ROCKLER 56889 Material Mate Panel Cart and Shop Stand Instructions

ROCKLER 56889 Material Mate Panel Cart and Shop Stand

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the Material Mate™: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

• Always confirm that you are using the most recent version of the Instructions and safety warnings for your product (see the Instructions link on the product page at Rockler.com).

• Before using another tool with this product, always read, understand and follow the instructions and safety warnings in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.

• Before using any chemical with this product, always read, understand and follow all safety warnings and guidelines in the manufacturer’s Safety Data Sheet (SDS; formerly called “MSDS”), especially regarding:

• How to safely use the chemical, including potential hazards and recommended first aid measures;

• Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.);

• Proper and safe handling, storage and disposal of
  the chemical.

• Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool’s owner’s manual.

• Do not use this product until you have read and are confident you understand:

  • Product Specific Safety Warnings (p. 3);
  • Material Mate™ Assembly (pp. 4-7);
  • Material Mate™ Loading (pp. 8-9);
  • Lifting the Sheet Upright (p. 9);
  • Transporting the Sheet (p. 9);
  • Unloading the Material (p. 10);
  • Postioning the Material at the Table Saw (p. 10);
  • Using as a Work Table (p. 11).

• The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.

• It is the sole responsibility of the purchaser of this product to ensure that anyone you allow to use this product reads
  and complies with all instructions and safety precautions outlined in this manual prior to use.

• Follow all standard shop safety practices, including:

  • Keep children and bystanders away from the tool operating area;
  • Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust;
  • TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories;
  • Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue;
  • Keep your work area well lit and clean;
  • Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product;
  • ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards;
  • Use dust collection tools and dust face masks to reduce exposure to dust;
  • Use safety equipment such as featherboards, push sticks and push blocks, etc., when appropriate;
  • Maintain proper footing at all times and do not overreach;
  • Do NOT force woodworking tools.

• These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known to the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury or property damage.
Notice indicates important or helpful information and/or user tips.

PRODUCT-SPECIFIC SAFETY WARNINGS

• Load is not secured when in vertical position. Do not attempt to machine or otherwise work on the material in any way while it is upright on the cart.
• Make sure Material Mate™ is assembled so that its height, when flat, is 1/2″ below the surface of the table saw. This includes any top attached to the Material Mate™.
• Table Extension (23) is not locked when in the upright position and could unexpectedly tip back to horizontal position if downward pressure is inadvertently applied.
• Do not load sheet goods onto the Material Mate™ on slanted or uneven ground or the cart could move or tip. Only load on level ground.
• Never feed sheet directly from the Material Mate™ into the table saw. Transfer sheet to table saw first, before turning on saw.
• Make sure that there is proper outfeed support for the material as it leaves the table saw.
• Overloading cart will cause tipping and potential injury. Do NOT load more than one sheet of 3/4″ thick (max.) material at a time.
• Always make sure the two locking casters are fully engaged before loading or unloading the Material Mate™.

PARTS DESCRIPTION

Material Mate™ Assembly

1. Attach the two Casters (17) and two Locking Casters (16) to the Base (15) with 1/4″-20 x 3/4″ Hex Bolts (3), Small Washers (2) and 1/4″-20 Lock Nuts (1). Fig. 1. Make sure to install the casters in the orientation shown — the Locking Casters (16) must be installed on the same end of the base so they are side by side.
2. Attach the four Leg Supports (18) to the Base (15 with M6 x 5/8″ Carriage Bolts (5) and M6 Flange Nuts (4). Fig. 2.

Fig. 1 – Base Assembly

Fig. 2 – Leg Support Assembly

Slide the Vertical Supports (19) into the Leg Supports (18), aligning the bottom set of holes in the Vertical Supports with the holes in the Leg Supports, and secure with
M6 x 11⁄2″ Carriage Bolts (6) and M6 Flange Nuts (4). Fig. 3. You will need to adjust the height setting in a later step.
Position the Crossbar (20) between the Vertical Supports (19) and attach with M6 x 11⁄2″ Carriage Bolts (6) and M6 Flange Nuts (4). Fig. 3.
Attach a Safety Locking Pin (8) to the outside face of each Vertical Support (19) with an M6 x 1/2″ Machine Screw (7) threaded into the integral nut in the support. Fig 3.

Slide the Table Extension (22) into the Frame Assembly (21), depressing the bullet pins in the Table Extension to
allow it to fully insert. Fig. 4.
Attach the Left and Right Flip Stops (23 and 24) at the appropriate locations on the Table Extension (22) with 4-Star Knobs (9) and Medium Washers (14). The small tabs at the bottom of the Flip Stops should be oriented toward the outside edge of the assembly. Fig. 4.
Attach the Latch Arm (25) to the back of the Frame Assembly (21) with 1/4″-20 x 2″ Machine Screws (10), Small Washers (2) and 1/4″-20 Lock Nuts (1). Fig. 4.
Set the Frame Assembly (21) on the Vertical Supports (19), aligning the holes in the downward-facing tabs of the frame with the holes at the top of the supports. Attach with Shoulder Bolts (11), Large Washers (12) and 3/8″ Lock Nuts (13). Fig. 4.

Adjust the height of the Material Mate™ cart by removing the M6 x 11⁄2″ Carriage Bolts (6) and M6 Flange Nuts (4) holdingthe Vertical Supports (19) to the Leg Supports (18) and reattaching using the sets of holes that produce the proper height. The Material Mate™ must be assembled so that its height, when the Frame Assembly is horizontal, is at least 1/2″ below the surface of the table saw. This includes any topattached to the Material Mate™. Fig. 5.

Material Mate Loading

WARNING:

• Overloading cart will cause tipping and potential injury. Do not load more than one sheet of 3/4″ thick (max.) material at a time.
• Always make sure the two locking casters are fully engaged before loading or unloading the Material Mate™.

CAUTION:

• Do not attempt to lift more than you are physically able.
  Get help if necessary. Use proper lifting techniques.

1. Position the Material Mate™ far enough from your vehicle so you will be able to center the sheet on the cart during unloading.

2. Engage the Locking Casters (16) and rotate the Flip Stops (23 and 24) on the Table Extension (22) to the side so they are parallel to the Table Extension and tighten the 4-Star Knobs (9). Fig. 6.

3. Make sure the Latch Arm (25) is fully engaged to keep the top secure in a horizontal position and to prevent it from inadvertently tipping upright. Fig. 7.
   CAUTION : To avoid accidental vertical tilting and unintended movement of the materials, Latch Arm (25) must be fully engaged (“clicked”) to hold the Frame Assembly (21) and Crossbar (20) together.

4. Pull the Safety Locking Pins (8) from the Vertical Supports (19) and depress the bullet pins to pull the Table Extension (22) outward. Continue to pull the Table Extension until the pins re-engage. The Locking Pins must be re-inserted to secure the Table Extension in place. Fig. 8.

5. Pull the sheet of material onto the Material Mate™ and center it on the cart.

6. Adjust the position of the sheet material until the long edge nearest the Table Extension (22) is flush with the Table Extension.

7. Rotate the Flip Stops (23 and 24) up and secure in place by tightening the 4-Star Knobs (9). Failure to secure the knobs could allow potentially dangerous shifting of the material during transport. Fig. 9.

8. Make sure the sheet remains centered on the cart, both front to back and side to side. Off-center positioning could cause the load to become unstable or the cart to tip.

Lifting the Sheet Upright

1. Position yourself on the side of the sheet opposite the Flip Stops (23 and 24).

2. Holding the sheet securely, reach underneath and release the Latch Arm (25).
   CAUTION : Flip Stops (23 and 24) must be rotated up and secured by tightening the 4-Star Knobs (9) before the sheet can be safely tilted upright. Load will fall when tilted unless Flip Stops are engaged. Fig. 9. Keep hands clear of the pivot point to avoid pinching fingers.

3. With the sheet positioned against the Flip Stops (23 and 24) slowly allow the sheet to tip upright, maintaining a secure hold until the sheet stops moving and you’re sure the load is stable on the cart. Fig. 10.

Transporting the Sheet

CAUTION: Take special care and go slowly when moving across uneven surfaces such as a door threshold; material could shift or become unstable during transport.

1. Holding the material securely, release the Locking Casters (16).
2. With one hand on the material and one hand on the cart, carefully push the cart to its destination, paying close attention to the terrain in front of the cart. Fig. 11.

Unloading Material

1. Make sure the cart is on a flat, level surface. The cart could move or tip, or the load could become unstable if unloaded on uneven terrain.
   WARNING: Sliding sheets off the cart while in the upright position could cause the cart to tip, resulting in injury or property damage. Only unload when table frame is in
   a horizontal position.

2. Engage the Locking Casters (16).

3. Lift the sheet above the Flip Stops (23 and 24) and off the cart

Positioning the Material at a Table Saw

1. Position the cart so that, when the sheet is tipped to the horizontal position, the leading edge of the sheet will be near but not on the saw’s table. Engage the Locking Casters (16). Fig. 12.
2. With the saw turned off, verify that the cart is positioned correctly. Holding the sheet with both hands, carefully tip it and guide it to the horizontal position. Keep your hands clear of the cart to avoid pinching your fingers, and make sure the Latch Arm (25) engages against the Crossbar (20) with a “click” to keep the table in the horizontal position.
3. If necessary, adjust the cart position by carefully tilting the sheet back upright, unlocking the casters and moving thecart. Repeat Steps 2-3 until optimal position is achieved. Engage the Locking Casters (16).
4. Holding the sheet with both hands, carefully slide it off the cart so one corner is on the edge of the table saw. Fig. 13.
5. Turn on the saw.
6. Make sure there is proper outfeed support for the material when it leaves the table saw.
7. Advance the material into the blade, keeping the edge tight against the fence. If necessary, use a push stick at the end of the cut to keep your hands away from the blade.

Using as a Worktable

CAUTION:

• The Table Extension (22) must be retracted and secured if the Material Mate™ is to be used as a worktable. Use of the Material Mate™ as a table
  with the Table Extension extended creates a
  tipping hazard. Make sure bullet pins and Safety Locking Pin (8) are fully engaged.

• The maximum thickness for a top is 11⁄8″. If a top is attached, a narrower strip of equal thickness must be attached separately to the Table Extension (22). Fig. 14. This is necessary to maintain an even surface for stable handling of sheet goods.

1. Attach a top and narrow extension strip to the Material Mate™ by driving screws (not included) through the predrilled holes in the frame. Fig. 14.

Check Rockler.com for updates. If you have further questions, please contact our Technical Support Department at 1-800-260-9663
or [email protected]

References

• Woodworking Tools, Hardware, DIY Project Supplies & Plans - Rockler
• P65Warnings.ca.gov/wood
• Woodworking Tools, Hardware, DIY Project Supplies & Plans - Rockler

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