Tigerstop SawGear Automated Table Saw User Manual

: June 13, 2024
: TigerStop

Table of Contents

SawGear Automated Table Saw
Product Information
Safety Warnings
- Product Usage Instructions
1. SawGear Installation
2. SawGear Operation
3. Troubleshooting

SawGear Automated Table Saw

Product Information

The SawGear is a machine designed to assist with cutting tasks.
It features a control panel with an LCD display for easy operation.
The machine can be installed on a workbench using the included
bench mount brackets. It also comes with a flip-away stop and stop
bar for precise cutting measurements. The SawGear requires
electrical power to operate and comes with a power head for
controlling its functions.

Safety Warnings

Before operating the SawGear, it is important to read and follow
all safety warnings. The machine can start, move, and stop
automatically, so it is crucial to keep hands and loose clothing
away from moving parts. Safety guards should not be removed when
using the machine with a saw or other cutting equipment. Operators
must wear adequate eye and ear protection.

Product Usage Instructions

1. SawGear Installation

Before using the SawGear, it needs to be installed properly.
Follow the steps below:

Ensure the SawGear is placed on a stable workbench or
surface.
Connect the machine to the appropriate electrical power source
based on the provided electrical requirements.
Attach the bench mount brackets securely to the workbench.
Connect the flip-away stop and attach the stop bar to ensure
accurate cutting measurements.
Connect the power head to the SawGear.

2. SawGear Operation

Once the SawGear is installed, you can begin operating it using
the control panel and LCD display. Follow the steps below:

Power on the SawGear using the designated power-on procedure
based on your situation (first power-on, repeat power-on, or normal
power-on).
Start the SawGear by following the instructions provided on the
control panel.
Adjust the contrast of the LCD display if necessary.
Set up password protection if desired, following the steps in
the user manual.
Enter the required measurements using feet, inches, fractions,
or millimeters based on your cutting needs.
Perform calibration if needed for accurate cutting.
Use the SawGear for straight cutting or custom miter cutting,
following the instructions provided in the user manual.

3. Troubleshooting

If you encounter any issues while using the SawGear, refer to
the troubleshooting section in the user manual. It provides
guidance on correcting entry errors, dealing with error messages,
and performing specific routines to address common problems.

SawGear
User Manual

Table of Contents

1 Contact Us

2 Parts Inventory

9 SawGear Installation

9

ELECTRICAL REQUIREMENTS

9

SAWGEAR BENCH MOUNT BRACKETS

11

CONNECTING THE FLIP-AWAY STOP

11

ATTACHING THE STOP BAR

12

CONNECTING THE POWER HEAD

13 SawGear Operation

13

SAWGEAR CONTROL PANEL

14 SAWGEAR LCD DISPLAY

14 1ST POWER-ON

15

REPEAT A 1ST POWER-ON

15

NORMAL POWER-ON

16 START SAWGEAR

16 SLEEP MODE

16

SET CONTRAST

17

PASSWORD PROTECTION

17

CHANGE THE PASSWORD

18

DEACTIVATE THE PASSWORD

18

INCREMENT

19 LISTS

20 ENTERING FEET, INCHES, AND FRACTIONS

21

ENTERING FEET AND DECIMAL INCHES

21

ENTERING NON-STANDARD FRACTIONS

21

ENTERING MILLIMETERS

22 ENTERING NEGATIVE NUMBERS

22 CALIBRATION

24 STRAIGHT CUTTING

24 45° MITER CUTTING

25 CUSTOM MITER CUTTING

26 Pivot Point Calibration

26 MITER SAW ACCURACY
28 Crown + Miter Pro

28 GETTING STARTED 28 HOW TO USE CROWN & MITER PRO
31 Troubleshooting

31

CORRECTING ENTRY ERRORS

31 “TOO BIG” ERROR

31 “TOO SMALL” ERROR

32 HOME ROUTINE AFTER IMPACT

32 SCALING INSTRUCTIONS
33 Appendix A: Power Head Controller Stand
34 Appendix B: Panel Saw Retrofit
34 UNIVERSAL BRACKET INSTALLATION 34 BENCH MOUNT BRACKET INSTALLATION 35 SAWGEAR MOUNTING 35 ASSEMBLE SUPPORT LEG 36 ATTACH SUPPORT LEG 37 CONNECTING THE POWER HEAD 37 CONNECT CABLE GUARD TO POWER HEAD 38 CONNECTING THE FLIP- AWAY STOP 38 ATTACHING THE STOP BAR 39 ATTACH CONTROLLER TO SAW
iii

SAFETY FIRST!
IMPORTANT SAFETY INFORMATION. READ ALL WARNINGS BEFORE OPERATING THIS PRODUCT.
GENERAL WARNINGS
WARNING: Installation of your TigerStop® Product must be done by a person trained in the safe design and installation of automation products, and in the safe operation of power equipment. Ensure that such installation meets all legally required safety requirements and guidelines, and that proper guarding and safety devices are provided on all sides of the equipment to preclude unintended access during operation. Consult with and follow the recommendations of a qualified safety engineer. WARNING: TigerStop® Products are components intended for use in conjunction with potentially dangerous machinery. The use of TigerStop® Products does not make other machinery safe. TigerStop® Products are not intended to substitute, in any manner, for safe operating practices in general, or for safety features present in other machines designed to make those machines as safe as possible. TIGERSTOP® PRODUCTS, IF USED OR INSTALLED IMPROPERLY, MAY CAUSE PERSONAL INJURY OR DEATH AND SHOULD ONLY BE OPERATED BY PERSONS TRAINED IN THEIR SAFE OPERATING PROCEDURES. Illustrations of TigerStop® Products in use do not show, and are not intended to show, all safety features and practices necessary for their safe operation.
INSTALLATION WARNINGS
WARNING: TigerStop® Products must be installed in accordance with all local, state, and federal regulations. Only personnel properly trained in the safe design and installation of automation machinery and related power equipment should install TigerStop® Products onto other equipment, to ensure a safe and proper work station. TigerStop® Products should not be operated without proper training, both in the operation of TigerStop® Products, and in the operation of related equipment. IMPORTANT CAUTION: The motor box (compartment) contains DC voltage with potentially FATAL amperage. NEVER attempt any unauthorized actions inside the motor box.
INTERCONNECTS
WARNING: Using a TigerStop® interconnect does not relieve you of the responsibility for making sure that your saw or other tool has all the necessary safety equipment in place. All installations must meet all legally required safety requirements and guidelines. Installation and training should be done following the recommendations of a qualified safety engineer.
OPERATION
DANGER: This machine can start, move and stop automatically. Keep hands and loose clothing clear of moving parts while operating. Moving parts can crush and cut. When used with a saw or other cutting equipment, bodily injury and death may result if operated without safety guards on all machines. Do not operate with guards removed. Operators must wear adequate eye and ear protection.
iv

IMPORTANT SAFETY INFORMATION. READ ALL WARNINGS BEFORE OPERATING THIS PRODUCT.
DANGER! Don’t get pinched by the push feeder. Keep your hands away when in motion!
Keep the work area clean and well lighted to avoid accidental injury.
Do not use TigerStop® machines in a dangerous environment. Using power tools in damp or wet locations or in rain can cause shock or electrocution.
Do not operate near flammable liquids or in gaseous or explosive atmospheres!
Wear proper apparel, no loose clothes, long hair or jewelry which could get pulled into moving machinery or materials. Wear non slip footwear, safety glasses, ear protection and a dust mask. Use only 3-wire extension cords that have 3-prong grounding type plugs and 3-pole receptacles that accept the tools plug for 120VAC. Use only 5-wire cords and plugs when using 3 phase.
Do not open motor compartment or controller keypad. DC Voltage with potentially FATAL amperage! Disconnect power before servicing. No user- serviceable parts inside.
DO NOT operate this or any machine under the influence of drugs or alcohol! No one should operate this machine except for fully qualified personnel. READ THE MANUAL!
v

Enable your SawGear
SawGear won’t function until it is enabled.
1. Receive an enable code by either: a. Registering your warranty at: https://www.tigerstop.com/eu/servicecenter/#warranty b. Calling Customer Service at: +31 546 57 51 71 (option 1), M-T 8am 5pm CET (F 8am – 4pm CET)
2. After installing SawGear, power it on and the screen displays: “Enter Serial#”, enter your serial number and press
3. Next, the screen displays: “SN=### Enter enable code”, enter your enable code and press
vi

Contact Us
TigerStop® technical support on the web, including manuals and videos:

Service Center

TigerStop® customer service and technical support by email:
service@tigerstop.com (Americas, Australia) sos@tigerstop.nl (Europe)
TigerStop® customer service and technical support by phone:
1 (360) 448 6102 (Americas, Australia) 00 31 546 575 171 (Europe)
1

Parts Inventory
POWER HEAD
PART

DESCRIPTION (NUMBER)

QUANTITY

SawGear Power Head (SA2520)

1

Power Cable (PC)

1

FLIP-AWAY STOP ASSEMBLY

PART

DESCRIPTION (NUMBER)

Flip-Away Stop (SA2545)

QUANTITY 1

M6 Adjustable Handle (F7306)

2

STOPS
PART

Parts Inventory

DESCRIPTION (NUMBER)
Stop Bar (SA2555)

QUANTITY 1

Crown Moulding Foot

(Optional)

1

(SG-CMF)

BENCH MOUNT ASSEMBLY

PART

DESCRIPTION (NUMBER)

QUANTITY

Bench Mount Bracket (M1016)

5

M8 Star Knob (F7304)

5

Bench Mount Hardware

Pack

1

(F0038)

3

Parts Inventory

POWER HEAD CONTROLLER (OPTIONAL)

PART

DESCRIPTION (NUMBER)
SawGear Power Head (PH-PS) &
SawGear Power Head Controller (PS-CON)

QUANTITY 1

Power Cable (PC)

1

POWER HEAD CONTROLLER STAND (OPTIONAL)

PART

DESCRIPTION (NUMBER)

QUANTITY

SawGear Controller

Mount

1

(M1047)

M5x8mm Socket Head

Screw

2

(F1008)

M5 Washer (F3024)

2

M5 Weld Nut (F2008)

2

Square Tube (M1808)

1

4

PART

DESCRIPTION (NUMBER)
Round Tube (M1807)

Parts Inventory
QUANTITY 1

Controller Stand

Base Bracket

2

(M10070)

M6x14mm

Socket-Head Screw

1

(F7216)

M6x10mm

Socket-Head Screw

1

(F7208)

M8x50mm

Hex-Head Screw

1

(F9827)

M8x45mm

Hex-Head Screw

2

(F9826)

Spacer (F6702)

1

M8x35mm

T-Bolt

2

(F0184)

M8

Flange Nut

5

(F0419)

5

Parts Inventory

PANEL SAW RETROFIT KIT (OPTIONAL)

PART

DESCRIPTION (NUMBER)

QUANTITY

Cable Guard (M9959)

1

Universal Bracket (M5100)

3

Universal Bracket

Hardware Pack

3

(F0032)

Control Stand Base

Half-Bracket

2

(M10070)

Round Tube (M1807)

1

M6x25mm Leveling Foot (F9848)

1

Foot Adapter (M10180)

1

6

PART

DESCRIPTION (NUMBER)

Parts Inventory
QUANTITY

M6x8mm Set Screw (F4005)

1

M8x50mm Hex Head

Screw

2

(F9827)

M8 Flange Nut (F0419)

2

M5x16mm Flat Head

Screw

6

(F1016)

M5 Washer (F9847)

6

M5 Hex Nut (F2001)

6

7

SawGear Installation
ELECTRICAL REQUIREMENTS

VOLTS
208/230/240V

CIRCUIT BREAKER
16A

SawGear requires a dedicated, grounded circuit. Operating SawGear without proper grounding risks electrocution.

SAWGEAR BENCH MOUNT BRACKETS
Secure SawGear in the brackets
1. Make sure both Bench Mount Brackets are approximately in line. Fasten them in place with the supplied hardware.

2. Lay SawGear across the Bench Mount Brackets.

8

3. When SawGear is facing front, there is an angled channel running along the full length of the beam at the bottom. Pivot SawGear, so the curled front edge of the SawGear Bench Mount Brackets fit into this channel.
4. Let SawGear lie flat against the surface of the brackets, so the beveled back lip of the SawGear can be secured by the locking knobs.
5. Turn the locking knobs to secure SawGear. Always firmly tighten the locking knobs and all fasteners before using SawGear.

SawGear Installation

Dismounting SawGear from the saw stand
Dismount SawGear from the saw stand by loosening the locking knobs and pivoting it off the brackets.

9

SawGear Installation CONNECTING THE FLIP-AWAY STOP
1. Remove the rod from the Flip-Away Stop. 2. Insert the Adjustable Handles and tighten with their supplied hardware. 3. Align the cylinders of the Flip- Away Stop and SawGear carriage and
insert the rod’s washers between them. 4. Re-attach the rod to connect them. 5. Tighten the rod until the Flip-Away Stop holds its position when raised.
ATTACHING THE STOP BAR
1. Insert the Stop Bar into the Flip-Away Stop. 2. Secure the Stop Bar with the Adjustable Handles.
10

SawGear Installation CONNECTING THE POWER HEAD

1. Insert the Power Head into either of the SawGear beam’s attachment points. Ensure it is rotated slightly counter-clockwise when inserted.

2. Rotate into place, clockwise.

3. Turn the knobs on both sides to secure the Power Head to the beam.

11

SawGear Operation
SAWGEAR CONTROL PANEL
[Sleep] Puts the Power Head to sleep to save energy. [W] Moulding Width Entry for miter cuts. [X] Left Inside Length Entry for miter cuts. [Y] Header Inside Length Entry for miter cuts. [Z] Right Inside Length Entry for miter cuts. [Ft] Designates input numbers as Feet.
[In] Designates input numbers as inches. [/] Press Slash to enter fractional numbers. [<±>] Increment adds or subtracts from current position by a given amount. [List] Stores and accesses cut lists. [-D-] Calibrate sets the distance from the saw blade. Can also set or disable sleep mode. [STOP] Halts movement immediately. [START] Accepts an entered dimension and causes movement. [Clr] Clear erases one digit at a time to correct a data entry error. Can also clear a cut length. [.] Press to enter decimal numbers in both metric and inches. [.][.][.] Inserts a minus sign before a dimension indicating a negative number.
[n] Press the Number buttons to enter dimensions.
12

SawGear Operation

SAWGEAR LCD DISPLAY
Display Size
·16 characters wide x 1 character high. Messages longer than 16 characters scroll across the screen.
Ready Screen
·When the stop is at position and the last two characters fluctuate between upper and lower case (heartbeat).
Display at Position in Inches Mode
·Fractions separated from whole inches by an underscore.
·Feet separated from inches by “ft” and a space.
·”in” for inches is ALWAYS at the end.

Display at Position in Metric Mode:

·”mm” for millimeters is ALWAYS at the end.

Switch between Inches and Metric

1. Press

to enable sleep mode.

2. Press 3. Press for

inches or

for metric.

When in Metric mode

,

, and

1ST POWER-ON

are disabled.

1. Plug the Power Head into AC power. 2. Press

3. Select a language when prompted.
SawGear can display text in English, Spanish, French, Dutch, and German.

4. Press

or

to select a measurement system.

5. Press

if the saw is to the left of SawGear, or

if the saw is to the right. 13

SawGear Operation

6. Press

to move.

SawGear displays the working length, +/- 0.5″ (13mm).

7. Press

to confirm the SawGear working length.

If the displayed working length is incorrect, enter the correct working length (in mm) found on the back side of the SawGear’s beam. SawGear backs out and stops at 6″ (152mm). CUT a sample at this length and MEASURE it.
8. Enter the length of the sample and press
SawGear is now ready to use!

REPEAT A 1ST POWER-ON
Required when changing the interface language, saw side, or working length.
1. Unplug the machine and plug it in again while HOLDING DOWN

2. While still HOLDING DOWN step 3 on page 13.

, hold down

until the active screen displays, and continue at `1st Power-On’,

NORMAL POWER-ON
The following routine is followed whenever SawGear is used, AFTER the first time.
1. Plug into AC POWER. 2. Press

3. Press

SawGear homes itself and displays copyright info.

4. Enter length and press 5. Cut and repeat.

14

START SAWGEAR

SawGear Operation

If SawGear is plugged into power but does not display the active screen, press

to wake it up.

·When powered ON, SawGear’s display is on. ·When powered OFF or asleep, SawGear’s display is off.

·To wake SawGear up, push

and the display turns on.

·If Password Protection is enabled, SawGear requires password entry whenever SawGear is powered-on or awoken.

SLEEP MODE
SawGear will automatically sleep after ten minutes of inactivity. Follow these instructions to change the idle time before entering sleep mode or to disable it.

Disable Sleep Mode

1. Press 2. Press

and to disable sleep mode.

3. Press

to save the setting or

to cancel.

Set Sleep Mode

1. Press

and

2. Enter an idle time in minutes to activate sleep mode.

3. Press

to save the setting or

to cancel.

The shortest possible idle time is 0.25 (1/4) minutes.

SET CONTRAST
Adjust the SawGear Power Head contrast to lighten or darken the screen.

1. Press

and then

,

2. Enter the desired contrast and press
100 is maximum contrast and 1 is minimum contrast. 15

SawGear Operation
PASSWORD PROTECTION
Secure SawGear with a password to prevent its use by unauthorized persons. After setting a password, SawGear cannot be operated without it. DON’T LOSE IT!
1. Unplug SawGear from AC power.

2. While holding down power.

, plug SawGear into AC

3. Press

4. Enter a password consisting of 4-8 digits and press
5. Re-enter password and press

6. Press

SawGear is ready to use! The password MUST be entered whenever SawGear is powered-on/awoken.

CHANGE THE PASSWORD

To change the password: 1. Unplug SawGear from AC power.

2. While holding down

, plug SawGear into AC power.

3. Enter the old password and press 4. Enter a new password consisting of 4-8 digits,
and press
5. Re-enter password and press
6. Press
SawGear is now ready to use! 16

DEACTIVATE THE PASSWORD

To deactivate the password: 1. Unplug SawGear from AC power.

2. While holding down

, plug SawGear into AC power.

3. Enter the old password and press

4. Press

twice.

5. Press

twice again. This clears the password.

6. Press SawGear is now ready to use! SawGear no longer requires a password when powered-on/awoken.

INCREMENT
Make small incremental moves by pressing the increment button: The increment button is two buttons in one.
Press the button’s left arrow to nudge the stop to the left.

Press the button’s right arrow to nudge the stop to the right. To calibrate the increment distance, see page 22.

SawGear Operation

17

LISTS
SawGear stores up to 10 lists with 9 cuts each. Follow these instructions to make a sample list.
1. Press

SawGear Operation

2. Enter any number from 0 to 9. 3. Press

If the displayed list number is incorrect, exit by pressing [Stop].

4. Enter

SawGear will move to each new dimension as it is entered. Ensure nothing is in the way. and press

The dimension displays exactly as entered. In inches mode, inches is assumed.

5. Press

to advance to the next line in the cut list.

6. Enter

and press

7. Press

When entering inches and a fraction, use the [In] button to separate the fraction. to advance to the next line in the cut list.

8. Continue entering dimensions into the cut list, as desired.

Pressing start after cut #9 returns the list to cut #1.

9. Press

to exit the list. Any dimensions entered are saved to the list.

18

SawGear Operation ENTERING FEET, INCHES, AND FRACTIONS

1. Enter

and press

SawGear moves to position at 6 inches.

RULE: SawGear assumes inches when entering neither

nor

after a dimension.

2. Enter

and press

SawGear moves to position at 5/8 inch.

RULE: SawGear assumes inches when entering

in a dimension.

3. Enter

and press

SawGear moves to position at 6_5/8 inches. RULE: An underscore separates inches from fractions when at position.

4. Enter

and

press

SawGear moves to position at 3 feet 6_5/8 inches. RULE: “ft” follows feet and a space separates feet from inches when at position.

5. Enter

and press

SawGear moves to position at 3 feet 6 inches.

RULE: SawGear interprets any number entered after

as inches.

6. Enter

and press

SawGear moves to position at 3 feet.

RULE: Follow a number in exclusively whole feet with RULE: “0in” displays at the end of the number when entering a dimension in whole feet, only.
19

SawGear Operation ENTERING FEET AND DECIMAL INCHES

1. Enter

and press

SawGear moves to position at 0.875 inches.

RULE: SawGear assumes inches when entering neither

nor

after a dimension.

2. Enter

and press

SawGear moves to position at 11.875 inches.

3. Enter

and press

SawGear moves to position at 3 feet 9.875 inches. RULE: SawGear interprets any number entered after

as inches.

ENTERING NON-STANDARD FRACTIONS
Enter a non-standard fraction of an inch and SawGear moves to the exact position.

1. Enter

and press

SawGear moves to position at 16-2/3 inches, but the display shows the position as 16_21/32.

When working with lengths more precise than a 64th of an inch, enter decimal inches. Avoid non-standard fractions.

ENTERING MILLIMETERS

When in Metric mode

,

, and

are disabled.

1. Enter

and press

SawGear moves to position at 111.8 millimeters.

RULE: SawGear assumes every dimension is in millimeters in Metric mode. 20

ENTERING NEGATIVE NUMBERS
SawGear is in Inches mode for this example.

1. Enter

2. Enter

and press

SawGear moves to position at minus 3/4″.

SawGear Operation

CALIBRATION
Set the distance between the stop and the saw blade using the Calibrate button:

The Calibrate button sets five distances:
Between stop and saw blade (Stored increment) Between stop and saw blade (Straight Cut Distance) Inside length between stop and saw blade at 45º miter (X in Figure 1) Inside length between stop and saw blade at dual facing 45º miter (Y in Figure 1) Inside length between stop and saw blade at 45º miter (Z in Figure 1)

Calibrate Straight Cut Distance
1. Cut a sample board at least 12″ (305mm) long.

2. Measure the cut board, and press

3. Enter the actual length of the sample part and

press

to return to the ready screen.

21

Figure 1

SawGear Operation

Calibrate Miter Cut: X Distance
The calibration of the X, Y and Z values uses a calculated value base on the value of W (moulding width). SawGear will use the value of W to calibrate X, Y, and Z values.

1. Press

, enter the width of the moulding being cut, and

press

2. Cut a sample `X’ moulding at least 12″ (305mm) long.

3. Measure the X distance of the cut board and press then

4. Enter the actual X length of the sample part and press

to return to the ready screen.

Calibrate Miter Cut: Y Distance
1. Cut a sample `Y’ moulding at least 12″ (305mm) long. 2. Measure the Y distance of the cut board and press
then
3. Enter the actual Y length of the sample part and press

to return to the ready screen.

Calibrate Miter Cut: Z Distance
1. Cut a sample `Z’ moulding at least 12″ (305mm) long. 2. Measure the Z distance of the cut board and press
then
3. Enter the actual Z length of the sample part and press

to return to the ready screen.

Calibrate Increment Distance

1. Press

then

2. Enter the length of the desired increment and press

to return to the ready screen.

22

STRAIGHT CUTTING
Consists of two simple steps: 1. Enter a dimension and press 2. When SawGear moves to position: cut.

SawGear Operation

45° MITER CUTTING

Correct miter cuts require an accurate width entry in

1. Press

, enter the width of the moulding, and

press 2. Make a square trim cut with the exterior edge to fence.

3. Press

to set the length of the left part, enter the

interior dimension of the moulding, and press

SawGear moves to a length based on the width of the stock and a 45° miter angle. 4. Swing the saw to the left, set it at -45°, make a trim cut from the front to the back fence, and remove the left part. 5. Swing the saw to the right, set it at 45°, and trim off the residual miter from the previous cut.

6. Press

to set the length of the header, enter the

interior dimension of the moulding, and press

SawGear moves to a length accounting for the 45° angle of the two miter cut ends. 7. Move the part to the stop, swing the saw to the left, set it at -45°, make the cut and remove the part. 8. Swing the saw to the right, set it at 45°, and trim off the residual miter from the previous cut.

9. Press

to set the length of the right part, enter the

interior dimension of the moulding, and press

SawGear moves to a length based on the width of the stock and the 45° angle of the last miter. 10. Move the part to the stop, return the saw to 0°, make the final square cut, and remove the right part.

23

CUSTOM MITER CUTTING

SawGear Operation

Use

to input the angle of any miter cut that is not 45°.

1. Press

, enter the width of the moulding being cut,

and press

again.

2. Enter the angle of the miter cut and press

SawGear ignores angles greater than 89°. Exit the input screen by pressing miter angle of 45° or saves the most recently input angle.
3. Make a square trim cut with the exterior edge to the back fence.

SawGear reverts to the default

4. Press

to set the length of the left part, enter the

interior dimension of the moulding, and press

SawGear moves to a length based on the width of the stock and the custom angle.
5. Swing the saw the left, set it at the negative custom angle, make a trim cut from the front to the back fence, and remove the left part.
6. Swing the saw to the right, set it at custom angle, and trim off the residual miter from the previous cut.

7. Press

to set the length of the header, enter the

interior dimension of the moulding, and press

SawGear moves to a length accounting for the custom angle of the two miter cut ends.
8. Move your part to the stop, swing the saw to the left, set it at the negative custom angle, make the cut, and remove the part.
9. Swing the saw to the right, set it at the custom angle, and trim off the residual miter from the previous cut.

10. Press

to set the length of the right part, enter the

interior dimension of the moulding, and press

SawGear moves to a length based on the width of the stock and the custom angle of the last miter. 11. Move your part to the stop, return the saw to 0°, make the final square cut, and remove the right part.

24

Pivot Point Calibration
MITER SAW ACCURACY
Miter saws rotate around a center called the `pivot point.’ A useful pivot point is in exact alignment with the saw’s back fence. If the pivot point is in poor alignment and the fence is fixed, maintain accuracy by adjusting the length entered into SawGear by the amount of offset measured.
Note that each cut shares the identical starting point.
Check the Pivot Point
This example assumes that SawGear is on the right of the saw, and that the observed pivot point is on the right side of the saw blade. Check for accuracy by comparing the straight cut and the left & right miter cuts: 1. End trim a sample board. 2. Using a tape measure, mark 8″ (203mm) from the right end with a pencil and square. 3. Line up the pencil mark with the right side of the saw kerf, and clamp the sample board against the back fence.
Keep the clamp away from the path of the saw blade. 4. With the saw set at 0° make a partial cut into the sample board. This is the straight cut. 5. With the saw set at -45° make another partial cut into the sample. This is the outside corner miter cut. 6. With the saw set at 45° make another partial cut into the sample. This is the inside corner miter cut. 7. Release the board and measure carefully from the right end of the board to each of the cuts. If the pivot point is
correct, all three cuts are the same distance. If they are not, adjust the back fence and repeat the test process. Otherwise, record the offset distance to compensate in future cuts.
25

Pivot Point Calibration

Adjusting the Miter Saw Pivot Point

The examples below show in which direction to adjust the fence to improve pivot point alignment.

Pivot point too far BACK

Pivot point too far FORWARD

Using SawGear to Adjust Pivot Point

If the back fence of the saw is fixed, adjust the pivot point offset using SawGear’s pivot point adjustment system.

1. Press

then press

2. If SawGear calibration is necessary, press

and

calibrate as usual.

If calibration is correct, press

3. Place the square end of the stock against the SawGear and press

4. Swing the miter saw left to -45°. Cut the part and then measure it from the back edge. Enter this dimension and
press

5. Take a new part of stock and place the square end against the

SawGear. Press

button.

6. Swing the miter saw right to 45°. Cut the part and then measure it from the back edge.
Enter this dimension and press
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Crown + Miter Pro

The Crown & Miter Pro feature calculates saw angles for crown and base moulding while ensuring accurate cut lengths.
GETTING STARTED
To activate the Crown & Miter Pro feature:

1. Press 2. Press

twice. then

Measuring Angles and Lengths
Start with the longest wall and, working counter-clockwise around the room, make a list of angles and cut lengths. See the example table 1.
If cutting base moulding, work clockwise around the room.

HOW TO USE CROWN & MITER PRO

[W] Button

Press

to set the width of the moulding.

[X] Button

In Crown & Miter Pro mode,

acts as the first angle of the part.

1. Press

and the following screen displays:

A’ is the angle.I’ or O’ indicates whether it’s an inside or outside corner.S’ is the required saw angle. <‘ or>’ tells in which direction to set the saw (Left or Right).
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Crown + Miter Pro

2. Enter the first angle of the part to be cut.

3. Press

to select if this is an inside or outside corner.

4. The required saw angle displays.

5. Set the saw, press

, and SawGear moves to the proper length for the cut.

[Y] Button
sets the part length.

1. Press

and the following screen displays:

B’ orF’ indicates either Back or Front length.

2. Enter the length of the part to be cut.

3. Press

to switch between Back and Front lengths (Back is the recommended setting).

[Z] Button

acts as the final angle of the part.

1. Press

and the following screen will display:

2. Enter the final angle of the part to be cut.

3. Press

to select if this is an inside or outside corner.

4. The required saw angle displays.

5. Set the saw, press

, and SawGear moves to the proper length for the cut.

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Work Flow Example
1. Press

Crown + Miter Pro

2. Enter the first angle and use outside corner.

to select inside or

From table 1 above we can see it’s 45° and an outside corner.

After angle entry, SawGear displays the required saw angle and direction. Set the saw and cut your first angle.

3. Press
4. Enter the length of the part. From table 1 above, we would enter

5. Press

6. Enter the final angle and use outside corner.

to select the inside or

From table 1 above we can see that it’s 90° and an outside corner.

After angle entry , SawGear displays the required saw angle and direction. Set the saw and press 7. Cut the part.

Exit Crown + Miter Pro

1. Press

twice.

2. Set a new angle to exit Crown + Miter Pro mode.

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Troubleshooting
CORRECTING ENTRY ERRORS
The following example shows how to correct an entry error using the Clear button:

1. Enter You entered 3/8 by mistake. It should have been 5/8.
2. Press SawGear erases digits starting with the last digit entered.

3. Enter Your new entry replaces the error.
4. Press SawGear moves to position at 32-5/8 inches.
“TOO BIG” ERROR
SawGear rejects dimensions longer than the maximum limit.

1. Enter

and press

SawGear assumes “inches” and displays an error message.
It returns to the ready screen and displays the actual position, waiting for valid input.

2. Enter any dimension within SawGear’s maximum limit and press

“TOO SMALL” ERROR
SawGear rejects dimensions shorter than the minimum limit.

1. Enter

and press

SawGear assumes “inches” and displays an error message.
It returns to the ready screen and displays the actual position, waiting for valid input.

2. Enter any dimension within SawGear’s minimum limit and press

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HOME ROUTINE AFTER IMPACT

Troubleshooting

If material is thrust against SawGear with sufficient force, it can bump the stop off position. Whether it does or not, a warning message appears to allow for re-homing the machine or continuing work. As a sensible precaution, choose to re-home it.

After significant impact, the screen displays: OPTION 1: Re-home SawGear.
· Press SawGear homes itself.
· Enter a length and press

OPTION 2: Keep working. (Strongly discouraged) · Press

SCALING INSTRUCTIONS

Calibration adjusts the displayed position to match the actual position at a single point. If accuracy decreases as the stop moves away from the calibration point, then the SawGear requires scaling.

1. Unplug SawGear from power and plug it back in.

2. Press

and then press

three times.

3. If the long cuts are too long, increase the working length by 0.03 inches (0.8mm) or decrease by the same amount if the short cuts are too short.

4. Press

to view and modify Scale. Scale defaults to 3.047 inches (77.4 mm), but you must allow this setting to

float as you change the working length.

5. Press

to view and modify Throttle. Throttle defaults to 300 inches (7,620 mm).

6. Press

to view and modify Throttle Base. Throttle base default to 8,000 inches (203,200mm).

7. Press

to move the stop to the ready position.

8. Cut a sample board as short as 2″ (51mm) and measure its actual length with calipers. Use that sample board to calibrate straight cuts (see page 21).

9. Cut a sample board as long as possible and verify the cut’s accuracy.

10. Repeat, if necessary.

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Appendix A: Power Head Controller Stand

ASSEMBLY

1. Place the Controller Stand Base Brackets against the Round Tube and insert two M8x45mm Hex-Head Screws through all three parts.
2. Fasten the Base Brackets to the round tube with M8 Flange Nuts. 3. Insert one M8x35mm T-bolt through each vertical slot in the Controller Stand Base Brackets. Fasten with M8 Flange
Nuts. 4. Insert the Round Tube into the Square tube and fasten with an M6x14mm Socket-Head Screw. 5. Place the Spacer between the Square Tube’s holes. 6. Connect the Spacer, Mount, and Tube with an M8x50mm Hex-Head Screw. 7. Fasten with an M8 Flange Nut. 8. Attach the Power Head Controller to the Controller Mount.
a. Slide an M5 Weld Nut into the vertical slots on each side of the Power Head Controller. b. Use an M5x8mm Socket Head Screw and M5 Washer to fasten the Power Head Controller to the Controller Mount.

32

Appendix B: Panel Saw Retrofit
UNIVERSAL BRACKET INSTALLATION
Use the supplied Universal Bracket Hardware Pack to fasten the Universal Brackets to the base of the panel saw. Ensure the brackets are level and in alignment with each other.
Installing the brackets may require drilling and tapping.
BENCH MOUNT BRACKET INSTALLATION
Install one Bench Mount Bracket to each Universal Bracket. Use two M5x16mm Flat Head Screws, M5 Washers, and M5 Hex Nuts to fasten each bracket. Ensure the Star Knobs are facing the user.
33

SAWGEAR MOUNTING

Appendix B: Panel Saw Retrofit

Secure the SawGear in the Bench Mount Brackets according to the instructions on page 8.

ASSEMBLE SUPPORT LEG

Leveling Nuts

Fasten the Foot Adapter to the Round Tube with an M6x8mm Set Screw. Screw the Leveling Foot into the Foot Adapter.
34

Place the Controller Stand Base Brackets against the Round Tube and insert two M8x50mm Hex-Head Screws through all three parts. Fasten the Base Brackets to the round tube with M8 Flange Nuts.

Appendix B: Panel Saw Retrofit

Install a Bench Mount Bracket to the Base Brackets. Use two M5x16mm Flat Head Screws, M5 Washers, and M5 Hex Nuts to fasten the brackets.
ATTACH SUPPORT LEG

Loosely screw on a Star Knob. Ensure it is attached to the side farther from the Round Tube.

Attach the Support Leg to the far end of the SawGear from the blade. Ensure the Star Knob is facing the user and adjust the Leveling Foot until the SawGear is level throughout.
35

Appendix B: Panel Saw Retrofit CONNECTING THE POWER HEAD
Locking Handle Connect the Power Head as described on page 11. Make sure the cable is facing the user, in this case.
CONNECT CABLE GUARD TO POWER HEAD
Remove the 4 screws on the sides of the Power Head. Hold the Cable Guard in alignment with the fastener-holes and replace the 4 Power Head screws.
36

Appendix B: Panel Saw Retrofit CONNECTING THE FLIP-AWAY STOP
Follow the instructions on page 10 to connect the Flip-Away Stop.
ATTACHING THE STOP BAR
Lock
Follow the instructions on page 10 to attach the Stop Bar.
37

Appendix B: Panel Saw Retrofit ATTACH CONTROLLER TO SAW
Use fasteners appropriate to the saw to attach the Power Head Controller. Attaching the Controller may require drilling and tapping.
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TigerStop Product

COMPARISON CHART

Product

Max Load Push

Power Requirement

Drive Type

Accuracy

Working Length

TigerSPC

Caliper

2 AA Battery

N/A

+/- .008″ +/- 0.2mm

0′ – 20′ 0m – 6m

SawGear

Stop Only

110 Vac

32mm Belt
Steel Reinforced

+/- .008″ +/- 0.2mm

8′ – 20′ 2.4m – 6m

TigerFence

Stop Only 110 / 240 Vac

3/4″
Hi-Lead Screw

+/- .003″

51″ or 70″

+/- 0.08mm 1.29m – 1.77m

TigerStop TigerRack TigerTurbo HeavyDuty 2

90lbs/41kg Solid Tables 180lbs/81kg Roller Tables
300lbs/136kg Solid Tables 720lbs/327kg Roller Tables
350lbs/159kg Solid Tables 840lbs/381kg Roller Tables
490lbs/222kg Solid Tables 2100lbs/952kg Roller Tables

110 / 240 Vac 110 / 240 Vac 110 / 240 Vac 110 / 240 Vac

32mm Belt
Steel Reinforced

+/- .004″ +/- 0.1mm

4′ -30′ 1.2m – 9.1m

+/- .008″

12′ – 108′

Rack & Pinion +/- 0.2mm 3.7m – 32.9m

75mm Belt
Steel Reinforced

+/- .008″ +/- 0.2mm

12′ – 42′ 3.7m – 12.8m

Rack & Pinion

+/- .008″ +/- 0.2mm