeforepluggingintool.Donotcarrya
pluggedintoolwithfingeronswitch.
22. Inspect workpiece.Alwaysinspectworkpiecetomake
suretherearen’tanynailsorforeignobjectsinthepart
oftheworkpiecetobeworkedon.
23. Plan ahead.Mentallyplanaheadtoprotectyoureyes,
hands,body,faceandhearing.Dolayout,assembly,
setupwork,materialhandling,andplanningbefore
usingtool.
24. Disconnect tools. Alwaysturntool“OFF”and
disconnectthecordfromthepowersourcebeforetool
isservicedorwheninstallingorremovingaccessories
suchasblades,bits,orcuttersetc.
25. Maintain tools with care. Inspecttoolbeforeeachuse.
Itisrecommendedthatthegeneralconditionofanytool
beexaminedbeforeitisused.
26. Check damaged parts.Beforefurtheruseofthetool,a
guardorotherpartthatisdamagedshouldbecarefully
checkedtoensurethatitwilloperateproperlyand
performitsintendedfunction.
27. Ground all tools. Makesurewiringcodesand
recommendedelectricalconnectionsarefollowedand
thattoolisproperlygrounded.
 28. Outdoor use extension cords. Whentoolisused
outdoors,useonlyextensioncordsmarked“suitablefor
usewithoutdoorappliances–storeindoorswhennotin
use.”
29. Ground Fault Circuit Interrupters - (GFCI’s)
provideadditionalmeanstoreduceseriouselectrical
shockwhileusingapowertool.Theyareeasilyinstalled
betweenthepowerreceptacleandthecord.Leakageof
currentwillshutoffthetool,preventingpossibleserious
injuryfromelectrocution.
3

LVC Box
Tag and label
wires for removal
Relocated LVC box with main frame
Attention Delta Unisaw Owners
 IfyourtablesawisaDeltaUnisaw,withanLVC(LowVoltageController)
boxmountedontherearofthetablesawcabinet,pleasereadandfollowthe
instructionsinthissectioncarefullybeforeproceedingwithinstallationofthe
HTC OutfeedRollerSystem.Otherwiseskiptonextpage.
 TheLVCboxmayneedtobelowered3"toprovideenoughspaceforthe
topmountingchanneloftheOutfeedRollerMainFrame.Readthroughthe
entireinstallationinstructionspriortomovingyourLVCbox.Thefollowing
instructionswillguideyoustepbystepthroughthesimpleprocedureof
loweringtheLVCbox,ifnecessary.
Tools needed to lower the Delta Unisaw LVC Box
 Safetygoggles
 Handdrillwith1/8"and11/32"drillbits
 Scribe,awlormarkingdevice
 Fileordeburringtooltoremovesharpedgefromholes
Center punch
 Ballpeenhammer
 1-1/2"diameterholesaw(availableatanyhardwarestore)
 Two(2)1/2"wrenches
Lowering the Delta Unisaw LVC Box
WARNING: Toavoidelectrocutiondisconnectpowerfromthetable
sawbeforeproceeding.
1. RemovethecoveroftheLVCbox.Taganddisconnectthesix (6)wires
fromtheterminals.
2. Removelocknutsfromthetwo(2)wireclampsandpullthewiresthrough
thebackoftheLVCbox.
3. DisconnectLVCboxbyremovingthree(3)5/16"boltsandnuts.
4. Locatetoptwo(2)existingmountingholes.Relocatethesesameholes
3"lowerthanoldholes.Markwithcenterpunch.Drill1/8"pilotholesto
reducewanderinsheetmetal.Drillthetwonew11/32"holes.Remove
sharpedgeonholes.
5. TemporarilyremountLVCboxwiththetwo(2)topmountingboltsinthe
new3"lowerholes.Tracetheoutlineofthelowermountingholeandthe
two(2)wireaccessholes.
6. RemovetheLVCboxagain.Markandcenterpunchthethree(3)holes
tracedinStep5.
7. Drillthree(3)1/8"pilotholes.Drill11/32"lowermountinghole.Drilltwo
(2)wireaccessholeswith1-1/2"diameterholesaw.Removesharpedge
onholes.
8. RemounttheLVCbox,rewiremakingsuretomatchtaggedwiresfrom
Step1andreplacecover.
4
LVC box may need to be lowered 3"
3"

5
Pageleftintentionallyblank.

Key Part # Name Qty
A5131 Upper Support Bracket 1
B2887 Stud Pad 2
CG501 Tube Closer Plug 2
DC206 5/16"-18 X 1" Hex Bolt 5
E5132 Lower Support Bracket 1
FC408 3/8"-16 Acorn Nut 4
G2272 3/8" Pivot Rod 2
HC204 5/16" Flat Washer 10
IC208 5/16" Lock Washer 10
JC202 5/16"-18 Hex Nut 8
K5094 Folding Support Arm 1
L 3089 Table Adjustment Plate 1
M C306 5/16"-18 x 1" Carriage Bolt 4
N 2106 Cam 2
OG101 5/16"-18 x 1/2" 3 Point Knob 2
P2343 Cam Bolt 2
Q2036 3/8" Pivot Pin 2
R5007 Outfeed Roller Section 1
S2032 13" Roller 5
T2031 10" Roller 8
U2030 9.5" Roller 2
BASE LINE
CENTER LINE
CENTER LINE
BASE LINE
MAIN FRAME MOUNTING TEMPLATE
SET BASELINE AT 31/2" BELOW
TOP FINISHED SURFACE OF
MACHINE TABLE
TAPE THIS TEMPLATE TO MACHINE CABINET
WITH “BASE LINE” EXACTLY 31/2" BELOW
FINISHED SURFACE OF MACHINE TABLE AND
“CENTER LINE” ON CENTER OF MACHINE
CENTER PUNCH 4 POINTS ABOVE, AND DRILL PILOT HOLE WITH 1/8
" DRILL. THEN ENLARGE WITH 11/32" DRILL FOR 5/16" MOUNTING BOLTS.
FOR MODELS HOR-1026U HOR-1038U
TM
6
Unpacking and Checking Contents
 Separateallpartsandhardwarefrompackingmaterials.Checkeachpart
withthetableandhardwarecharttomakesureallitemsareaccountedfor
andareingoodcondition.Donotdiscardpackagingmaterialsuntilassembly
iscompletedandyouaresatisfiedwiththeproduct.






Support Arm Plate, Table
Adjustment

BASE LINE
CENTER LINE
CENTER LINE
BASE LINE
MAIN FRAME MOUNTING TEMPLATE
SET BASELINE AT 31/2" BELOW
TOP FINISHED SURFACE OF
MACHINE TABLE
TAPE THIS TEMPLATE TO MACHINE CABINET
WITH “BASE LINE” EXACTLY 31/2" BELOW
FINISHED SURFACE OF MACHINE TABLE AND
“CENTER LINE” ON CENTER OF MACHINE
CENTER PUNCH 4 POINTS ABOVE, AND DRILL PILOT HOLE WITH 1/8" DRILL. THEN ENLARGE WITH
11/32" DRILL FOR 5/16" MOUNTING BOLTS.
FOR MODELS HOR-1026U HOR-1038U
TM
7
WARNING:
Donotattempttousethe
productifpartsaremissing.
Contactfactoryat800-624-2027
toobtainthenecessaryparts.
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




















Roller
Frame
Main Frame

8
Installation Instructions
Tools needed for Assembly
 Safetygoggles
 Scribe,awlormarkingdeviceformarkingonsheetmetal
Center punch
 Ballpeenhammer
 Fileordeburringtooltoremovesharpedgefromholes
 Combinationsquare
 Framingsquareorlongstraightedge
 Handdrillwith1/8"and11/32"drillbits
 1/2"deepsocketwrench
 1/2"openendwrench
 7/16"socketwrenchand/oropenendwrench
Note:ReadthroughALLinstallationinstructionsandreviewalldiagrams
beforeattemptinginstallation.
WARNING: Toavoidelectrocutiondisconnectpowerfromthetable
sawbeforeproceeding.
Figure 1

READ THROUGH ENTIRE INSTALLATION
INSTRUCTIONS BEFORE PROCEEDING
1. PositionandmountwithtapetheenclosedMainFrameMounting
TemplatetotherearofTableSaw,asshowninFigure1.SettheBase
Line(onthetemplate)31/2"belowthetabletopsurfaceofthetablesaw.
Important:BaseLinemustbeparallelwiththetabletoporOutfeed
Rollerunitwillnotworkproperly.
2. Usingacenterpunch,markthefour(4)mountingholesontheTemplate.
Drill1/8"pilotholestoreducebitwanderinsheetmetal.Thenenlarge
holesbydrillingwith11/32"drilltoaccommodate5/16"mountingbolts.
Stepdrillsworkespeciallygoodinsheetmetal.
3. MounttheMainFrameAtothesawcabinetusingtwo(2)studpadsB,
alongwith(2)5/16"-18x1"boltsD,(2)5/16"-18nutsJ,(4)5/16"flat
washersHand(4)5/16"lockwashersI.(Handtightenonly.)
Tip:WheninstallingthestudpadsandMainFrameonsomemachine
models,you’llneedto“hang”thestudthroughoneoftheholes,then
rotatethestudpadintopositionandthreadtheboltintoplace.Usually
thebackofthesawcabinetcanbereachedfromtheopeningontheside
ofthesaw.Ontherareoccasionsit’snecessarytolaythesawonits
sideandfeedtheminfromthebottom.Figure2.
4. AssembletheLowerMainFrameBrackettotheMainFrame.Mountas
lowasispracticallypossible,forbestresults.Itcanbeflippedoverif
needed.Thepointistoavoidanyinterferencesonthecabinet.
Important:DoNotDrillthelowerholesinthecabinetatthistime.
5. AttachtheCamsNtotheMainFrameusingCamBolts Pand Knobs O
asshowninFigures3&4.
6. Install(1)oneofthePivotBoltsQintooneoftheCams,asshownin
Figures4&5.ThensliptheRollerFrameontothisPivotBolt.Swingthe
FrameintopositionbetweentheCamsandthreadtheotherPivotBolt
intoplace.Refertophotostogetthecorrectorientation.
7. AttachtheAdjustmentPlateLtotheundersideoftheRollerFrameas
showninFigure11using(4)four5/16"CarriageBoltsM,washers,lock
washersandnuts.UsecaretoorienttheAdjustmentBolttothe‘front’as
shown.
8.PivotRollerFrameoutofyourway.Itcanflipoverontothetopofthe
saw.AttachtheSupportArmAssembly K,asshowninFigure6,tothe
bottomoftheMainFramewithaPivotRod Gand(2)twoAcornNuts.
Note:ItisveryimportanttomountthecorrectendoftheSupportArm
Assembly.
Roller
Roller
Frame
Cam
Cam
Main
Frame
Main
Frame
Front
View
Side
View
Lock
Knob
Lock
Knob
Cam
Bolt
Cam
Bolt
Pivot
Pin Pivot
Pin
Figure 4
9
Figure 2
Figure 3
Figure 5
Figure 6

9. PivottheRollerFramebackoverandattachtheupperendofthe
SupportArmtotheAdjustmentPlateLusingaPivotRodGand(2)two
Acorn Nuts F.
10. Insert(2)91/2"RollersintoRollerFrameasshowninFigure7&8.Use
thinputtyknife(orsomethingsimilar)tocompressthespringloadedaxle.
Note:Itisveryimportanttoinstalltherollerswithfixedendinoutsideframe.
 YouarenowreadytomakethefinaladjustmentstoyourOutfeedRoller.
11.Layastraightedgeonsawtabletopextendingouttofirstrollerclosest
tosawtable(Figure9).AdjustpositionofMainFrametobringbothends
ofrollerslevelwithsawtabletop.Tableremainsfoldeddown—cams
positionedasinFigure3&4.TightentopMainFramenutsandbolts.
12.Swingrollersectionintoit’sextendedposition.Tightenorloosen
AdjustmentBolttobringoutboardrollerslevelandparallelwithsawtable
top.TightenthetoplevelingbracketmountingboltsFigures10&11.
13.DoublecheckandmakesureRollerSectionismountedlevelwiththe
sawtabletop(sidetoside).Thenmarkanddrilllowermountingholes.
Install(2)5/16"-18x1"boltswithflatwashersthroughtheoutsideof
thesawcabinet,withflatwashersH,lockwashers I,and5/16"-18
nuts Jontheinside.Tightensecurely.
Note:Beforedrillingthelowermountingholesonsomesawmodelsyou
mayfindtheangleddustpanwithinthecabinetbecomesanobstruction
toproperinstallation.YoumaywanttoadjustthepositionofLowerMain
FrameBracket.
14.Measuretheapproximatedistancebetweenthemountingholesonthe
MainFrameBracket.
15.Fromtheinsideofthecabin,usingthemeasurementfromStep14,
measurefromthetopholesdowntodeterminetheapproximatelocation
lflowermountingholes.Theymayfallabovethedustpan,belowthepan
orstraddlethepan.
16.Iftheapproximatelocationoftheholesfallabovethepan,proceedwith
normalinstallation.Ifthemountingboltswillfallbelowthedustpan,
proceedtothenextstep.
17.Ifthedustpanismountedtothecabinetusingscrewsandthestudfalls
belowthepan,thepancanberemovedtocompletetheinstallation.
18.Ifthedustpanisweldedinandtheholeswillfallbelowthedustpan,the
boltscanbeinstalledfromthebottom,bytippingofblockingthesawup.
Useextremecautionwhenworkingonthesawfromthebottom.
19.PositionCamNsoRollerFrameisinthelowerposition.Makesuremiter
gaugeguidebarrestslevelonfirstroller.
Re-checkandtightenallfasteners.
10
Figure 11
Figure 7
Figure 8
Cam
13"
9
1
/
2
"
Pivot Pin
This End Must Be
Inserted First
Figure 9
Figure 10

Outfeed Roller Feature
and Operating Instructions
Cam Action
Theuniquecam-actionoftheHTCOutfeedRollersallowtherollersurface
tobequicklyandeasilylowered3/8"tosupportthemitergaugebar.This
allowstheuseofmiterorcross-cutboxesoranyotherslidingmiterfixtures
orjigs.Thecam-actionassuresthattherollersremainparalleltothetable
sawandthatthefullyadjustableheightmechanismremainsinprecise
alignmentwiththetablesawsurfaceandmitergaugeslot.
Figure12showsthecam-actioninthedownpositionwiththerollersinthe
uppositionforsupportingtheworkpieceinanormalcuttingmode.
Figure13showsthecam-actionintheuppositionwiththerollersinthe
downpositiontosupportthemitergaugeguidebarforjigorfixturemode.
Storage
How to Fold Outfeed Rollers
TherecommendedprocedureforfoldingtheOutfeedRollersistoreleasethe
lockingmechanismwithyourfootwhileholdingtherollersectionfirmlywith
twohands.(SeeFigure14)Makesuretherearenoworkpiecesoranything
elseontheOutfeedRollerswhenfoldingtothedownposition.Afterthe
lockingmechanismisreleased,gentlyfoldtheOutfeedRollersdownasin
Figure15.
WARNING: Keephandsandbodypartsawayfrompinchpoints
whenfoldingOutfeedRollerstodownposition.
Care and Maintenance
WhiletheHTCOutfeedRollerisdesignedandbuilttowithstandtheeveryday
activitiesofvirtuallyanyworkshopenvironment,afewcommonsensecare
andmaintenanceprocedurescanhelpincreasethelifeandenjoymentof
yournewpurchase.Keepingthreadedandhingedpartsfreefromdust
buildupwillkeepthosepartsmovingasfreelyastheyareintended.Dust
buildupshouldalsobeavoidedontheaxlesoftheballbearingrollers
byregularcleaning.Alightlubrication(whenneeded)oftherolleraxles
andOutfeedRollerhingeinthesupportarmactionisalsosuggestedfor
consistent,easyoperation.Adampragisrecommendedforcleaningthe
frameandsupportarmofyourOutfeedRoller.
NOTE:DO NOThoseyourOutfeedRollerdownwithwatertocleanit.
11
Workpiece
Guide Bar
3/8''
Saw
Cross Cuts
Down Position
Figure 13
Workpiece
Saw
Rip Cuts
Up Position
Figure 12
Figure 14
Figure 15

HTC Products, Inc.
1161RankinDr.
Troy,MI48083
800-624-2027
www.htcproductsinc.com
LIMITED LIFETIME WARRANTY
Products manufactured by HTC Products are guaranteed
to be free from defects in material and workmanship under
normaluseandservice.HTC’sobligationunderthiswarranty
shall be limited to repairing or replacing for the original
owner,atouroption,anypartofsaidequipmentwhichHTC’s
examinationshalldisclosetoitssatisfactiontobedefective.
Anysaidproductorcomponentclaimedtobedefectiveisto
besentprepaidto:HTCProducts,1161RankinDr.,Troy,MI
48083Attn:WarrantyDepartment,togetherwithacopyof
theoriginal,datedsalesreceipt.Callforauthorizationnumber
beforeshipping.
This warranty does not apply to damages resulting from
shipping,accident,misuse,abuseoralteration.
Wearitems(i.e.wheels,bearings,bushings,rubberfeet,etc.)
arewarrantedforaperiodofoneyear,fromdateofpurchase.
Consumableitems(i.e.fencefaces,sawguardshields,etc.)
arewarrantedforaperiodof60days.
©2013HTCProductsPartNo.P-009