To prevent injury or electrocution, always unplug the tool from the power supply outlet before performing any maintenance or repair work on the tool! Do not use compressed air to clean the motor housing of the tool, as you could inject foreign objects into the motor through the ventilation openings. Compressed air may be used on other components, but personal safety protection should be employed (hearing, vision, and respiratory). Certain cleaning agents and solvents are harmful to plastic parts. Some of these include, but are not limited too: Gasoline, Acetone, Methyl Ethyl Ketone (MEK), Carbonyl Chloride, cleaning solutions containing Chlorine, Ammonia, and household cleaners containing Ammonia. To ensure proper cooling of the tool and motor, the cooling vents in the motor housing must always be kept clear and clean. Keep the Saw Clean Dust and debris from some materials can be extremely abrasive and cause components within the saw to wear prematurely. It is important to keep moving parts cleared of abrasive dusts. > As a general rule, keep the saw clean of all dust and debris. Even soft-wood dust can be abrasive over time. > Examine all moving parts for dust and debris. > Keep the bevel hinges clean of dust using compressed air or cotton swabs. If the hinges wear due to abrasive particles, the saw will not perform optimally. > Keep the blade area and dust extraction port clean of debris. Debris can cause wear and reduce the effectiveness of the dust extraction system. Keep the Sawblades Sharp Using a dull sawblade can be extremely dangerous and provide poor cut quality. > Never attempt to sharpen a sawblade manually. Special equipment is necessary to properly sharpen a circular sawblade. An improperly sharpened sawblade can injure the operator, destroy the saw, and damage the workpiece. > The sawblades should be sharpened regularly, and only by a qualified sharpening service. > Improper grinding of the carbide teeth of a sawblade can result in serious injury to the saw operator. Adjust and Inspect the Saw To ensure the saw is in proper working order, periodically inspect the operation of the saw and ensure it is properly adjusted. > Observe the function of the saw during normal operation. > Unusual sounds are indicative of pending problems. > A reduction in the cut quality indicates the saw is either improperly adjusted or not functioning properly. > A reduction in cutting power or speed may indicate a dull blade or a motor problem. > If any of the safety devices on the saw are inoperable or disabled, immediately stop using the saw and have it serviced. > Periodically inspect the guide rail gibs cams for wear and proper adjustment. If the cams are worn or misadjusted, the saw will not cut straight. Replacing the Guide Rail Gib Cams If the gib cams are over tightened, or the saw is used in an environment with abrasive dust, the cams may develop flat spots and should be replaced. Maintaining proper adjustment and keeping the saw clean will increase the life of the cams. > Unplug the saw for safety, and lay the saw on its side on a stable work surface. > Using a T-15 Torx® driver, remove the screw that secures each cam to the sole plate, and remove the cam and friction washer. > The replacement parts kit will include 2-cams, 2-friction washers, and 2-screws. > Install the new cams and friction washers with the screws provided. > Make sure the limit tabs are pointing away from the guide rail slot as shown. > Tighten the screws enough to compress the friction washers, but take care not to over tighten the screws. > Adjust the cams according to the procedure on page 8. Replacing the Guide Rail Splinter Guard The splinter guard prevents splintering and chipping of the workpiece by holding the top edge of the workpiece down as the teeth of the sawblade move upward against it. The splinter guard needs to be replaced if it becomes damaged or worn. 1. Peel the original splinter guard away from the guide rail. 2. As needed, clean residual adhesive and debris from the guide rail. 3. Peel off the plastic backing from the new splinter guard to expose the adhesive. 4. Without stretching the rubber, carefully place the new splinter guard on the underside of the guide rail tight to the alignment rib (14-b). 5. Make sure the splinter guard is firmly pressed down to the guide rail. 6. Trim the splinter guard as described on page 8. Changing the Motor Brushes The motor brushes wear out over time and need to be replaced by an authorized service center. Festool does not condone brush replacement by the end-user. Completion of this procedure by an unauthorized service center will void the tool's warranty. The motor brushes are graphite bars that provide an electrical connection between the motor controller and the rotating armature. When the brushes have worn past their useful length, spring loaded wear pins are exposed that separate the brush from the armature contacts. This disables the motor to prevent damage. For a shorter ...