4. POWER TOOL USE AND CARE a. Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d. Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e. Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tools operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g. Use the power tool, accessories and tool bits etc., in accordance with these instructions and in the manner intended for the particular type of power tool, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. 5. SERVICE a. Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. Electrical Safety The electric motor has been designed for one voltage only. Always check that the power supply corresponds to the voltage on the rating plate. 230 V AC means your tool will operate on alternating current. As little as 10% lower voltage can cause loss of power and can result in overheating. All DEWALT tools are factory tested; if this tool does not operate, check the power supply. Your DEWALT tool is double insulated, therefore no earth wire is required. • Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision. Young children should be supervised to ensure that they do not play with this appliance. • Replacement of the supply cord. If the supply cord is damaged, it must be replaced by the manufacturer or an authorised DEWALT Service Centre in order to avoid a hazard. Extension Cords DW682-XE PLATE JOINER INSTRUCTION MANUAL CAUTION: Use only extension cords that are approved by the country’s Electrical Authority. Before using extension cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary. MINIMUM GAUGE FOR CORD SETS For Cable length (m): 7.5 15 25 30 45 60 Use Cable with minimum rating (Amperes) Tool Amperes 0 - 3.4 7.5 7.5 7.5 7.5 7.5 7.5 3.5 - 5.0 7.5 7.5 7.5 7.5 10 15 5.1 - 7.0 10 10 10 10 15 15 7.1 - 12.0 15 15 15 15 20 20 12.1 - 20.0 20 20 20 20 25 – DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 • 20 Fletcher Road, Mooroolbark, VIC 3138 Australia (JUL10) Part No. N075831 DW682-XE Copyright © 1997, 2006, 2010 DEWALT The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool. Definitions: Safety Guidelines The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols. DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE: indicates a practice not related to personal injury which, if not avoided, may result in property damage. IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US AT: 1800 654 155 (Aust) or 0800 339258 (NZ). SAFETY INSTRUCTIONS FOR POWER TOOLS When using power tools, always observe the safety regulations applicable in your country to reduce the risk of fire, electric shock and personal injury. Read the following safety instructions before attempting to operate this product. Keep these instructions in a safe place. General Safety Rules WARNING! Read all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term “power tool” in all of the warnings listed below refers to your mains operated (corded) power tool or battery operated (cordless) power tool. SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE 1. WORK AREA a. Keep work area clean and well lit. Cluttered and dark areas invite accidents. b. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. c. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. 2. ELECTRICAL SAFETY a. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b. Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. 3. PERSONAL SAFETY a. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. b. Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c. Avoid accidental starting. Ensure the switch is in the off position before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents. d. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. e. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of these devices can reduce dust related hazards. Additional Safety Warnings for Jointers • Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator. • Saw blades must be rated for at lest the speed recommneded on the tool. Saw blades running over the rated speed can fly apart and cause injury. • ALWAYS use a guard. The guard protects the operator from broken saw blade fragments and unintentional contact with the saw blade. WARNING: ALWAYS wear approved protective safety equipment complying with the following standards: • Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications; • Hearing protection: AS/NZS1270 Acoustics – Hearing Protection; • Respiratory protection: AS/NZS1716 Respiratory Protective Devices. 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 paints, • crystalline silica from bricks and cement and other masonry products, and • arsenic and chromium from chemically-treated lumber (CCA). 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 specially designed to filter out microscopic particles. • Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals. WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. Always use AS/NZS standard approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body. WARNING: We recommend the use of a residual current device with a residual current rating of 30mA or less. CAUTION: Wear appropriate personal hearing protection during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss. • The label on your tool may include the following symbols. The symbols and their definitions are as follows: V .........................volts A .......................... amperes Hz .......................hertz W ......................... watts min .....................minutes ...................... alternating current ................direct current ...................... alternating or direct current no ........................ no load speed ......................Class I Construction ...........................(grounded) ........................ earthing terminal ......................Class II Construction ....................... safety alert symbol ...........................(double insulated) BPM ..................... beats per minute …/min ................per minute RPM..................... revolutions per minute sfpm ...................surface feet per minute SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Introduction Examine Figure 1 and your plate joiner for a few minutes to become familiar with the various features and the names used to describe them. The following sections will discuss the various controls and you will need to know where they are. Overview You have purchased a precision woodworking tool. The function of the plate joiner is to enable you to make extremely strong and accurate joints in wood and wood by products. The tool works by a plunging action to precisely cut crescent shaped slots for the placement of flat wooden dowels or “biscuits” like those shown in Figure 2. The various adjustments on the patented base/fence assembly will enable you to make virtually any biscuit joint imaginable. The tool may be further enhanced by some simple jigs and fixtures that can be easily made. Some of the more common biscuit joinery applications are shown in Figure 3 and are discussed in detail in the applications section of this manual. ASSEMBLY AND ADJUSTMENTS WARNING: To reduce the risk of injury, turn unit off and disconnect tool from power source before installing and removing accessories, before adjusting or changing set-ups or when making repairs. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury. Switch Your plate joiner has a trigger switch located on the underside, as shown in Figure 1. To turn the tool on, depress the trigger. To turn the tool off, release the trigger. To lock the tool on for continuous operation, there is a lock on button located at the rear of the tool just above the cord. When cutting always hold the tool with one hand on the switch handle and one hand on the auxiliary handle. To lock the tool on, depress and hold the trigger as you depress the lock button. Hold the lock button in as you gently release the trigger. The tool will continue to run. To turn the tool off from a locked on condition, depress and release the trigger once. Blade Replacement In time your saw blade will wear out and need replacement. To remove the blade, follow the steps below. 1. Turn off and unplug the plate joiner. 2. Remove the four torx head screws from the bottom of the shoe, using the T20 torx screwdriver provided. 3. Rotate the shoe out of the way. 4. Use the spanner wrench provided to loosen (counterclockwise) the blade nut. Depress the spindle lock pin on the top of the gear case to hold the spindle while you unscrew the nut. 5. Remove the blade and have it sharpened or replace it with a new one. 6. Reinstall the blade by reversing the steps above. Be sure blade teeth point counterclockwise as shown in Figure 4. 7. IMPORTANT: Always check the fine depth adjustment when sharpening or replacing the blade. Adjust if necessary. (See Controls). The Controls SPINDLE LOCK PIN FIG 1 DANG _B E R: LOCK ON BUTTON R 0 75 90 GH PER HI ANTI-SLIPPAGE PIN OOLS MA LT D E IN T H E U . S . A . PLUNGE DEPTH ADJUSTMENT KNOB FIXED SHOE AUXILIARY HANDLE HEIGHT ADJUSTMENT KNOB LOCK KNOB DUST EXHAUST PORT FIG 2 FIG 3 (FLAT BISCUITS) FIG 4 FIG 5 ADJUSTMENT KNOB R LOCK KNOB FIG 7 FIG 6 POINTER POINTS TO 12.7 mm (1/2") MARK M 20 R 0 10 1. EDGE TO EDGE JOINTS (Figure 16) This is the simplest to make and most common joint for the plate joiner. Follow the steps below to produce this joint. A. Prepare the workpieces and lay them on a work surface exactly as they are to be assembled. B. Spacing biscuits 50 mm – 75 mm (2-3") in from the ends and 150 mm – 250 mm (6–10") apart, layout the biscuit centers. C. Set up the plate joiner by first selecting the proper depth setting. Set the fence to 90°. Set the height adjustment to position the biscuit in the approximate center of the stock thickness. D. Clamp the workpiece and position the tool so that the center indicator mark lines up with the first layout mark (Figure 17). Turn on the tool and make the plunge cut. Retract the tool and release the trigger to turn the tool off. Repeat for each layout mark. E. Glue, assemble and clamp the joint. F. For stock thicker than 25 mm (1"), you may wish to use double biscuits at each location. Set the height adjustment to allow at least 4.76 mm (3/16") of stock between the biscuit and the edge of the work surface. Make all cuts at this fence setting before readjusting the fence for the lower cuts. Again, there should be at least 5 mm (3/16") of stock between the biscuit and the outside wall and between the biscuits themselves (Figure 18). 2. FRAME JOINTS (Figure 19) Frame joints are an ideal application for biscuit joinery. With the plate joiner you can create a very strong, precise joint that is much faster to make than a dowel or mortise and tenon joint. Figure 19 shows two types of frame joints. Follow the steps outlined below. A. Arrange the workpieces on a flat work surface exactly as they are to be assembled. 60 Applications TRIGGER SWITCH ANCE INDUSTR IA ORM F OPERATION WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. Plate joiners are primarily used for making cabinetry and furniture, joining millwork or other similar applications where a strong, accurate joint is required in wood or wood by-products. There are literally hundreds of variations of joints that can be made with your Plate Joiner. We will limit our discussion to six basic joints that can be used to build on and adapt to your own applications. The following are some basic set-up steps that will apply to all biscuit joints. 1. BISCUIT SIZE SELECTION As mentioned earlier, the three biscuit sizes are #0, #10 and #20. It is a good rule of thumb to use the largest biscuit size that will physically fit in the application. Unless you are joining narrow face or picture frames or using 12 mm (1/2") or thinner stock, you will find the #20 biscuit size to suit most applications. After selecting the biscuit size, set the depth adjustment knob to the corresponding size (see Controls section). Also, be sure the fine depth adjustment is correctly set by first testing in a scrap piece. This is extremely important as you do not want to discover during glue-up that your biscuit slots are not quite deep enough. 2. BISCUIT LOCATION AND LAYOUT Generally, biscuits may be spaced and located at your discretion. For edge joints, a good rule of thumb is to space biscuits every 150 mm – 250 mm (6–10") on center. It is further recommended that biscuits be placed so that the centerline of the end biscuits is 50 mm – 75 mm (2-3") from the end of the workpiece. When joining face frames or picture frames where the workpiece is narrow, you may have to choose the smaller biscuit sizes to keep from “breaking out" on the end of the joint. Breaking out should be avoided if possible, but if not you can assemble the joint and trim off the exposed biscuit tip after the glue sets (Figure 13). When working with material up to 25 mm (1") thick, we advise to use a single biscuit located in the approximate center of the material thickness. If thicker stock is to be joined, you may choose to use 2 biscuits across the thickness for greater strength (Figure 14). Biscuit locations should be marked by first positioning the mating pieces exactly as they are to be assembled. Next, make a mark at 90° to the joint interface across both pieces at the desired biscuit locations (Figure 15). See Application section for more specific information on joint layout. The marks you make will then be aligned with one of the center registration marks on the tool, again, depending upon your specific application. 3. MAKING THE CUT Prior to making any cut, be sure that all fence adjustments are set and lock knobs are tight. Also, be sure you have selected the proper depth setting. Clamp your workpiece firmly and align the plate joiner’s center registration mark with your layout mark. Turn on the tool and let the blade come up to full speed (approximately 1 second). Grasping the switch handle and auxiliary handle and positioning the fence firmly and squarely against the workpiece, plunge the blade until it bottoms against the stop. Continuing to hold the tool squarely and firmly, allow the return spring to retract the blade from the work and then release the switch to shut the tool off. It will take some practice to obtain a “feel” for the tool to produce accurate joints, so practicing in scrap wood first is advisable. 4. JOINT ASSEMBLY After your joints are cut, you may wish to trial fit everything together before gluing. When you are satisfied with your joints, evenly spread any good quality woodworking glue in each slot as well as on the mating flat surfaces of your joint. Place biscuits in the slots, assemble the joint and clamp until dry. For a biscuit joint to be most effective, it is important that the biscuits themselves be in contact with the glue. This is because the biscuits absorb the moisture in the glue and expand to form a tight joint. 15 30 ADJUSTABLE FENCE 45 The heart of your plate joiner is the base/fence assembly. All of the controls that let you make a variety of precision cuts are located on this assembly. Take a few minutes to become familiar with the various controls. ALWAYS TURN OFF AND UNPLUG PLATE JOINER BEFORE MAKING ANY ADJUSTMENTS. 1. ADJUSTABLE FENCE The adjustable fence provides a sturdy, precise reference surface to determine the point at which the slots for the biscuits will be cut. Its adjustable height feature allows you to position biscuit slots as close as 5 mm (3/16") and as distant as 35 mm (1-3/8") measured from the workpiece surface to the centerline of the blade (Figure 6). The adjustable angle feature allows a full range of settings from 0° to 90 as well as a reverse 45° bevel which allows outside registration on miter joints. (See Applications section under Miter Joints, Figure 26.) The height adjustment is accomplished by first loosening the lock knob on the right side of the fence and then rotating the knurled adjustment knob until the desired height is reached (Figure 5). Tightening the lock knob will then automatically align the fence parallel to the blade and lock it in position. The vertical scale and pointer located directly under the lock knob can be used to assist in setting this height. The scale readings indicate distance from the blade centerline to the fence surface when the fence is set at 90° (see Figure 6). The fence angle can be set simply by loosening the lock knob on the left side of the tool, aligning the protractor scale with the pointer and tightening the lock knob. 2. PLUNGE DEPTH ADJUSTMENT The depth of cut can be set to match the dimensions of the particular size biscuit you will be using. The numbers on the depth adjustment knob (0, 10, 20, M) coincide with the three sizes of biscuits shown in Figure 2. The letter M stands for the maximum depth capacity of the tool which is 20 mm (25/32"). This depth is obtainable only with a new blade and by backing out the fine adjustment screw (see next section). NOTE: The M setting has been provided for future use and will not be necessary for most biscuiting operations. To select a depth, align the appropriate number with the red mark scribed in the tool’s housing, as shown in Figure 7. Rotate the depth adjustment knob to the desired position and it will “click” into place. 3. FINE DEPTH ADJUSTMENT You may encounter situations where you want to leave a little looseness in your joint so that you can move it slightly before the glue sets up. For these instances a fine depth adjustment has been provided. To adjust, you must first raise the adjustable fence to its uppermost position. Then insert the T20 torx wrench provided into the opening as shown in Figure 8. Turn the depth adjustment screw clockwise for less depth and counterclockwise for increased depth. Each full turn causes a change in depth of 1 mm (0.04"). Always check the depth adjustment by first making test cuts in scrap wood. 4. ANTI-SLIPPAGE PINS Plate Joiners tend to slide to the right with respect to the workpiece when making a cut. This tendency is increased with a dull blade or when plunging very rapidly. Anti-slippage pins have been provided to reduce this tendency and are located on the front registration surface on either side of the blade opening slot. When making some joints, you may wish to retract the anti-slippage pins so as not to scratch your workpiece in a visible area. For this purpose, simply rotate the anti-slippage pins approximately 1/6 of a turn and they will retract back behind the front registration surface. A flat blade screwdriver can be used to rotate the pins as shown in Figure 9. 5. BOTTOM REGISTRATION SURFACE For certain applications, you will want to use the bottom surface of the plate joiner for alignment. When using the bottom registration surface, the adjustable fence should be set to 0° and the height setting is unimportant. This surface is used primarily when making ‘T’ joints (see applications section). The distance between the centerline of the blade and the bottom registration surface is fixed at 9.5 mm (3/8") which allows centering on 19mm (3/4") thick stock. The 3 red marks on the bottom registration surface indicate the centerline (or the deepest point) of the biscuit cut and the approximate width of a #20 biscuit so that you’ll know where the edge of the blade is and can prevent breakthrough. To avoid breaking through the workpiece, align the shoe so that neither outside mark extends beyond the end of the workpiece. If either side does, there is a good chance that the blade will break through the surface and ruin your work. 6. DUST EXTRACTION There are three options provided for collecting dust from your plate joiner as described below. A. Adjustable Direction Elbow (Figure 10) This attachment inserts into the dust exhaust port on the right side at the rear of the base assembly and clicks into place. To remove, pull out firmly. The directional elbow rotates easily to aim the dust in the most convenient direction suitable for the particular application. B. Dust Adaptor (Figure 11) This attachment, when inserted as described above, allows the use of several common sizes of vacuum hose to be attached for direct vacuum pick-up of the dust. C. Dust Bag (Figure 12) The dust bag provided fits snugly over the dust adaptor described above. To empty the bag, open the zipper underneath and dump dust out. NOTE: When the bag becomes full, the dust will back-up into the adaptor and the exhaust port on the right rear of the tool. To clean out, turn off and unplug the tool and remove packed dust. The bag will hold the dust generated from approximately 70 to 100 #20 biscuit cuts before filling up. 12.7 mm (1/2") CENTERLINE OF BLADE RED MARK FIG 8 FIG 9 R FINE DEPTH ADJUSTMENT ANTI-SLIPPAGE PIN FIG 11 FIG. 10 R R ROTATE ELBOW FOR DESIRED EXHAUST DIRECTION VACUUM HOSE CONNECTION FIG 13 R FIG 12 R PROTRUDING BISCUIT END (TRIM OFF WITH SAW AND SAND SMOOTH) FIG 15 FIG 14 FIG 17 FIG 16 R 25 mm (1") OR GREATER STOCK THICKNESS FIG 18 5 mm (3/16") MINIMUM FIG 21 FIG 20 FIG 19 5 mm (3/16") MINIMUM R 5 mm (3/16") MINIMUM FIG 25 FIG 23 FIG 22 FIG 24 POSITION BISCUIT CLOSER TO INSIDE EDGE TO INCREASE DIMENSION “A” FIG 26 INSIDE EDGE REVERSE 45° BEVEL: ALLOWS OUTSIDE REGISTRATION ON MITER JOINTS. (NOTE: THE TOOL IS REGISTERED AGAINST THE OUTSIDE SURFACE.) R A FIG 28 FIG 29 “T” JOINT FIG 27 FIG 30 3. CORNER JOINTS (Figure 21) Corner joints are another common and excellent application for biscuit joinery. Follow the procedure below. A. Arrange the workpieces exactly as they are to be joined. B. Select the biscuit size and layout the biscuit locations. C. Set up the tool by selecting the proper depth setting, adjusting the fence to center on the stock thickness and setting the angle to 90°. D. For this joint, you will make cuts into the edge of one workpiece and the face of another. The edge cut is performed the same as for edge to edge joints. The face cut is made by clamping the workpiece and aligning the tool as shown in Figure 22. Turn the tool on, make the plunge cut and repeat for each layout mark. E. Glue, assemble and clamp the joint. 4. OFFSET JOINTS (Figure 23) You may wish to have a deliberate offset between two workpieces. This is easily accomplished with your plate joiner by performing the following steps. A. Arrange the workpieces as they are to be assembled and layout the biscuit locations. B. Set up the tool by selecting the proper biscuit size and adjusting the fence angle to 90°. Select the workpiece that will be set back and adjust the fence height to center the cut within the thickness of that piece. C. Clamp the workpiece, align the tool and make the plunge cut. D. Next, adjust the fence up by an amount equal to the desired offset. Use the scale and pointer located on the right side of the tool under the fence lock knob. E. Clamp the second workpiece, align the tool and make the plunge cut. F. Glue, assemble and clamp the joint. 5. EDGE MITER JOINTS (Figure 24) Edge miters are most commonly used in box structures or for making multisided pedestals where you would like to hide the end grain. Once again, biscuit joinery is an outstanding method to use both for added strength as well as ease of assembly. Follow the steps below to assemble a 90° joint. A. Position the workpieces as they are to be assembled and layout biscuit locations on the outside of the joint. B. Set up tool by first setting fence angle to 90°. Make the fence adjustment such that the biscuit is located toward the inside of the joint where the material is thicker, then select the biscuit size so that the blade does not protrude through the outside wall when the cut is made (Figure 25). C. Clamp the workpiece and align the tool as shown in column in Figure 26. D. Turn on the tool and make the plunge cut. E. Glue, assemble and clamp the joint. F. For joints other than 90° see outside registration column Figure 27 for proper fence angle setting. The above method will produce a joint where the outside surfaces of the joint are aligned. If you wish to produce a joint where the inside surfaces are aligned, use the following procedures for a 90° joint. A. Position workpieces as they are to be assembled. B. Layout biscuit locations on the inside of the angle. C. Set up tool by setting fence angle to 45°. Set vertical fence adjustment so that the biscuit is located toward the inside of the joint where material is thicker. Select biscuit size so that the blade does not protrude through the outside face of the material. D. Clamp the workpiece and align the tool as shown in Figure 28. E. Make the plunge cut and repeat for all biscuit locations. F. Glue, assemble and clamp the joint. G. For joints other than 90° see inside registration column in Figure 27 for proper fence angle setting. 6. T-JOINTS (Figure 29) Biscuit joining is a viable alternative to dadoing when making a T-joint. T-joints are most commonly used when attaching shelves to the sides of a case. The method described below will work if your shelf material is at least 5/8" thick. A. Place the workpieces on a work surface exactly as you will be assembling them in the form of an upside down “T.” Mark lightly along the joint where the top of the shelf is to end up (Figure 30). Mark biscuit locations at the joint interface on the shelf piece only. B. Lay the shelf down on the mating workpiece. Clamp the two workpieces together and to the work surface in this position (Figure 31). FIG 32 LAYOUT LINE FIG 33 R B. Select the proper biscuit size based on the length of the joint. (If the frame pieces are too narrow for a #0 biscuit, you will have to allow the biscuit tip to protrude slightly and then trim it off after the joint is dry (Figure 13). C. Lay out the biscuit locations. D. Set up the tool by selecting the depth that corresponds to the chosen biscuit size. Lock the fence at 90° and adjust the fence height to center the biscuit on the stock thickness. E. Clamp the workpiece and position the Plate Joiner to make the first cut (Figure 20). F. Turn on the tool and make the plunge cut. G. Repeat for each layout mark. H. Glue, assemble and clamp the frame. FIG 31 C. Set up the tool by selecting the proper biscuit size and setting the adjustable fence angle at 0°. D. Using the bottom registration surface, align the tool with the biscuit location marks and make a vertical and a horizontal plunge cut for each biscuit location as shown in Figure 32. E. Glue, assemble and clamp the joint. MAINTENANCE WARNING: To reduce the risk of injury, turn unit off and disconnect tool from power source before installing and removing accessories, before adjusting or changing set-ups or when making repairs. Be sure the trigger switch is in the OFF position. An accidental start-up can cause injury. Repairs To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by certified service centers or other qualified service organizations, always using identical replacement parts. ACCESSORIES WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT, recommended accessories should be used with this product. Recommended accessories for use with your tool are available at extra cost from your local service center. If you need any assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 20 Fletcher Road, Mooroolbark, VIC 3138 Australia or call 1800 654 155 or (NZ) 0800 339258. Guarantee Applicable to hand held Power Tools, Lasers and Nailers. Three Year Limited Warranty DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. Please return the complete unit, transportation prepaid, to any DEWALT Service Centre, or any authorised service station. For warranty repair information, call (AUS) 1800 654 155 or (NZ) 0800 339258. This warranty does not apply to • Accessories • Damage caused where repairs have been made or attempted by others. • Damage due to misuse, neglect, wear and tear, alteration or modification. This warranty gives you specific legal rights and you may have other rights under the provisions of the Consumer Guarantee Act 1993 (New Zealand only), Trade Practices Act 1974 and State Legislation (Australia only). In addition to the warranty, DEWALT tools are covered by our: FREE ONE YEAR SERVICE CONTRACT DEWALT will also maintain the tool for free at any time during the first year of purchase. This includes labour, parts and lubrication required to restore the product to sound mechanical and/or electrical condition. Normal wear parts are not covered in this service. Carbon brushes worn more then 50% will be replaced. NOTE: Three Year Warranty is not applicable to items deemed as consumables. Radial arm saws are covered by a one (1) year warranty only. DEWALT Reserves the right to review its warranty policy prior to launch of any new business development products. 30 DAY NO SATISFACTION GUARANTEE If you are dissatisfied with any DEWALT power tool, laser or nailer, for any reason, simply return it to the point of purchase with your sales receipt within 30 days for a replacement unit or a full refund. FREE WARNING LABEL REPLACEMENT: If your warning labels (Fig. 33) become illegible or are missing, call (AUS) 1800 654 155 or (NZ) 0800 339258 for a free replacement.