SawStop TSG-FDC Floating Dust Collection Guard Owner’s Manual

SawStop TSG-FDC Floating Dust Collection Guard

PRODUCT SPECIFICATIONS

The SawStop Floating Dust Collection Guard is designed as a blade cover and dust collection hood. It is intended for use on SawStop cast iron table saws. The transparent floating guard back plate can be cut or removed to provide clearance for safety devices such as riving knives, splitters, and anti- kickback pawls. The Floating Dust Collection Guard is compatible with dado stacked blades.

Product Specifications

Net Weight| 58 lbs
Floating Blade Guard Dimension| 3.5” x 18.5”
Distance Between Blade and End of Extension Table| 35.75” to 68”
Inner Dust Tube Diameter| 3”
Outer Dust Tube Diameter| 4”
Outer Dust Tube Height Above Table| 13.6”
Outer Dust Tube Height Above Floor| 33.5” to 50”

PARTS INVENTORY

Parts and Hardware Lists

The Floating Dust Collection Guard is shipped partially assembled. Please unpack the parts carefully and confirm you have received each item on the list below.

Parts

• A Extension Leg (1)
• B Dust Collection Guard Mounting Bracket (1)
• C Upper Leg (1)
• D Leg Support Bracket (2)
• E Outer Dust Tube – Curved (1)
• F Outer Dust Tube – Straight (1)
• G Inner Dust Tube (1)
• H Dust Collection Hose w. clamps (1)
• I Floating Blade Guard (1)
• J Hardware Pack (1)

Hardware

• K Bolt – M6 x 1.0, 40mm, Hex Head (4)
• L Nut – M6 x 1.0 (4)
• M Bolt – M6 x 1.0, 18mm, Flat Head, Socket (2)
• N Eye Bolt – 10.5mm, M5X1.0, 80mm (2)
• O L Bracket – Leg Support (2)
• P Lock Washer – M6 (6)
• Q Bolt – M6 x 1.0, 16mm, Hex Head (2)
• R Flat Washer – M5, 12mm x 0.8mm (2)
• S Screw – M5 x 2.1, 32mm, Button Head, Phillips (2)
• T Nut – M8 x 1.25 (3)
• U Lock Nut – M6 x 1.0 (8)
• V Bolt – M8 x 1.25, 45mm, Hex Head (1)
• W Bolt – M5 X 0.8, 10mm, Button Head, Socket (6)
• X Washer – M8, 17mm x 2mm (4)
• Y Flat Washer – M6, 20mm x 1mm (8)
• Z Lock Washer – M8 (2)
• BB Bolt – M8 x 1.25, 60mm, Hex Head (1)
• CC Bolt – M8 x 1.25, 80mm, Hex Head (1)
• DD Knob – M6, Extension Leg Lock (2)

Tools Needed

• Measuring Tape
• Flathead and Phillips Screwdrivers or Driver Bits
• Pen or Pencil
• Drill with 1/4”, 5/16”, and 7/64”
• Drill Bits Wrenches – 10mm, 13mm, and 17mm
• Allen wrenches – 3mm and 4mm

ASSEMBLY INSTRUCTIONS

Attaching the Upper Leg and Leg Support to the Dust Collection Mounting Bracket

1. Insert the Upper Leg [C] into the Dust Collection Guard Mounting Bracket [B] while ensuring that the pair of holes in each piece align. Secure C and B with hardware described in Step 2.
2. Add a Flat Washer – M8, 17mm x 2mm [X] to the Bolt – M8 x 1.25, 60mm, Hex Head [BB]. Insert the bolt into the lower hole of the Dust Collection Guard Mounting Bracket [B] then add another Flat Washer – M8, 17mm x 2mm [X] onto the end of the bolt. Next, stack on a Lock Washer – M8 [Z] and finally a Nut – M8 x 1.25 [T]. Using a 13mm wrench at both the nut and bolt, tighten the nut to secure the Upper Leg [C] into the Dust Collection Guard Mounting Bracket [B].
3. Slide the hollow end (the end without the cap) of the Extension Leg [A] into the Upper Leg [C]
4. Adjust the overlap between the Extension Leg [A] and the Upper Leg [C] until the total length of the assembly (top of the dust collection guard mounting bracket to the end of the extension leg) approximates height of the extension table of your saw from the floor.
5. Thread the two Knob – M6, Extension Leg Lock [DD] into the two nuts on the Upper Leg [C]. The knobs need only be moderately snug at this time. Upon completion of the installation of your TSG-FDC, tighten the extension leg lock knobs evenly to secure the extension leg. The knobs should engage the Extension Leg [A] and secure it against further movement. This will help prevent potential injury due to unexpected movement of the floating dust collection guard.

Attaching the Dust Collection Guard Mounting Bracket to the Extension Table

1. Place the flat edge of the Dust Collection Guard Mounting Bracket [B] against the right edge of the extension table on your saw. Ensure the top of the bracket is flush or just below flush with the top of the extension table.

2. Reference the table and figure below for accurate placement of the bracket based on your saw model configuration. The mounting pins on the Dust Collection Guard Mounting Bracket [B] should align with the center of the blade.
   Bracket Mounting

   Saw| Extension Table| Distance Between Bracket and Rear of Extension Table
   ICS| 36”| 4”
   52”| 4”
   PCS| TGP2 36”| 1 5/8”
   TGP2 52”| 1 5/8”
   CNS| TGP2 36”| 1”
   TGP2 52”| 1”

The distance between the mounting bracket and the rear edge of the extension table should match the value listed for your model saw in the table above.

3. Place a mark on the extension table in the center of each of the four elongated mounting slots in the Dust Collection Guard Mounting Bracket [B].

4. Locate an additional mark using the upper round hole where the Upper Leg [C] is joined to the Dust Collection Guard Mounting Bracket [B] to locate the mark.

5. Using a 1/4” drill bit, drill four through-holes in the extension table at the locations marked in step 3.

6. Use a 5/16” drill bit to drill one additional hole at the location you marked in step 4.

7. Add a Flat Washer – M8, 17mm x 2mm [X] onto the Bolt – M8 x 1.25, 80mm, Hex Head [CC]. Next, with the newly drilled mounting holes of the extension table aligned with the Dust Collection Guard Mounting Bracket assembly, insert the bolt [CC] through the upper round hole where the Upper Leg [C] is joined to the Dust Collection Guard Mounting Bracket [B] and through the drilled hole in the extension table. Next add Flat Washer – M8, 17mm x 2mm [X] followed by Lock Washer – M8 [Z] followed by Nut

   • M8 x 1.25, [T] to the bolt at the extension table facing side.
     The nut should be only finger tight at this time.  Set the dust collection guard mounting bracket and extension leg assembly aside.

8. Insert a single Bolt – M6 x 1.0, 40mm, Hex Head [K] through a Flat Washer – M6, 20mm x 1mm [Y] then through one of the four exposed elongated holes in the Dust Collection Guard Mounting Bracket (B) and extension table. Next add a second Flat Washer -M6, 20mm x 1mm [Y] followed by a Nut – M6 x 1.0 [L] to the bolt at the extension table facing side. The nut should be only finger-tight at this time.

9. Repeat step 8 for the remaining three elongated holes in the mounting bracket assembly and extension table.

10. Confirm that the dust collection guard mounting bracket is still positioned correctly against the extension. If the position needs to be adjusted, make use of the clearance afforded by the elongated slots.

11. Using a 10mm wrench on the head of each of the four M6 bolts and a 10mm wrench on each nut, tighten the nuts to secure the dust collection guard mounting bracket to the extension table. Using a 13mm wrench on the head of the M8 bolt and a 13mm wrench on its nut that you placed in step 8, tighten the nut to further secure the dust collection guard mounting bracket to the extension table.

12. Confirm that the Extension Leg [A] is vertical. If necessary, adjust the extension leg lock knobs and/or the bolts attaching the dust collection guard mounting bracket to the extension table.

Assembling the Leg Support Brackets

1. Insert a Bolt – M6 x 1.0, 18mm, Flat Head, Socket [M] through the eye of an Eye Bolt – 10.5mm, M5X1.0, 80mm [N], and then through one of the holes in L Bracket – Leg Support [O]. Next, place a Lock Washer – M6 [P] onto the bolt, followed by a Lock Nut – M6 x 1.0 [U]. The nut should be only finger tight at this time.
2. Step 1 process for the second eye bolt and L bracket.
3. Thread a Lock Nut – M6 x 1.0 [U] about half way up the shaft of each eye bolt [N].
4. Insert the shaft of an Eye Bolt -10.5mm, M5X1.0, 80mm [N] as shown through the hole in the bent end of a Leg Support Bracket [D], followed by a Lock Washer – M6 (P) and a Lock Nut – M6 x 1.0 [U]. The nut should be only finger tight at this time.
5. Repeat step 4 for the second Leg Support Bracket [D].

Attaching the Leg Support Brackets to the Dust Collection Guard Mounting Bracket

1. Place the flat, non-bent end of a Leg Support Bracket [D] against the exterior side of the front tab welded to the Upper Leg [C]. Make sure the bent sections of the Leg Support Bracket [D] and the L Bracket – Leg Support [O] face out toward the front of the saw.
2. Insert a Bolt – M6 x 1.0, 16mm, Hex Head [Q] through the hole in the Leg Support Bracket [D] and then through the tab of the Upper Leg
3. Repeat steps 1-2 to attach the[C], followed by a Lock Washer – M6 [P] and a Lock Nut – M6 x 1.0 (U). The nut should be only finger-tight at this time. second Leg Support Bracket [D] to the exterior side of the rear tab, making sure the bent sections of the leg support bracket and the leg support mounting bracket face out toward the rear of the saw. The nut should be only finger-tight at this time.

Attaching the Leg Support Brackets to the Extension Table

1. Pivot the bent end (with the eye bolt assembly) of the front Leg Support Bracket [D] up toward the underside of the wooden extension table support frame.

2. Rotate the L Bracket – Leg Support [O] and/or Eye Bolt – 10.5mm, M5X1.0, 80mm [N] until the flat side of the L Bracket – Leg Support [O] is flush with the outer portion of the extension table support frame.
   If you have a 36” extension table, rotate the leg support mounting bracket (O) and/or eye bolt (N) until the flat side of the leg support mounting bracket is flush with the cross support frame of the extension table.

3. Make a mark on the underside of the extension table support frame in the center of the hole of the L Bracket – Leg Support [O].

4. Pivot the leg support bracket back down to rest on the floor. Drill a pilot hole in the location you marked in step 3 with a 7/64” drill bit. Be sure to drill into the cross-support frame if you have a 36” extension table.

5. Pivot the leg support bracket and attached components up again and align the leg support mounting bracket hole with your drilled pilot hole.

6. Insert a Screw – M5 x 2.1, 32mm, Button Head, Phillips [S] through a Flat Washer – M5, 12mm x 0.8mm [R] and then through the exposed hole in the L Bracket – Leg Support [O]. Secure the bracket to the underside of the extension table support frame using a Phillips screwdriver or drill.

7. Repeat steps 1-6 for the rear leg support mounting bracket.

8. Check to make sure the Extension Leg [A] is still vertical and make any necessary adjustments.

9. Use a 10mm wrench to tighten the six Lock Nut – M6 x 1.0 [U] on the  eye bolts for the front and rear Leg Support Brackets [D]. Adjust the position of the first lock nut on the shaft of the eye bolt if needed to achieve ample tension to support the assembly.

10. Use a 10mm wrench to tighten the two Lock Nut – M6 x 1.0 [U] on both leg support brackets.

Attaching the Dust Tubes to the Dust Collection Guard Mounting Bracket

IT IS RECOMMENDED THAT TWO PEOPLE ATTACH THE DUST TUBES, AS THE DUST TUBE ASSEMBLY IS HEAVY AND COULD CAUSE SERIOUS PERSONAL INJURY OR DAMAGE IF DROPPED.

1. First, remove the end cap from Outer Dust Tube – Straight [F] .
2. Insert the reduced end of the Outer Dust Tube – Curved [E] into the larger diameter end of Outer Dust Tube – Straight [F]. Be mindful that the gasket included with the curved tube is remains properly seated and aligned while joining parts [E] and [F]. Align the pre-drilled holes in [E] and [F] then insert four Bolt – M5 X 0.8, 10mm, Button Head, Socket [W] into the holes and tighten to secure the outer tube sub-assembly together.
3. With the help of another person, lift the dust tube assembly (comprised of the inner and outer dust tubes [E, F, G]) and set them on the dust collection guard mounting bracket. Be sure that the pins (indicated by the red arrows) on the Dust Collection Guard Mounting Bracket [B] pass through the holes in the bracket on the outer dust tube (indicated by the yellow circles).

Attaching the Floating Blade Guard to the Dust Tube

1. Slide the Floating Blade Guard (I) onto the end of the Inner Dust Tube (G) until about 1” of the inner dust tube extends past the floating blade guard.

2. Slide a Bolt – M6 x 1.0, 40mm Hex Head (K) through the two holes in the clamping portion of the Floating Blade Guard (I), with the threaded portion of the bolt facing towards the front of the floating blade guard.
   It may be useful to loosen the spring tension knob on the rear side of the clamping portion of the floating blade guard so the spring can be pushed out of the way.

3. Secure the button head socket screw in place with a Lock Nut – M6 x 1.0 (U), using a 4mm Allen wrench and a 10mm wrench.

4. Lock the floating blade guard in its upper, retracted position. To do this, loosen the floating guard lock handle and lift the clear hood portion up towards the inner dust tube. When the Floating Blade Guard (I) is in its upper position, re-tighten the floating guard lock handle.

5. Loosen the inner dust tube lockknob and extend or retract the Inner Dust Tube (G) to center the Floating Blade Guard (I) over the blade. Then re-tighten the inner dust tube lock knob to secure the inner dust tube and floating blade guard.

IT IS RECOMMENDED THAT THE FLOATING BLADE GUARD ALWAYS BE LOCKED IN ITS UPPER POSITION BEFORE THE DUST TUBES ARE MOVED OR PIVOTED.

For bevel cuts, where the blade is tilted to the left, you may need to move the Floating Blade Guard (I) to the left so it does not interfere with the teeth on the saw blade. First, turn off your saw and lock the floating blade guard in the upper, retracted position. Then, position the saw blade at the desired angle and elevation. Carefully lower the guard and telescope the Inner Dust Tube (G) further to the left side of the saw as necessary, checking the clearance between the sides of the guard and the teeth on the blade.

ALWAYS CHECK THE POSITION OF THE FLOATING BLADE GUARD (I) PRIOR TO BEGINNING ANY CUTS, TO MAKE SURE IT WILL NOT INTERFERE WITH THE TEETH ON THE SAW BLADE.

Install the Limit Bolt and Adjust the Dust Tube Lock Knob Tension

1. Insert and adjust the limit bolt and nut as follows: Thread the Nut – M8 x 1.25 [T] onto the Bolt – M8 x 1.25, 45mm, Hex Head [V] about 1/3 of theway down the shaft for now. Next, thread the through the Bolt – M8 x 1.25, 45mm, Hex Head [V] into the mounting bracket as shown.Adjust the nut and bolt to tunethe positioning of the dust tube assembly such that the Floating Blade Guard [I] aligns with (over) the blade. Additionally, the bolt head should contact the Dust Collection Guard Mounting Bracket [B] and act as a stop when alignment that offers optimal dust collection is achieved.
2. Continue with the dust tube assembly positioned over the table saw and it’s flat plate portion of Outer Dust Tube – Curved [E] rests securely against the Dust Collection Guard Mounting Bracket [B].
3. Grasp the end of the Dust Tube Lock Knob and pivot it towards the dust tube assembly until the end of the threaded portion of the lock knob lines up with the depression in the flat plate portion of Outer Dust Tube – Curved [E] and push it until it is over center past the depression.

The amount of clamping force exerted by the Dust Tube Lock Knob can be adjusted by loosening the nut adjacent to the pivot point of the handle using a 17mm wrench and threading the handle in or out. Once the desired clamping pressure has been reached, the nut can be re-tightened.

Attaching the Dust Collection Hose to the Dust Tube and the Floating Blade Guard

1. Slide one end of Dust Collection Hose [H] over the end of the Inner Dust Tube [G], making sure that the included hose clamp is about 1/4” to 1/2” inset from the end of the dust tube.
2. Slide the other end of the Dust Collection Hose [H] onto the Floating Blade Guard (I), making sure the hose clamp is about 1/4” to 1/2” over the edge of the Floating Blade Guard [I] 4” port.
3. Using a screwdriver, tighten the included hose clamps to secure the dust hose both fittings described in steps 1 and 2.

Connecting to a Dust Collection System

CONNECT YOUR FLOATING DUST COLLECTION GUARD TO A DUST COLLECTION SYSTEM BEFORE STARTING YOUR TABLE SAW.

1. Using a 4” hose (not included) and a hose clamp (not included), connect the base of the Outer Dust Tube – Curved [E] to a dust collection system. Make sure that both ends of the dust hose are securely connected and tightly sealed.

ALWAYS TURN THE DUST COLLECTION SYSTEM ON BEFORE STARTING YOUR TABLE SAW, AND TURN THE DUST COLLECTION SYSTEM OFF AFTER STOPPING YOUR TABLE SAW.

ADJUSTING YOUR FLOATING DUST COLLECTION GUARD

Adjusting the Dust Tube Parallelism

1. If the dust tubes are not parallel with the front and back of the table, the parallelism will need to be adjusted. Ensure the floating blade guard is locked in its retracted position. Next, release the dust tube lock knob and pivot the dust tubes towards the rear of the table.
2. Loosen the Nut – M8 x 1.25 [T] using a 13mm wrench and thread the Bolt – M8 x 1.25, 45mm, Hex Head [V] in or out relative to the dust collection guard mounting bracket. Once the bolt is in the correct position, use a 13mm wrench to re-tighten the nut in order to secure the bolt.

Adjusting the Dust Tube Length

1. Loosen the inner dust tube lock knob by turning the handle counter-clockwise and slide the inner dust tube in or out of the outer dust tube until the desired position of the floating blade guard is reached.
2. Tighten the inner dust tube lock knob by turning the handle clockwise. Do not over-tighten the inner dust tube lock knob.

Adjusting the Floating Blade Guard

1. The floating guard lock handle can be used to secure the floating blade guard and prevent vertical movement. Loosen the lock handle by rotating it in a counter-clockwise direction.
2. Move the floating blade guard up or down to the desired position and then tighten the lock handle by rotating it in a clockwise direction.

There are some operations in which the use of the floating dust collection guard system is not practical, and in those cases, the floating blade guard can be lifted up towards the dust tubes and the floating guard lock handle can be tightened to secure it in place.
When pivoting the dust tubes relative to the dust collection guard mounting bracket and when adjusting the lateral position of the floating blade guard, the floating blade guard should always be locked in its upper, or retracted, position.

Over the life of your TSG-FDC, the motion of raising and lowering the blade guard may begin to feel stiff. You can change this tension to your liking by loosening the four bolts indicated in the image.

Adjusting the Floating Blade Guard Spring

1. The spring tension knob can be used to adjust the tension of the floating guard spring, which controls the extent to which the floating blade guard is biased towards its upper, retracted position. Rotate the knob clockwise to increase the tension or counter-clockwise to decrease the tension.

MAINTENANCE

• Keep the floating blade guard clean and free of dust to allow unobstructed viewing of the blade and workpiece.
• If any portion of the floating dust collection guard ceases to function properly, replace or repair it before continuing to use the saw.
• When not in use, the floating blade guard can be stored in its upper position, or the dust tube lock knob can be unlocked and the dust tubes and floating dust collection guard can be pivoted away from the saw.
• For more information on dust control and installing a dust collection system, see Woodshop Dust Control, by Sandor Nagyszlanczy, Taunton Press, 2002.

REFERENCE

Warranty

SawStop warrants to the original retail purchaser of a new Floating Dust Collection Guard from an authorized SawStop distributor that the floating dust collection guard system will be free from defects in material and workmanship for ONE YEAR from the date of purchase. SawStop warrants to the original retail purchaser of a refurbished Floating Dust Collection Guard from an authorized SawStop distributor that the floating dust collection guard system will be free from defects in material and workmanship for SIX MONTHS from the date of purchase. This warranty does not apply to defects arising from misuse, abuse, negligence, accidents, normal wear-and-tear, unauthorized repair or alteration, or lack of maintenance. This warranty is void if the floating dust collection guard system or any portion of the floating dust collection guard system is modified without the prior written permission of SawStop, LLC, or if the floating dust collection guard system is located or has been used outside of the country where the authorized SawStop distributor from whom the floating dust collection guard system was purchased resides. Please contact SawStop to take advantage of this warranty. If SawStop determines the floating dust collection guard system is defective in material or workmanship, and not due to misuse, abuse, negligence, accidents, normal wear-and-tear, unauthorized repair or alteration, or lack of maintenance, then SawStop will, at its expense and upon proof of purchase, send replacement parts to the original retail purchaser necessary to cure the defect. SawStop disclaims any and all other express or implied warranties, including merchantability and fitness for a particular purpose. SawStop shall not be liable for death, injuries to persons or property, or incidental, consequential, contingent or special damages arising from the use of the floating dust collection guard system. This warranty gives you specific legal rights. You may have other rights which vary from state to state.

Safety

A table saw is a dangerous tool and there are hazards inherent with using your saw. Some of these hazards are discussed below. Use common sense when operating the saw and floating dust collection guard system and use them only as instructed.
You are responsible for your own safety!

Warnings

1. Read and understand the instruction manual and all safety warnings before operating the saw and floating dust collection guard. Failure to follow instructions or heed warnings may result in electric shock, fire, serious personal injury or property damage. Save these instructions and refer to them whenever necessary.
2. WARNING: This product can expose you to chemicals including wood dust, which is known to the State of California to cause cancer. This exposure can come from drilling, sawing, sanding or machining wood products. For more information go to www.P65Warnings.ca.gov/wood. In addition, some types of dust created by sawing, power sanding, grinding, drilling, and other construction activities also contain chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are lead from lead-based paints, crystalline silica from bricks, cement, and other masonry products, and arsenic and chromium from chemically treated lumber. In addition, wood dust has been listed as a known human carcinogen by the U.S. government. The risk from exposure to these chemicals and to dust varies depending on how often you do this type of work. To reduce your exposure, work in a well ventilated area and work with approved safety equipment including dust masks or respirators designed to filter out such dust and chemicals.
3. Keep guards in place and in working order. Use the floating dust collection guard and spreader for every operation for which it can be used, including all-through sawing. Use a push stick when required.
4. Wear proper apparel when using the saw and floating dust collection guard. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear a protective hair covering to contain long hair.
5. Always wear safety glasses when using the saw. Also use a face or dust mask if the cutting operation is dusty. Everyday eyeglasses are not safety glasses.
6. Keep hands out of the line of the saw blade. Never reach around or over the saw blade. Keep proper footing and balance at all times.
7. Maintain the floating dust collection guard as specified in this manual. Use only identical replacement parts when servicing the floating dust collection guard.
8. Turn the power disconnect switch to OFF before servicing the saw and/or floating dust collection guard. Always ensure the power is OFF before changing components or accessories such as blades, brake cartridges, and the like.
9. Check to make sure the saw and floating dust collection guard are in proper working order before using them. For example, check the alignment of moving parts, look to see whether moving parts are binding or rubbing, check to see whether parts are broken, make sure accessories are properly mounted in the saw, and check any other conditions that may affect the operation of the saw or floating dust collection guard. A guard or other part that is damaged should be properly repaired or replaced.

Warning Labels

The following warning labels are located on the floating guard support arm within the floating blade guard. Be sure to read all warnings and the warning labels before using the saw. A copy of the English text of the warning labels is reproduced below:

WARNING

1. Use the blade guard and spreader for every operation for which it can be used.
2. Use the riving knife for non-through sawing.
3. Keep hands away from the saw blade. Use a push stick when required.

WARNING:

This product can expose you to chemicals including wood dust, which is known to the State of California to cause cancer. For more information, go to www.P65Warnings.ca.gov.

SawStop, LLC
11555 SW Myslony Street Tualatin, Oregon 97062 USA www.sawstop.com

• Technical Support
  • 503-582-9934
  • service@sawstop.com
• Parts
  • 503-486-6923
  • parts@sawstop.com
• Sales
  • 503-595-2662
  • sales@sawstop.com

References

• P65Warnings.ca.gov
• P65Warnings.ca.gov/wood
• America's #1 table saw. The leader in table saw safety | SawStop

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