Ace 16" Scroll Saw Instruction Manual

Limited Warranty

Products for Home Use

Manufacturuer (Seller) warrants to the original Buyer only, that each product will be free from defects in material and workmanship for a period of one (1) year from date of purchase. SELLER’S SOLE

OBLIGATION AND BUYER’S EXCLUSIVE REMEDY UNDER THIS LIMITED WARRANTY SHALL BE

THE REPAIR OR REPLACEMENT OF PARTS, WITHOUT CHARGE, WHICH ARE DEFECTIVE IN

MATERIAL OR WORKMANSHIP. ANY PARTS AS DETERMINED BY THE SELLER WHICH HAVE BEEN

MISUSED; ABUSED OR DAMAGED EITHER DIRECTLY OR INDIRECTLY FROM REPAIRS OR

ALTERATIONS ATTEMPTED BY UNAUTHORIZED PERSONS; IMPROPER MAINTENANCE, NEGLECT

OR ACCIDENT ARE NOT COVERED BY THIS LIMITED WARRANTY. This warranty does not apply to damage, heat-induced coloration changes, scratching or alteration due to normal use or weathering. To make a claim under this Limited Warranty, you must return the complete product with proof of purchase, transportation prepaid, to any Manufacturuer's authorized service center. Call 1-888-424-3354 for the location of the nearest authorized service center.

Additional Limitations

THIS LIMITED WARRANTY DOES NOT APPLY TO ACCESSORY OR CONSUMABLE ITEMS RELATED

TO THIS PRODUCT. ALL IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO ONE (1) YEAR

FROM DATE OF PURCHASE. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS,

ARISING FROM THE SALE OR USE OF THIS PRODUCT.

If any provision of this Limited Warranty is for any reason held to be invalid or unenforceable, such provision shall not affect any other provision herein, this Limited Warranty shall be construed as if such invalid and/or unenforceable provision had never been contained herein.

This Warranty contains the entire agreement between Seller and Buyer and supersedes any and all prior agreements, arrangements, or understandings between the parties relating to product warranty.

IF YOU HAVE ANY PROBLEMS OR QUESTIONS CONCERNING THIS PRODUCT,

DO NOT RETURN IT TO YOUR RETAILER , CONTACT CUSTOMER SERVICE AT

1-888-424-3354 .

NOTE: This product is intended for residential, non-commercial use.

Due to ongoing product development the actual product or products may vary from the illustrations or photos shown within this manual.

Scroll Saw

Technical Data

Type/Model

Throat Depth

Blade Length

Max Cutting Depth

No Load Speed

Table Tilt

2205375/60701040

16 in. (406 mm)

5 in. (127 mm)

2 in. (55 mm)

400-1600 SPM (Strokes per min)

0-45 degrees to the left

200409rev1

Manufactured in China for

Ace Hardware Corp.

Oak Brook, Illinois 60523, USA©2009 www.acehardware.com

16" Scroll Saw

Instruction Manual

Ace No. 2205375

Model No: 60701040

Read the instructions and precautions before use of this product

Please keep this instruction manual for future reference

IF YOU HAVE ANY PROBLEMS OR QUESTIONS CONCERNING THIS PRODUCT,

DO NOT RETURN IT TO YOUR RETAILER , CONTACT CONSUMER SUPPORT AT

1-888-424-3354

OR

IF YOU ARE A STORE MANAGER OR EMPLOYEE IN NEED OF ASSISTANCE CALL

1-888-851-5569

PLEASE HAVE YOUR STORE NUMBER READY

GENERAL SAFETY RULES

WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instructions listed below may result in electric shock and/or serious personal injury.

NOTE: This stationary tool has been manufactured in accordance with the applicable standard and equipment safety legislation. When using electrical appliances, it is important to take safety precautions to avoid possible injury and damage. For that reason, you should carefully read and store these instructions so that this information is available at all times.

SAVE THESE INSTRUCTIONS.

1. KEEP GUARDS IN PLACE and in working order.

2. REMOVE ADJUSTING KEYS AND WRENCHES.

Form habit of checking to see that keys and adjusting wrenches are removed from tool before turning it on.

3. KEEP WORK AREA CLEAN.

Cluttered areas and benches invite accidents.

4. DON'T USE IN DANGEROUS ENVIRONMENT.

Don't use power tools in damp or wet locations, or expose them to rain. Keep work area well lighted.

5. KEEP CHILDREN AWAY.

All visitors should be kept safe distance from work area.

6. MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys.

7. DON'T FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

8. USE RIGHT TOOL.

Don't force tool or attachment to do a job for which it was not designed.

9. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.

10. ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

11. SECURE WORK. Use clamps or a vise to hold work when practical. It's safer than using your hand and it frees both hands to operate tool.

12. DON'T OVERREACH. Keep proper footing and balance at all times.

13. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance.

Follow instructions for lubricating and changing accessories.

14. DISCONNECT TOOLS before servicing; when changing accessories, such as blades, bits, cutters, and the like.

15. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off position before plugging in.

16. USE RECOMMENDED ACCESSORIES. Consult the owners manual for recommended accessories. The use of improper accessories may cause risk of injury to persons.

17. NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.

18. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function ñ check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

19. DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only.

20. NEVER LEAVE TOOL RUNNING UNATTENDED. Turn Power OFF. Don't leave tool until it comes to a complete stop.

TROUBLESHOOTING

WARNING:

To prevent the saw from starting accidentally and causing serious injury, turn off and unplug the saw before carrying out any maintenance work on the saw.

WARNING:

Failure to unplug your saw could result in accidental starting and cause serious injury.

PROBLEM

Motor will not run.

CAUSE SOLUTION

1. Problem with ON-OFF Switch, • Have worn parts replaced before power cord or outlet using your scroll saw again. Have a proper outlet installed by a

2. Motor defective qualified electrician.

• Do not attempt any repair. Have it replaced by a qualified service technician

Blades breaking.

1. Too much tension.

2. Feeding too quickly.

3. Wrong blade.

4. Blade twisting in wood.

• Adjust blade tension

• Reduce feed rate.

• Narrow blades are for cutting thin wood or tight corners and curves, wide blades are for thicker wood wide curves.

• Reduce side pressure on blade, check blade tension.

Vibration (there is always when the saw is running).

1. Improper mounting of saw.

• Check mounting.

a certain amount of vibration 2. Improper bracing.

3. Loose table or table resting against motor.

4. Loose motor mounting.

• Check saw mounting instructions.

• Tighten table lock knob.

• Tighten motor mounting bolts.

Blade runout (blade not properly aligned with arm motion).

1. Blade holders out of line • Realign blade holders and blade.

ACCESSORIES

WARNING:

RISK OF PERSONAL INJURY. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.

Recommended Accessories:

• Scroll saw blades

• Workpiece supports

• Workpiece clamps

• Lubricating oil

• Hydrophobic grease

1 14

Arm Bearing (Figure 15)

1. Lubricate the arm bearings after the first 10 hours of use. Oil them every 50 hours of use or whenever the bearing squeaks.

2. Carefully place the saw on its side as shown in figure 15.

3. Remove the rubber cap (1) from the upper and the lower arm of the saw.

4. Squirt a few drops of oil (2) on the end of the shaft and arm bearings.

5. Leave the saw in this position overnight to allow the oil to soak in.

NOTE: Lubricate the bearings on the other side of the saw in the same manner

Figure 15

1

2

Carbon Brushes (Figure 16)

The saw's motor has externally accessible carbon brushes that should be checked periodically for wear. When one of the two brushes becomes worn, replace both brushes.

Figure 16

1. Unplug the saw from the power source.

2. Carefully place the saw on its side exposing the underside of the saw housing.

1

3. Using a flat blade screwdriver, remove the bottom brush assembly cap (1) through the access hole in the base and the top brush assembly cap from the top of the motor.

2

4. Gently pry the brush assemblies (2) out using a small screwdriver, the pointed end of a nail or paper clip.

5. If one of the brushes is worn down shorter than one fourth of an inch (6 mm) in size, replace both brushes. Do not replace one brush without replacing the other at the same time.

Make sure the curvature at the end of the brush matches the curvature on the motor and that each carbon brush moves freely into its brush holder. Use the blunt end of something thin

(e.g. eraser end of a pencil) to push the carbon brush into its holder until it is in place.

6. Make sure the brush cap is positioned correctly (straight). Tighten the carbon brush cap using a hand powered screwdriver only. Do not over tighten.

WARNING:

To prevent accidental starting that could cause serious injury, turn off and unplug the saw before carrying out any maintenance work on the saw.

WARNING:

Failure to unplug your saw could result in accidental staring causing serious injury.

13

ELECTRICAL SAFETY

Grounding Instructions

1. (SEE FIGURE 1) In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Figure 1

3-Prong Plug

Grounding

Prong

Properly Grounded

3-Prong Outlet

2.

Do not modify the plug provided - if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

3.

Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.

4.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

5. Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerator.

There is an increased risk of electrical shock if your body is grounded.

6. Repair or replace damaged or worn cord immediately.

7. Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electrical shock.

Extension Cords

1. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Table 1 (page 3) shows the correct size to use depending on cord length and nameplate Ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

2. Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug.

3. Do not abuse the cord. Never use the cord to carry the tools or pull the plug from the outlet.

4. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electrical shock.

5. When operating a power tool outside, use an outdoor extension cord marked "W-A" or "W".

These cords are rated for outdoor use and reduce the risk of electrical shock.

Rating

Table 1.

Minimum Gage For Power Cord

Amp

1-5

6-10

11-12

12-16

Volts

120V

120V

120V

120V

25 ft.

18

16

14

14

Total Length of cord in feet

50ft 100ft

AWG

16

16

14

12

150 ft

16

14

14

12

14 12

Not Recommended

2

SPECIFIC SAFETY RULES FOR SCROLL SAW

WARNING!

For Your Own Safety Read Instruction Manual before Operating Saw

1. DO NOT OPERATE scroll saw until it has been assembled and installed according to the assembly instructions.

2. ALWAYS wear eye protection.

3. ALWAYS clamp or bolt scroll saw to workbench or table before use.

4. DISCONNECT the power cord and wait for the blade to come to a complete stop before making any adjustments or changing blade.

5. BE SURE all adjustments knobs, screws or levers are tight and secure before use.

6. KEEP ARMS, HANDS AND FINGERS away from the blade and blade guard (drop foot) during use.

7. NEVER use damaged or dull blades.

8. ALWAYS use appropriate speed for material and cutting tool being used.

9. ALWAYS support long workpieces to prevent the cutting tool from binding.

10. DO NOT operate scroll saw with guard or covers removed or modified. Make sure guards are in place and working properly before use.

11. ALWAYS adjust the blade guard (drop foot) so that it rests on the workpiece.

12. NEVER cut through nails.

13. DO NOT cut work pieces that are too small to hold safely.

14. MAKE SURE table is clear of tools, marking equipment or other debris before operation.

15. NEVER start saw when blade is in contact with workpiece.

16. NEVER leave tool unattended while running. Turn power off and do not leave the tool until the blade has come to a complete stop.

17. ALWAYS allow the motor to reach full speed before starting a cut to avoid the blade from jamming or binding.

18. NEVER feed workpiece too quickly. Do not force the workpiece against the blade.

19. ALWAYS maintain good balance and avoid awkward operations and hand positions.

20. NEVER remove jammed or scrape pieces of material until the blade has completely stopped.

21. NEVER attempt to adjust or touch the blade tension knob or blade guard (drop foot) when the saw is on or the blade is moving.

CALIFORNIA PROPOSITION 65

WARNING: CHEMICAL HAZARD. Use of this tool may cause exposure to chemicals that are known to the state of California to cause cancer, birth defects or other reproductive harm. Dust and debris created during cutting, drilling, grinding or sanding on some materials may contain chemicals known to the State of California to cause cancer or 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

• Arsenic and Chromium from chemically- treated lumber.

To reduce exposure to these chemicals, always use approved safety equipment, work in a well-ventilated area and wear dusk mask that filters out microscopic particles.

Stack Cutting (Figure 14)

Stack cutting may be used when several identical shapes need to be cut.

Several workpieces (2) may be stacked one on top of the other and secured to each other before cutting.

Pieces of wood may be joined together by placing double sided tape (1) between each piece or by wrapping tape around the corners or ends of the stacked wood.

Figure 14

2

1

1

The stacked pieces must be attached to each other in such a way that they can be handled on the table as a single workpiece.

WARNING:

To avoid serious personal injury, do not cut several workpieces at a time unless they are properly attached to each other.

WARNING:

Do not let familiarity with the saw create carelessness. Remember that a careless decision made quickly can create a serious injury.

MAINTENANCE

WARNING:

RISK OF PERSONAL INJURY. Always disconnect tool from power source before making any adjustments, installing or changing accessories.

CAUTION:

Tool service must be preformed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electrical shock or injury.

General Maintenance

1. Clean the housing, table, base and motor vents after each use.

2. Lubricate moving parts with light weight oil.

3. Apply a thin coat of hydrophobic grease to table so that the workpiece slides easily while cutting.

4. Store the tool on a safe and dry place, and out of reach of children.

5. If tool begins to make abnormal noise, vibrations, produces smoke or burning odor, turn the tool off immediately and do not operate, until repaired.

6. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

7. Do not allow any build up of resins or sap on the saw table. Clean with gum and pitch remover as needed.

WARNING:

When replacing parts, use only identical replacement parts. The use of any other part may create a hazard or damage the saw.

3

12

Blade Information

Scroll blades wear out and must be replaced frequently for best cutting results. Scroll saw blades generally become dull after one half hour to 2 hours of cutting, depending on the type of material and speed of operation.

When cutting wood, best results are achieved when cutting pieces less than one inch (25mm) thick.

When cutting wood thicker than one inch (25mm), the user must guide the workpiece very slowly into the blade and take extra care not to bend or twist the blade while cutting.

When choosing a blade, carefully consider the following:

Very fine, narrow blades should be used to scroll cut thin material one fourth of an inch (6mm) thin or less.

Most blade packages state the size or thickness and type of material which the blade is intended to cut. The package should also state the radius or size of curve that can be cut with that blade.

Wider blades cannot cut curves as tight or small as thinner blades.

Main causes of blade wear:

• Cutting plywood, hardwood and other laminates.

• Cutting material thicker than three fourths of an inch (19mm).

• Side pressure on the blade.

Speed Setting (Figure 12)

By turning the speed selector (1), the saw's speed may be adjusted from 400 to 1,600 SPM

(Strokes per Minute). To increase the strokes per minute, turn the speed selector clockwise (3). To decrease the strokes per minute, turn the speed selector counterclockwise (2).

Scroll Cutting

Scroll cutting consists of following the pattern lines by pushing and turning the workpiece at the same time. Once you have started a cut, do not try to turn the workpiece without also pushing it; the workpiece could bind or twist the blade, causing it to break.

Figure 12

3

1

2

Interior Scroll Cutting (Figure 13)

One feature of the scroll saw is that it can be used to make scroll cuts within a workpiece without cutting through the edge or perimeter of the workpiece.

To make interior cuts in the workpiece:

1. Remove the scroll saw blade as explained in the section Installing Blades.

2. Drill a hole (1) one fourth of an inch (6 mm) in size in the workpiece (3).

3. Place the workpiece on the saw table with the drilled hole over the hole in the table.

4. Install the blade, feeding it though the hole in the workpiece.

5. Adjust the drop foot and blade tension.

Figure 13

3

1

2

6. When finished making the interior scroll cut (2), simply remove the blade from the blade holders as described in the section on Installing Blades.

7. Remove the workpiece.

11

GLOSSARY OF TERMS

Bevel Cut - A cut made with the saw table at any angle to the blade other then 90 degrees.

Crosscut - Any cut made across the width or grain of the workpiece.

Freehand - Any cut made when the workpiece is not guided by a fence or mitre gauge.

Gum - A sap or sticky substance in wood products.

Kerf - The slot that is produced by the blade in a partial cut (a non-through cut) or the material removed from the workpiece by the blade.

Kick back - A sudden movement of the workpiece, typically in the opposite direction of the cut.

Leading end - The end of the workpiece that is pushed into the blade first.

Non-ferrous Metal or Alloy - A metal or ally that does not contain iron (such as aluminum, copper or brass)

Push Stick - A device which is used to push the workpiece through the saw. Typically used when cutting very narrow workpiece.

Resin - A sticky, sap based substance that has hardened.

Ripping - A cut made along the length of the workpiece.

Saw Blade Path - The area on the workpiece that is directly in line with the blade.

SPM - Storks per minute. The number of times the blade travels up (or down) in a minute of operation.

Through Cut - A cutting operation in which the blade completely cuts through a workpiece.

Workpiece - The item being cut by the saw.

Worktable (Saw Table) - The surface on which the workpiece rests during the cutting operation.

SYMBOLS

The following symbols are used for this tool:

Symbol

V

Amp

SPM

~

HZ

Min

Name

Volts

Amperes

Strokes per minute

Alternating Current

Hertz

Minutes

Designation/Explanation

Voltage

Current

Speed

Type of current

Frequency (cycles per second)

Speed

4

KNOW YOUR TOOL

Blade Tension Knob Figure 2

Blade Clamp Screw

Drop Foot

Lock Knob

Sawdust

Blower

Throat

Plate

Bevel Scale

Table

Lock Knob

30

15

0

Saw

Blade

Drop Foot

(blade guard)

Work table

Variable Speed

Selector Knob

Dust Port

On/Off Switch with Lockout Key

ASSEMBLY

WARNING!

RISK OF PERSONAL INJURY. ALWAYS DISCONNECT THE TOOL FROM THE POWER

OUTLET BEFORE MAKING ANY ADJUSTMENT, INSTALLING OR CHANGING SAW BLADES.

CAUTION: The scroll saw must be completely assembled before use. DO NOT plug unit into power source until the unit has been completely assembled and all guards are in place.

Install the Sawdust Blower Tube (Figure 3)

1. Attach one end of the plastic tubing (1) to the back of the sawdust blower (3) and the other end to the pump mechanism (2).

2. Apply a coat of hydrophobic grease to the saw table surface so that the workpiece can slide easily. Wipe off all excess grease with a dry cloth.

Figure 3

1

2

3

5

Jamming of the Saw Blade and Workpiece

When backing out the workpiece, the blade may bind in the kerf (cut). This is usually caused by sawdust clogging the kerf or by the blade coming out of the blade holder. If this happens:

1. Place the switch in the off position

2. Wait until the saw has come to a full and complete stop.

3. Unplug the saw from the power source.

4. Remove the blade and workpiece (see section on Removing Saw Blade)

5. Wedge the kerf open with a flat screw driver or wooden wedge then remove the blade from the workpiece.

Avoiding Injury

1. Make sure the saw is level and does not rock. The saw should always be mounted on a firm level surface with plenty of room for handling and properly supporting the workpiece.

2. Bolt the saw to the support surface to prevent slipping, walking or sliding during operations.

3. Turn the saw off and unplug it form the power source before moving the saw.

4. Do not remove jammed offcuts until the blade has completely stopped.

5. Choose the right size and type of blade for the material and type of cut you plan to make.

6. Use only recommended accessories.

7. Before turning the saw on, clear everything off the saw table except the workpiece and clamps.

8. Properly support round materials such as dowel rods or tubing because they have a tendency to roll during cutting, causing the blade to "bite". To avoid this, always use a "V" block or clamp the workpiece to a mitre gauge.

9. Before removing offcuts from the saw table, turn the saw off and wait for all moving parts to stop.

Choosing the Right Blade

The scroll saw accepts a wide variety of blades and thicknesses for cutting wood and other fibrous materials. This saw uses 5 in. (127mm) long blades of either the pin end or the plain end types.

The blade width and thickness, as well as the number of teeth per inch are determined by the type of material and the size of the radius being cut.

NOTE: As a general rule, always select narrow blades for intricate curve cutting and wide blades for straight and large curve cutting.

Teeth/Inch Teeth/cm Width

10 4 .110 in.

(2.8 mm)

Thickness Speed (SPM)

.020 in.

(.5 mm)

1200-1600

15

18

6

7

.110 in.

(2.8 mm)

.095 in.

(2.4 in.)

.020 in.

(.5 mm)

.010 in.

(.3 mm)

600-1200

400-600

Material Cut

Popular size for cutting hard and soft woods

3/16 in. (4.8 mm) up to

2 in. (51 mm) plastics, paper, felt, bone etc.

Wood, plastics, extremely thin cuts on materials

3/32 in. (2.4 mm) to

1/2 in. (13 mm) thick

For tight radius work in thin materials 3.32 in.

(2.4 mm) to 1/8 in. (3mm) such as wood, veneer, bone, fibre, ivory, plastic etc.

10

OPERATION

WARNING:

RISK OF PERSONAL INJURY. NEVER PLACE YOUR HANDS NEAR THE BLADE WHILE

PERFORMING ANY CUTTING OPERATION. To avoid serious personal injury, always keep your hands at least 3 inches from the saw blade.

WARNING:

RISK OF PERSONAL INJURY. ALWAYS DISCONNECT THE TOOL FROM THE POWER

OUTLET BEFORE MAKING ANY ADJUSTMENT, INSTALLING OR CHANGING BLADES OR

OTHER TOOLS.

CAUTION:

DO NOT OPERATE scroll saw until it has been assembled and installed according to the "Assembly" instructions. Read and follow all safety rules within this Instructions Manual, failure to do may result in electric shock and/or serious personal injury.

On/Off Switch (Figure 11)

Scroll saw is equipped with an "On/Off" switch key. Removal of the key prevents the saw from being turned "On". Remove the key to avoid unintentional start up or unauthorized use of the scroll saw.

1. To start the saw, move the "On/Off" switch to the "On" position.

2. To stop the saw, move the switch to the

"Off" position

Figure 11

Off On

Before Cutting

NOTE: Before starting a cut, turn the saw on and listen to the sound it makes. If you notice vibration or an unusual noise, stop the saw immediately and unplug it. Do not restart the saw until you have located and resolved the source of the problem.

NOTE: After the saw is turned on, a hesitation before blade movement is normal.

Cutting Instructions

1. There is a learning curve for each person who uses a scroll saw. During that period it is expected that some blades will break until the proper use of the saw is learned and the blade it properly adjusted.

2. Plan the way the workpiece will be cut from start to finish and ensure that there is adequate room around the saw to complete the cut.

3. Keep your hands away from the blade. Do not hold pieces so small that your figures would have to go under the drop foot in order to make the planned cut.

4. Hold the workpiece firmly against the saw table.

5. The blade teeth will only cut the work piece during the down stroke.

6. Use gentle pressure with both hands when feeding the workpiece into the blade. Do not force the cut.

7. Guide the workpiece into the blade slowly since the blade teeth are very small and can only remove material on the down stroke.

8. Avoid awkward operations and hand positions where sudden slips could cause injury from contact with the blade. Never place hands in the path of the blade.

9. For accurate wood cuts, compensate for the blade's tendency to follow the grain in the wood as you cut.

10.Use extra support (table, blocks, etc) when cutting large, small or awkward workpieces.

11.Never use another person as a substitute for a table extension or as an additional support for a workpiece that is longer or wider then the basic saw table.

12.When cutting irregular shaped workpieces, plan your cuts so that the workpiece will not pinch the blade. Workpieces must not twist, rock or slip while being cut.

9

Mounting the Scroll Saw to a Work Bench (Figure 4)

WARNING!

To avoid serious personal injury from unexpected tool movement, securely mount the scroll saw onto a workbench.If the saw is to be used in a specific location, it should be permanently secured to a work bench by drilling holes through the surface of the work bench.

1. Each hole in the base should be bolted to securely using machine bolts, washers and nuts (not included).

2. Drill four holes through the work bench (2).

3. Place the scroll saw on the work bench by aligning the holes in the saw base with the drilled holes in the workbench.

4. Insert bolts (4) (not Included) and tighten securely with washers and nuts (not included).

NOTE: all bolts should be inserted from the top. Install washers and nuts from the underside of the work bench.

Figure 4

5

4

3

Reducing Noise and Vibration

2

To reduce noise and vibration, the saw can be mounted with a piece of carpet or foam between the saw and the work bench.

30

15

0

1

Clamping the scroll saw to the work bench

If the saw is to be used in several locations it should be mounted to a mounting board (1) using the same steps noted above and then the mounting board should be securely clamped (3 & 5) to the work bench (2).

ADJUSTMENTS

WARNING!

RISK OF PERSONAL INJURY. Always disconnect tool from power source before making any adjustments, installing or changing accessories.

Drop Foot (Figure 5)

1. To prevent the workpiece from lifting off the saw table during cutting, the drop foot rod (4) should be adjusted so that drop foot rests on top of the workpiece. The drop foot should not be adjusted too tightly or the work piece may drag and not move freely.

2. Loosen the drop foot lock knob (1). Lower or raise the drop foot rod (4) to the desired position. Retighten the drop foot.

3. The two prongs (2) at the front of the drop foot act as a blade guard to prevent the accidental touching of the blade.

Figure 5

1

3

4

2

Sawdust Blower

1. The sawdust blower (3) is designed to direct air to the cutting line.

2. Make sure the drop foot is properly adjusted to secure the workpiece and direct the air to the cutting surface.

6

Squaring the Saw Table (Figure 6)

1. Loosen the drop foot lock knob (1) and move the drop foot rod (4) all the way up.

2. Retighten the drop foot lock knob.

3. Loosen the table lock knob (3) and tilt the saw table until it is approximately at a right angle to the blade.

4. Place a small combination square (5) on the table top next to the blade.

5. Loosen the screw (Figure 7; Item 2) that holds the scale indicator (4).

6. Move the indicator to the "0" mark on the bevel scale (1) and securely tighten the screw.

7. Adjust the drop foot to the desired location and securely retighten the drop foot lock knob.

Setting the Table for Horizontal or

Bevel Cutting (Figure 7)

1. A bevel scale (1) is located under the saw table as a guide for setting the approximated saw table angle. When greater precision is required, make practice cuts on scrap material and adjusted the saw table as needed.

2. To change the saw table angle, loosen the table lock knob (3) and tilt the saw table until it is at the desired location and then retighten the table lock knob.

Figure 6

5

3

Figure 7

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1

1

2

3

Adjusting the Blade Tension (Figure 8)

1. Check tension by listening to the sound the blade makes when plucked like a guitar string.

2. Pluck the back of the straight side of the blade while turning the tension adjusting knob (1).

The sound should be like a musical note. The sound becomes flatter as the tension increases. The sound level decreases with too much tension.

3. Turning the blade tension knob counterclockwise will decrease the blade tension.

Turning the blade tension knob clockwise will increase the blade tension.

Note: be careful not to adjust the blade too tightly.

Too much tension may cause the blade to break as soon as you start cutting. Too little tension may cause the blade to bend or break before the teeth wear out.

Figure 8 1

4

2

7

Changing Blades (Figures 9 & 10)

Scroll saw blades wear out quickly and must be replaced frequently. Expect to break some blades while the proper cutting techniques are learned.

Blades usually become dull after 1 hour to 2 hours of cutting, depending on the type of material and speed of operation. The scroll saw accepts two types of blades: plain end blades that are the same thickness for the entire length of the blade, and pin end blades that have small pin at each end.

Plain End Blades

Removing plain end saw blades

Figure 9

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1. Turn the saw off and unplug it from the power source.

2. Turn the blade tension knob (Figure 8 - 1) counterclockwise to reduce the blade tension.

3. Remove the throat plate (3) by pushing it up from under the saw table.

4. Loosen both the upper blade clamp screw

(Figure 9 - 1) and lower blade clamp screws

(Figure 10 - 2; access from below table on left side) with the provided T-handle hex key tool.

Figure 10

2

1

5. The blade is now released from the saw.

6. Remove the blade.

Replacing plain end saw blades

1. Place the new blade through the opening in the saw table (Figure 9) with the teeth to the front of the saw and pointing down toward the saw table.

2. Insert the bottom blade end into the lower blade clamp (Figure 10 - 2) and tighten the lower blade clamp screw with the provided T-handle hex key tool.

3. Insert the top blade end into the upper blade clamp (Figure 9 - 1). It might be necessary to push down on the blade arm (Figure 9 - 2) to lower the blade arm to the same level as the blade end.

4. Securely tighten the upper blade clamp with the provided T-handle hex key tool.

5. Turn the blade tension knob (Figure 8 - 1) clockwise to increase the blade tension.

6. Reinstall the throat plate (Figure 9 - 3).

Pin End Blades

Removing pin end saw blades

1. Turn the saw off and unplug it from the power source.

2. Turn the blade tension knob (Figure 8 - 1) counterclockwise to reduce the blade tension.

3. Remove the throat plate (Figure 9 - 3) by pushing it up from under the saw table.

4. Pull up on the blade and push down on the saw arm (Figure 9 - 2) to disengage the upper pins on the blade from the V-notch on the upper blade holder.

5. Push the blade downward to disengage the lower pins on the blade from the V-notch of the lower blade holder Figure 10 - 1).

6. Remove the blade.

Replacing pin end saw blades

1. Place the new blade through the opening in the saw table (Figure 9) with the teeth to the front of the saw and pointing downward toward the saw table.

2. Fit the pins on the blade into the lower blade holder (Figure 10 - 1).

3. Pull up on the blade and press the upper arm (Figure 9 - 2) down to position the pins on the blade into the V-notch in the upper blade holder (Figure 9 - 1).

4. Release the upper arm to secure the blade to the saw.

5. Turn the blade tension knob clockwise until blade has the right amount of tension (Figure 8 - 1).

6. Reinstall the throat plate (Figure 9 - 3).

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