metabo KS 305 M Miter Saw Instruction Manual

: June 3, 2024
: metabo

Table of Contents

metabo KS 305 M Miter Saw
Declaration of Conformity
Specified Use
General Safety Instructions
Safety instructions for mitre saws
Overview
Setup and transport
The device in detail
Commissioning
Operation
Tips and Tricks
Accessories
Repairs
Environmental Protection
Troubleshooting
Technical Specifications
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

metabo KS 305 M Miter Saw

Declaration of Conformity

We declare under our sole responsibility: These crosscut and miter saws, identified by type and serial number 1), comply with all relevant requirements of the directives 2) and standards 3). Technical file at 4) – see page 4.

Specified Use

The mitre saw is suited for longitudinal and cross cuts, inclined cuts, miter cuts and double miter cuts. Furthermore grooves can be machined.
Only materials for which the respective saw blade is suited may be machined (approved saw blades see chapter 12. Accessories).
The permissible dimensions of the stock have to be adhered to (see chapter 16. Technical Specifications).
Workpieces with round or irregular cross-section (such as firewood) must not be cut, as they cannot be held securely during the cutting process. When sawing a thin workpiece laid on its edge, a suitable guide must be used for firm support.
Any other use does not comply with the intended purpose. Unspecified use, modification of the tool or use of parts that have not been tested and approved by the manufacturer can cause unforeseeable damage!

General Safety Instructions

For your own protection and for the protection of your electrical tool, pay attention to all parts of the text that are marked with this symbol!

WARNING – Reading the operating instructions will reduce the risk of injury.
Pass on your power tool only together with these documents.

General Power Tool Safety Warnings

WARNING – Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
Keep all safety instructions and information for future reference! The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

Keep work area clean and well lit. Cluttered or dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
When operating a power tool outdoors, use an extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use reduces the risk of electric shock.
If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

Personal safety

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
Do not overreach. Keep proper footing and balance at all times.This enables better control of the power tool in unexpected situations.
Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
If devices are provided for the connection
of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.
Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless
action can cause severe injury within a fraction of a second.

Power tool use and care

Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Battery tool use and care

Always charge the batteries only in chargers recommended by the manufacturer.
Chargers designed for a specific type of battery may pose a fire hazard when used together with other battery types.
Use only the batteries provided for this purpose in the power tools. Using other
batteries may cause injuries and pose a fire hazard.
When not in use, keep batteries away from paper clips, coins, nails, screws or other small metal objects that could bridge the contacts.
Short circuits between battery contacts can cause burns or fires.
Fluid may escape if batteries are used inappropriately. Avoid all contact with this fluid. In the event of accidental skin contact, rinse the affected area thoroughly. If the fluid enters your eyes, seek immediate medical assistance. Escaping battery fluid can cause skin irritation or burns.
Do not use damaged or modified batteries. Damaged or modified batteries may behave unpredictably and lead to fire, explosion or risk of injury.
Do not expose the battery pack to fire or excessive temperatures. Fire or temperatures above 130 °C can cause an explosion.
Follow all instructions on charging and never charge the battery or the cordless tool outside the temperature range indicated in the operating instructions. Incorrect charging or charging outside the permitted temperature range may destroy the battery and increase the risk of fire.

Service

Have your power tool serviced by a qualified technician using only original replacement parts. This will ensure that the safety of the power tool is maintained.
Never service damaged batteries. Any servicing of batteries should only be carried out by the manufacturer or authorized customer service points.

Additional Safety Instructions

These operating instructions are intended for people with basic technical knowledge in handling machines such as the one described here. If you have had no experience with machines of this kind, you should initially work under the supervision of people with previous experience.
The manufacturer bears no liability for damage caused by non-compliance with these operating instructions.

Information in these operating instructions is designated as shown below:

Danger!
Risk of personal injury or environ-mental damage.
Risk of electric shock!
Risk of personal injury from electric shock.
Drawing-in/trapping hazard!
Risk of personal injury by body parts or clothing being drawn into the ro- tating saw blade.
Caution!
Risk of material damage.

Note: Additional information.

Safety instructions for mitre saws

Mitre saws are intended to cut wood or wood-like products, they cannot be used with abrasive cut-off wheels for cutting ferrous material such as bars, rods, studs, etc. Abrasive dust causes moving parts such as the lower guard to jam. Sparks from abrasive cutting will burn the lower guard, the kerf insert and other plastic parts.
Use clamps to support the workpiece whenever possible. If supporting the workpiece by hand, you must always keep your hand at least 100 mm from either side of the saw blade. Do not use this saw to cut pieces that are too small to be securely clamped or held by hand. If your hand is placed too close to the saw blade, there is an increased risk of injury from blade contact.
The workpiece must be stationary and clamped or held against both the fence and the table. Do not feed the workpiece into the blade or cut “freehand” in any way. Unrestrained or moving workpieces could be thrown at high speeds, causing injury.
Push the saw through the workpiece. Do not pull the saw through the workpiece. To make a cut, raise the saw head and pull it out over the workpiece without cutting, start the motor, press the saw head down and push the saw through the workpiece. Cutting on the pull stroke is likely to cause the saw blade to climb on top of the workpiece and violently throw the blade assembly towards the operator.
Never cross your hand over the intended line of cutting either in front or behind the saw blade. Supporting the workpiece “cross handed” i.e. holding the workpiece to the right of the saw blade with your left hand or vice versa is very dangerous.
Do not reach behind the fence with either hand closer than 100 mm from either side of the saw blade, to remove wood scraps, or for any other reason while the blade is spinning.
The proximity of the spinning saw blade to your hand may not be obvious and you may be
seriously injured.
Inspect your workpiece before cutting. If the workpiece is bowed or warped, clamp it with the outside bowed face toward the fence. Always make certain that there is no gap between the workpiece, fence and table along the line of the cut. Bent or warped workpieces can twist or shift and may cause binding on the spinning saw blade while cutting. There should be no nails or foreign objects in the workpiece.
Do not use the saw until the table is clear of all tools, wood scraps, etc. except for the workpiece. Small debris or loose pieces of wood or other objects that contact the revolving blade can be thrown with high speed.
Cut only one workpiece at a time. Stacked multiple workpieces cannot be adequately clamped or braced and may bind on the blade or shift during cutting.
Ensure that the mitre saw is mounted or placed on a level, firm work surface before use. A level and firm work surface reduces the risk of the mitre saw becoming unstable.
Plan your work. Every time you change the bevel or mitre angle setting, make sure the adjustable fence is set correctly to support the workpiece and will not interfere with the blade or the guarding system. Without turning the tool “ON” and with no workpiece on the table, move the saw blade through a complete simulated cut to assure there will be no interference or danger of cutting the fence.
Provide adequate support such as table extensions, saw horses, etc. for a workpiece that is wider or longer than the table top. Workpieces longer or wider than the mitre saw table can tip if not securely supported. If the cut-off piece or workpiece tips, it can lift the lower guard or be thrown by the spinning blade.
Do not use another person as a substitute for a table extension or as additional support.
Unstable support for the workpiece can cause the blade to bind or the workpiece to shift during the cutting operation pulling you and the helper into the spinning blade.
The cut-off piece must not be jammed or pressed by any means against the spinning saw blade. If confined, i.e. using length stops, the cut-off piece could get wedged against the blade and thrown violently.
Always use a clamp or a fixture designed to properly support round material such as rods or tubing. Rods have a tendency to roll while being cut, causing the blade to “bite” and pull the work with your hand into the blade.
Let the blade reach full speed before contacting the workpiece. This will reduce the risk of the workpiece being thrown.
If the workpiece or blade becomes jammed, turn the mitre saw off. Wait for all moving parts to stop and disconnect the plug from the power source and/or remove the battery pack. Then work to free the jammed material. Continued sawing with a jammed workpiece could cause loss of control or damage to the mitre saw.
After finishing the cut, release the switch, hold the saw head down and wait for the blade to stop before removing the cut-off piece. Reaching with your hand near the coasting blade is dangerous.

Additional Safety Instructions

Please also observe the special safety instructions in the respective chapters.
Where applicable, follow the legal directives or regulations for the prevention of accidents.

General hazards!

Consider environmental conditions:
Use suitable workpiece supports when cutting long stock.
The saw shall only be started and operated by persons familiar with circular saws and who are at any time aware of the dangers associated with the operation of such tools.
Persons under 18 years of age shall use this tool only in the course of their vocational training, under the supervision of an instructor.
Keep bystanders, particularly children, out of the danger zone. Do not permit other persons to touch the tool or power cable while it is running.
Avoid overheating of the saw teeth.
When sawing plastic, avoid melting of the plastic.

Risk of personal injury and crushing by moving parts!

Do not operate the tool without installed guards.
Always keep sufficient distance to the saw blade. Use suitable feeding aids, if necessary. Keep sufficient distance to driven components when operating the power tool.
Wait for the saw blade to come to a complete stop before removing cutoffs, scrap, etc. from the work area.
Cut only workpieces of dimensions that allow for safe and secure holding while cutting.
Use clamping devices or a vice to hold the workpiece. It is held safer by these devices than by your hand.
Do not attempt to stop the saw blade by pushing the workpiece against its side.
Remove the mains plug from the socket or remove the detachable battery pack before carrying out any settings, maintenance or repairs.
If the device is not in use, pull the mains plug or remove the detachable battery pack.

Cutting hazard, even with the cutting tool at standstill!

Wear gloves when changing cutting tools.
Store saw blade in such manner that nobody will get hurt.

Danger from kickback of the saw head (saw blade gets caught in the workpiece and the saw head suddenly kicks back)!

Select a saw blade suited for the material to be cut.
Keep the handle tight. When the saw blade enters the workpiece, the risk of kickback is particularly high.
Cut thin or thin-walled workpieces only with fine-toothed saw blades.
Always use sharp saw blades. Replace damaged saw blades immediately. There is an increased risk of kickback if a blunt sawtooth gets caught in the workpiece’s surface.
Do not jam workpieces.
If in doubt, check workpiece for inclusion of foreign matter (e.g. nails or screws).
Never cut several workpieces at the same time – and also no bundles containing several individual pieces. Risk of personal injury if individual pieces are caught by the saw blade uncontrolled.
When making grooves avoid lateral pressure on the saw blade – use a clamping device.

Drawing-in/trapping hazard!

Ensure that during operation no parts of the body or clothing can be caught and drawn in by rotating components (no ties no gloves, no clothes with wide sleeves; contain long hair with a hairnet).
Never cut workpieces to which ropes, cords, strings, cables or wires are attached or which contain such materials.

Hazard generated by insufficient personal protection gear!

Wear hearing protection.
Wear protective goggles.
Wear dust mask.
Wear suitable work clothes.
Wear non-slip footwear.
Wear gloves when handling saw blades and rough tools. Carry saw blades in a container.

Risk of injury by inhaled wood dust!

Work only with a suitable dust collector attached to the saw. The dust extraction unit must comply with the values stated in chapter 16..

Reduce dust exposure:

Some dust created by using this power tool may contain chemicals known to cause cancer, allergic reaction, respiratory disease, birth defects or other reproductive harm. Some examples of such substances are, lead (in paint containing lead), additives used for wood treatment (chromate, wood preservatives), some wood types (such as oak or beech dust).
The risk from these exposures depends on how long you or bystanders are being exposed.
Do not let particles enter the body.
To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles.
Observe the relevant guidelines for your material, staff, application and place of application (e.g. occupational health and safety regulations, disposal).
Collect the generated particles at the source, avoid deposits in the surrounding area.
Use the supplied dust collection unit and a suitable extraction unit. This ensures that fewer particles enter the environment in an uncontrolled way.
Reduce dust exposure with the following measures:
- Do not direct the escaping particles and the exhaust air stream at yourself or nearby persons or on dust deposits.
- Use an extraction unit and/or air purifiers
- Ensure good ventilation of the workplace and keep clean using a vacuum cleaner Sweeping or blowing stirs up dust
- Vacuum or wash the protective clothing Do not blow, beat or brush

Hazard generated by modification of the machine or use of parts not tested and approved by the equipment manufacturer!

Assemble tool in strict accordance with these instructions.
Use only parts approved by the equipment manufacturer. This applies especially for:
- saw blades (for order numbers, refer to chapter 12. Accessories).
- Safety devices.
- Cutting laser
- Illumination of cutting line
Do not change any parts.
Ensure that the speed indicated on the saw blade is at least the same as the speed indicated on the saw.

Hazard generated by tool defects!

Before every use check tool for possible damage: before operating the tool all safety devices, protective guards or slightly damaged parts need to be checked for proper function as specified. Check to see that all moving parts work properly and do not jam. All parts must be correctly installed and fulfil all conditions necessary to ensure perfect operation of the unit.
Do not used any damaged or contorted saw blades.

Risk of injury by noise!

Wear hearing protection.

Danger from blocking workpieces or workpiece parts!
If blockage occurs:

Switch machine off,
Pull the mains plug or remove the detachable battery pack,
Wear gloves,
Clear the blockage using a suitable tool.

Special safety instructions for cordless machines

Remove the battery pack from the machine before making any adjustments, changing tools, maintaining or cleaning.

Protect battery packs from water and moisture!
Do not expose battery packs to fire!

Do not use faulty or deformed battery packs! Do not open battery packs!
Do not touch contacts or short-circuit battery packs!

A slightly acidic, flammable fluid may leak from defective Li-ion battery packs!

If battery fluid leaks out and comes into contact with your skin, rinse immediately with plenty of water. If battery fluid leaks out and comes into contact with your eyes, wash them with clean water and seek medical attention immediately!

Symbols on the machine (depends on model)

Read the operating instructions.
Never place hands into running saw blade.
Wear protective goggles and ear protectors.
Never operate the tool in a damp or wet environment.

Laser radiation – Do not look into the light beam. LASER CLASS 2

Safety devices

Retractable blade guard (6)
The retractable blade guard protects against unintentional contact with the saw blade and from chips flying about.
Safety lock (26)
Cordless tools: The machine can only be switched on when the safety lock is activated.
Mains-powered tools: The retractable blade guard opens and the saw can be lowered only when the safety lock is activated.
Parallel guide/ ripping fence (25)
The parallel guide/ ripping fence prevents that the workpiece can be moved during the cutting process. During operation, the parallel guide/ ripping fence always has to be installed.
Make sure the additional profile (34) is set correctly to support the workpiece in the best manner possible and will not interfere with the blade or the guard. Lock using the set screw (35).
An incorrectly adjusted additional profile (34) can, in the event of sloped cuts and double mitre cuts, get in contact with the saw blade and thus lead to serious injuries.
The additional profile (34) at the parallel guide/ ripping fence has to be moved for inclined cuts after loosening the set screw (35).

Overview

See page 2.
The illustrations are regarded as exemplary for all devices. Therefore, the equipment of your device may differ from the illustrations.

Closing the chip bag
Chip bag
Chip extraction nozzle
Laser beam egress point
Cutting line illumination *
Retractable blade guard
Longitudinal stop *
Table
Turntable
Table insert
Locking lever for turntable
Safety catch for stop positions of the turntable*
Set screw for pulling device*
Allen key / tool storage for Allen key
Work clamp
Table extension
Locking screw of the table width extension
Saw blade lock
Saw handle
Handle *
Hook for cable winding
Locking lever for setting the angle of inclination
Locking button (to extend the angle of inclination by +/- 2 °)
Transport lock
Parallel guide / ripping fence
Safety lock
On/off switch of the saw
On/off switch of the cutting laser
On/off switch of the cutting line illumination *
Battery pack release button *
Capacity indicator button *
Capacity and signal indicator *
Battery pack*

depends on model / equipment

Setup and transport

Install handle (20) if required (depending on model)

Fix the handle (20) as shown.

Install table width extension (16) if required (depending on model)

Remove right and left table width extension from the transport packaging.
Remove screws (36) at the guide rails of the right and left table width extension.
Push the guide rails of the table width extensions completely into the recesses. Equipment-specific: Insert the table width extension with folding length guide (7) on the right side.
Lift the device at the front legs, carefully tilt it backwards and put it down so it will not fall over.
Tighten again the screws (36) at the guide rails.
Take the front legs of the device, carefully tilt it forwards and put down.
Set the desired table width and lock the table width extensions with locking screws (17).

Installation
The device has to be mounted on a stable support for safe working.

The support can be either a firmly mounted work top or work bench.
Even when machining larger workpieces the device has to have a secure stand.
Long workpieces must get additional support with suitable accessories.

Note: For mobile use, the device can also be fixed to a plywood or coreboard panel (500 mm x 500 mm, at least 19 mm thick) using screws. During use, the panel has to be fixed to a work bench using screw clamps.

Fix device to the support using screws.
Loosen transport lock (24): Push saw head slightly downwards and hold. Pull out transport lock (24).
Swivel saw head slightly upwards.

Transport

Swivel saw head downwards and push in transport lock (24).
Lock the pulling device in the front position using the set screw (13).
Caution!
Do not hold the saw at the protective installations during transport.
Lift the device at the handle (20) (equipment-specific) and carry it.
For devices without handle: Push in both table width extensions completely (16) and fix with locking screws (17) . Lift the machine on both table width extensions (16) and carry it.

The device in detail

On/Off switch motor (27)

Switching on the motor:

Press the on/off switch and keep pressed. Switching off the motor:
Let go of the on/off switch.

On/off switch cutting line illumination (29) (equipment-specific)

Switching on/ off the illumination of the cutting line.

Danger!
Do not direct the light beam into the eyes of people or animals.

CAUTION Do not stare at operating lamp.

Note:
Cordless devices: During a short break the cutting line illumination goes off (sleep mode) and is automatically reactivated when resuming work. In case of a long break the cutting line illumination switches off automatically. Reactivation: Use switch (29).

On/off switch cutting laser (28) Switching on/off of the cutting laser.

The cutting laser marks a line to the left of the saw’s cut. Make a trial cut to become familiar with the positioning.
Danger!
LASER BEAM DO NOT LOOK INTO THE BEAM LASER CLASS 2
EN 60825-1:2014 P<1mW, λ=650nm

Note:
Cordless devices: During a short break the cutting laser goes off (sleep mode) and is automatically reactivated when resuming work. In case of a long break the cutting laser switches off. Reactivation: Use switch (28).

Setting the angle of inclination

After loosening the locking lever (22), the saw can be infinitely inclined between 0° and 45° to the left of the vertical position (39).
Press the locking button (23) during the adjustment process in order to also set angles up to 47° to the left of the vertical/ up to 2° to the right of the vertical.

Danger!
In order for the angle of inclination not to change when cutting, the locking lever (22) of the swivel arm has to be tightened.
You can adapt the position of the locking lever according to your requirements: pull out locking lever, turn and push in the desired position and let engage.

Turntable

After loosening the locking lever (11) and activating the safety catch (12), the turntable can be turned by 47° to the left or by 47° to the right for mitre cuts. In this manner the cutting angle to the support edge of the workpiece is adjusted.

Danger!
In order for the mitre angle not to change during cutting, the locking handle (11) of the turntable has to be tightened (also in the stop positions!).

Pulling device

Using the pulling device, also larger workpieces with greater cross sections can be cut. The pulling device can be used for all types of cuts
(straight cuts, mitre cuts, slanted cuts and double mitre cuts, and cutting of grooves).
If the pulling device is not required, lock the pulling device in the rear position using the set screw (13).

Cutting depth limitation

Together with the pulling device the cutting depth limitation (50) permits the cutting of grooves.
Turn the set screw and fix with the counter nut. The cutting depth limitation can be deactivated, if the parallel guide (51) is pushed towards the rear.

Commissioning

Connect chip sack / chip and dust extraction unit

Danger!
Dust of certain timber species (e.g. beech, oak, ash) can cause cancer when inhaled.

Only use a suitable dust extraction unit or installed dust sack.
In addition, use a dust mask, as not all saw dust is collected or extracted.
Regularly empty the dust sack. Wear a dust mask while emptying the sack.

If you operate the device with the supplied dust sack:

Attach the dust sack (2) to the chip extraction adapter nozzle (3). Ensure that the closure (1) of the dust sack is closed.

If you connect the device to a dust extraction unit:

Use a suitable adapter to connect it to the chip extraction adapter nozzle (see chapter 12.
“Accessories”).
Ensure that the dust extraction unit meets the requirements stated in chapter 16. “Technical Specifications”.
Observe the dust collector’s operating instructions as well!

Installing the workpiece clamping device

The workpiece clamping device (15) can be installed in two positions:

For wide workpieces:
Insert the workpiece clamping device into the rear drilling (37) of the table.
For narrow workpieces:
Insert the workpiece clamping device into the front drilling (38) of the table.

For mains powered machines only

Danger! High voltage
Operate machine only on a power source meeting the following requirements (see also chapter 16. “Technical Specifications”):

Mains voltage and system frequency must conform to the voltage and frequency shown on the machine´s rating label;
fuse protection by a residual current operated device (RCD) of 30 mA sensitivity;
outlets properly installed, earthed or grounded, and tested.
Position power supply cable so it does not interfere with the work and is not damaged.
Use only rubber-jacketed extension cables with sufficient lead cross-section (3 × 1.5 mm2).
Use extension cables for outdoor areas. When working outdoors, only use the correspondingly marked extension cable approved for this purpose.
Avoid accidental start-up. Ensure that the on/off switch is switched off when inserting the plug in the socket.

For cordless machines only

Avoid accidental start-up. Before fitting the battery pack, make sure that the machine is switched off.
If the machine is defective, remove the battery pack from the machine.

Battery pack
Charge the battery pack (33) before use.
If performance diminishes, recharge the battery pack.
Instructions on charging the battery pack can be found in the operating instructions of the Metabo charger.
Li-Ion battery packs “Li-Power” have a capacity and signal indicator (32):

Press the button (31), the LEDs indicate the charge level.
If one LED is flashing, the battery pack is almost flat and must be recharged.

Transport of li-ion battery packs:
The shipping of li-ion battery pack is subject to laws related to the carriage of hazardous goods (UN 3480 and UN 3481). Inform yourself of the currently valid specifications when shipping li-ion battery packs. If necessary, consult your freight forwarder. Certified packaging is available from Metabo.
Only send the battery pack if the housing is intact and no fluid is leaking. Remove the battery pack from the machine for sending. Prevent the contacts from short-circuiting (e.g. by protecting them with adhesive tape).

Removing and inserting the battery pack
Removal: Press the battery pack release button (30) and pull out the battery pack (33) towards the rear.
To insert: Slide the battery pack (33) in until it engages.

Operation

Before starting work, check to see that the following are in proper working order.
Assume proper operating position:
- at the front of the saw;
- in front of the saw;
- next to the line of cut.

Danger!
If possible, fix the workpiece using the workpiece clamping device (15).

Danger of crushing!
When inclining or swivelling the saw head, never reach into the hinge area or below the device!

Hold the saw head during inclination.
Use during work:
- workpiece support – for long workpieces, if otherwise workpiece would fall off the table after cutting;
- dust sack or dust extraction unit.
Cut only workpieces of dimensions that allow for safe and secure holding while cutting.
Always hold the workpiece down on the table and do not jam it. Do not attempt to stop the saw blade by pushing the workpiece against its side. Risk of personal injury if the saw blade is blocked.

Straight cuts

Starting position:

Transport lock (24) pulled out.
Saw head swivelled upwards.
Cutting depth limitation (51) deactivated.
Turntable is in 0° position, locking button (11) for turntable is tightened.
The inclination of the swivel arm to the vertical is 0°, locking lever (22) for inclined position is tightened.
Pulling device at the very rear.
Set screw (13) of the pulling device has been loosened.
Set workpiece stop (25):
Release locking screw (35). Move the additional profile (34) in such a way that the workpiece is supported in the best manner possible and will not interfere with the blade or the guard. Fasten with locking screw (35).

Cutting the workpiece:

Push the workpiece against the parallel guide/ripping fence and clamp using the workpiece clamping device (15).
For wider workpieces: pull the saw head forwards (towards the operator) (pulling device).
Activate the safety lock (26) ,press on/off switch (27) and keep pressed.
Slowly lower the saw head at the handle all the way down and, if required, push towards the rear (away from the operator). During the sawing process press on the workpiece just enough for the motor speed not to lower too much.
Cut the workpiece in one operation.
Release the on/off switch (27) and slowly let the saw head swivel back into the upper starting position.

Mitre cuts

Starting position:

Transport lock (24) pulled out.
Saw head swivelled upwards.
Cutting depth limitation (51) deactivated.
Inclination of the swivel arm to the vertical is 0°, locking lever (22) for inclination setting is tightened.
Pulling device at the very rear.
Set screw (13) of the pulling device has been loosened.
Set workpiece stop (25):
Release locking screw (35). Move the additional profile (34) in such a way that the workpiece is supported in the best manner possible and will not interfere with the blade or the guard. Fasten with locking screw (35).

Cutting the workpiece:

Loosen locking lever (11) of the turntable and loosen safety catch (12).
Set the desired angle.
Tighten the locking button (11) of the turntable.
Cut workpiece, as described for “Straight cuts”.

Inclined cuts

Starting position:

Transport lock (24) pulled out.
Saw head swivelled upwards.
Cutting depth limitation (51) deactivated.
Turntable is in 0° position, locking button (11) for turntable is tightened.
Set screw (13) of the pulling device has been loosened.
Pulling device at the very rear.
Set workpiece stop (25):
Release locking screw (35). Move the additional profile (34) in such a way that the workpiece is supported in the best manner possible and will not interfere with the blade or the guard. Fasten with locking screw (35). For particular angle settings it might be necessary to completely pull out the additional profile (34), after loosening the locking screw (35). Retighten locking screw (35). (After the saw cut, reattach the additional profile (34) and fasten with locking screw (35) so that it is not lost.)

Cutting the workpiece:

Loosen the locking lever (22) for the inclination setting at the rear side of the saw.
Slowly tilt the swivel arm into the desired position.
Tighten the locking lever (22) for the inclination setting.
Cut the workpiece, as described for “Straight cuts”.

Double mitre cuts

Note:
The double mitre cut is a combination of mitre cut and inclined cut. This means, the workpiece is cut at an angle to the rear contact edge and at an angle to the top.
Danger!
With a double mitre cut, the saw blade is easier accessible due to the steep inclination – this results in a higher risk of injury. Always keep sufficient distance to the saw blade!

Starting position:

Transport lock (24) pulled out.
Saw head swivelled upwards.
Cutting depth limitation (51) deactivated.
Lock the turn table in the desired position.
Swivel arm inclined at desired angle to the workpiece surface and locked.
Set screw (13) of the pulling device has been loosened.
Pulling device at the very rear.
Set workpiece stop (25):
Release locking screw (35). Move the additional profile (34) in such a way that the workpiece is supported in the best manner possible and will not interfere with the blade or the guard. Fasten with locking screw (35). For particular angle settings it might be necessary to completely pull out the additional profile (34), after loosening the locking screw (35). Retighten locking screw (35). (After the saw cut, reattach the additional profile (34) and fasten with locking screw (35) so that it is not lost.).

Cutting the workpiece:

Cut the workpiece, as described for “Straight cuts”.

Cutting grooves

Note:
The cutting depth limitation together with the pulling device permits the cutting of grooves. This does not result in a separating cut, but only a cut of a certain depth is effected in the workpiece.

Risk of kickback!
When cutting grooves it is particularly important that no lateral pressure is exerted on the saw blade. Otherwise, the saw head might suddenly kick back! Use a clamping device when cutting grooves. Avoid lateral pressure on the saw head.

Starting position:

Transport lock (24) pulled out.
Saw head swivelled upwards.
Swivel arm inclined at desired angle to the workpiece surface and locked.
Lock the turn table in the desired position.
Set screw (13) of the pulling device has been loosened.
Pulling device at the very rear

Cutting the workpiece:

Set the cutting depth limitation (50) to the desired cutting depth and fix with counter nut.
Loosen safety lock (26) and swivel saw head downwards to check the set cutting depth:
Effect trial cut.
If required, repeat steps 1 and 3 until the desired cutting depth has been set.
Cut the workpiece, as described for “Straight cuts”.

Care And Maintenance

Danger!
Prior to all maintenance and cleaning jobs pull the mains plug or remove the detachable battery pack (33).

Repair and maintenance work other than described in this section should only be carried out by qualified specialists.
Replace damaged parts, in particular safety installations, only with original parts. Parts not approved by the equipment manufacturer can cause unforeseeable damage.
Check that all safety devices are operational again after each service.

Saw blade change

Risk of burning!
Directly after cutting the saw blade can be very hot. Let a hot saw blade cool down. Do not clean the hot saw blade with combustible liquids.

Risk of burning!
Directly after cutting the saw blade can be very hot. Let a hot saw blade cool down. Do not clean the hot saw blade with combustible liquids. Risk of injury, even with the blade at standstill!
When loosening and tightening the tensioning screw (40) the retractable blade guard (7) has to be swiveled over the saw blade. Wear gloves when changing blades.

Disconnect the mains plug.
Put the saw head in the upper position.
Lock saw blade: press the locking button and turn the saw blade with the other hand until the locking button engages. Hold down the locking button.
Remove the tensioning screw with washer (40) on the saw blade shaft with Allen key (17) in a clockwise direction (left-hand thread!).
Loosen the safety lock (29) and push the retractable blade guard (7) upwards and hold.
Carefully remove the outer flange (41) and saw blade (42) from the saw blade shaft and close again the retractable blade guard.
Danger!
Do not use cleaning agents (e.g. to remove resin residue) that could corrode the light metal components of the saw; the stability of the saw would be adversely affected.
7. Cleaning the clamping surfaces:
- Saw blade shaft (45),
- aw blade (42),
- uter flange (41),
- nner flange (44).
  Danger!
  Place inner flange properly! If this is not the case, the saw can block or the saw blade could work loose. The inner flange is in the correct position if the ring groove points towards the saw blade and the flat side to the motor.
Put on inner flange (44).
Loosen the safety lock (29) and push the retractable blade guard (7) upwards and hold.
Put on a new saw blade – observe the
direction of rotation: Seen from the left (open) side, the arrow on the saw blade has to correspond to the direction of the arrow (43) on the saw blade cover!
Danger!
Use only saw blades, which fulfill the requirements and specifications listed in these operating instructions.
Use only saw blades designed for the maximum speed (see “Technical Specifications”) – if unsuitable or damaged saw blade parts are used, parts can be ejected due to centrifugal force in an explosive-type manner. Saw blades intended for cutting wood or similar materials have to conform to EN 847-1. Do not use:
saw blades made of high-alloy speed steel (HSS);
damaged saw blades;
cut-off wheel blades.
Danger!
Mount saw blade using only genuine parts.
Do not use loose-fitting reducing rings; the saw blade could work loose.
Saw blades have to be mounted in such a way that they do not wobble or run out of balance and cannot work loose during operation.
Close again retractable blade guard (7).
Push on the outer flange (41) – The flat side must point towards the tensioning screw with a washer (40)!
Put on the tensioning screw with the washer (40) in an anti-clockwise direction (left-hand thread) and tighten by hand.
Lock saw blade: press the locking button (15) and turn the saw blade with the other hand until the locking button engages. Hold down the locking button.
Danger!
- Do not extend the hexagon wrench.
- Do not tighten the tensioning screw by hitting the hexagon wrench.
Firmly tighten the tensioning screw (40) using the hexagon wrench (17).
Check function. Loosen the safety lock (29) and fold the saw downwards:
when folding down the retractable blade guard, it has to provide free access to the saw blade without touching other parts.
When folding the saw upwards into the starting position, the retractable blade guard has to cover the saw blade automatically.
Rotate the saw blade manually. You should be able to rotate the saw blade into any possible position without touching other parts.

10.2 Table insert change
Danger!
With a damaged table insert (20) there is a risk of small parts getting stuck between the table insert and saw blade, blocking the saw blade. Replace damaged table inserts immediately!

Remove screws at table insert. If required, rotate the turntable and incline the saw head to be able to reach the screws.
Remove table insert.
Insert new table insert.
Tighten the screws at the table insert.

10.3 Adjust parallel guide/ripping fence

Loosen Allen screws (46).
Adjust the parallel guide/ripping fence (30) in such a way that it is exactly perpendicular to the saw blade when the turntable engages in the 0° position.
Tighten the Allen screws (46).

10.4 Adjust the cutting laser

Danger!
LASER BEAM
DO NOT LOOK INTO THE BEAM
You will need a 2.5 mm hexagon wrench for the adjustment. Place a board with a vertical line at the parallel guide/ripping fence to see the laser beam better.

Twist the screw (38), thus setting the laser beam parallel to the saw blade (42).
Twist the screw (37) OR (39), thus setting the laser beam parallel to the saw blade (42).
Twist the screw (37) AND (39), thus adjusting the clearance to the saw blade (42)
Repeat steps 1 to 3 if required.

10.5 Cleaning the device
Remove chips and sawdust with a vacuum cleaner or brush from:

adjustment installations
controls;
motor vent slots;
pace under table insert;
space under turntable (accessible through openings on the rear);
cutting laser;
Cutting line illumination

10.6 Storage of the device

Danger!

Store the device in such a way that it cannot be put into operation by unauthorized personnel.
Ensure that the stationary device cannot cause injury.

Caution!

Do not store the tool outdoors or in damp conditions without protection.

10.7 Maintenance
Prior to each use

Remove saw chips with a vacuum or brush.
Check power cable and power cable plug for damage; if necessary have damaged parts replaced by a qualified electrician.
Check all movable parts if they can be moved freely across the entire range of movement.
Check whether that retractable blade guard (7) works correctly and does not stick. When folding down, it has to provide free access to the saw blade without touching other parts. When folding the saw upwards into the starting position, it must cover the saw blade automatically. If damaged or not functioning correctly, have the device repaired before use.

Regularly, depending on conditions of use

Check all screwed joints, and retighten if necessary.
Check the reset function of the saw head (saw head has to return to the upper starting position by means of spring force), and if required have spring replaced.
Slightly oil guide elements

Tips and Tricks

Use appropriate supports on the left and right of the saw for long workpieces.
When cutting small pieces, use an additional guide (a suitable wooden board attached with screws to the guide of the device, can be used as an additional guide).
When cutting a curved (contorted) board (49) place the convex side at the parallel guide/ ripping fence.
Do not cut the workpiece upright, but flat on the turntable.

Accessories

Use only genuine Metabo accessories.
Use only accessories which fulfill the requirements and specifications listed in these operating instructions.
A Spray for maintenance and care for the removal of resin residues and to preserve the metal surfaces: 0911018691
B Metabo all-purpose vacuum cleaner (see catalog)

C Stands:
Universal machine stand UMS:6.31317 Machine stand KSU 251:6.29005 Machine stand KSU 401:6.29006

D Saw blade Power Cut: 6.28009
216 × 2.4 / 1.8 × 30 24 WZ 5° neg
For good cutting results for longitudinal and cross cuts in solid wood
E Saw blade Precision Cut Classic 6.28060
216 × 2.4 / 1.8 × 30 40 WZ 5° neg
For good cutting results for longitudinal and cross cuts in solid wood and chipboard
F Saw blade Multi-Cut Classic: 6.28066
216 × 2.4 / 1.8 × 30 60 FZ/TZ 5° neg
For good cutting results with longitudinal and cross cuts in coated materials, laminate, plastic, and aluminum profiles
G Saw blade Precision Cut: 6.28041
216 x 2.4 x 30 48 WZ 5°neg for very good cutting results with longitudinal and cross cuts in solid wood
H Saw blade Multi-Cut: 6.2808 216 x 2.4 x 30 60 FZ/TZ 5° neg for very good cutting results in coated materials, laminate, plastic, and aluminum profiles For a complete range of accessories, see www.metabo.com or the catalog

Repairs

Danger!
Repair of power tools must be carried out by qualified electricians only!
If the supply cord of this power tool is damaged, it must be replaced by a specially prepared supply cord available through the service organization.
If you have Metabo power tools that require repairs, please contact your Metabo service center. For addresses see www.metabo.com.
You can download a list of spare parts from www.metabo.com.

Environmental Protection

Observe national regulations on environmentally compatible disposal and on the recycling of disused machines, packaging, and accessories.
Only for EU countries: Never dispose of power tools in your household waste! Used power tools must be collected separately and handed in for environmentally compatible recycling in accordance with European Directive 2012/19/EU on waste electrical and electronic equipment and its implementation in national legal systems.

Troubleshooting

Following you will find a description of problems and faults that you may remedy yourself. If the corrective measures described here do not help, kindly refer to chapter 13. “Repairs”.

Danger!
There are particularly many accidents in connection with problems and faults. Therefore keep in mind:

Disconnect the mains plug prior to any fault service.
Check that all safety devices are operational again after each fault service.

No trimming function Transport lock activated:

pull out the transport lock.
Safety lock activated:
loosen safety lock.

Cutting power too low
Saw blade blunt (possibly tempering marks on blade body);
The saw blade is unsuitable for the material (see chapter 12. “Accessories”);
Saw blade contorted:

Replace saw blade (see chapter 10.
“Maintenance”).
Saw vibrates a lot
Saw blade contorted:
Replace saw blade (see chapter 10.”Maintenance”).
Saw blade not installed properly:
Install saw blade properly (see chapter 10.”Maintenance”).
Turntable hard to turn Chips under turntable:
remove chips.
KGSV 72 Xact SYM: Angle setting hard to the effect when moving the table halves (9) Chips under turntable:
remove chips. The space under the turntable is accessible through openings on the rea

Technical Specifications

Explanatory notes on the specifications on page 3.
Changes due to technological progress are reserved.

U= mains voltage
I= rated power
F = min. fuse protection
P1 = rated input power
IP = protection class
n0 = No-load speed
v0 = max. cutting speed
D = saw blade diameter (outer)
d = saw blade hole (inside)
b = max. tooth width of the saw blade
a1= angle range saw head adjustment
a2 = angle range turntable
aSYM1 = inside angle at the guide system
aSYM2 = outside angle at the guide system
A = dimensions (lxwxh)
m= weight

Requirements for chip and dust extraction unit:

D1 = connection diameter of the extraction nozzle
D2 = minimum air throughput
D3 = minimum negative pressure at the extraction nozzle
D4 = minimum airspeed at extraction nozzle

Maximum cross-section of the workpiece, see table on page 4.
~ AC Power
Machine in protection class II
The technical specifications quoted are subject to tolerances (in compliance with the relevant valid standards).
Emission values
These values make it possible to assess the emissions from the power tool and to compare different power tools. The actual load may be higher or lower depending on the operating conditions, the condition of the power tool, or the accessories. Please allow for breaks and periods when the load is lower for assessment purposes. Arrange protective measures for the user e.g. organizational measures based on the adjusted estimates.
Typical A-effective perceived sound levels:
LpA = sound-pressure level
LWA = acoustic power level
KpA, KWA= uncertainty
Wear ear protectors