AEG PS254DB Original Instructions Manual

PS254DB

Original instructions

I

mportant!

It is essential that you read the instructions in this manual before assembling, operating and maintaining the product.

Subject to technical modifications.

2 2

27

1

2

Ø 254 mm

Ø 30 mm max.

7000

48 HW 2.2 mm

25

26 3

37

22

23

18

8

24

17

6

16

21

15

20

14

2

13

38

12

5

4

28

11

29

3. Switch lock off

4. Lower blade guard plates

30

31

6

17

7

8

10

9

19

7. “No hands zone” label

8. “No hands zone” boundary line

9. Table lock button

10. Mitre detent bypass button

11. Mitre lock lever

12. Control arm

13. Mitre scale

14. Turning table

15. Rotating extension table

16. Saw base

17. Fixed fence

18. Work clamp

19. Mounting holes x 4

20. Slide lock knob

21. Slide bar

22. Crown and baseboard setting lever

23. Crown stop

24. Baseboard lock groove

25. Dust bag

26. Upper blade guard

27. LED switch

28. Depth control knob

29. Head lock pin

30. Blade wrench storage

31. Carrying handle

32. Bevel lock knob

33. Bevel detent lever

34. Fence lock knob

35. Mitre detent override lever

36. Spindle lock button

37. Saw blade

38. Bevel scale

36

35

32

34

The following tools (not included) are needed for making adjustments:

FRAMING SQUARE COMBINATION WRENCH

33

COMBINATION SQUARE

3 3

Fig. 1 Fig. 3

2

1

4

1

1 - Mounting holes

2 - Mounting surface

3 - Base

2

M8

M8

M8

M8

3

1

3

1 - Depth control knob

2 - Lock nut

3 - Depth stop

4 - Head lock pin

Fig. 4

1

2

Fig. 2

2

PSU1000 PSUM1000

1 - “D” handle

2 - Head lock pin

Fig. 5

1

2

3

1 - Sliding fence

2 - Fence lock knob

3 - Slot

4

3

1

4

1 - Dust bag

2 - End of frame assembly

3 - Exhaust port

Fig. 6

1

4

3

2

5

Fig. 7

6

4

To loosen

3

Ø 254 mm n

Ø 30 mm max.

7000

48 HW 2.2 mm

7

To tighten

2

5

1 - Adjustable throat plate

Fig. 8

1

1

1 - Work clamp shaft

2 - Work clamp

3 - Work clamp hole

Fig. 9

3

1

2

1 - Spindle lock button

2 - Saw blade

3 - Outer flange

4 - Blade bolt

5 - Arbor

6 - Lower blade guard

7 - Blade wrench

5

1 - Mitre detent bypass button

2 - Mitre lock lever 2

5

Fig. 10

Fig. 11

Underside of mitre lock lever

3

1

2

2

1

1 - Mitre lock shoe

2 - Mitre lock screw

3 - Saw base

4 - Mitre lock nut

Fig. 12

3

4

1 - Mitre lock nut

2 - Mitre lock screw

3 - Mitre lock lever

7

6

2

1

3

1 - Sliding fence

2 - Fixed fence

3 - Framing square

4 - Turning table

5 - Mitre lock lever

6 - Mitre detent bypass button

7 - Saw blade

8 - Screws

6

4

5

6

8 8

Fig. 13

4

3

6

1 - Handle

2 - Detent disengaged

3 - Detent engaged

4 - Bevel detent lever

5 - Bevel lock knob

6 - To tighten

7 - To loosen

Fig. 14

1

2

5

Fig. 15

1

7

1 - Mitre scale

2 - Scale indicator

Fig. 16

1

2

1

2

4

1

3

2

3

1 - Saw blade

2 - Framing square

3 - Turning table

4 - Fixed frence

4

2

1

View of blade not square with fence, adjustments are required.

2

1 - Saw blade

2 - Framing square

3 - Turning table

View of blade not square with turning table, adjustments are required.

7 7

Fig. 17

4

Fig. 19

1

1 - Screws

2 - Bevel lock dust cover

3 - Bevel lock knob


2

Fig. 18

1

Back of bevel lock bracket

1

3

2

1 - LED switch

2 - Shadow of blade teeth projected onto workpiece

Fig. 20

CROSS CUT

2

3 Front of bevel lock bracket 1

2

1 - Slide lock knob

2 - Work clamp

1 - Screws

2 - Bevel detent plate

3 - Micro adjust screw

8 8

1

Fig. 21

MITRE CUT

1

Fig. 24

EXTENDED MITRE CUT

1 - Work clamp

Fig. 22

1

2

1 - Sliding fence

2 - Rotating extension table

Fig. 23

1

Fig. 25

BEVEL DETENT LEVER

1

2

5

4

3

6

1 - Handle

2 - Detent disengaged

3 - Detent engaged


Fig. 26

5 - Bevel lock knob

6 - To tighten

7 - To loosen

BEVEL CUT

7

1

1 - Table lock button

9

1 - Work clamp

9

Fig. 27

1

Fig. 30

45º x 45º COMPOUND MITRE CUT

1 - Compound mitre cut

Fig. 28

SLIDE CUT

1

3

2

Fig. 31

1

1 - Slide saw arm forward

2 - Push down

3 - Push back

Fig. 29 1 - Long workpiece

2 - Workpiece supports

2

Fig. 32

1

1 - Auxiliary fence

2 - Align board with edge of mitre table

10

2

1

10

1 - Wide board

Fig. 33

2

1

3

1 - Depth control knob

2 - Lock nut

3 - Depth stop

Fig. 34

1

Fig. 36

52°

38°

Ceiling

45°

45°

Ceiling

Wall Wall

1

Top edge against fence: s-FGUTJEFJOTJEFDPSOFS s3JHIUTJEFPVUTJEFDPSOFS

2

4

1 - Sliding fence

2 - Mitre table

Fig. 37

2

1 - Work clamp

2 - C clamp

3 - Workpiece

4 - Spacer

Fig. 35

3

1

2

1 - Cut these grooves with saw

2 - Use a chisel to cut out the middle

3 - Workpiece

3

11

1 - Inside corner

2 - Sliding fence

3 - Outside corner

4 - Mitre table

1

2

Top edge against fence: s-FGUTJEFJOTJEFDPSOFS s3JHIUTJEFPVUTJEFDPSOFS

4

3

11

Fig. 38

Fig. 40

3

2

1 - Hole “A”

2 - Crown stop

3 - Hole “B”

4 - Crown stop lock knob

Fig. 39

1

4

3

4

1

2

Fig. 41

Fig. 42

1

RIGHT

1 - Slide lock knob

2 - Crown and baseboard setting lever

3 - Crown stop

4 - Baseboard lock groove

12 12

WRONG

TECHNICAL DATA SLIDING COMPOUND MITRE SAW

Rated input

Rated current

Rated power

Weight

Maximum cutting depth

No-load speed

Saw blade diameter x hole diameter

Saw blade thickness / kerf

Maximum cutting capacity

Mitre 0°/ Bevel 0° Hi-capacity

Mitre 45°/ Bevel 0°

Mitre 0°/ Bevel 45° (left)

Mitre 0°/ Bevel 45° (right)






Mitre 45° (left) / Bevel 48° (right)


Vertical Base (laid flat on turning table)


Nested Crown (laid flat on turning table)


Maximum mitre angle

Maximum bevel angle

Minimum workpiece dimensions

Measured values determined according to EN 62841

A-weighted sound pressure level

Uncertainty K

Measured values determined according to EN 62841

A-weighted sound power level

Uncertainty K

PS254DB

220V - 240V ~ 50 Hz

7.5 A

1800 W

24.6 kg

89 mm

4800 min -1

254 x 30 mm

1.8 mm / 2.5 mm

89 mm x 305 mm

89 mm × 203 mm

51 mm × 305 mm

38 mm × 305 mm

38 mm × 305 mm

19 mm × 305 mm

51 mm × 203 mm

38 mm × 203 mm

38 mm × 203 mm

19 mm × 203 mm

38 mm × 102 mm

153 mm × 19 mm

168 mm

70°

48°

215 mm × 35 mm × 2.5 mm

L pA

= 95.2 dB(A)

K = 3 dB(A)

L wA

= 108.1 dB(A)

K = 3 dB(A)

REPLACEMENT PARTS

Saw blade 089315001009

Combination wrench 089240013065

Work clamp

Dust bag

089315001301

089315001302

Throat plate

Crown stop

Brush

089240013085

089041028721

089041028055

WARNING!

The declared noise emission value(s) have been measured in accordance with a standard test method of EN 62841-1 and EN 62841-3-9, and may be used for comparing one tool with another.

The declared noise value(s) may also be used in a preliminary assessment of exposure.

The noise emissions during actual use of the power tool can differ from the declared values depending on the ways in which the tool is used especially what kind of workpiece is processed.

Identify safety measures to protect the operator based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time).

Wear hearing protection. Exposure to noise can cause hearing loss.

13 13

GENERAL POWER TOOL SAFETY WARNINGS

WARNING! Read all safety warnings, instructions, illustrations and specifications provided with this power tool.

Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

The term “power tool” in the warnings refers to your mains-operated

(corded) power tool or battery-operated (cordless) power tool.

WORK AREA SAFETY

Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

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.

Keep children and bystanders away while operating a power tool.

Distractions can cause you to lose control.

ELECTRICAL SAFETY

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.

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.

Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of electric shock.

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.

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.

If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

PERSONAL SAFETY

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.

Use personal protective equipment. Always wear eye protection.

Protective equipment such as dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.

Prevent unintentional starting. Ensure the switch is in the offposition before connecting to power source and/or battery pack, picking up or carrying the tool.

Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.

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.

Do not overreach. Keep proper footing and balance at all times.

This enables better control of the power tool in unexpected situations.

Dress properly. Do not wear loose clothing or jewellery. Keep your hair and clothing away from moving parts.

Loose clothes, jewellery or long hair can be caught in moving parts.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used.

Use of dust collection can reduce dust-related hazards.

Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles.

careless action can cause severe injury within a fraction of a second.

POWER TOOL USE AND CARE

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.

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.

Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools.

Such preventive safety measures reduce the risk of starting the power tool accidentally.

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.

Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use.

Many accidents are caused by poorly maintained power tools.

Keep cutting tools sharp and clean. to control.

situation.

Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier

Use the power tool, accessories and tool bits etc. in accordance with these instructions, 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

Keep handles and grasping surfaces dry, clean and free from oil and grease.

Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

SERVICE

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.

SAFETY INSTRUCTIONS FOR MITRE SAWS

A

Mitre saws are intended to cut wood or wood-like products, they cannot be used with abrasive cut-off wheels for cutting ferrous material such as bars, rods, studs, etc.

Abrasive dust causes moving parts such as the lower guard to jam. Sparks from abrasive cutting will burn the lower guard, the kerf insert and other plastic parts.

Use clamps to support the workpiece whenever possible. If supporting the workpiece by hand, you must always keep your hand at least 100 mm from either side of the saw blade. Do not use this saw to cut pieces that are too small to be securely clamped or held by hand.

If your hand is placed too close to the saw blade, there is an increased risk of injury from blade contact.

The workpiece must be stationary and clamped or held against both the fence and the table. Do not feed the workpiece into the blade or cut “freehand” in any way.

Unrestrained or moving workpieces could be thrown at high speeds, causing injury.

Push the saw through the workpiece. Do not pull the saw through the workpiece. To make a cut, raise the saw head and pull it out over the workpiece without cutting, start the motor, press the saw head down and push the saw through the workpiece.

Cutting on the pull stroke is likely to cause the saw blade to climb on top of the workpiece and violently throw the blade assembly towards the operator.

Never cross your hand over the intended line of cutting either in front or behind the saw blade.

Supporting the workpiece “cross

14 14

handed” i.e. holding the workpiece to the right of the saw blade with your left hand or vice versa is very dangerous.

Do not reach behind the fence with either hand closer than 100 mm from either side of the saw blade, to remove wood scraps, or for any other reason while the blade is spinning.

The proximity of the spinning saw blade to your hand may not be obvious and you may be seriously injured.

Inspect your workpiece before cutting. If the workpiece is bowed or warped, clamp it with the outside bowed face toward the fence. Always make certain that there is no gap between the workpiece, fence and table along the line of the cut.

Bent or warped workpieces can twist or shift and may cause binding on the spinning saw blade while cutting. There should be no nails or foreign objects in the workpiece.

Do not use the saw until the table is clear of all tools, wood scraps, etc., except for the workpiece.

Small debris or loose pieces of wood or other objects that contact the revolving blade can be thrown with high speed.

Cut only one workpiece at a time.

Stacked multiple workpieces cannot be adequately clamped or braced and may bind on the blade or shift during cutting.

Ensure the mitre saw is mounted or placed on a level, firm work surface before use.

A level and firm work surface reduces the risk of the mitre saw becoming unstable.

Plan your work. Every time you change the bevel or mitre angle setting, make sure the adjustable fence is set correctly to support the workpiece and will not interfere with the blade or the guarding system.

Without turning the tool “ON” and with no workpiece on the table, move the saw blade through a complete simulated cut to assure there will be no interference or danger of cutting the fence.

Provide adequate support such as table extensions, saw horses, etc. for a workpiece that is wider or longer than the table top.

Workpieces longer or wider than the mitre saw table can tip if not securely supported. If the cut-off piece or workpiece tips, it can lift the lower guard or be thrown by the spinning blade.

Do not use another person as a substitute for a table extension or as additional support.

Unstable support for the workpiece can cause the blade to bind or the workpiece to shift during the cutting operation pulling you and the helper into the spinning blade.

The cut-off piece must not be jammed or pressed by any means against the spinning saw blade.

If confined, i.e. using length stops, the cut-off piece could get wedged against the blade and thrown violently.

Always use a clamp or a fixture designed to properly support round material such as rods or tubing.

Rods have a tendency to roll while being cut, causing the blade to “bite” and pull the work with your hand into the blade.

Let the blade reach full speed before contacting the workpiece.

This will reduce the risk of the workpiece being thrown.

If the workpiece or blade becomes jammed, turn the mitre saw off. Wait for all moving parts to stop and disconnect the plug from the power source and/or remove the battery pack. Then work to free the jammed material.

Continued sawing with a jammed workpiece could cause loss of control or damage to the mitre saw.

After finishing the cut, release the switch, hold the saw head down and wait for the blade to stop before removing the cut-off piece.

Reaching with your hand near the coasting blade is dangerous.

Hold the handle firmly when making an incomplete cut or when releasing the switch before the saw head is completely in the down position.

The braking action of the saw may cause the saw head to be suddenly pulled downward, causing a risk of injury.

deformation and vibration.

Do not use the product without the guards in position. Keep guards in good working order and properly maintained.

Ensure the operator is adequately trained in safety precautions, adjustment and operation of the product.

Always wear goggles and ear protection when using the product. It is recommended to wear gloves, sturdy non slipping shoes and apron.

Before using any accessory, consult the instruction manual. The improper use of an accessory can cause damage and increase the potential for injury.

Use only blades specified in this manual, complying with EN 847-1.

Observe the maximum speed marked on the saw blade. Ensure the speed marked on the saw blade is at least equal to the speed marked on the saw.

Always use blades with correct size and shape of arbor holes.

Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.

Do not use blades of larger or smaller diameter than recommended.

Do not use any spacers to make the blade fit onto the spindle.

Check the tips of the saw blade for damage or abnormal appearance before each use. Tips that are damaged or loose can become flying objects in use and increase the chance of personal injury.

Do not use cracked or distorted saw blades. Do not use saw blades that are damaged or deformed.

Scrap the saw blade if damaged, deformed, distorted or cracked, repairing is not permitted.

Do not use HSS blades.

Ensure the saw blade is mounted correctly, tighten the arbor nut securely before use (tightening torque approx. 12 Nm).

Fastening screw and nuts shall be tightened using the appropriate spanner, etc.

Extension of the spanner or tightening using hammer blows is not permitted.

Make sure the blade and flanges are clean and the recessed sides of the collar are against the blade.

Make sure the blade rotates in the correct direction.

Before work, make a dummy cut without the motor turned on so the position of the blade, operation of the guards with respect to other machine parts and workpiece may be checked.

Never leave the product unattended.

Do not apply lubricants on the blade when it is running.

Never perform any cleaning or maintenance work when the machine is still running and the head is not in the rest position.

Never attempt to stop a machine in motion rapidly by jamming a tool or other means against the blade, serious accidents can be caused unintentionally in this way.

Disconnect the product from the mains supply or remove battery pack before changing blades or carrying out maintenance.

Pay attention to blade packing and unpacking, it is easy to be injured by the sharp blade tips.

Use a blade holder or wear gloves when handling a saw blade.

Keep and store the blade in original packaging or other suitable packaging, keep in dry conditions and away from chemicals which may damage the blade.

ADDITIONAL SAFETY WARNINGS

SAFETY INSTRUCTIONS FOR WOOD CUTTING BLADE

Please read the manual and instructions carefully before using the saw blade and the machine.

The product must be in good condition, the spindle without

Always clamp the workpiece safely and securely.

Ensure that the product is always stable and secure (e.g., fixed to a bench).

Always wear ear protectors. Exposure to noise can cause hearing loss.

Always wear safety goggles when using the product. It is recommended to wear gloves for handling blades and rough material, plus sturdy non slip shoes to protect the feet from workpieces which

15 15

may fall from the cutting area.

Disconnect the product from the mains supply or remove battery pack before carrying out any maintenance or cleaning the product.

Only connect to the mains supply when the product is switched off.

Never reach into the area near the blade unless the blade has completely stopped.

Before use, thoroughly check the product, cable and plug for any damage or material fatigue. Repairs to the whole product should only be carried out by an authorised service centre.

Always use the guards on the product. Do not use the product if the guards are not in place and working correctly.

The lower blade guard should only open when the blade is lowered to the workpiece and must always be able to move freely and close automatically.

Always fix and use extension bar holders for workpiece support during operation.

Never alter of modify the product or its function. Your safety may be compromised.

Do not use saw blades which are cracked, damaged or deformed.

Do not use saw blades made of high-speed steel.

Only use blades that are sharp. Replace dull blades.

Always use blades with correct size and shape of arbor holes.

Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.

Use only woodworking blades specified in this manual, which comply with EN 847-1.

Do not use any flanges, washers and nuts to secure the saw blade other than those supplied or indicated in the instruction manual.

It is necessary to select a saw blade which is suitable for the material being cut. Never use the product to cut materials other than those specified in the intended use section in this manual.

It is important to avoid overheating the blade and melting the plastic workpiece when cutting.

It is essential to adhere to the maximum speed specified on the saw blade, only use saw blade that are marked with a speed equal or higher than the speed marked on the tool.

Replace the table insert when worn or damaged.

Before work, make a dummy cut without the motor turned on so the position of the blade, operation of the guards with respect to other machine parts, and workpiece may be checked.

When performing mitre, bevel or compound mitre cuts, adjust or remove the sliding fence to ensure the correct clearance from the blade.

The bracket stop must always be engaged when transporting the product.

Keep the floor area free of loose materials, such as chips and cut-offs.

Refrain from removing any cut-offs or other parts of the workpiece from the cutting area whilst the product is running and the saw head is not in the rest position.

Long workpieces must be adequately supported. The working area of the saw includes the whole extent of the workpiece. The operator should secure this area from accidental contact from other persons or objects which may move the workpiece during operation.

The dust produced when using the product may be harmful to health.

Use a dust suction system and wear a suitable dust protection mask.

Remove deposited dust thoroughly with a vacuum cleaner.

Do not replace the LED with a different type. Any repairs must only be carried out by the manufacturer or authorised service agent.

It is recommended that the product always be supplied via a residual current device having a rated residual current of 30mA or less.

When using the product, voltage fluctuations may affect other electrical products or lighting on the same power circuit. Connect the product to a power source with an impedance equal to 0.

299

:

to minimize voltage fluctuations. Contact your electric power supplier for further clarification.

SPECIFIED CONDITIONS OF USE

The mitre saw is intended for sawing solid and bonded wood, materials similar to wood, with or without glued veneer and plastics.

The mitre saw is intended to be used only by adult operators who have read the instruction manual and understand the risks and hazards.

The mitre saw is designed to be fixed at the base to a solid bench top or a dedicated work stand. If the base is not securely fixed, the whole machine may move during cutting operations, which increases the possibility of serious personal injury.

The mitre saw is designed to make bevel and mitre cuts. The capacities for the various cuts are provided in the sliding compact mitre saw product specifications in this manual.

The mitre saw is to be used in dry conditions, with excellent ambient lighting and adequate ventilation.

The mitre saw is intended for consumer use and should only be used as described above and is not intended for any other purpose.

RESIDUAL RISKS

Even when the slide compound mitre saw is used as prescribed, it is still impossible to completely eliminate certain residual risk factors.

The following hazards may arise and the operator should pay special attention to avoid the following:

Ŷ

Risk of contact with uncovered parts of the rotating saw blade.

Ŷ Kick-back of work pieces or parts of work pieces due to improper adjustment or handling.

Ŷ

Catapulting of faulty carbide tips from the saw blade. Wear Eye protection at all times.

Ŷ

Damage to the respiratory system. Wear respiratory protection masks containing filters appropriate to the materials being worked. Ensure adequate workplace ventilation. Do not eat, drink or smoke in the work area.

Ŷ

Damage to hearing if effective hearing protection is not worn.

WARNING! Dust from certain paints, coatings, and materials may cause irritation or allergic reactions. Dust from wood such as oak, beech, MDF, and others are carcinogenic. Materials containing asbestos should only be worked on or processed by qualified specialist operators.

WARNING! Injuries may be caused or aggravated by prolonged use of a tool. When using any tool for prolonged periods, ensure you take regular breaks.

ASSEMBLY

UNPACKING

Packing list

Ŷ

Mitre saw x 1

Ŷ

Saw blade x 1

Ŷ Dust bag x 1

Ŷ

Work clamp x 1

Ŷ

Left sliding fence x 1

Ŷ Right sliding fence x 1

Ŷ

Operator’s manual x 1

The product requires assembly.

Carefully lift the saw from the carton by holding both the “D” handle and carrying handle, and place it on a level work surface.

The product has been shipped with the saw arm secured in the down position. To release the saw arm, push down on the top of the saw arm, cut the tie-wrap, and pull out the head lock pin.

16 16

WARNING! The saw arm is spring loaded. Hold the handle down to prevent saw arm from snapping up when cutting the tie-wrap.

Failure to do so could result in possible serious injury.

Ŷ

Lift the saw arm by the handle. Hand pressure should remain on the saw arm to prevent sudden rise upon release of the tie wrap.

Ŷ

Inspect the product carefully to make sure no breakage or damage occurred during shipping.

Ŷ

Do not discard the packing material until you have carefully inspected and satisfactorily operated the product.

Ŷ

The product is factory set for accurate cutting. After assembling it, check for accuracy. If shipping has influenced the settings, refer to specific procedures explained in the manual.

WARNING! If any parts are damaged or missing, do not operate the product until the parts are replaced. Use of the product with damaged or missing parts could result in serious personal injury.

WARNING! Do not attempt to modify the product or create accessories not recommended for use with the product. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury.

WARNING! To prevent accidental starting that could cause serious personal injury, always disconnect the product from the mains supply or remove the battery pack(s) from the product when assembling parts.

MOUNTING HOLES

See figure 1.

WARNING! Before starting any cutting operation, mount the product to a solid workbench. Never operate the product on the floor or in a crouched position. Failure to heed this warning can result in serious personal injury.

The product should be mounted to a firm supporting surface such as a workbench, mounting board. Four bolt holes have been provided in the saw base for this purpose. Each of the four mounting holes should be bolted securely using 7.9 mm (5/16 in.) machine bolts, lock washers, and hex nuts (not included). Bolts should be of sufficient length to accommodate the saw base, lock washers, hex nuts, and the thickness of the workbench. Tighten all four bolts securely.

The hole pattern for mounting to a workbench is shown in Figure 1.

Carefully check the workbench after mounting to make sure that no movement can occur during use. If any tipping, sliding, or walking is noted, secure the workbench to the floor before operating.

Mounting on a stand

The product is compatible with mitre saw stands PSU1000 and

PSUM1000 (sold separately). To mount the product on the PSU1000 or PSUM1000, use the four bolts supplied. Align the mounting holes on the saw with the ones on the mounting brackets. Secure the saw by tightening all bolts. For detailed mounting instructions, refer to the user manual of respective stands.

CARRYING HANDLE

WARNING! Use both the “D” handle and the carrying handle to move or carry the product. Always disconnect the mains supply before moving.

INSTALLING MITRE FENCES

See figure 2.

Ŷ

Turn the fence lock knob counterclockwise to clear fixed fence slots.

Ŷ Install the sliding mitre fence. Lower fence into fence slots. Be sure side of fence lines up flush with side of fixed fence.

Ŷ

Tighten fence lock knob securely. Repeat on other side.

USING THE DEPTH GUIDE

See figure 3.

When used, the depth guide limits the downward travel of the blade when cutting dadoes and other non-through cuts.

To use the depth guide:

Ŷ

Unplug the saw.

Ŷ

Rotate the depth stop outward.

Ŷ

Loosen the lock nut.

Ŷ

With the depth control knob touching the depth stop, adjust the depth control knob by turning the knob until the desired depth of cut is attained.

Ŷ

Tighten the lock nut.

Ŷ

A wooden spacer must be placed between the workpiece and the fence to create a distance of 90 mm inches between the workpiece and the fence for a consistent depth of cut in the workpiece. Use the work clamp to clamp the spacer and another suitable clamp to clamp the workpiece. Make the slide cut at the desired depth. See Figures 34 and 35.

Ŷ

Rotate the depth stop inward for normal through cuts.

NOTE: The depth stop must be pushed in before locking/unlocking the saw arm.

LOCKING/UNLOCKING THE SAW ARM

See figure 4.

When locking and unlocking the saw arm, it is not necessary to loosen the depth control knob. However, the depth stop must be pushed in.

To unlock and raise the saw arm:

Ŷ

Firmly grasp the “D” handle and apply downward pressure while at the same time pulling the head lock pin out and away from the saw housing.

Ŷ

Release the head lock pin and slowly raise the saw arm.

To lock the saw arm:

Ŷ Firmly grasp the “D” handle and apply downward pressure until head stops. Push in the head lock pin toward the saw.

Ŷ

Release the head lock pin allowing it to lock the saw into place.

NOTE : Do not use saw to cut while in the locked position.

DUST BAG AND FRAME ASSEMBLY

See figure 5.

To install the dust bag and frame assembly, slide the open end of the frame assembly onto the exhaust port.

For efficient operation, empty the dust bag before it is half full. This will permit better air flow through the bag.

INSTALLING/REPLACING THE BLADE

See figure 6.

WARNING! Before removing and fitting the blade, make sure to wear safety gloves.

WARNING! A 254 mm (10 in.) blade is the maximum blade capacity of the product. Never use a blade that is too thick to allow outer flange to engage with the flats on the spindle. Larger blades will come in contact with the blade guards, while thicker blades will prevent the blade bolt from securing the blade on the spindle. Either of these situations could result in a serious accident and can cause serious personal injury.

WARNING! Only use the blade specified in this manual and its speed is at least equal to the speed marked on the product.

Ŷ Unplug the saw.

Ŷ

Raise the saw arm.

Ŷ

Rotate the lower blade guard to expose the blade bolt.

Ŷ Depress the spindle lock button and rotate the blade bolt until the spindle locks.

Ŷ

Using the hex end of the blade wrench, loosen and remove the blade bolt from the arbor.

17 17

NOTE : The blade bolt has left hand threads. Turn blade bolt clockwise to loosen.

Ŷ

Remove the outer blade washer.

NOTE : The inner blade washer is integrated into the spindle and cannot be removed.

Ŷ Wipe a drop of oil onto inner blade washer and outer blade washer where they contact the blade.

Ŷ

Rotate the lower blade guard to expose the arbor.

Ŷ Fit saw blade inside blade guard and onto the arbor and against the inner blade washer. The blade teeth point downward at the front of saw as shown.

Ŷ Replace the outer blade washer. The double “D” flats on the blade washers align with the flats on the spindle.

Ŷ

Depress spindle lock button and replace blade bolt.

NOTE: The blade bolt has left hand threads. Turn blade bolt counterclockwise to tighten.

WARNING! Always install the blade with the blade teeth and the arrow printed on the side of the blade pointing down at the front of the saw. The direction of blade rotation is also stamped with an arrow on the upper blade guard.

Ŷ Tighten the blade bolt securely.

Ŷ

Lower the blade guard.

Ŷ

Raise and lower the saw arm to ensure the lower blade guard functions correctly.

WARNING! Make sure the spindle lock button is not engaged before reconnecting saw into power source. Never engage spindle lock button when blade is rotating.

REMOVING/REPLACING THE ADJUSTABLE THROAT PLATES

See figures 7.

When squaring the saw blade, it may be necessary to move the throat plate away from the blade. Once the saw’s alignment has been confirmed, return the throat plate to its original position. Never operate the saw without a throat plate installed.

Ŷ

Unplug the saw.

Ŷ

Using the blade wrench provided, loosen the screws securing the right side of the adjustable throat plate.

NOTE : The throat plate may be adjusted to (near) zero clearance to support thin materials.

Ŷ

Slide the throat plate away from the blade as far as possible.

Ŷ

Retighten the screws, being careful not to overtighten which can cause the throat plate to bow or bend.

Ŷ

Repeat the above steps for the left side of the throat plate.

Ŷ

Visually inspect and make sure that the throat plates fit flush with the tuning table.

INSTALLING THE WORK CLAMP

See figure 8.

WARNING! In some operations, the work clamp assembly may interfere with the operation of the blade guard assembly. Always make sure there is no interference with the blade guard prior to beginning any cutting operation to reduce the risk of serious personal injury.

The work clamp provides greater control by clamping the workpiece to the mitre table. It also helps to prevent the workpiece from creeping toward the saw blade. This is helpful when cutting compound mitres.

Depending on the cutting operation and the size of the workpiece, it may be necessary to use a C-clamp instead of the work clamp to secure the workpiece prior to making the cut. The work clamp can be installed and used on either side of the blade.

To install the work clamp:

Ŷ Place the work clamp shaft in one of the holes located behind the sliding mitre fence.

Ŷ

Rotate the knob on the work clamp to move it up or down as needed.

ADJUSTING THE MITRE LOCK

See figure 9 - 10.

Prior to squaring the saw blade to the fence, ensure the mitre table moves and locks securely.

Ŷ

Unplug the saw.

Ŷ

Locate the mitre lock nut, mitre lock screw and mitre lock shoe on the rear underside of the saw.

To check the clamping force of the mitre lock:

Ŷ

Unplug the saw.

Ŷ

Lift the mitre lock lever and press the mitre detent bypass button to unlock the mitre table.

Ŷ

Rotate the mitre table to an “unindexed” mitre position other than

0˚, 15˚, 22.5˚, 31.6˚, 45˚, 60˚, and 67.5˚.

Ŷ Push the mitre lock lever down and attempt to move the mitre table. If the table moves easily when in the “locked” position, adjust the mitre lock screw.

Ŷ Using a 4 mm hex key, adjust the mitre lock screw. Make adjustments of one-quarter turn or less.

NOTE: Turning the mitre lock screw clockwise will increase the clamping force. Turning the mitre lock screw counterclockwise decreases the clamping force.

Ŷ

After making the adjustment, test the clamping force.

To adjust mitre table movement:

Ŷ

Lift the mitre lock lever, press the mitre detent bypass button, and move the mitre table left to right. If the mitre table does not move freely, adjust the mitre lock nut.

Ŷ

Using the 4 mm hex key, hold the mitre lock screw stationary and use the 13 mm combination wrench to adjust the nut holding the mitre lock shoe.

NOTE: Turning the mitre lock nut clockwise will move the shoe closer to the mitre saw base and make it harder to move the mitre table. Turning the mitre lock nut counterclockwise will move the shoe farther away from the base and make it easier to move the table.

Ŷ

Adjust the mitre lock nut until the shoe and mitre saw base are close but not in contact with each other.

Ŷ

After making the adjustment, test the movement of the mitre table.

Ŷ Rotate the mitre table to an “unindexed” mitre position other than

0˚, 15˚, 22.5˚, 31.6˚, 45˚, 60˚, and 67.5˚ and push the mitre lock lever down. Test the clamping force.

NOTE: It should take considerable force to move the table in the locked position.

ADJUSTING THE MITRE LOCK LEVER

See figure 11.

Ŷ

Unplug the saw.

Ŷ

Lift the mitre lock lever to unlock the mitre table.

Ŷ If the mitre lock lever is not parallel with the top of the mitre table, adjustments are needed.

Ŷ

Using a 10 mm combination wrench and a flat head screwdriver, hold the mitre lock screw in place and loosen the mitre lock nut.

Ŷ

Turn the mitre lock screw clockwise to lower the lever.

Ŷ

Turn the mitre lock screw counterclockwise to raise the lever.

Ŷ

Continue to adjust the lock lever until it is parallel with the mitre table.

Ŷ

Hold the screw in place and tighten the lock nut securely.

SQUARING THE SAW BLADE TO THE FENCE

See figures 12 - 15.

Ŷ

Disconnect the mains supply from the product.

18 18

Ŷ

Pull the saw arm all the way down and lock in transport position.

Ŷ Loosen the bevel lock knob and disengage the bevel detent lever.

Ŷ

Set the saw at the 0º bevel angle, engage the bevel detent lever, and ensure the saw engages the detent.

Ŷ

Tighten the bevel lock knob.

Ŷ


Ŷ

Press the mitre detent button and rotate the mitre table until the pointer on the mitre scale is positioned at 0°.

Ŷ Release the mitre detent button and allow the mitre table to engage the 0° detent position.

Ŷ

Push the mitre lock lever down to lock the mitre table.

Ŷ Lay a framing square flat on the mitre table. Place one leg of the square against the fixed fence. Slide the other leg of the square against the flat part of the saw blade.

NOTE: Make sure that the square contacts the flat part of the saw blade, not the blade teeth.

Ŷ

The edge of the square and the saw blade should be parallel.

Ŷ

If the front or back edge of the saw blade angles away from the square as shown in figure 14, adjustments are needed.

Ŷ

Rotate the extension tables to their fully extended position. See

“To Make Extended Mitre Cuts” later in this manual.

Ŷ Lift the mitre lock lever to unlock the mitre table.

Ŷ

Press the mitre detent bypass button. Rotate the mitre table until the pointer is at the left 15° position on the mitre scale.

Ŷ

Using a 4 mm hex key, loosen the 5 screws that hold the mitre scale/detent plate in place.

Ŷ

Rotate the mitre table to the 0° position on the mitre scale and detent engages in the detent plate.

Ŷ Rotate the mitre table until the blade is parallel with the framing square.

Ŷ


Ŷ Tighten the 4 visible screws that secure the mitre scale/detent plate.

Ŷ


Ŷ Press the mitre detent bypass button. Rotate the mitre table until the pointer is at the left 15° position on the mitre scale.

Ŷ

Tighten the remaining screw to secure the mitre scale/detent plate.

SQUARING THE BLADE TO THE MITRE TABLE

See figures 16.

Ŷ

Unplug the saw.

Ŷ

Pull the saw arm all the way down and lock in transport position.

Ŷ


Ŷ

Press the mitre detent bypass half way and rotate the mitre table until the pointer on the mitre scale is positioned at 0°.

Ŷ

Release the mitre detent bypass and allow the mitre table to engage the 0° detent position.

Ŷ


Ŷ

Loosen the bevel lock knob and disengage the bevel detent lever.

Ŷ Set the saw at the 0º bevel angle, engage the bevel detent lever and ensure the saw engages the detent.

Ŷ


Ŷ Place a combination square against the mitre table and the flat part of the saw blade.

NOTE: Make sure that the square contacts the flat part of the saw blade, not the blade teeth.

Ŷ Rotate the blade by hand and check the blade-to-table alignment at several points.

Ŷ

The edge of the square and the saw blade should be parallel.

Ŷ

If the top or bottom of the saw blade angles away from the square as shown in figure 16, adjustments are needed.

19

TO ADJUST THE BEVEL


Ŷ Remove the bevel lock dust cover.

Ŷ

Move the bevel detent lever to the detent disengaged position.

Ŷ

Set the bevel at any angle that allows access to the 4 screws on the back of the bevel lock bracket.

Ŷ


Ŷ

Using a 4 mm hex wrench, loosen the 4 screws that hold the bevel detent plate in place. Do not remove the screws.

Ŷ

Loosen the bevel lock knob and move the bevel detent lever to the detent disengaged position.

Ŷ

Set the bevel angle at 0°.

Ŷ Move the bevel detent lever to the detent engaged position.

Ŷ

Check the 0° angle using a combination square.

Ŷ

If adjustment is needed, use a 4 mm hex key to turn the micro adjust screw on the front of the bevel lock bracket to adjust the saw to the 0° bevel angle.

Ŷ


Ŷ Tighten the 2 outermost screws that retain the bevel detent plate.

Ŷ

Loosen the bevel lock knob and set the bevel at any angle that allows access to the 2 remaining screws on the back of the bevel lock bracket.

Ŷ


Ŷ

Tighten the remaining 2 screws that retain the bevel detent plate.

Ŷ

Replace the bevel lock dust cover and tighten the screws securely.

OPERATION

WARNING! Do not allow familiarity with products to make you careless. Remember that a careless fraction of a second is sufficient to inflict severe injury.

WARNING! Always wear eye protection with side shields. Failure to do so could result in objects being thrown into your eyes, resulting in possible serious injury.

WARNING! Do not use any attachments or accessories not recommended by the manufacturer of the product. The use of attachments or accessories not recommended can result in serious personal injury.

WARNING! To avoid serious personal injury, always push the mitre lock lever down and tighten the bevel lock knob securely before making a cut. Failure to do so could result in movement of the control arm or mitre table while making a cut.

WARNING! To avoid serious personal injury, keep your hands outside the no hands zone, at least 100 mm from blade. Never perform any cutting operation freehand (without holding workpiece against the fence). The blade could grab the workpiece if it slips or twists.

WARNING! Before starting any cutting operation, clamp or bolt your mitre saw to a workbench or leg stand. Never operate your mitre saw on the floor or in a crouched position. Failure to heed this warning can result in serious personal injury.

WARNING! Do not start your compound mitre saw without checking for interference between the blade and the mitre fence.

Damage could result to the blade if it strikes the mitre fence during operation of the saw. Failure to heed this warning can also result in serious personal injury.

CUTTING WITH YOUR SLIDING COMPOUND MITRE SAW

WARNING! When using a work clamp or C-clamp to secure your workpiece, clamp workpiece on one side of the blade only. The workpiece must remain free on one side of the blade to prevent the blade from binding in workpiece. The workpiece binding the blade will cause motor stalling and kickback. This situation could cause an accident resulting in possible serious personal injury.

WARNING! Never move the workpiece or make adjustment to

19

any cutting angle while the saw is running and the blade is rotating.

Any slip can result in contact with the blade causing serious personal injury.

WARNING! Do not try to cut narrow pieces using the sliding feature. Failure to heed this warning could result in serious personal injury.

LED LIGHTING SYSTEM

See figure 19.

The LED lighting system casts the shadow of the blade onto the workpiece. This results in greater accuracy of cuts and requires no adjustments.

To use this feature, turn the LED switch on.

Bring the saw arm down so the blade is approximately 10 mm from the workpiece. The shadow of the blade will be projected onto the workpiece, indicating where the blade teeth will make contact as the cut is made.

WARNING! Do not stare at the LED light when it is switched on.

TO MAKE NON-SLIDING CUTS

WARNING! Securely tighten the slide lock knob when making any non-sliding cuts. Failure to tighten the knob could result in the saw head moving during the cutting operation.

TO MITRE CUT/CROSS CUT


A cross cut is made by cutting across the grain of the workpiece. A straight cross cut is made with the mitre table set at the 0° position.

Mitre cross cuts are made with the mitre table set at some angle other than 0°.

Ŷ

Slide the saw head to its most rearward position and tighten the slide lock knob securely.

Ŷ Pull out the head lock pin and lift saw arm to its full height.

To move the mitre table to any of the indexed mitre stops (0°,

15°, 22.5°, 31.6°, 45°, 60° and 67.5° left or right):

Ŷ

Move the mitre table to an indexed mitre stop position and release mitre detent bypass button. The mitre table will click into place when it reaches an indexed stop.

Ŷ


To move the mitre table to any desired position on the mitre scale:

Ŷ Lift the mitre lock lever, then press the mitre detent bypass button. The mitre table will move freely left or right.

Ŷ


Ŷ

Place the workpiece flat on the mitre table with one edge securely against the fence. If the board is warped, place the convex side against the fence. If the concave edge of a board is placed against the fence, the board could collapse on the blade at the end of the cut, jamming the blade. See Figures 41 - 42.

Ŷ When cutting long pieces of lumber or molding, support the opposite end of the workpiece with a roller stand or with a work surface level with the saw table. See Figure 31.

Ŷ

Align cutting line on the workpiece with the edge of saw blade.

Ŷ

Turn the LED switch on to project the blade shadow onto the workpiece.

Ŷ

Grasp the workpiece firmly with one hand and secure it against the fence. Use the work clamp or a C-clamp to secure the workpiece when possible.

Ŷ Before turning on the saw, perform a dry run of the cutting operation to make sure that no problems will occur when the cut is made.

Ŷ

Grasp the saw handle firmly. Turn the switch on and allow several seconds for the blade to reach maximum speed.

Ŷ

Slowly lower the blade into and through the workpiece.

Ŷ

Release the switch trigger and allow the saw blade to stop rotating before raising the blade out of workpiece and removing

20 20 the workpiece from the mitre table.

TO MAKE EXTENDED MITRE CUTS


The extended mitre capacity of the saw allows you to make mitre cuts up to 70°. Using the mitre extension tables, you can cut 22.5° mitres for acute 45° corners.

WARNING! When performing 70° mitre cut, only 0° bevel angle is allowed.

The rotating extension tables can be set to one of three positions, depending on the desired type of cut.

WARNING!

Do not set the extension tables to the unlocked positions. Set to one of the three locked positions only.

Use the rotating extension tables when making mitre cuts greater than 45°.

Ŷ


Ŷ

Pull out the head lock pin and lift saw arm to its full height.

Ŷ Slide out the fence on the side opposite of where the cut will be made. This ensures that the bevel lock bracket will not bump against the fence when setting the blade for extended mitre cuts.

Ŷ

To rotate the extension tables outward, press the table lock button and select one of the preset positions.

Ŷ

Release the table lock button and move the table until it locks into position.

Ŷ

Lift the mitre lock lever to unlock the mitre table and press the detent bypass button. Rotate the mitre table until the pointer aligns with the desired angle on the mitre scale.

Ŷ


Ŷ


Ŷ


WARNING! For extended mitre cuts, place the clamp on the large mitre angle side of the table. Clamping or holding the workpiece on the small mitre angle side of the table may place your hand too close to the blade and cause serious personal injury.

Ŷ Grasp the workpiece firmly with one hand and secure it against the fence. Use the work clamp or a C-clamp to secure the workpiece when possible.

Ŷ

Before turning on the saw, perform a dry run of the cutting operation to make sure that no problems will occur when the cut is made.

Ŷ

Grasp the saw handle firmly. Turn on the switch and allow several seconds for the blade to reach maximum speed.

Ŷ Slowly lower the blade into and through the workpiece.

Ŷ

Release the switch trigger and allow the saw blade to stop rotating before raising the blade out of the workpiece and removing the workpiece from the mitre table.

TO BEVEL CUT


A bevel cut is made by cutting across the grain of the workpiece with the blade angled to the workpiece. A straight bevel cut is made with the mitre table set at the zero degree position and the blade set at an angle.

Bevel cuts may be made by angling the blade to the left or right.

NOTE: It may be necessary to adjust or remove the sliding mitre fence to insure proper clearance prior to making the cut. Make sure the fence lock knob is tightened securely to avoid interference with the saw head.

Ŷ

Make sure the slide lock knob is tightened securely.

Ŷ


Ŷ

Lift the mitre lock lever and press the mitre detent bypass button.

Set the mitre table to zero.

Ŷ


Ŷ

Loosen the bevel lock knob.

NOTE : Firmly grasp the “D” handle while loosening the bevel lock knob to prevent the saw head from shifting unexpectedly.

Ŷ

Move the bevel detent lever to the detent engaged position to select one of the preset bevel settings or place the bevel detent lever in the detent disengaged position to select any desired setting.

NOTE : Indexed bevel positions are located at 0°, 15°, 22.5°, 33.9°, and 45° left or right.

Ŷ


Ŷ Place the workpiece flat on the mitre table with one edge securely against the fence. If the board is warped, place the convex side against the fence. If the concave edge of a board is placed against the fence, the board could collapse on the blade at the end of the cut, jamming the blade. See Figures 41 - 42.

Ŷ

When cutting long pieces of lumber or molding, support the opposite end of the workpiece with a roller stand or with a work surface level with the saw table. See Figure 31.


Ŷ


Ŷ


Ŷ


Ŷ

Grasp the saw handle firmly. Turn on the saw and allow several seconds for the blade to reach maximum speed.

Ŷ


Ŷ Release the switch trigger and allow the saw blade to stop rotating before raising the blade out of the workpiece and removing the workpiece from the mitre table.

TO COMPOUND MITRE CUT

See figure 27.

A compound mitre cut is a cut made using a mitre angle and a bevel angle at the same time. This type of cut is used to make picture frames, cut molding, make boxes with sloping sides, and for certain roof framing cuts.

To make this type of cut the control arm on the mitre table must be rotated to the correct angle and the saw arm must be tilted to the correct bevel angle. Care should always be taken when making compound mitre setups due to the interaction of the two angle settings.

Adjustments of mitre and bevel settings are interdependent with one another. Each time you adjust the mitre setting you change the effect of the bevel setting. Also, each time you adjust the bevel setting you change the effect of the mitre setting.

It may take several settings to obtain the desired cut. The first angle setting should be checked after setting the second angle, since adjusting the second angle affects the first.

Once the two correct settings for a particular cut have been obtained, always make a test cut in scrap material before making a finish cut in good material.

NOTE : It may be necessary to adjust or remove the sliding mitre fence to insure proper clearance prior to making the cut. Make sure the fence lock knob is tightened securely to avoid interference with the saw head.

Ŷ


Ŷ

Pull out the lock pin and lift saw arm to its full height.

Ŷ

Lift the mitre lock lever and depress the detent release button to release the mitre table.

Ŷ

Rotate the control arm until the scale indicator aligns with the desired angle on the mitre scale.

NOTE : When performing 45° bevel compound cut, the maximum mitre angle is 45°. When performing 70° mitre cut, only 0° bevel angle is allowed.

Ŷ Release the detent release button, then push the mitre lock lever down to secure the mitre table.

Ŷ

Loosen the bevel lock knob.

NOTE : Firmly grasp the “D” handle while loosening the bevel lock knob to prevent the saw head from shifting unexpectedly.

Ŷ

Move the bevel detent lever to the detent engaged position to select one of the preset bevel settings or place the bevel detent lever in the detent disengaged position to select any desired setting.

NOTE : Indexed bevel positions are located at 0°, 15°, 22.5°, 33.9°, and 45° left or right.

Ŷ Tighten the bevel lock knob.

Ŷ

Recheck mitre angle setting. Make a test cut in scrap material.

Ŷ


Ŷ When cutting long pieces of lumber or molding, support the opposite end of the workpiece with a roller stand or with a work surface level with the saw table. See Figure 31.



Ŷ


Ŷ


Ŷ

Make a test cut in scrap material.

Ŷ

Grasp the saw handle firmly. Turn the saw on and allow several seconds for the blade to reach maximum speed.

Ŷ


Ŷ Release the switch trigger and allow the saw blade to stop rotating before raising the blade out of workpiece and removing the workpiece from the mitre table.

WARNING! Never make a cut by pulling the saw toward you as the blade can climb on top of the workpiece and come toward you.

Failure to heed this warning could result in serious personal injury.

TO SLIDE CUT

See figure 28.

The sliding feature will cut nominal workpieces 305 mm wide by 38 mm thick or 152 mm wide by 89 mm thick.

With the saw off, pull the saw arm forward. Turn the saw on (let blade reach maximum speed), push the blade down cutting into the workpiece then back toward the rear of the saw to make a cut. Cuts are made by pushing the saw blade away from you and toward the bevel scale at the back of the saw stopping when the full rear position has been reached after each cut. When the saw is running (turned on),

Never pull the saw blade toward you or toward the front of the saw.

Ŷ


Ŷ


Ŷ

When cutting long pieces of lumber or molding, support the opposite end of the workpiece with a roller stand or with a work surface level with the saw table. See Figure 31.

Ŷ

Align the cutting line on the workpiece with the edge of saw blade.

21 21

Ŷ


Ŷ

Loosen the slide lock knob by turning the knob counterclockwise.

Ŷ

Grasp the workpiece firmly with one hand and secure it against the fence. Use the work clamp or a C-clamp to secure the workpiece when possible.

Ŷ


Ŷ

With the saw off, grasp the saw handle firmly then pull the saw forward until the blade arbor (center of the saw blade) is over the front of the workpiece.

Ŷ

Turn the saw on and allow several seconds for the blade to reach maximum speed.

Ŷ Slowly lower the blade into and through the front edge of the workpiece.

Ŷ

Push the saw handle away from you and toward the bevel scale at the back of the saw.

Ŷ

Release the switch trigger and allow the saw blade to stop rotating before raising the blade out of workpiece and removing the workpiece from mitre table.

MAKING AN AUXILIARY FENCE

See figure 29.

Depending on the size and position of the workpiece, certain unusual cuts may benefit from the additional support that can be provided by an auxiliary fence. The holes provided in the mitre fence are used to secure an auxiliary fence in place. To make an auxiliary fence, we recommend using two pieces of wood 10 mm thick, 90 mm. high, and

250 mm. long.

NOTE

SUPPORTING LONG WORKPIECES


Long workpieces need extra support. Supports should be placed along the workpiece so it does not sag. The support should let the workpiece lay flat on the base of the saw and mitre table during the cutting operation. Use the work clamp or a C-clamp to secure the workpiece.

NOTE: When making a compound mitre cut as shown in figure 30, it may be necessary to adjust or remove the sliding mitre fence to ensure proper clearance prior to making the cut. Make sure the fence lock knob is tightened securely to avoid interference with the saw head.

: The auxiliary fence can only be used when the bevel is set at

0°. When making a bevel cut, the auxiliary fence must be removed.

To attach the auxiliary fence to the saw:

Ŷ

Make sure the fence lock knob is tightened securely.

Ŷ

Place the 250 mm. long piece of wood against the mitre fence and aligned with the left edge of the mitre table.

Ŷ

Clamp the wood tightly against the fence and drive wood screws from the back of the fence through the two holes and into the auxiliary fence. If necessary, drill a pilot hole into wood first to prevent splitting. Remove clamp when finished.

NOTE : Make sure the screws you use to attach the auxiliary fence do not pass through the front face of the fence and the length of the screws will not put them in the path of the blade at any angle.

Ŷ Make full 45° left and right mitre cuts through the auxiliary fence.

NOTE : Check for interference between the auxiliary fence and the lower blade guard. Correct any interference before proceeding.

Ŷ

Repeat steps with second board by aligning with right side of mitre table.

WARNING! Both sides of the auxiliary fence must be aligned on the same plane.

WARNING! When using an auxiliary fence, check and ensure that there is no interference with any part of the saw during operation.

CLAMPING WIDE WORKPIECES

See figure 32.

When cutting wide workpieces, such as a nominal 50 mm. x 50 mm, boards should be clamped securely.

WARNING! Never make a cut by pulling the saw toward you as the blade can climb on top of the workpiece and come toward you.

Failure to heed this warning could result in serious personal injury.

ROUGH CUTTING A DADO


Using a wood chisel and the depth control knob, it is possible to make a rough dado cut. Always make a practice cut on scrap wood.

To use the depth control knob:

Ŷ

Unplug the saw.

Ŷ

Rotate the depth stop outward.

Ŷ Loosen the lock nut.

Ŷ

With the depth control knob touching the depth stop, adjust the depth control knob by turning the knob until the desired depth of cut is attained.

Ŷ

Tighten the lock nut.

Ŷ

A wooden spacer must be placed between the workpiece and the fence to create a distance of 3-1/2 inches between the workpiece and the fence for a consistent depth of cut in the workpiece. Use the work clamp to clamp the spacer and another suitable clamp to clamp the workpiece. Make the slide cut at the desired depth.

Ŷ

Rotate the depth stop inward for normal through cuts.

NOTE : The depth stop must be pushed in before locking/ unlocking the saw arm.

To make the cut:

Ŷ

Unlock the slide lock knob.

Ŷ


Ŷ

With the saw off, pull the saw arm forward. Turn the saw on (let blade reach maximum speed), then push the blade down on top of the workpiece then back toward the rear of the saw to make a cut.

Ŷ Cut two outside grooves in the workpiece.

Ŷ

Using a wood chisel, remove the material between the two outside grooves.

CUTTING CROWN MOLDING

The compound mitre saw does an excellent job of cutting crown molding. In general, compound mitre saws do a better job of cutting crown molding than any other tool.

In order to fit properly, crown molding must be compound mitred with extreme accuracy.

The two contact surfaces on a piece of crown molding that fit flat against the ceiling and the wall of a room are at angles that, when added together, equal exactly 90°. Most crown molding has a top rear angle (the section that fits flat against the ceiling) of 52° and a bottom rear angle (the section that fits flat against the wall) of 38°.

LAYING MOLDING FLAT ON THE MITRE TABLE


To use this method for accurately cutting crown molding for a 90° inside or outside corner, lay the molding with its broad back surface flat on the mitre table and against the fence.

When setting the bevel and mitre angles for compound mitres, remember that the settings are interdependent; changing one angle changes the other angle as well.

Keep in mind that the angles for crown molding are very precise and difficult to set. Since it is very easy for these angles to shift, all settings should first be tested on scrap molding. Also most walls do not have angles of exactly 90°; therefore, you will need to fine tune your settings.

22 22

When cutting crown molding by this method the bevel angle should be set at 33.9°. The mitre angle should be set at 31.6° either right or left, depending on the desired cut for the application. See the chart below for correct angle settings and correct positioning of crown molding on mitre table.

The settings in the chart below can be used for cutting crown molding with 52° and 38° angles or 45° and 45° angles. The crown molding is placed flat on the mitre table using the compound features of the product.

Type of crown molding

38

38

38

38

38

38

38

38

45

45 o o o o o o o o o o

Bevel angle type of cut

33.9

o

33.9

o

33.9

33.9

o o

(Left)

(Left)

(Left)

Setting

Left side of inside corner

1. Top edge of molding against fence

2. Mitre table set right 31.6

3. Save left end of cut

(Left) Right side of inside corner

2. Mitre table set left 31.6

o

3. Save right end of cut

3. Save right end of cut o

1. Bottom edge of molding against fence


3. Save left end of cut o

Left side of outside corner


Right side of outside corner



o

33.9

o (Right) Left side of inside corner



o


33.9

o (Right) Right side of inside corner



o


33.9

o (Right) Left side of outside corner



o


33.9

o (Right) Right side of outside corner



o


30 o (Left) Left side of inside corner



o


30 o (Left) Right side of inside corner



o


45

45

45

45

45

45 o o o o o o

30

30 o o

(Left)

(Left)

Left side of outside corner



o


Right side of outside corner



o


30 o (Right) Left side of inside corner



o


30 o (Right) Right side of inside corner



o


30 o (Right) Left side of outside corner



o


30 o (Right) Right side of outside corner



o


CUTTING NESTED CROWN MOLDING USING CROWN STOPS

(Crown stops not included)

See figure 38.

Crown stops may be purchased as an accessory to this saw for use in cutting crown molding in a nested position and should be installed on both the right and left side.

To attach the crown stops to the extension table:

Ŷ

Position a crown stop on the right extension table.

Ŷ

Insert the threaded crown stop lock knob through the long slot in the crown stop and into Hole A as shown, but do not fully tighten to allow for adjustment of the crown stop.

Ŷ

Set the top of the piece of crown molding on the table. Position the spring angles so that the bottom angle is flat on the table and the top angle is flush against the mitre fence.

Ŷ

Tighten the lock knob securely before making the cut.

NOTE : Hole B is used for extended mitre cuts when the rotating

Ŷ extension table is in the farthest outboard position.

Repeat steps for the left side.

CROWN AND BASEBOARD SETTING LEVER

See figure 39.

The crown and baseboard setting lever is helpful when making mitre cuts up to 45° for tall crown molding and vertical baseboard.

Use the crown setting for tall crown molding of 120 mm and taller.

NOTE : For cutting crown molding less than 120 mm tall, slide the saw head to the rear most position with the crown and baseboard setting lever in the down position.

To position for tall crown molding:

Ŷ

Unplug the saw.

Ŷ

Loosen the slide lock knob and pull the saw head forward.

Ŷ

Flip the crown and baseboard setting lever up.

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NOTE : This lever position is for left and right mitre cuts up to 45°

Ŷ

Push the saw head all the way toward the rear of the saw until the saw head stops and tighten the slide lock knob.

Ŷ

Perform a dry run prior to making any cut after repositioning the sliding mitre fences to ensure there is no interference.

Ŷ

To disengage the crown setting lever, unlock the slide lock knob, push the crown and baseboard setting lever in.

To position for vertical base molding:

Ŷ

Unplug the saw.

Ŷ Loosen the slide lock knob and push the saw away from you and toward the rear of the saw.

Ŷ

Flip the crown and baseboard setting lever up while pulling the saw head toward the front of the saw until the baseboard lock groove engages.

NOTE : This lever position is for cuts between 45° left and 45° right.

Ŷ

Tighten the slide lock knob securely.

Ŷ Perform a dry run prior to making any cut after repositioning the sliding mitre fences to ensure there is no interference.

Ŷ

To disengage the baseboard setting lever, unlock the slide lock knob, push the crown and baseboard setting lever in.

CUTTING BASE MOLDING

See figure 40.

Ŷ Set the mitre angle at 0° and the bevel angle at 45° to either the left or the right. (For making 90° corners.)

Ŷ

Place and secure the base molding flat against the fence using the work clamp and hold the base molding securely.


Ŷ

Grasp the saw handle firmly. Squeeze the switch trigger. Allow several seconds for the blade to reach maximum speed.

Ŷ

Slowly lower the blade into and through the base molding.

CUTTING WARPED MATERIAL


When cutting warped material, always make sure it is positioned on the mitre table with the convex side against the fence as shown in figure 41.

If the warped material is positioned the wrong way as shown in figure

42, it will pinch the blade near the completion of the cut.

WARNING! To avoid kickback and to avoid serious personal injury, never position the concave edge of bowed or warped material against the fence.

TRANSPORTATION AND STORAGE

When storing the product, disconnect the mains supply. Store the product in a secure place that is not accessible to children.

Clean the product using a brush and vacuum cleaner before storage.

If you remove the saw blade or keep spares with the unit, ensure they are in the original packaging to prevent injury.

To secure the product prior to movement:

Ŷ

The product should be stored at the zero degree mitre and bevel angle and locked in position. The slide should be locked.

The handle should be locked in the lower (safe) position with the guards closed.

To move or transport in a vehicle:

Ŷ

Secure the product prior to movement as described in the manual.

Ŷ

Remove the product from the bench top by releasing the 4 bolts, one at each corner. Secure the bolts for future use.

Ŷ

When lifting to a height, carry the product by holding both the “D“ handle and carrying handle.

Ŷ

When transporting in a vehicle, set the product on its base and secure against movement.

MAINTENANCE

Do not modify this saw in any way or use accessories not approved by the manufacturer. Your safety and that of others may be compromised.

Do not use the saw if any switches, guards or other function of this saw does not work as it is intended to. Return to an authorised service centre for professional repair or adjustment.

Do not make any adjustments whilst the saw blade is in motion.

Disconnect the mains supply before making adjustments, lubricating or when doing any maintenance on the machine.

Before and after each use, check your saw for damage or broken parts and keep it in top working condition by replacing parts immediately with spares approved by the manufacturer.

The blade is very hot after use, wear gloves or allow to cool before maintenance or cleaning procedures.

Clean out accumulated dust using a brush or vacuum cleaner. Do not use compressed air.

If the power cord is damaged, it must be replaced by an authorised service centre in order to avoid a safety hazard.

To assure safety and reliability, all repairs, including changing brushes, should be performed by an authorised service centre.

WARNING! For greater safety and reliability, all repairs should be performed by an authorised AEG service centre.

Use only AEG accessories and spare parts. Should components need to be replaced which have not been described, please contact one of our AEG service agents (see our list of guarantee/service addresses).

If needed, an exploded view of the product can be ordered. Please state the Article No. as well as the machine type printed on the label and order the drawing at your local service agents or directly at:

Techtronic Industries GmbH

Max-Eyth-Straße 10,

D-71364 Winnenden,

Germany.

SYMBOLS

Safety alert

Regulatory Compliance Mark (RCM).

Product meets applicable regulatory requirements.

Please read the instructions carefully before starting the machine.

Class II tool, double insulation

Always wear goggles when using the machine.

Wear ear protectors.

Wear gloves

24 24

48 HW

2.2 mm

Do not expose to rain or use in damp locations.

Keep hands away from the cutting area and sharp blade.

CAUTION! Do not stare at the operating lamp.

Blade rotation direction

Blade teeth

Width of cut

Arbor hole and blade size

2

1

For cutting wood only

1

2

Adjust the position of sliding fence before performing bevel or compound cuts.

Do not dispose of electric tools together with household waste material. Electric tools and electronic equipment that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

25 25

26 26

27 27

www.aeg-pt.com

Techtronic Industries GmbH

Max-Eyth-Straße 10

D-71364 Winnenden

Germany

AEG PS254DB Original Instructions Manual

Original instructions

mportant!

It is essential that you read the instructions in this manual before assembling, operating and maintaining the product.

Subject to technical modifications.

www.aeg-pt.com

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