metabo KT 66 BL Plunge Cut Circular Saw Instruction Manual

: August 13, 2024
: metabo

Table of Contents

metabo KT 66 BL Plunge Cut Circular Saw
Specifications
FAQs
Original instructions
Special safety instructions
Overview
Initial Operation and Setting
Use
Maintenance
Cleaning
Accessories
Technical Specifications
CONTACT INFORMATION
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

metabo KT 66 BL Plunge Cut Circular Saw

Specifications

Model: KT 18 LTX 66 BL
Serial Number: 01866.. 18
Speed: 2250-5000 min-1 (rpm)
Blade Diameter: 66mm (2 19/32 inches)
Cutting Depth: 43mm (1 11/16 inches)
Battery Voltage: 18V
Weight: 5.3kg (11.7 lbs)
Noise Level: 89.5 dB (A) LpA / 100.5 dB (A) LWA

FAQs

Q: Can I use the saw to cut metal?
- A: The saw is not designed for cutting metal, except for thin aluminum sheets less than 2mm thick.
Q: How do I adjust the cutting depth?
- A: To adjust the cutting depth, use the depth adjustment feature on the saw according to the material thickness you are cutting.

Original instructions

Declaration of Conformity

We, being solely responsible: Hereby declare that these plunge-type circular saws, identified by type and serial number 1), meet all relevant requirements of directives 2) and standards 3). Technical documents for 4) – see page 4.

Specified Conditions of Use

The plunge-type circular saw is suitable for sawing wood, plastics, and other similar materials. It must not be used for sawing metals, except for thin aluminium sheets (thinner than 2 mm) and aluminium-laminated wooden or composite boards.
The user bears sole responsibility for any damage caused by inappropriate use.
Generally accepted accident prevention regulations and the enclosed safety information must be observed.

General Safety Information

For your protection and the protection of your power tool, pay attention to all parts of the text that are marked with this symbol!
WARNING – Read the operating instructions to reduce the risk of injury.
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.
Always include these documents when passing on your power tool.

Special safety instructions

Cutting procedures

a) DANGER: Keep hands away from the cutting area and the blade. Keep your second hand on the auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
b) Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
c) 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.
d) 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. insulated gripping surfaces, when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock.
e) Mains-powered machines: Hold the power tool by the insulated gripping surfaces when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and could give the operator an electric shock.
f) When ripping, always use a rip fence or straight-edge guide. This improves the accuracy of the cut and reduces the chance of blade binding.
g) Always use blades with the correct size and shape (diamond versus round) of arbor holes. Blades that do not match the mounting hardware of the saw will run off-center, causing a loss of control.
h) Never use damaged or incorrect blade washers or bolts. The blade washers and bolts 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 theoperator. 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.
- a) 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 backward, but kickback forces can be controlled by the operator if proper precautions are taken.
- b) When the 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.
- c) When restarting a saw in the workpiece, center the saw blade in the kerf so that the saw teeth are not engaged in the material. If a saw blade binds, it may walk up or kick back from the workpiece as the saw is restarted.
- d) Support large panels to minimize the risk of blade pinching and kickback. Large panels tend to sag under their weight. Supports must be placed under the panel on both sides, near the line of cut, and near the edge of the panel.
- e) Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding, and kickback.
- f) Blade depth and bevel adjusting locking levers must be tight and secure before cutting. If blade adjustment shifts while cutting, it may cause binding and kickback.
- g) Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

Guard function

a) Check the guard for proper closing before each use. Do not operate the saw if the guard does not move freely and enclose the blade instantly. Never clamp or tie the guard so that the blade is exposed. If the saw is accidentally dropped, the guard may be bent. Check to make sure that the guard moves freely and does not touch the blade or any other part, in all angles and depths of cut.
b) Check the operation and condition of the guard return spring. If the guard and the spring are not operating properly, they must be serviced before use. The guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
c) Assure that the base plate of the saw will not shift while performing a “plunge cut”. Blade shifting sideways will cause binding and likely kickback.
d) Always observe that the guard is covering the blade before placing the saw down on a bench or floor. An unprotected, coasting blade will cause the saw to walk backward, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after the switch is released.

Additional safety instructions

Do not use any abrasive wheels. Keep your hands away from the rotating tool! Remove debris and similar material only when the machine is at a standstill.
- Wear a suitable dust protection mask.
- Wear ear protectors.
- Wear protective goggles.
Only turn the lever (14) with the battery pack removed/ mains plug pulled and the motor section pivoted up completely.
Do not reduce the speed of the saw blade by pressing on the sides.
The movable motor section must move freely, automatically, easily, and exactly back into its end position. It must not be clamped in place for sawing.
When sawing materials that generate large quantities of dust, the machine must be cleaned regularly. Make sure that the safety appliances, e.g. the movable motor section, are in perfect working order.
Materials that generate dust or vapors that may be harmful to health (e.g. asbestos) must not be processed.
Check the workpiece for foreign bodies. When working, always make sure that no nails or other similar materials are being sawed into.
If the saw blade blocks, turn the motor off immediately.
Do not try to see extremely small workpieces.
During machining, the workpiece must be firmly supported and secured against moving.
Clean gummy or glue-contaminated saw blades. Contaminated saw blades cause increased friction, jamming of the saw blade and increase the risk of kickback.
Avoid overheating of the saw tooth tips. Avoid melting of the material when sawing plastic.
Use a saw blade that is suitable for the material being sawn.
For cleaning (e.g. the extraction channel) switch the machine off, wait until the saw blade comes to a standstill, and remove the battery pack/ pull the mains plug.
Remove the battery pack from the machine / pull the mains plug out of the socket before making any adjustments, changing tools, carrying out maintenance, or cleaning.

Reducing dust exposure:

WARNING – Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains 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 and cement and other masonry products, and
- arsenic and chromium from chemically treated lumber.
Your 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 those dust masks that are specially designed to filter out microscopic particles.
This also applies to dust from other materials, such as some timber types (like oak or beech dust), metals, and asbestos. Other known diseases are e.g. allergic reactions and respiratory diseases. Do not let dust enter the body.
Observe the relevant guidelines and national regulations for your material, staff, application, and place of application (e.g. occupational health and safety regulations, disposal).
Collect the particles generated at the source, and avoid deposits in the surrounding area.
Use suitable accessories for special work. In this way, fewer particles enter the environment in an uncontrolled manner.
Use a suitable extraction unit.

Reduce dust exposure with the following measures:

do not direct the escaping particles and the exhaust air stream towards yourself or nearby persons or towards dust deposits,
use an extraction unit and/or an air purifier,
ensure good ventilation of the workplace, and keep it clean using a vacuum cleaner. Sweeping or blowing stirs up dust.
Vacuum or wash protective clothing. Do not blow, beat, or brush protective gear.

Special safety instructions for cordless tools:

If the machine is defective, remove the battery pack from the machine.

Protect battery packs from water and moisture!
Do not use faulty or deformed battery packs!
Do not expose battery packs to fire!
Do not open battery packs!
Do not touch or short circuit battery pack contacts!
Remove the battery pack from the machine when not in use.
Remove the battery pack from the machine before any adjustment or maintenance is carried out.
Make sure that the tool is switched off before fitting the battery pack.
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!

Transport of Li-Ion battery packs:

The shipping of Li-Ion battery packs 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).

Overview

See pages 2 and 3. The illustration is exemplary.

The illustration is exemplary.

2 Clamping lever (for rip fence)
Cutting indicator
Adjusting screw (for adjusting the 45° saw blade angle).
Scale (diagonal cut angle)
2 Locking screws (diagonal cuts)
Undercut button
Adjusting screw (for adjusting the 0° saw blade angle).
Marking (for reading off the cut width when the rip fence is used)
Read-off edge “FS” (for reading off the cutting depth when the guide rail “FS” is used)
Read-off edge (for reading off cutting depth)
Handle
Handle (additional handle) (motor housing can be alternative handle)
Locking button (for setting cutting depth)
Lever (for changing the saw blade)
Rotary button (for setting a clearance-free fit on the guide rails)
Guide plate
Locking button
Trigger
Battery pack release button*
Electronic signal indicator *
Speed preselection wheel
Capacity indicator button *
Capacity and signal indicator *
Battery pack *
Hexagon wrench / Storage for hexagon wrench
The guide grooves to place the machines on guide tracks from different manufacturers
Dust bag
Connector (extraction connection piece / dust ejection)
Preselection wheel for precision setting of the cutting depth
Glass guard
Saw blade fixing screw
Outer saw blade flange
Saw blade
Inner saw blade flange
- depending on the model

Initial Operation and Setting

Especially for cordless machines:

Remove the battery pack from the machine before any adjustment or maintenance is carried out.
Make sure that the tool is switched off before fitting the battery pack.

Battery pack

We recommend the use of LiHD battery packs with a capacity of at least 5.5 Ah. If other battery packs are used, a reduced performance is to be expected.
Charge the battery pack (24) before use.
Recharge the battery pack if performance diminishes.
Instructions on charging the battery pack can be found in the operating instructions of the Metabo charger.

In the case of Li-Ion battery packs with capacity and signal display (23) (equipment-specific):

Press the button (22), the LEDs indicate the charge level.
The battery pack is almost empty and must be recharged if one LED is flashing.

Removing:

Press the battery pack release (19) button and remove the battery pack (24).

Inserting:

Slide in the battery pack (24) until it engages.

Especially for mains powered machines:

Before commissioning, check that the rated mains voltage and mains frequency stated on the type plate match your power supply.
Always install a universal current-sensitive ground fault circuit interrupter (type B RCD) with a maximum trip current of 30 mA upstream.
Pull the plug out of the plug socket before any adjustments or servicing are performed.

Setting cutting depth

It is advisable to set the depth of cut in such a way that no more than half of each tooth on the saw blade juts out under the workpiece.

Adjustment in mm steps:

Press the locking button (13) and move. Read off the set cutting depth at the read-off edge (10). (When the guide rail “FS” is used, read off at the “FS” read-off edge (9).) Release the locking button (13) again.

Precise adjustment (for extremely precise cutting depth adjustment):

The cutting depth can be set extremely precisely by turning the preselection wheel (29).
Determine the exact cutting depth by measuring the projecting saw blade or check the result by a trial cut.

Slanting saw blade for diagonal cuts

Loosen the two locking screws (5) to make the setting. Tilt the motor section against the guide plate (16). Read the angle which has been set from the scale (4). Retighten both locking screws (5).

For a diagonal cut angle smaller than 0° or greater than 45° (undercut):

Press the undercut button (6) in and then slant. (During the next adjustment the undercut function is automatically deactivated.)

Rotational speed preselection

Select the speed at the setting wheel (21). For recommended speeds, see page 4.

Setting extraction connection piece/dust ejection

The connection piece (28) can be rotated to the desired position to extract or eject sawdust. To do this, push the connection piece in up to the stop, turn, and pull out again. The connection piece can thus be locked in 7 increments so that it cannot turn.

Sawdust extraction

To extract the sawdust, connect a suitable extraction unit with a suction hose to the extraction adapter (28).

Dust bag:

Remove the connection piece (28) (push the connection piece in up to the stop. Turn it so that it is facing upwards. Remove and set to one side). Attach the dust bag (27).

Adjusting the glass guard

Move the glass guard (30): top position for diagonal cuts, central position for 0° cuts, and bottom position when a guide rail is used.

Use

The machine’s multifunctional monitoring system

If the machine switches off automatically, the machine electronics have activated automatic protection mode. A warning signal sounds(continuous beeping). The beeping stops after a maximum of 30 seconds or when the trigger switch (18) is released.
Despite this protective function, overloading is still possible with certain applications and can result in damage to the machine.

Causes and remedies:

The battery pack is almost empty (the electronics prevent the battery pack from discharging totally and avoid irreparable damage). If one LED (23) is flashing, the battery pack is almost empty. If necessary, press the button (22) and check the LED lamps (23) to see the charge level. If the battery pack is almost empty, it must be recharged.
Long continuous overloading of the machine will activate the temperature cut-out.
- The machine continues to run with reduced performance until the temperature is back to normal.
- In case of excessive overheating, the machine will switch off completely.
- Leave the machine or battery pack to cool.
- Note: If the battery pack feels very warm, the pack will cool more quickly in your “AIR COOLED” charger.
- Note: The machine will cool more quickly if you operate it at idling speed.
If the current is too high (for example, if the machine seizes continuously for long periods), the machine switches off. Switch off the machine at the trigger switch (18). Then continue working as normal (in this case, read in particular the safety instructions in Chapter 4.2 kickback…). Try to prevent the machine from seizing.
In the event of kickback, the machine is switched off. There will be a warning signal (3 x beeps and 3 x flashes of the electronic signal indicator (20). Switch off the machine at the trigger switch (18) and let the saw blade come to a standstill. Centre the saw blade in the saw gap and check that the saw teeth are not caught in the workpiece. Then continue working as normal (in this case, read in particular the safety instructions in Chapter 4.2 kickback…).

Switching on and off

When the locking button (17) is pushed forward, the motor section can be moved downwards. The saw blade then emerges from the guard. Caution, risk of injury.

Switching on: Push the locking button (17) forward and hold, then actuate the trigger (18).
Switching off: Release the trigger switch (18).

Working Directions

Do not switch the machine on or off while the saw blade is touching the workpiece.
Let the saw blade reach its full speed before making a cut.
When sawing, never remove the machine from the material with the saw blade turning.
Allow the saw blade to come to a standstill.
If the saw blade blocks, turn the machine off immediately.
Do not set the machine down until the saw blade has come to a standstill.

Plunge cuts:

The motor section is in the upper position, the saw blade does not project from the guide plate. Hold the machine tightly with both hands and place the guide plate onto the workpiece. Switch on the machine.
Lower the motor section slowly to the set cutting depth and then move slowly in the cutting direction.
Sawing along a straight line: the cutting indicator is used here (2). The left edge (marked red) indicates the direction of the cut if the saw blade is held vertically.
The right edge indicates the direction of the cut if the saw blade is held at 45°.

Sawing along a rail secured on the workpiece:

To achieve an exact cutting edge, you can attach a rail to the workpiece and then guide the hand-held circular saw employing the guide plate along this rail.

Sawing with a rip fence (see Accessories chapter):

For cuts parallel to a straight edge. The rip fence can be inserted from either side into the support provided for it. The cut width can be read off at the mark (8). Fix using both clamping levers (1). It is best to calculate the exact cut width by making a test cut.

Sawing with a guide rail (see Accessories chapter):

For dead straight, tear-free cutting edges with millimeter precision. The anti-slip coating keeps the surface safe and protects the workpiece against scratches. See the Accessories section.
The rotary button (15) is used for setting a clearance-free fit.

Only for cordless machines Battery pack heat generation:

Under extremely hard application conditions (e.g. sawing thick wooden planks), the heavy load can cause the battery pack to heat (> 60 °C). To conserve the battery pack, allow it to cool down before continuing work.

Maintenance

Changing saw blades

The saw blade must be stationary.
Remove the battery pack from the machine / pull the mains plug from the socket.
Risk of injury, even with the blade at a standstill. Wear protective gloves.

Press the locking button (13) and move.
Move in such a way that the read-off edge (10) is pointed to the symbol “saw blade changing”.
Release the locking button (13) again.
Turn the lever (14) clockwise up to the stop.
Push the locking button (17) forward and lower the motor section a little. Release the locking button (17) again
Push the motor section down until it locks in place at the stop.

Changing

Turn the saw spindle slowly with the spanner (25) in the saw blade fixing screw (31) until the lock catches.
Unscrew the saw blade fixing screw in an anticlockwise direction and remove the outer saw blade flange (32). Remove the saw blade.
Ensure that the inner saw blade flange (34) is inserted in the right way: The inner saw blade flange (34) has 2 sides, a diameter of 20 mm and 5/8“ (16 mm). Ensure a precise fit of the saw blade mounting hole to the inner saw blade flange (34)!
Incorrectly installed saw blades do not run smoothly and lead to loss of control.
Insert a new saw blade. Make sure the direction of rotation is correct. The direction of rotation is indicated by arrows on the saw blade and guard.
The contact areas between the inner saw blade flange (34), the saw blade (33), the outer saw blade flange (32), and the saw blade fixing screw (31) must be clean.
Put on the outer saw blade flange (32). Ensure that the outer saw blade flange (32) is inserted the correct way round. Tighten the saw blade fixing screw (31) using a hexagon wrench (25) (max. 5 Nm).
Use only sharp, undamaged saw blades. Do not use saw blades that are cracked or that have changed their shape.
Do not use any saw blades made from high alloy high-speed steel (HSS).
Do not use any saw blades which do not conform to the specified rating.
Use only saw blades with a diameter according to the markings on the saw.
The saw blade must be suitable for the no-load speed.
Use a saw blade that is suitable for the material being sawn.
Use only genuine Metabo saw blades. Saw blades intended for cutting wood or similar materials have to conform to EN 847-1.

Getting the machine ready for operation

Turn the lever (14) anti-clockwise up to the stop.
The motor section swings upwards.

Correcting the saw blade angle

The saw blade angle has been adjusted at the factory. If necessary, the saw blade angle can be adjusted for 0° and 45°. Turn the adjusting screw (7) (for 0°) or (3) (for 45°).

Cleaning

Remove the battery pack from the machine / pull the mains plug from the socket.
Dust deposits must be regularly removed from the machine. This includes cleaning the ventilation slits on the motor with a vacuum cleaner.
Make sure that the safety appliances are in perfect working order (e.g. the motor section must move freely, and return automatically, smoothly, and precisely to its end position).

Accessories

Use only original Metabo or CAS (Cordless Alliance System) battery packs and accessories. Use only accessories that fulfill the requirements and specifications listed in these operating instructions.

A Rip fence
B Guide rail
C Fast-action clamp clip. To secure the guide rail.
D Circular saw blades. For clean-cutting results for straight and cross cuts in soft and hardwood.
E Battery charger
F Battery packs with different capacities. Only buy battery packs with voltage suitable for your power tool
G Metabo universal vacuum cleaner
H Suction hose

For a complete range of accessories, see www.metabo.com or the catalog.

Repairs

Repairs to electrical tools must ONLY be carried out by qualified electricians!
A defective mains cable must be replaced only with a special, original mains cable from Metabo available from the Metabo service.
Contact your local Metabo representative if you have Metabo power tools requiring repairs. 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.
Packaging materials must be disposed of according to their labeling per municipal guidelines. Further information can be found at www.metabo.com in the “Service” section.
Battery packs may not be disposed of with regular waste. Return faulty or used battery packs to your Metabo dealer!
Do not allow battery packs to come into contact with water!
Only for EU countries: never dispose of power tools in your household waste!
According to European Directive 2012/19/EU on Waste from Electric and Electronic Equipment and implementation in national law, used power tools must be collected separately and recycled in an environmentally friendly manner.
Discharge the battery pack in the power tool before disposal. Prevent the contacts from short-circuiting (e.g. by protecting them with adhesive tape).

Technical Specifications

Explanatory notes regarding the specifications. Subject to change by technical progress.

U =Voltage of battery pack
P1 =Rated input
P2 =Power output
n0 =No-load speed
n1 =On-load speed
Tmax =maximum depth of cut
T90° =adjustable depth of cut (90°)
T45° =adjustable depth of cut (45°)
A =adjustable angular cut angle
Ø =saw blade diameter
d =saw blade drill diameter
a =max. base body thickness of the saw blade
b =max. cutting the width of the saw blade
m =weight

Measured values determined in conformity with EN 62841.

Permitted ambient temperature during operation: -20 °C to 50 °C (limited performance with temperatures below 0 °C).
Permitted ambient temperature for storage: 0 °C to 30 °C
- direct current
- Machine in Protection Class II
- ~ AC Power

The technical specifications quoted are subject to tolerances (in compliance with 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 operating conditions, the condition of the power tool or the accessories used. Please allow for breaks and periods when the load is lower for assessment purposes. Arrange protective measures for the user, such as organizational measures based on the adjusted estimates.

Vibration total value (vector sum of three directions) determined by EN 62841: