SafetySpeed C4 User manual

Panel Saw and Router
Owner’s Manual
13943 LINCOLN ST. NE
HAM LAKE, MN 55304
763-755-1600 Fax: [phone]
w w w . p a n e l s a w . c o m
[e-mail]

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A message from all of us at SAFETY SPEED MANUFACTURING:
Thank you for purchasing a Safety Speed vertical panel saw or router. We take pride in building these fine
products in the U.S.A.
Each SSC product is designed to give years of dependable service. Our saws and routers are built from the finest
components we can specify, and every machine is individually assembled by our employees some of whom
have been building these products for more than 25 years. We appreciate your choosing our products for your
application.
The employees of Safety Speed
Ham Lake, Minnesota
Warranty
Safety Speed (SSC) warrants the parts and workmanship of this tool, except for the electric motor, for
one year from the date of manufacture. SSC will repair or replace, at our cost, any component that is
determined to be defective. Such repair or replacement is limited to providing satisfactory replacement
parts from the factory. SSC assumes no responsibility for making repairs on site. Any parts returned to
the factory must be returned freight prepaid.
All saw and router motors are warranted directly by the manufacturer. See local repair and maintenance
centers for warranty claims for motors.
Safety Speed assumes no responsibility for any damage or accidents resulting from the misuse of this
tool, its misapplication, or failure to follow precautionary safety measures. SSC assumes no
responsibility for any consequential damage or loss of production. SSC will not be responsible for claims
made for machines that are not used or maintained in the normal course of business, used for
applications not intended, or modified in any way.
This manual covers the following SSC panel saw models:
C4 H6 7400
C5 6400(P5) 7400XL
H4 6800(P6)
H5
the following router models:
3400 TR2
and the following saw/router combination machines:
SR5 SR5U

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C NTENTS
Safety.......................................................................................... 4
Electrical Safety.......................................................................................... 7
Extension Cords......................................................................................... 8
Short-Circuit Protection .............................................................................. 8
Installation................................................................................... 9
Tools Required for Installation ................................................................... 9
Operating Environment .............................................................................. 9
Unpacking .................................................................................................. 9
Machine Assembly ..................................................................................... 9
Operation .................................................................................... 18
Limitations of the Tool ................................................................................ 18
Selecting a Saw Blade ............................................................................... 19
Basic Operating Functions ......................................................................... 19
General Operating Tips.............................................................................. 23
Operating Procedure: Crosscutting........................................................... 23
Operating Procedure: Rip cutting.............................................................. 25
Operating Procedure: Routing .................................................................. 26
Switching Between a Saw and Router (Model SR5) .................................. 27
Removing the Motor................................................................................... 27
Maintenance ............................................................................... 29
General Maintenance................................................................................. 29
Cleaning ..................................................................................................... 29
Maintaining the Motor................................................................................. 29
Lubricating the Guides ............................................................................... 29
Service ........................................................................................ 30
Repairs....................................................................................................... 30
Replacement Parts..................................................................................... 30
Alignment ................................................................................................... 30
Accessories................................................................................. 33
Frame Wheels............................................................................................ 33
Frame Stand .............................................................................................. 33
Frame Extensions ...................................................................................... 34
Dust Collection Kits .................................................................................... 35
Stop Bar ..................................................................................................... 36
Quick Stop.................................................................................................. 37
Midway Fence ............................................................................................ 38
Hold-Down Bar ........................................................................................... 40
Air Clamping Package (for routers) ........................................................... 41
Carbide Knife Scoring System (Models 7400 and 7400XL) ...................... 41
Specifications.............................................................................. 42
Warning Labels Identified ........................................................... 43
SSC is a registered trademark of Safety Speed Manufacturing Co., Inc.
U.S. Patent Numbers: 3,008,498; 3,090,578; 3,151,642; 3,565,139; 4,253,362

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SAFETY
WARNING: When using electric tools, always follow basic safety precautions to reduce
the risk of fire, electric shock, and personal injury.
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE. Before use, be sure everyone using this tool reads
and understands this manual as well as any labels packaged with or attached to the tool.
1. KNOW YOUR POWER TOOL. Read this manual carefully to learn your power tool’s applications and
limitations as well as potential hazards associated with this type of tool.
2. DO NOT ALLOW UNQUALIFIED PEOPLE TO OPERATE the tool.
3. AVOID DANGEROUS ENVIRONMENTS. Do not use your power tool in rain, damp or wet locations, or in the
presence of explosive atmospheres (gaseous fumes, dust, or flammable materials). Remove materials or
debris that may be ignited by sparks.
4. KEEP WORK AREA CLEAN AND WELL LIT. Cluttered, dark work areas invite accidents. Provide at least
200 watts of lighting at the front work area of the tool. Eliminate all shadows that could interfere with clear
viewing of the work area.
5. DRESS PROPERLY. Do not wear loose-fitting clothing or jewelry. Wear a protective hair covering to contain
long hair, as it may be caught in moving parts. When working outdoors, wear rubber gloves and insulated,
nonskid footwear. Keep hands and gloves away from moving parts.
6. USE SAFETY EQUIPMENT. Everyone in the work area should wear safety goggles or glasses with side
shields that comply with current safety standards. Wear hearing protection during extended use and a dust
mask for dusty operations. Hard hats, face shields, safety shoes, etc. should be used when specified or
necessary. Keep a fire extinguisher nearby.
7. KEEP BYSTANDERS AWAY. Keep children and bystanders at a safe distance from the work area to avoid
distracting the operator and contacting the tool or extension cord.
8. MAKE THE WORKSHOP CHILD PROOF with padlocks, master switches, etc.
9. NEVER LEAVE THE TOOL RUNNING UNATTENDED. Turn the power off. Do not leave the tool until it
comes to a complete stop.
10. PROTECT OTHERS IN THE WORK AREA from debris such as chips and sparks. Provide barriers or shields
as needed.
11. SECURE THE WORK. Use a clamp, vise, or other practical means to hold your work securely, freeing both
hands to control the tool.
12. USE THE RIGHT TOOL. Do not use a tool or attachment to do a job for which it is not recommended. For
example, do not use a circular saw to cut tree limbs or logs. Do not alter the tool, remove guards, or operate
the saw when removed from the carriage and frame.
13. USE PROPER ACCESSORIES. Using non-recommended accessories may be hazardous. Be sure
accessories are properly installed and maintained. Do not defeat a guard or other safety device when
installing an accessory or attachment.
14. CHECK FOR DAMAGED PARTS. Inspect guards and other parts before use. Check for misalignment,
binding of moving parts, improper mounting, broken parts, and any other conditions that may affect operation.
If abnormal noise or vibration occurs, turn the tool off immediately and have the problem corrected before
further use. Do not use a damaged tool. Tag damaged tools “DO NOT USE” until repaired. Repair or replace
a damaged guard or other part. For all repairs, insist on identical replacement parts.
15. REMOVE ALL ADJUSTING WRENCHES AND TOOLS from the tool before turning it on. Make this a habit.
16. GROUND YOUR TOOL. See “Electrical Safety,” page 7.

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17. AVOID ACCIDENTAL STARTING. Be sure your tool is turned off before plugging it in. Do not use the tool if
the power switch does not turn it on and off. Observe correct lockout/tag out procedures when performing
maintenance on the tool.
18. DO NOT FORCE THE TOOL. Your tool will perform best at the rate for which it was designed. Excessive
force only causes operator fatigue, increased wear, increased risk of binding or sudden breakage, and
reduced control.
19. KEEP HANDS AWAY FROM ALL CUTTING EDGES AND MOVING PARTS.
20. DO NOT ABUSE THE CORD. Never unplug the cord by yanking it from the outlet. Pull the plug rather than
the cord to reduce the risk of damage. Keep the cord away from heat, oil, sharp objects, cutting edges, and
moving parts.
21. DO NOT OVERREACH. MAINTAIN CONTROL. Keep proper footing and balance at all times. Maintain a
firm grip.
22. STAY ALERT. Watch what you are doing, and use common sense. Do not use a tool when you are tired,
distracted, or under the influence of drugs, alcohol, or any medication causing decreased control.
23. UNPLUG THE TOOL when it is not in use, before changing items such as blades, and before performing
recommended maintenance. Observe appropriate lockout/tag out procedures.
24. MAINTAIN TOOLS CAREFULLY. Keep handles dry, clean, and free from oil and grease. Keep cutting edges
sharp and clean. Follow instructions for lubricating and changing accessories. Periodically inspect tool cords
and extension cords for damage. Have damaged parts repaired or replaced.
25. MAINTAIN LABELS AND NAMEPLATES. These carry important information. If unreadable or missing,
contact Safety Speed for a free replacement.
26. AVOID KICKBACK. Kickback is a violent reaction to a pinched or binding saw blade. It throws the saw
upward when crosscutting and throws the work piece out when ripping. Firm control, proper support of the
work piece, and concentration on the job are essential to reduce the risk of injury from kickback:
a. KEEP SAW BLADE CLEAN AND SHARP. A dull or improperly sharpened blade produces a narrow kerf
and is likely to be pinched by the work piece. Any blade with a small set, even though sharp, may be
likely to kick back. A dull blade encourages you to force the saw, causing reduced control and blade
binding. The excessive friction generated can cause the blade to warp or bind. Use only blades that are
recommended for use with your tool. Do not use blades with mounting holes that are not the correct size
or shape. Never use defective or incorrect blade washers or bolts. Be sure the blade bolt is tight. Select
the proper blade for the application. Blade speed specifications must be at least as high as the
nameplate RPM.
b. DO NOT FORCE THE TOOL. Let the saw do the work. A saw is more easily controlled and will do a
better job when used in the manner for which it was designed.
c. SECURE WORK PROPERLY. If a piece is supported on both sides of the cut in such a way that it allows
the material to bow and pinch the blade, it may produce kickback. Do not cut pieces smaller than the
saw carriage. Support large panels properly.
d. IF THE BLADE BINDS, the saw or work piece may kick back. Keep hands, body, and bystanders out of
the path of the blade and material.
e. STAY ALERT. Watch what you are doing and use common sense. Do not allow yourself to be
distracted. Do not operate the tool when you are tired or under the influence of drugs or alcohol. Hold the
tool and material firmly and exercise control at all times. Position yourself and co-workers out of the
kickback path. Repetitive cuts that lull you into careless movements can also cause kickback. A brief
“stretch” may be all that is necessary to avoid a problem.
f. RESTARTING IN MID-CUT. If the saw is stopped in mid-cut, allow the blade to stop. Then back up the
saw (if crosscutting) or the board (if rip cutting) before restarting.
g. IF THE BLADE STALLS, DO NOT TURN THE SWITCH ON AND OFF. A dull blade or excess pressure
may cause stalling. Release the switch immediately if the blade binds or the saw stalls, and remove the
saw from the cut.
h. AVOID CUTTING NAILS OR OTHER FASTENERS. Inspect for and remove all metal fasteners before
cutting.

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i. SUPPORT THIN MATERIAL. Large sheets such as paneling, Formica, etc., tend to warp or sag and
must be well supported over their entire length to avoid pinching the blade.
27. HANDLE THE COUNTERBALANCE WITH CARE. The counterbalance cable is under tension. Always attach
the cable to the saw carriage before removing the cable clip. Do not pull on the cable by hand or attempt to
disassemble or repair the counterbalance. Replacement counterbalances can be purchased directly from
Safety Speed.
28. DO NOT USE PUSH STICKS.
29. CROSSCUTTING (VERTICAL CUTTING) MUST ALWAYS BE DONE FROM THE TOP DOWN. Raise the
saw carriage to the uppermost position on the guides and lock it into position with the carriage lock whenever
the tool is not in use. See “Operating Procedure: Crosscutting”, for more information.
30. RIPPING (HORIZONTAL CUTTING) MUST ALWAYS BE DONE WITH THE DIRECTION OF THE ARROW.
Raise the saw carriage to the top of the guides and lock it into position with the carriage lock whenever the tool
is not in use. See “Operating Procedure: Rip cutting”, for more information.
31. ALWAYS WAIT FOR THE BLADE TO STOP COMPLETELY BEFORE CHANGING POSITIONS. Unplug the
tool before transporting or moving it.
32. DO NOT PLACE YOUR HANDS ON OR UNDER THE SAW CARRIAGE OR IN THE PATH OF THE BLADE.
Do not try to retrieve a piece of cut material while the blade is rotating. This symbol is to remind you:
33. DO NOT DEFEAT THE GUARDS OR OPERATE THE TOOL WITHOUT THE GUARDS IN PLACE. Do not
remove the saw motor from the carriage.
34. NEVER STAND ON THE TOOL. Serious injury could occur if the tool is tipped or if you unintentionally contact
the cutting tool.
35. DIRECTION OF FEED. Always feed work into the blade or cutter against the direction of the rotation of the
blade or cutter.
36. HOME CENTERS AND COMMERCIAL LOCATIONS should check with their local electrical contractor to be
sure the proper amount of electrical power (volts/amps) will be available for this machine during all operating
hours and conditions. Be aware of any special electrical safety requirements for this machine (examples: key
lock offs, timers, coded security, touch pads, or time lockouts) required by local codes.
37. DISCONNECT AND LOCK THE POWER OFF before changing saw blades or making any adjustments.
38. BEFORE CONNECTING THE SAW MOTOR TO THE POWER SUPPLY BE SURE THE SAW MOTOR
SWITCH IS IN THE OFF POSITION.
39. KEEP THE CARRIAGE LOCK SECURELY TIGHTENED when the machine is not in use.
40. REFER TO PAGE 42 FOR WARNING LABEL IDENTIFICATION.
Please Read Before Operating the Saw
WARNING! Some dust created by power sanding, sawing, grinding, drilling, and other construction activities
contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these
chemicals are:
• Lead from lead-based paint
• Crystalline silica from bricks and cement and other masonry products, and
• Arsenic and chromium from chemically treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure
to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust
masks that are specifically designed to filter out microscopic particles.

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Electrical Safety
WARNING: Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualified electrician if you are not sure that the outlet is
properly grounded. Do not modify the plug provided with the tool. Never
remove the grounding prong from the plug. Do not use the tool if the cord or
plug is damaged. If damaged, have it repaired by a qualified electrician
before use. If the plug will not fit the outlet, have a proper outlet installed by
a qualified electrician.
Some of our machines are equipped with a polarized plug (one blade is wider than the other). This plug
will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it
still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any
way. Double insulation eliminates the need for the three wire grounded power supply system mentioned above.
Do not expose your tool to rain or wet conditions. Water entering a power tool will increase the risk of
electric shock.
The plug must be connected to a properly grounded outlet (see Figure 1). If the tool should electrically
malfunction or break down, grounding provides a low-resistance path to carry electricity away from you, reducing
the risk of electric shock.
Figure 1: Grounded Plug and Outlet
The grounding prong on the plug is connected through the green wire inside the cord to the grounding system in
the tool. The green wire in the cord must be the only wire connected to the tool’s grounding system and must
never be attached to an electrically “live” terminal.
Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes
and ordinances. The plug and outlet should look like those in Figure 1.
Figure 2 illustrates a temporary adapter available for connecting grounded plugs (Figure 1) to two-prong outlets.
The green rigid ear or lug extending from the adapter must be connected to a permanent ground such as a
properly grounded outlet box or receptacle. Simply remove the center screw from the outlet, insert the adapter
and reattach the screw through the green grounding ear to the outlet. If in doubt of proper grounding, call a
qualified electrician. A temporary adapter should only be used until a qualified electrician can install a properly
grounded outlet. The Canadian Electrical Code prohibits the use of temporary adapters.
Figure 2: Temporary Grounding Adapter

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Extension Cords
Grounded tools require a three-wire extension cord. As the distance from the supply outlet increases, you must
use a heavier-gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible tool damage. Refer to Table I below to determine the required
minimum wire size.
Table I: Recommended Minimum Wire Gauge for Extension Cords
Extension Cord Length *
Nameplate Amps 25’(7.6m) 50’(15m) 75’(23m) 100’(31m) 150’(46m) 200’(61m)
< 5 16 16 16 14 12 12
5 - 8 16 16 14 12 10 
8 - 12 14 14 12 10 
12 - 15 12 12 10 10 
15 - 20 10 10 10 
* based on limiting the line voltage drop to 5V at 150% of the rated amperes.
The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14-gauge cord
can carry a higher current than a 16-gauge cord. When using more than one extension cord to make up the total
length, be sure each cord contains at least the minimum wire size required. If you are using one extension cord
for more than one tool, add their nameplate amperes and use the sum to determine the required minimum wire
size.
Guidelines for Using Extension Cords
If you are using an extension cord outdoors, be sure it is marked with the suffix “W-A” (“W” in Canada) to indicate
that it is acceptable for outdoor use.
Be sure your extension cord is properly wired and in good electrical condition. Always replace a damaged
extension cord or have it repaired by a qualified person before using it.
Protect extension cords from sharp objects, excessive heat, and damp or wet areas.
Short-Circuit Protection
This tool must only be plugged into a circuit that has a short-circuit protection device which is located ahead of the
equipment in the circuit, in accordance with local codes.
General guidelines are as follows:
120 volt: 20 amp protection
These models can include: C4, C5, H-series, 6400/6800, 3400, TR-2, SR5, SR5U
220 volt: 10 amp protection
These models can include: C4, C5, H-series, 6400/6800, 3400, TR-2, SR5, SR5U
Reference your motor label and your local codes before installation.
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE REFERENCE.

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INSTALLATI N
Your Safety Speed saw or router comes from the factory assembled and aligned. You will only have to mount the
following parts before you can run this tool:
•Counterbalance (on Models C4, C5, H-Series, and SR5)
•Motor (except for Models 6400/6800, 7400/7400XL, and the SR5/SR5U)
•Cord keeper (except for Models 7400 and 7400XL).
If you have ordered a Frame Stand, Frame Wheels, Dust Collector, or other accessories, you will find assembly
instructions packed with them (and repeated at the end of this manual).
Tools Required for Installation
NOTE: Additional tools may be required for installing accessories.
•7/16” wrench
•9/16” wrench (for Frame Stand Accessory)
•5/8” wrench
•3/4” wrench (for Frame Wheels Accessory)
•9/16” blade wrench (provided)
perating Environment
For safe operation, install the tool in an area that is well lit. Eliminate all shadows that could interfere with clear
viewing of the work area.
Do not locate the tool in a damp or wet location, or a location where it may be exposed to rain.
If the tool will be operated in an enclosed area, SSC recommends installing a Dust Collection System (see pg 34).
Avoid explosive atmospheres (gaseous fumes, dust, or flammable materials).
Secure the area so that children and bystanders are kept a safe distance from the work area. Provide barriers
and shields as needed.
NOTE: The average noise level of SSC saws and routers is less than 80 dB.
Unpacking
1. Remove all the plastic sheeting, protective cardboard, and wood crating.
2. One or more boxes of parts are attached to the frame. The cord keeper is taped to the carriage. Remove
these items for later installation.
Machine Assembly
Installing the Counterbalance (if required-C4, C5, H-series, and SR5)
WARNING: To reduce the risk of injury or damage to components, do not attempt to
disassemble or repair the counterbalance. Do not pull on the counterbalance
cable. The cable is under strong spring force: the unit must be properly
assembled before you remove the cable clip.

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A counterbalance is used on Models C4, C5, H-Series, and SR5, to offset the weight of the carriage and saw or
router. Other models use a counterweight system that is factory installed.
The counterbalance is shipped with the necessary hardware attached, and is in the box marked “Saw Motor.”
Remove the two 1/4-20 x 1/2” carriage bolts, nuts, and washers from the counterbalance. Do not remove the bolt
and nut that are on the counterbalance cable.
1. Pull the end of the cable from the inside of the counterbalance. Set the counterbalance on top of the tool
frame, slightly off-center to either the left or right, so that the cable is aligned vertically with an oval hole near
the top of the carriage. See Figure 3. Some model tools have two oval holes in the carriage, one off-center
each way; other models have only a single hole. (Do not mount the counter balance in the center holes)
2. Secure the counterbalance to the top of the tool frame, using the two attached carriage bolts, washers, and
nuts. Tighten the nuts securely.
Figure 3: Installing the Counterbalance
3. Hold the carriage securely while you loosen the red carriage lock (Figure 13 through Figure 18). Raise the
carriage until the hole in the top of the carriage aligns with the eye in the end of the counterbalance cable,
making sure the cable is behind the carriage. Then lock the carriage rip lock.
4. Hold the cable end behind the carriage. Remove the carriage bolt and nut, and use them to attach the end of
the counterbalance cable end to the oval hole in the carriage. Tighten securely.
5. Bend the cable clip tabs forward by hand, so they look like the ones in Figure 4.
Figure 4: Attaching the Counterbalance Cable
6. Loosen the carriage lock and lower the carriage until the cable clip is fully exposed, then lock the carriage rip
lock. Remove the cable clip from the counterbalance cable and save it for future use (e.g., if you remove the
counterbalance in the future, you will need the cable clip to support the tension in the counterbalance).
Standing Up the Tool
With the help of an assistant, stand up the tool and position it in its intended operating location:
•If the tool is to be mounted to the floor, or to a wall or post, it must be attached securely to avoid injury from
tipping.