KOBALT KT1015 (01) PDF Document

The definitions describe the level of severity for each signal word:

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

READ INSTRUCTION MANUAL AND KNOW YOUR TOOL. Read and familiarize yourself with the entire instruction manual. Learning the tool’s proper applications, limitations, and specific potential hazards will greatly minimize the possibility of accidents and injury.

KEEP GUARDS AND SAFETY DEVICES IN PLACE and working properly.

REMOVE ADJUSTING KEYS AND WRENCHES. Form a habit of checking to see that all adjusting keys and wrenches are removed before starting the tool.

KEEP WORK AREA CLEAN AND WELL LIT. Cluttered or poorly-lit work areas can lead to accidents.

DO NOT USE OR STORE TOOL IN DANGEROUS ENVIRONMENTS. Exposure to rain, damp, or wet locations can result in shock or electrocution. DO NOT operate near flammable liquids or in gaseous or explosive atmospheres.

KEEP CHILDREN AND BYSTANDERS AWAY from the work area.

LOCK TOOLS AND WORK AREA. Use padlocks and master switches, or remove starter keys to prevent operation by unauthorized users.

DO NOT FORCE TOOL OR WORKPIECE. Operate at the intended speed and feed rate for better and safer operation.

USE PROPER TOOL. DO NOT force the tool to do a task for which it was not designed.

DO NOT ABUSE POWER CORDS. Never yank the cord to disconnect from a receptacle.

USE PROPER EXTENSION CORD. Ensure it is in good condition and heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating.

WEAR PROPER APPAREL. DO NOT wear loose clothing, gloves, jewelry, or other items that may get caught in moving parts. Nonslip protective footwear is recommended.

WEAR PROPER EYE PROTECTION. All persons in the work area should wear safety glasses with side shields that comply with ANSI Z87.1 standards.

HEARING PROTECTION. Wear proper hearing protection consistent with noise levels and exposure, complying with ANSI S3.19 standards.

DUST PROTECTION. Operate in a well-ventilated area and use a dust collection system whenever possible. Use properly fitting NIOSH/OSHA approved respiratory protection.

SECURE WORKPIECE. Use clamps or a vise to hold the workpiece when practical.

DO NOT OVERREACH. Keep proper footing and balance to maintain control.

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

DISCONNECT TOOL from the power source before servicing, adjusting, or changing accessories.

TO REDUCE RISK OF ACCIDENTAL STARTING, make sure power switches are in the “OFF” position before plugging the tool in.

USE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories.

NEVER STAND ON TOOL. Serious injury could occur if the tool tips or you contact the cutting surface.

CHECK TOOLS FOR DAMAGE. Before use, check guards and parts for proper operation. Do not use a damaged product.

USE PROPER FEED DIRECTION. Feed the workpiece against the direction of rotation of the blade.

NEVER LEAVE TOOL RUNNING UNATTENDED. Turn the power OFF and wait for the tool to come to a complete stop before leaving.

STAY ALERT, WATCH WHAT YOU ARE DOING, AND USE COMMON SENSE. DO NOT use power tools when tired or under the influence of drugs, alcohol, or medication.

DO NOT perform cove cutting. Table saw blades are not designed for the excessive side loading needed.

USE SAW-BLADE GUARD, RIVING KNIFE AND ANTI-KICKBACK PAWLS. Use all modules for every possible operation, including all through cuts.

KEEP HANDS AND OTHER BODY PARTS OUT OF THE BLADE PATH. NEVER have any part of your body in line with the path of the saw blade.

USE A PUSH STICK whenever the size or shape of the workpiece would cause you to place your hands within 6 in. (152 mm) of the blade.

AVOID KICKBACK. Pay particular attention to instructions on reducing the risk of kickback.

NO FREEHAND CUTS. Always use a rip fence, miter gauge, or other appropriate devices to guide the workpiece.

DO NOT USE RIP FENCE AND MITER GAUGE AT THE SAME TIME.

DO NOT REACH OVER/REACH AROUND. NEVER reach over, in back of, or around the cutting tool with either hand while the blade is in motion.

STABILITY. Make sure the table saw is properly assembled and on a stable surface before use.

USE PROPER THROAT PLATE. The proper throat plate must be in place and properly secured at all times.

USE CORRECT BLADE AND RIVING KNIFE for the intended operation. The blade must be installed to rotate toward the front of the saw. Do not use a damaged or dull blade.

AVOID AWKWARD OPERATIONS AND HAND POSITIONS where a sudden slip could cause a hand to move into a saw blade.

KEEP ARMS, HANDS AND FINGERS AT LEAST SIX INCHES AWAY FROM THE BLADE.

NEVER CUT METALS, CEMENT BOARD OR MASONRY.

NEVER ATTEMPT TO FREE A STALLED BLADE without first turning the machine off and disconnecting it from the power source.

NEVER START THE MACHINE WITH THE WORKPIECE AGAINST THE BLADE.

SUPPORT YOUR WORKPIECE based on its size. Do not leave a wide panel or long board unsupported.

Kickback occurs when a part of the workpiece binds between the saw blade and the rip fence, or other fixed object, and rises from the table and is thrown toward the operator. Kickbacks can cause serious injury.

How to reduce the risk of kickbacks and protect yourself from possible injury:

1. Be certain that the rip fence is parallel to the saw blade.

2. DO NOT rip by applying the feed force to the section of the workpiece that will become the cut-off (free) piece. Feed force when ripping should always be applied between the saw blade and the fence; use a push stick for narrow work, 6 in. (152 mm) wide or less.

3. Keep saw blade guard assembly, riving knife and anti-kickback assembly in place and operating properly. The riving knife must be in alignment with the saw blade and the anti-kickback assembly must stop a kickback once it has started.

4. Plastic and composite materials (like hardboard) may be cut on your saw. However, since these are usually quite hard and slippery, the anti-kickback pawls may not stop a kickback. Therefore, be especially attentive to following proper set up and cutting procedures for ripping.

5. Use the saw blade guard assembly, anti-kickback assembly and riving knife for every operation for which it can be used, including all through-cut sawing.

6. Push the workpiece past the saw blade prior to releasing control.

7. NEVER rip a workpiece that is twisted or warped, or does not have a straight edge to guide along the fence.

8. NEVER saw a large workpiece that cannot be controlled.

9. NEVER use the fence as a guide or length stop when crosscutting.

10. NEVER saw a workpiece with loose knots, flaws, nails or other foreign objects.

11. NEVER rip a workpiece shorter than 10 in. (254 mm).

12. NEVER use a dull blade. A dull blade should be replaced or resharpened.

Use only 3-wire extension cords with 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug. The extension cord must be heavy enough to carry the current the tool will draw. An undersized cord will cause a drop in line voltage, loss of power, and motor overheating. Use the chart below to determine the minimum wire size (AWG) required.

Minimum Gauge Extension Cord (for 120V)

When working outdoors, use an extension cord designed for outside use, indicated by “W-A” or “W” on the cord’s jacket.

Estimated Assembly Time: 45 minutes

Tools Required for Assembly (not included):

Sharp knife or utility knife to cut carton, Phillips screwdriver, flathead screwdriver, combination square, framing square, tape measure or ruler, 13 mm open end wrench, 10 mm open end wrench or adjustable wrench, 8 mm Allen wrench, 5 mm Allen wrench.

1. Unpacking: Cut the sides of the box at all four corners. Separate the upper and lower packing trays, leaving the saw base section in the lower tray.

2. Wheel Assembly: Remove washers (KK) and nuts (JJ) from the lower right leg assembly (J). Attach wheels (K) to the leg assembly with washers (one on each side of the wheel) and the nut. Set this assembly aside.

3. Left Leg Assembly: Attach the left leg cross piece (R) to the left front leg (M) and left rear leg (N) using 2 in. bolts (CC).

4. Attach Leg End: Attach the left leg end (S) to the assembly from the previous step. The feet on the leg end should face to the outside. Secure with 1-1/2 in. cap screws (BB) and nuts (EE).

5. Attach Handles: While the table (V) is still in the packing tray, attach the two handles (I1 & I2) to the table using 1-1/2 in. cap screws (BB) and nuts (EE). Align the square and round holes.

6. Attach Leg Assembly to Table: Attach the leg assembly (from step 4) to the table (V). Insert a spacer (DD) between the legs and secure with a 3 in. carriage bolt (AA) and nut (EE). Cut the zip tie securing the preassembled upper leg.

7. Install Wheel Assembly: Install the wheel assembly (from step 2) to the leg assembly now attached to the saw. Insert a spacer (DD) between the legs and secure with a 3 in. carriage bolt (AA) and nut (EE).

8. Raise and Secure Narrowest Part: Raise the narrowest part of the stand to align the holes. Insert a spacer (DD) between the legs and secure with a 3 in. cap screw (AA) and nut (EE). Do not overtighten. Cut the zip tie securing the pedal.

9. Stand the Saw: Grasp the handles and tilt the table saw back onto its wheels. Remove the saw from the packing tray. Let the machine “stand” and then tighten all screws.

10. Remove Packing Material: Release the height adjustment locking lever and tilt the blade to 45° to release and remove the packing material from under the motor.

11. Install Height Knob: Install the height adjustment knob (FF) and hex bolt (GG) to the height adjustment wheel.

12. Extend Out Feed Support: Stand behind the saw, grasp the out feed support (C) with both hands and pull until it is fully extended. Install hex bolts (HH) to secure it.

The saw is shipped with the riving knife in the lowered position for non-through cuts. For through cuts, the riving knife must be placed in the raised position to attach the anti-kickback pawls and blade guard.

To place the riving knife in the raised position (for through cuts):

1. Raise the blade (W) to its highest position by turning the height adjusting wheel (P) clockwise.

2. Unscrew the riving knife lock knob with your fingers. Then push in on the loosened knob to release the riving knife.

3. Grasp the riving knife (X) and pull it toward the right side of the saw to release it from the spring-loaded clamp.

4. Position the riving knife in the raised position, with the through-cut position mark level with the tabletop, and ensure it locks into the clamp. Retighten the lock knob.

CAUTION: To work properly, saw blade teeth must point down toward the front of the saw. Failure to do so could cause damage to the saw blade, the saw, or the workpiece.

1. Ensure the blade is oriented correctly. Remove the blade wrenches from their storage area.

2. Place the open end wrench (G) on the flats of the arbor shaft to hold it in place.

3. Install the blade and washer (with the small side facing outward), then apply the nut to the shaft.

4. Insert the closed end wrench (F) over the blade nut.

5. To tighten, hold both wrenches firmly and push the closed end wrench (F) toward the back of the machine. Make sure the blade nut is securely tightened, but DO NOT over tighten.

6. Reinstall the throat plate (Y) and check all clearances for free blade rotation.

Anti-kickback pawls should only be installed for through cuts.

1. Unplug the saw. Raise the blade (W) by turning the height adjusting wheel (P) clockwise. Place the riving knife (X) in the raised position.

2. Press and hold the button on the right side of the anti-kickback pawls (B). Align the slot in the pawls over the center slot of the riving knife (X).

3. Push the anti-kickback pawls (B) down until they snap into place, then release the button.

Note: Pull up on the anti-kickback pawl assembly to make sure it is secured to the riving knife.

1. With the front of the blade guard (A) raised, hook the back end of the guard onto the rear slot of the riving knife (X).

2. Push the front of the guard down until it is parallel to the table.

3. Lock the blade guard (A) in place by pushing the lever down.

Note: If the blade guard is not parallel to the table, the riving knife (X) is not in the raised (through cut) position. Check the blade guard for clearances and free movement.

1. To fold the stand for moving, return the side and rear extension tables to their inner positions. Stow the rip fence and miter gauge.

2. Grasp the handles, push the stand release pedal with your foot, and tilt the saw up and forward until it rests on the wheels and stand feet.

3. The table saw can now be moved to a proper storage area.

The table saw has two convenient storage areas, one on either side of the saw cabinet, specifically designed for storage.

When not in use, store the rip fence, blade wrenches, miter gauge, push stick, kickback pawls, blade guard, and blades by securely snapping each in place.

The saw has a switch with a built-in locking feature to prevent unauthorized use. The off/on switch key (Q) should be removed when the saw is not in use.

Turning saw on and off:

1. Ensure that the off/on switch key (Q) is inserted into the switch.

2. Lift the switch to turn on the saw.

3. Press the switch down to turn off the saw.

The blade depth should be set so that the outer points of the blade (W) are higher than the workpiece by approximately 1/8 in. to 1/4 in., and the bottom of the gullets are below the top surface of the workpiece.

1. Make sure the release lever (O) is locked (in the down position).

2. Raise the blade (W) by turning the height adjusting wheel (P) clockwise. Lower the blade (W) by turning the wheel counterclockwise.

3. Make sure the blade (W) is at the proper height.

Note: A 90° cut has a 0° bevel and a 45° cut has a 45° bevel.

1. Loosen the bevel control by pulling the release lever (O) all the way to the right.

2. Adjust the bevel angle by first pushing the height adjusting wheel assembly all the way to the left.

3. Holding the knob/wheel, slide the bevel indicator to the right to increase the angle of the blade (W) (bringing it closer to 45° from the tabletop). Holding the knob/wheel, slide the bevel indicator to the left to decrease the angle (bringing it closer to 90° from the tabletop).

4. Make sure the blade (W) is at the desired angle. Tighten the bevel control by pushing the release lever (O) to the left.

WARNING: To reduce the risk of injury, always make sure the rip fence (T) is parallel to the blade (W) before beginning any operation.

Using Rip Fence:

1. Place the rip fence (T) flat on the table (V).

2. Push the rip fence (T) toward the front rail to align the fence to the table (V).

3. Push the locking lever down slowly to automatically align and secure the fence.

4. Lock the rear lever.

Setting Rip Fence Scale Indicator:

1. Loosen the rip fence (T) by lifting the front and rear locking levers. Use a tape measure or ruler to measure a distance (e.g., 6 in.) from the blade and move the fence until it aligns with that measured distance.

2. The scale indicator should align with the corresponding mark (e.g., 6 in.) on the fence scale.

3. To adjust the scale indicator, loosen the screw on the indicator, align it with the correct mark, and then retighten the screw.

Making a Cross Cut:

1. Remove rip fence (T).

2. Set blade (W) to correct depth.

3. Set miter gauge (U) to 0° and tighten lock knob.

4. Ensure wood is clear of blade before turning saw on.

5. Turn saw on and let blade reach full speed.

6. Place hand closest to blade on miter gauge lock knob and hand farthest from blade on workpiece. Feed workpiece into blade.

7. After cut, turn saw off and wait for blade to stop before removing workpiece.

Making a Rip Cut:

1. Set blade (W) to correct depth.

2. Position rip fence (T) at desired distance and lock both ends.

3. Ensure wood is clear of blade. Use support for long workpieces.

4. Turn saw on and let blade reach full speed.

5. Position workpiece flat on table (V) with edge against rip fence (T). Feed into blade.

6. Use hand closest to rip fence for guidance. Use a push stick (D) for narrow pieces.

7. After cut, turn saw off and wait for blade to stop before removing workpiece.

Making a Miter Cut: Follow the same steps as a Cross Cut, but set the miter gauge (U) to the desired angle.

Making a Bevel Cross Cut:

1. Remove rip fence (T).

2. Unlock bevel locking lever and adjust to desired angle, then re-lock.

3. Set blade depth and set miter gauge to 0°.

4. Follow steps 4-7 for a Cross Cut.

Making a Bevel Rip Cut:

1. Remove miter gauge (U).

2. Unlock bevel locking lever, adjust to desired angle, and re-lock.

3. Set blade depth and position rip fence.

4. Follow steps 3-7 for a Rip Cut.

Making a Compound (Bevel) Miter Cut:

1. Remove rip fence (T).

2. Adjust bevel angle and lock lever.

3. Set blade depth.

4. Set miter gauge (U) to desired angle and tighten knob.

5. Follow steps 4-7 for a Cross Cut.

WARNING: To reduce the risk of serious injury when making non-through cuts, follow all applicable warnings. Never feed wood with hands; always use push blocks, push sticks, and/or featherboards. Once cuts are completed, reinstall the riving knife in the raised position, anti-kickback pawls, and blade guard.

1. Unplug the saw.

2. Unlock the release lever (O), adjust the bevel angle to 0°, and re-lock the lever.

3. Remove the blade guard (A) and anti-kickback pawls (B).

4. Place the riving knife (X) in the “lowered” position.

5. Set the blade (W) to the correct depth for the non-through cut.

6. Use either the rip fence (T) or miter gauge (U) depending on the cut.

7. Plug the saw into a power source and turn it on.

8. Let the blade (W) build up to full speed before moving the workpiece into the blade.

9. Always use push blocks, push sticks, and/or featherboards to guide the workpiece.

10. When the cut is made, turn the saw off. Wait for the blade to come to a complete stop before removing the workpiece.

Note: Turn power off and unplug the saw. Set the bevel setting to “0”. Remove the blade guard (A), anti-kickback pawls (B), and throat plate (Y). Raise the saw blade (W).

1. Make sure the release lever (O) is locked. Insert the open end wrench (G) onto the flats on the arbor shaft. Insert the closed end wrench (F) over the blade nut.

2. Holding both wrenches firmly, pull the closed end wrench (F) forward while pushing the open end wrench (G) to the back of the saw to loosen the nut.

3. Remove the nut, washer, and blade (W).

4. Place the new blade on the arbor shaft (teeth must point down toward the front of the saw).

5. Place the blade washer and blade nut over the arbor shaft. Be sure the dome side of the blade washer faces out from the blade. Make sure the nut is securely tightened. DO NOT over tighten.

6. Rotate the blade by hand to make sure it turns freely.

7. Lower the saw blade and reinstall the throat plate (Y).

Note: Unplug the saw. Set the bevel to 0 degrees and raise the blade fully. Remove the anti-kickback pawls and blade guard.

To check/adjust horizontally:

1. Place a framing square or straight edge against both the blade (W) and riving knife (X). They are aligned if the square contacts both evenly with no gaps. Place the square between the carbide teeth for an accurate measurement against the blade body.

2. If they are not aligned, use a hex head wrench to slowly turn the top two set screws (located below and to either side of the riving knife lock knob) until the riving knife (X) is aligned with the blade (W).

To check/adjust vertically:

1. Place a framing square on the table and against both the blade (W) and riving knife (X). They are aligned if the square contacts both evenly with no gaps.

2. If they are not aligned, use a hex head wrench to slowly turn the bottom set screw (located below the riving knife lock knob) until the riving knife (X) is aligned with the blade (W).

Note: Unplug the saw. Remove the blade guard and anti-kickback pawls. Raise the blade.

1. Mark one blade tooth at the front of the blade. Place a combination square in the miter gauge groove and measure the distance from the square to the marked tooth.

2. Rotate the blade so the marked tooth is now at the back. Move the combination square to the rear and measure the distance again.

3. If the distances are the same, the blade is parallel. If the distances are different:

4. From underneath the table top, loosen the trunnion securing bolts with a hex wrench.

5. If the back of the blade was too close to the square, place a block of wood on the right side of the blade and gently tap it with a small hammer to align it.

6. Retighten the trunnion bolts with the hex wrench. Recheck the alignment after the bolts are retightened.

WARNING: When servicing, use only identical replacement parts. Before performing any maintenance, make sure the tool is unplugged and the switch is in the off position.

General Maintenance:

• Avoid using solvents when cleaning plastic parts, as they can be damaged. Use clean cloths to remove dirt, dust, oil, grease, etc.

• Periodically check all clamps, nuts, bolts, and screws for tightness and condition. Ensure the throat plate is in good condition and level with the table.

• Check the blade guard assembly after maintenance to ensure it is installed correctly and functioning properly.

• Clean plastic parts only with a soft damp cloth. DO NOT use any aerosol or petroleum solvents.

Lubrication:

• All bearings in this tool are lubricated with a sufficient amount of high-grade lubricant for the life of the unit under normal operating conditions. Therefore, no further lubrication is required.

Possible Cause 1: Blade is out of balance.

Corrective Action: Replace the blade.

Possible Cause 2: Blade is damaged.

Corrective Action: Replace the blade.

Possible Cause 3: Legs are not properly attached to saw.

Corrective Action: Tighten all hardware.

Possible Cause 4: Work surface is uneven.

Corrective Action: Reposition on a flat surface. Adjust legs of leg stand.

Possible Cause 5: Blade is warped.

Corrective Action: Check saw blade installation. Replace blade if necessary.

Possible Cause 1: Rip fence not mounted correctly.

Corrective Action: Remount the rip fence.

Possible Cause 2: Rails are dirty or sticky.

Corrective Action: Clean and wax rails.

Possible Cause 1: Blade is dull.

Corrective Action: Replace or sharpen the blade.

Possible Cause 2: Work is fed too fast.

Corrective Action: Slow the feed rate.

Possible Cause 3: Wood is warped.

Corrective Action: Replace the wood.

Possible Cause 4: Rip fence is misaligned.

Corrective Action: Check and adjust the rip fence. Align the rip fence.

Possible Cause 5: Riving knife is out of alignment.

Corrective Action: See “Checking and Aligning Riving Knife and Saw Blade” section.

Possible Cause: Blade not properly sharpened or set.

Corrective Action: Re-sharpen or replace the dull blade.

Possible Cause 1 (Bevel Cuts): Positive stops inside the cabinet need adjusting.

Corrective Action: Adjust positive stops.

Possible Cause 2 (Miter Cuts): Miter gauge is misaligned.

Corrective Action: Adjust the miter gauge.

Possible Cause: Gears or screw post inside the cabinet are clogged with saw dust.

Corrective Action: Clean the gears.

Possible Cause 1: Power cord or wall cord is not plugged in.

Corrective Action: Plug in the power cord or wall cord.

Possible Cause 2: Circuit fuse is blown. Circuit breaker is tripped.

Corrective Action: Replace the circuit fuse. Reset the circuit breaker.

Possible Cause 3: Cord or switch is damaged.

Corrective Action: Have the cord or switch replaced at your nearest authorized service center.

Possible Cause 1: Blade is dull or dirty.

Corrective Action: Clean, sharpen, or replace the blade.

Possible Cause 2: Blade is the wrong type for the cut being made.

Corrective Action: Replace with the correct type of blade.

Possible Cause 3: Blade is mounted backwards.

Corrective Action: Remount the blade correctly.

Possible Cause: Blade is not proper for a rip cut.

Corrective Action: Change the blade; a rip blade typically has fewer teeth.