Panel Saw and Router Owner’s Manual 13460 Highway 65 Anoka, MN 55304 USA 763-755-1600 763-755-6080 www.panel saw.com ssc.mail@safetyspeedcut.
A message from all of us at SAFETY SPEED CUT: Thank you for purchasing a Safety Speed Cut vertical panel saw or router. We take pride in building these fine products in the U.S.A. Each SSC product is designed to give years of dependable service. Our saws and routers are built from the finest components we can specify, and every machine is individually assembled by our employees some of whom have been building these products for more than 20 years.
CONTENTS Safety.......................................................................................... 4 Grounding.................................................................................................. Extension Cords ........................................................................................ Short-Circuit Protection ............................................................................. 7 7 8 Installation....................................................................
SAFETY WARNING: When using electric tools, always follow basic safety precautions to reduce the risk of fire, electric shock, and personal injury. READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE. Before use, be sure everyone using this tool reads and understands this manual as well as any labels packaged with or attached to the tool. 1. KNOW YOUR POWER TOOL. Read this manual carefully to learn your power tool’s applications and limitations as well as potential hazards associated with this type of tool. 2.
17. AVOID ACCIDENTAL STARTING. Be sure your tool is turned off before plugging it in. Do not use the tool if the power switch does not turn it on and off. Observe correct lockout/tagout procedures when performing maintenance on the tool. 18. DO NOT FORCE THE TOOL. Your tool will perform best at the rate for which it was designed. Excessive force only causes operator fatigue, increased wear, increased risk of binding or sudden breakage, and reduced control. 19.
27. HANDLE THE COUNTERBALANCE WITH CARE. The counterbalance cable is under tension. Always attach the cable to the saw carriage before removing the cable clip. Do not pull on the cable by hand or attempt to disassemble or repair the counterbalance. Replacement counterbalances can be purchased directly from Safety Speed Cut. 28. DO NOT USE PUSH STICKS. 29. CROSSCUTTING (VERTICAL CUTTING) MUST ALWAYS BE DONE FROM THE TOP DOWN.
Grounding WARNING: Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified electrician if you are not sure that the outlet is properly grounded. Do not modify the plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the cord or plug is damaged. If damaged, have it repaired by a qualified electrician before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician.
Table I: Recommended Minimum Wire Gauge for Extension Cords Extension Cord Length * Nameplate Amps 25 ft 50 ft 75 ft 100 ft 150 ft 200 ft <5 16 16 16 14 12 12 5-8 16 16 14 12 10 8 - 12 14 14 12 10 12 - 15 12 12 10 10 15 - 20 10 10 10 * based on limiting the line voltage drop to 5V at 150% of the rated amperes. The smaller the gauge number of the wire, the greater the capacity of the cord.
INSTALLATION Your Safety Speed Cut saw or router comes from the factory assembled and aligned. You will only have to mount the following parts before you can run this tool: • Counterbalance (on Models C-4, H-Series, and SR-5) • Motor (except for Models 6400/6800, 7400/7400XL, and the SR5/SR-5U) • Cord keeper (except for Models 7400 and 7400XL).
A counterbalance is used on Models C-4, H-Series, and SR-5, to offset the weight of the carriage and saw or router. Other models use a counterweight system that is factory installed. The counterbalance is shipped with the necessary hardware attached, and is in the box marked “Saw Motor.” Remove the two 1/4-20 x 1/2” carriage bolts, nuts, and washers from the counterbalance. Do not remove the bolt and nut that are on the counterbalance cable. 1.
the Stand (and repeated at the end of this manual). The Stand will correctly support the Tool under normal operating conditions. WARNING: A free-standing saw must be located away from areas where it could be accidentally tipped over. Mounting the Motor on the Carriage (Saws) Models C-4, H-4, H-5, H-6 The saw motor is inside the box marked “Saw Motor”. It is shipped with two washers, three nuts, and one bolt installed. Remove these items to mount the saw to the turntable on the carriage.
Mounting the Router Platform and Saw Platform on the Carriage (Combination Machines) Models SR-5 and SR-5U 1. Set the bottom of the router or saw platform behind the two clips at the bottom of the carriage. 2. Pivot the top of the platform into the carriage so its hole slips over the locating pin. 3. Attach the top of the platform to the carriage with two red thumbscrews. Models 3400 and TR-2 Remove the router motor from the box and screw it into the factory mounted router base on the lifting platform.
WARNING: To reduce the risk of injury, do not operate the tool without the blade guard in place. Installing the Blade Guard (Saws) NOTE: The Models 7400 and 7400XL do not have a separate blade guard. The blade guard (Figure 8 or Figure 9) is in the box marked “Saw Motor.” Always install the blade guard before operating the saw. The guard is shipped with two or three red torque knobs (22) installed, depending on the model. Remove the knobs to install the guard.
the saw. The rip ruler is set at the factory, but the two crosscut rulers must be adjusted to the specific blade that is mounted in the saw. Install a blade, then refer to “Adjusting the Crosscut Rulers” in the Operation Section. NOTE: After the saw is completely assembled, you can make a simple cut to verify that the rulers are lined up correctly. Installing the Cord Keeper The cord keeper keeps the cord away from the blade or bit and away from your workpiece.
Installing Accessories Refer to the instructions packed with each accessory (and repeated at the end of this manual).
Cord Keeper Carriage (see close-ups below) Frame Vertical Scale Guides Horizontal Scale Rollers Figure 12: Main Components of Saw or Router (Model H-5 Saw Shown) In d e x P in M o t o r H a n d le O n /O f f S w it c h H e ig h t In d e x T a b C a r r ia g e L o c k Knob B la d e Lock N y lo n B e a r in g s T u r n t a b le B la d e G u a r d Figure 13: Carriage (Models C-4, H-4, H-5, and H-6 Saws) Carriage Handle Indexing Pin Carriage Lock Knob Start-Stop Switch Turntable Blade Guard F
Indexing Pin Carriage Lock Knob Carriage Handle On and Off Switches Carriage Handle Figure 15: Carriage (Models 7400 and 7400XL Saws) Carriage Handle Carriage Lock Knob Carriage Lock Knob Motor Switch Router Lifting Handle Depth Adjusting Ring Figure 16: Carriage (Models 3400 and SR-5U Routers) Carriage Lock Knob Carriage Lock Knob Carriage Handle Carriage Handle Router Lifting Handle Depth Adjusting Ring Figure 17: Carriage (Model SR-5 Router) 17
Carriage Handle Carriage Lock Knob Hand Clamp Motor Switch Depth Adjusting Ring Figure 18: Model TR-2 Router Figure 18A: Knife Carriage (Signature Model) 18
OPERATION WARNING: The following are suggestions that give you a general idea of how a panel saw or router is intended to be operated. No instructions can replace common sense and experience. Be sure you and all operators have enough time and material to become familiar with the general operating characteristics of this tool, and have FULLY READ AND UNDERSTOOD all general operating and safety instructions.
least four rollers. Pieces shorter than 4 feet can be rotated 90° and be crosscut. This size limitation also applies when using the optional Midway Fence. See Figure 26 and 27. Do not attempt to ripcut boards longer than 6 feet on the Model C-4 (8 feet with the optional Frame Extensions, Figure 28). On all other models, there is no limit to the length of board that can be ripcut. However, you must insure that the board is properly supported at all times.
6. Clean the spindle, flanges, bolt, and blade to remove built-up dust and debris. 7. Reinstall the inner flange, slide on the new blade with the arrow pointing counterclockwise, reinstall the outer blade flange, and hand-tighten the bolt clockwise. 8. Use the allen wrench to tighten the bolt while pushing the spindle lock. 9. Reinstall the blade guard. 10. Loosen the carriage lock and allow the saw carriage to return to the top of the guides. 11. Reconnect the power.
2. Lock the carriage lock. 3. Loosen the wing nut on the router base. 4. Rotate the motor counterclockwise and remove it. 5. Using the wrench kit provided, loosen the collet and remove the bit. 6. Install the new bit and tighten the collet securely. Torque Knobs Figure 21: Installing the Blade Guard (Models 6400, 6800) Starting and Stopping the Motor C-4, SR5, and H-Series saws. Start the motor by lifting on the paddle switch located under the saw handle. Stop the motor by pressing the same switch down.
Locking the Carriage Lock the carriage by tightening the red lock knob(s): • On the C-4 and H-Series saws, located on the left guide tube. • On Models 6400 and 6800 saws, located on the right guide tube. • On Models 7400 and 7400XL saws, located to the left of the motor. • On routers, one lock knob located on each guide tube. Adjusting the Crosscut Rulers (Saws) The saw has one rip ruler mounted vertically, and two crosscut rulers, one attached to the frame on each side of the saw.
Adjusting the Kerf Spreader (Models 7400 and 7400XL) The 7400-Series saws have a kerf spreader (Figure 23) mounted on a vertical tube to the left of the saw carriage tracks. It is intended to run in the cut-out kerf from the saw cut when making horizontal cuts from the right to the left. The spreader keeps the upper part of the panel from sagging down and binding on the saw blade. Adjust the spreader to the vertical position where the saw blade is running, and tighten it in place with the red hand knob.
6. Make certain that the workpiece is adequately supported and stable in the machine. Refer also to “Limitations of the Tool”. The workpiece can be held with one hand; do not hold the workpiece so that your hand is anywhere behind the carriage or guides or in the path of the saw blade. 7. Start the motor (see “Starting and Stopping the Motor”), and allow it to reach full speed before beginning the cut. 8.
Operating Procedure: Ripcutting A ripcut is a horizontal cut that can be done either from the left to the right or from the right to the left, as shown in Figure 26 and Figure 27. Ripcuts must always be done by moving the workpiece in the direction of the arrow on the saw carriage. (See also “General Operating Tips” above and “Limitations of the Tool.”) WARNING: To reduce the risk of injury, ripping must always be done with the direction of the arrow on the saw. 1.
Figure 27: Ripcutting From the Right Using Optional Midway Fence (work extends beyond saw carriage at least 4”) 11. When making cuts that are less than 1 inch, the chatter guard (located inside the blade guard) must be resting on the workpiece, not on the cut-off piece. See Figure 28. If it is not positioned this way, it will jam the workpiece and prevent the carriage from continuing through the cut. If the saw jams, turn the tool OFF and wait for the blade to stop. Then back the saw out of the cut.
7. To raise or lower the bit, adjust the graduated depth adjusting ring on the router base. It indicates the exact distance of the bit below the sub-base. 8. Start the motor (see “Starting and Stopping the Motor”), and allow it to reach full speed before beginning the cut. 9. When the motor has reached full speed, slowly and smoothly pull the carriage so the blade runs through the workpiece. Keep one hand on the handle at all times. Be careful not to force the bit through the workpiece, to avoid binding.
To reattach the motor, reverse the above procedure. Use your set screw (11) to reset the motor. Figure 30: Removing the Motor (Models C-4, H-4, H-5, H-6) Models 6400 and 6800 1. Disconnect and lock off the power supply. 2. Remove the blade guard. 3. Remove the saw blade. 4. Support the motor by hand, and remove the two mounting bolts. To reattach the motor, reverse the above procedure. Upper Screw Lower Screw Figure 31: Removing the Motor (Models 6400, 6800) Models 7400 and 7400XL 1.
2. Loosen the wing nut on the router base. 3. Support the motor by hand and rotate it counterclockwise until it comes free of the housing. To reinstall the motor, reverse the above procedure.
MAINTENANCE WARNING: To reduce the risk of injury, always unplug the tool before doing any maintenance. Never disassemble the tool or try to do any rewiring to its electrical system. Contact a qualified electrician for electrical repairs. Always follow lockout/tagout procedures when servicing electrical equipment. General Maintenance Keep the tool in good repair by adopting a regular maintenance program.
SERVICE Repairs If your tool is damaged, call Safety Speed Cut at 800-772-2327 for technical advice or for the name of a dealer near you who can service your machine. Replacement Parts Refer to the separate replacement parts information provided with the tool. Alignment The tool is aligned at the factory to a tolerance of: • ±1/32”, on Models C-4, H-4, H-5, and H-6 • ±1/64”, on Models 3400, 6400, 6800, TR-2, SR-5, and SR-5U • ±.005”, on Models 7400 and 7400XL.
Step 1: Adjust the Blade Parallel to the Guides (Saws Only) The blade must move parallel to the guides, or tail burning may occur and the kerf will be wider than the set of the blade. Make the following adjustment only if the blade appears to be out of alignment. To check the blade parallelism: 1. Align the rollers and adjust the guides (see Steps 3 and 4 below). 2. If the blade “heels”, or leaves burn marks on the cut, position the carriage for a crosscut and make a sample cut.
Step 3: Align the Guides WARNING: Unplug the tool before beginning this adjustment. If the tool does not cut at 90°, the guides may not be perpendicular to the rollers. To check the guide alignment: 1. Unplug the tool before testing alignment or making adjustments. 2. Align the rollers (see Step 4 below). 3. Remove the blade guard to expose the blade. Mark a tooth to use as a reference.
ACCESSORIES Safety Speed Cut offers several accessories for our panel saws and routers. Frame Wheels The Frame Wheels Accessory allows the tool to be rolled from one location to another in the shop. It includes two wheels and mounting fasteners. Wheels are standard on the Models 7400 and 7400XL, and are not available for the Model TR-2. Installation Bolt one wheel to each end of the frame as shown in Figure 35.
Stands are standard on the Models 7400 and 7400XL. They are not available for the Model TR-2. The Model C4 also has an optional retractable stand that can be folded for fast transport of the tool. Installation Attach the components as shown in Figure 36 or 37. Figure 37: Installing the Frame Stand, Models H-6 and 6400 (Model 6400 shown) Frame Extensions The Frame Extensions Accessory adds 20” to each end of the tool frame. It includes two extensions and the necessary fasteners.
CAUTION: Before beginning installation, disconnect the power supply to the motor, raise the carriage to the top of the guides, and lock the carriage in place with the lock knob. CAUTION: Be sure the tool frame is securely supported and cannot be tipped over during this installation procedure. An additional person should support and stabilize the frame at all times during the installation.
CAUTION: Be sure the tool frame is securely supported and cannot be tipped over during this installation procedure. An additional person should support and stabilize the frame at all times during the installation. 1. Position the stop bar in the bottom left side of the frame as shown in Figure 40, resting against the bottom horizontal arm and the vertical back supports. Stop Bar Figure 40: Installing the Stop Bar 2.
Installation CAUTION: Before beginning installation, disconnect the power supply to the motor, raise the carriage to the top of the guides, and lock the carriage in place with the lock knob. CAUTION: Be sure the tool frame is securely supported and cannot be tipped over during this installation procedure. An additional person should support and stabilize the frame at all times during the installation. 1.
SR-5, 7400, and 7400XL, and is not available for the Model TR-2. Installation NOTE: All hex nuts furnished with this accessory are lock nuts. During preassembly, do not completely tighten these nuts. 1. Lay out the parts shown in Figure 44 on a horizontal surface (table or bench) for preassembly. Note that one end of each fence extrusion is cut at a 45° angle. The units should be preassembled so that these beveled ends will fit against the center of the tool frame at final assembly.
tapping screws. 6. Repeat Steps 2 through 5 on the left-hand side of the frame. 7. Mount the wooden fence sections (#4), with the 45° angle ends toward the center of the machine, between the aluminum extrusion sections and the cam-type spacers (#1). When not in use, the two wooden fence sections can be stored in the material support channels (#15) on each side. 8.
Vertical Tube Support Bracket Tension Lock Knob Spring Hold-Down Arm Figure 46: Installing the Hold-Down Bar Air Clamping Package (for routers) The Air Clamp Accessory replaces the manually operated clamps. It is not available for the Model SR-5. Installation Install as shown in Figure 47.
SPECIFICATIONS Table IV: Saw and Router Specifications Tool Model Length Dimensions Height Depth Weight Maximum Crosscut Cut Thickness Volts AC Horsepower C-4 60” 70” 14” 147 Ib 50” 1.75” 120 3.25 H-4 120” 70” 14” 197 lb 50” 1.75” 120 3.25 H-5 120” 83” 14” 220 lb 64” 1.75” 120 3.25 H-6 120” 95” 14” 251 lb 73” 1.75” 120 3.25 6400 120” 84” 14” 500 lb 64” 1.75” 120 3.0 6800 120” 96” 14” 600 lb 73” 1.75” 120 3.
