FESTOOL Cordless Plunge-Cut Saw Instruction Manual

: June 7, 2024
: FESTOOL

Table of Contents

Symbols
About this manual
- Save these instructions
Safety warnings
Technical data
Functional description
Intended use
Commissioning
- Changing the battery pack Removing the battery pack [2 A]
  - 2 A
- Inserting the battery pack [2 B]
  - 2 B
  - 2 C
  - Capacity display
Settings

Eng Original Instructions – Cordless plunge-cut saw

Read all instructions before using.

Symbols

CAUTION For use only with FESTOOL batteries BP 18

DANGER –
Keep hands and body away from and to the side of the blade. Contact with blade will result in serious injury.

WARNING –
Check guarding system. It must cover the blade instantly! Hold saw with both hands. Support and clamp work.

About this manual

Save these instructions

It is important for you to read and understand this manual. The information it contains relates to protecting your safety and preventing problems. The symbols below are used to help you recognize this information.

DANGER | Description of imminent hazard and failure to avoid hazard will result in death.

WARNING| Description of hazard and possible resulting injures or death.

CAUTION| Description of hazard and possible resulting injuries.
NOTICE | Description of possible damage of the device or its surroundings.

Safety warnings

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.
Save all warnings and instructions 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 a 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 energising 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 jewellery. 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

Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behaviour resulting in fire, explosion or risk of injury.
Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 130 °C (265 °F) may cause explosion.
Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

SERVICE

Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.
Only use original Festool parts for repair and maintenance. The use of incompatible accessories or spare parts can result in electric shocks or other injuries.

Safety instructions for specific circular saws

Cutting procedures

DANGER: Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.
Never hold the workpiece in your hands or across your leg while cutting. Secure the workpiece to a stable platform. It is important to support the work properly to minimize body exposure, blade binding, or loss of control.
Hold the power tool by insulated gripping surfaces, when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock.
When ripping, always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding.
Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades that do not match the mounting hardware of the saw will run off-centre, causing loss of control.
Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation.

Kickback causes and related warnings

kickback is a sudden reaction to a pinched, jammed or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator;
when the blade is pinched or jammed tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator;
if the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator. Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.
Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.
When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding.
When restarting a saw in the workpiece, centre the saw blade in the kerf so that the saw teeth are not engaged into the material. If a saw blade binds, it may walk up or kickback from the workpiece as the saw is restarted.
Support large panels to minimise the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.
Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
Blade depth and bevel adjusting locking levers must be tight and secure before making the cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

Lower guard function

Check the lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If the saw is accidentally dropped, the lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.
Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
The lower guard may be retracted manually only for special cuts such as “plunge cuts” and “compound cuts”. Raise the lower guard by the retracting handle and as soon as the blade enters the material, the lower guard must be released. For all other sawing, the lower guard should operate automatically.
Always observe that the lower guard is covering the blade before placing the saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

Function of the guide wedge [5-5]

Use the correct saw blade for the guide wedge. To ensure that the guide wedge functions properly, make sure the blade core of the saw blade is thinner than the guide wedge and that the tooth width is greater than the thickness of the guide wedge.
Do not operate the saw if the guide wedge is bent. Even the slightest problem can cause the protective cover to close more slowly.

Further safety instructions

Avoid blockages in the protective cover (e.g. plastic) as otherwise the safety function may be compromised.
Harmful/toxic dust may be produced during your work (e.g. paint containing lead, certain types of wood and metal). Only qualified persons are permitted to handle materials containing asbestos. Aontact with or inhalation of this dust may pose a risk for the operating personnel or persons in the vicinity. Comply with the safety regulations that apply in your country. Wear a P2 respiratory mask to protect your health.
Festool electric power tools must only be installed on work tables provided by Festool for this purpose. If the tool is installed in another, or self-made, work table, it can become unstable and result in serious accidents.
Do not use the power tool in the rain or in damp surroundings. Moisture in the power tool may cause a short circuit and fire.
Do not use power supply units or thirdparty battery packs to operate cordless. power tools. Do not use third-party chargers to charge the battery packs. The use of accessories not expressly authorised by the manufacturer can result in electric shocks and/or serious accidents.
Use only saw blades that are marked with a speed equal or higher than the speed marked on the tool.
In order to saw different materials quickly and cleanly, Festool offers saw blades for all applica-tions that are specially designed for your Festool portable circular saw, see Festool catalogue or www.festool.com.

Aluminium processing

When sawing aluminium, the following measures must be taken for safety reasons:

Connect the machine to a suitable dust extractor.
Regularly remove dust deposits from the motor housing.
Use an aluminium saw blade.
Close the viewing window/chipguard.
Wear protective goggles.
When sawing panels, they must be lubricated with paraffin but thin-walled profiles (up to 3 mm) can be sawed without lubrication.

Health hazard by dust

WARNING! various dust created by power sanding, sawing, grinding, drilling and
other construction activities contains chemicals
known (to the State of California) to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:

lead from lead-based paints,
crystalline silica from bricks and cement and other masonry products, and
arsenic and chromium from chemically treated lumber.

The risk from these exposures varies, depending on how often you do this type of work. 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. Wash hands after handling.

WARNING
TO REDUCE THE RISK OF INJURY, USER MUST READ INSTRUCTION MANUAL.

Technical data

Cordless plunge-cut saw TSC 55 REB
Motor voltage 14.4 – 2 x 18 V
Speed (idle) 1 x 18 V 2650 – 3800 min-1
Speed (idle) 2 x 18 V 2650 – 5200 min-1
Inclination -1° to 47°
Cutting depth at 0° 0 – 2-1/8″ (0 – 55 mm)
Cutting depth at 45° 0 – 1-11/16″ (0 – 43 mm)
Saw blade dimensions 6-1/4 x 1/8 x 3/4″ (160 x 2.2 x 20 mm)
Weight without battery pack 8.2 lbs (3.7 kg)

Functional description

[1-1] Handles
[1-2] Rotary knobs for angle adjustment
[1-3] Angle scale
[1-4] Lever for changing blades
[1-5] Switch-on lock
[1-6] On/Off switch
[1-7] Extractor connector
[1-8] Release buttons for undercuts -1° to 47°
[1-9] Adjustable jaws
[1-10] Speed control
[1-11] Battery packs
[1-12] Capacity display
[1-13] Button for releasing the battery pack
[1-14] Split scale for cutting depth stop (with/without guide rail)
[1-15] Cutting depth adjusting screw for resharpened saw blades
[1-16] Cutting depth stop
[1-17] Cut indicator
[1-18] Viewing window / chipguard
[1-19] Splinterguard

The pictures for the functional description are on a fold-out page at the beginning of the instruction manual. While reading the manual you can fold out the page for comparison and quick reference.
Accessories shown or described are not always included in the scope of delivery.

Intended use

Cordless circular saws are designed for sawing wood, materials similar to wood, plaster and cement-bonded fibre materials and plastics. When fitted with the special saw blades for aluminium that are offered by Festool, these machines can also be used for sawing aluminium. Only use saw blades with the following dimensions:

Saw blade according to EN 847-1
Saw blade diameter 6-1/4″ (160 mm)
cutting width 3/32″ (2.2 mm)
location hole 25/32″ (20 mm)
standard blade thickness max. 1/16″ (1.8 mm)
suitable for speeds of up to 9500 min-1

Never use machine with any abrasive wheels. Only saw materials for which the relevant saw blade has been designed.
This power tool may only be used by experts or instructed persons.

The user is liable for improper or non-intended use.
This power tool is suitable for use with BP Festool battery packs of the same voltage class.

Commissioning

Changing the battery pack Removing the battery pack [2 A]

2 A

Inserting the battery pack [2 B]

2 B

Please note! Machine operation is only possible under the following conditions [2 C]:

2 C

Both battery packs are used. Maximum power with two battery packs (36 V).

Only the lower battery pack is used. Less power with one battery pack (14.4 V/18 V).

Capacity display

The capacity display [1-12] automatically displays the charge state of the battery pack [1-6] when the ON/OFF switch is actuated:

Recommendation: Charge battery pack before further use.

LED red – lit continuously: battery, electronics or motor temperature is outside the permitted range.

LED red – flashing: indicates a general fault, e.g. incomplete contact, short circuit, battery pack faulty, etc.

Settings

WARNING

Risk of injury

Remove the battery pack from the power tool before performing any work on the power tool.

Electronics

Smooth start-up The electronically controlled smooth start-up function ensures that the power tool starts up smoothly.
Constant speed The motor speed is electronically kept constant. This ensures a uniform cutting speed even when under load.
Speed control You can continuously adjust the speed within the speed range using the adjusting wheel [1-10] (see Technical data). This enables you to optimise the cutting speed to suit specific surfaces (see Section 9.7 ).
Current limiting Current limiting prevents excessive current consumption under extreme overload, which can lead to a decrease in the motor speed. The motor immediately restarts after the load is removed.
Brake The power tool omes with an electronic brake. The saw blade is stopped electronically within approximately two seconds of switching off the machine.
Temperature cut-out When exceeding a certain engine temperature level, the machine power supply and speed are capped. The power tool continues operating at reduced power to allow the ventilator to cool the motor rapidly. The power tool resumes to full performance automatically once the motor has cooled sufficiently.

Adjusting the cutting depth

The cutting depth can be adjusted to between 0 – 2-1/8″ (0 – 55 mm) on the cutting depth stop [3-1]:
The sawing unit can now be pressed down to the set cutting depth.
Cutting depth without guide rails max. 2-1/8″ (55 mm)
Cutting depth with guide rail FS max. 1-15/16″ (51 mm)

Adjusting the cutting angle between 0° and 45°:

► Unscrew the rotary knobs [4-1].
► Swivel the sawing unit to the desired cutting angle [4-2].
► Tighten the rotary knobs [4-1].
Both positions (0° and 45°) are set at the factory and can be readjusted by the customer service team.
When making angled cuts, slide the viewing window/splinter guard to the highest position.
to undercut -1° and 47°:
► Swivel the saw unit to the end position (0°/ 45°) as described above.
► Pull out the release button [4-3] slightly.
► For -1° undercuts, also pull the release button [4-4]. The saw unit engages in the -1°/47° position.
► Tighten the rotary knobs [4-1].