Kapex Supplemental Owner`s Manual
Contents
1. For measuring an inside corner retract the extension arms as shown in the second image below Extension er Outside Comer Miter Line y gt a Lock Knob Align the laser with the miter line 1 Loosen the lock knob on the MiterFast tool 2 Place the MiterFast tool in or on the corner and slide gt the lock knob forward to expand the arms 3 When the arms are lined up with the corner walls retighten the lock knob er 8 Fold up the MiterFast tool and return it to its storage TPT position in the base of the saw MiterFast Storage Compartment Slide the knob forward to Supplemental User s Manual 15 Using the Bed Extensions and Crown Stops The optional bed extensions provide a Crown useful platform for using additional Stop workpiece control accessories as well as extending the size of the bed of the Kapex saw The optional bed extension accessory includes the crown stop as shown to the upper right The extension can be mounted to the left side or right side of the saw s bed or if two are used to both sides simultaneously The T channel can also be used to secure additional clamping elements such as the Festool Quick Clamp or Screw Clamp shown to the right These clamps can be used for clamping larger workpieces or used in conjunction with the Kapex hold down clamp for multiple clamping needs su2. A thick line will result in a less accurate cut length When fitting one piece to another it may be helpful to make the initial cut slightly long and then trimming the cut to final length after test fitting the piece When cutting a new board cut off the original factory end to ensure a square fresh end before measuring for your final length When cutting small trim use a zero clearance fence and or insert to prevent small offcuts from being thrown behind the fence by the windage from the Spinning blade see page 23 When cutting multiple pieces of varying lengths from a limited supply of stock always cut the longest pieces first and cut the remaining pieces from the leftovers Do not force the blade through the cut A cleaner edge will be achieved with a steady moderate feed rate A chop type of cut yields the lowest tearout on the front and top edges of the cut but the most tearout on the rear side of the cut A push type cut yields moderate tearout on the top surface but the best cut edge Diagram of Push C ut Method f Pull the saw head forward Supplemental User s Manual Turn the saw on and lower the head down Push the saw back through the workpiece 17 Miter Cuts Miter cuts are used when a board needs to be cut at an angle across its width The most common application for a miter cut is for joining two boards to form a corner without endgrain showing T
3. WS Bevel Range Selector e Dust Extraction Port 9 11 m BiadeGuard Sd UN Miter Stop Release Lever ___ 12 15 18 20 o Miter Lock tever r2 15 18 20 E Miter Gauge and Pointer 12 15 Trigger Lock 6 Kapex KS120 Miter Saw Functional Description continued Es e a vw i gatt dem Ve F zc 1 e E iL D Do E l Item Name or Description item Name or Description SS A Bevel Gauge and Pointer both sides S Speed Control Dial see Hee Dome tert E 1 Power SwitchTrigger J U Depth Limit adjustment rot f3 CK MainHandie AT u teser bust tens fan Leger ao m BladeGuard x en Fence ana hs 13 23 N Miter Stop Release Lever 12 15 18 20 O Miter Lock Lever R Bevel Adjustment Knob 12 15 18 20 12 18 Table Inserts Supplemental User s Manual Setup Setting Up a New Miter Saw Congratulations on your purchase of a new Kapex Sliding Dual Compound Miter Saw Before using your new miter Saw Make sure you fully read and understand all of the Instructions precautions and safety information presented in this manual For a more permanent installation the Kapex saw is equipped with 4 bolt holes to be used with Y4 20 M6 bolts to securely bolt the saw to a work table WARNING To avoid tipping the miter saw during use the miter saw must be placed on a stable Surface Note There is a 2 5 mm hex key needed for making ad
4. tables for standard mouldings but for non standard angles determining the proper saw settings requires mathematical calculation D Note that there are several methods for accurately cutting crown moulding depending on the circumstances Make sure to review the methods described in the applicable section on page 21 Calculating compound miter settings requires two parameters from the desired joint the corner angle and the slope Comer Angle The corner angle is the angle between the two pieces when viewed looking straight down on the joint The corner angle is relatively easy to determine but it is also the value that can cause the greatest amount of confusion for many woodworkers That s because most woodworkers view angles differently than a mathematician will A woodworker typically considers both inside and outside corners as 90 degrees with a 45 degree miter even though a mathematician would make the distinction that one corner is 90 degrees and the other is 270 degrees To be consistent with miter saw settings the corner angle is measured from a straight line between the two pieces as Shown above 20 Slope The Slope angle is the angle that each piece makes with respect to the base of the corner such as the ceiling or floor in the examples provided here For a roof like structure this would be the pitch of the roof For crown moulding this would be the compliment of the Spring Angle of the moulding
5. you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and use a properly functioning dust extraction system When the inhalation of dust cannot be substantially controlled i e kept at or near the ambient background level the operator and any bystanders should wear a respirator approved by NIOSH for the type of dust encountered Max Depth tall Top mm 4 75 at 60 mm 2 3 Max Depth at 45 Bevel 155mm 2 2 Max Width at 45 Miter All metric dimensions are controlling The arbor diameter is critical for safe operation and is presented in metric only Supplemental User s Manual Intended Use The Kapex miter saw is intended to cut wood plastic contravention to this manual may lead to injury and will aluminum and similar materials All applications beyond void your warranty The user shall be responsible and this are regarded as improper use The tool should not be liable for accidents injuries and property damage altered or used for any other purpose other than as resulting from misuse or abuse of this tool specified in these operating instructions Using the tool in Functional Description D se Wull 1 Item Name or Deseription _ Jet Page s 71 Power SwitchvTrigger fo m0 Ck mennene bii Item Name or Description A Bevel Gauge and Pointer both sides B Power Cord Storage Tall Miter Latch D Tall Miter Release EI Bevel Lock
6. Common spring angles for mouldings are 38 52 and 45 45 Determining the Comer Angle of Polygons The corner angle for standard polygons is shown in the table on page 18 Using the MiterFast Tool to Find a Comer Angle For non standard corner angles such as a room that is slightly out of square the MiterFast tool can be used to determine the corner angle To use the MiterFast tool to measure the corner angle follow the Using the MiterFast Tool procedure on page 15 but instead of making the cut record the saw s miter setting angle This angle is the corner angle so multiplying by 2 will give you the corner angle The compound angle calculator on page 21 also has an option for letting you enter this angle directly without needing to double it Determining the Slope of a Pyramid Polyhedron A polyhedron is a pyramid that can have any number of sides The easiest method for determining the slope of the polyhedron is by measuring the Drop and Projection of one face These are the distances from the center to the edge and the base to the point of the pyramid Note that with a polyhedron with an odd number of sides the center is found by drawing bisecting lines as shown in the image below Propstion Pi Kapex KS120 Miter Saw necessarily coincide with the points or Tails of the PEENI E OPE Or C TONN al moulding The slope is measured from the back side of As was mentioned previously the slope
7. E Des nl i Avertissement ae eee s ba manuei drieeteen Four votre pr a les pt ease la acia A ongiet 14 Vernier Indeces 12 image below To secure the workpiece press down on the green knob and rotate the locking handle down as shown in the image on the right below To release the clamp rotate the locking lever up 2 Press down on the miter stop release lever and rotate Miter Angle Gauge gt To stop at one of the preset positive lock miter positions release the miter stop lever just before reaching the angle and the miter stop will click as it locks into position gt To set the miter angle to degree between the primary angles line up the 2 vernier indices with the adjacent angle index marks The example shown to the left represents 20 3 When the desired miter angle is set engage the miter lock by pressing down on the miter lock lever Note When setting a miter angle very close to one of the miter stops for example at 4572 keep holding down the miter stop release lever until you fully engage the miter lock lever to prevent the miter angle from jumping to the nearby miter stop position Kapex KS120 Miter Saw Setting the Bevel Angle A beveled cut is where the saw head is tilted to the left or right from vertical The Kapex saw is capable of beveling up to 47 to the left and right The bevel range selector engages a series of angle stops The selector
8. There is a duplicate pointer on either side of the saw Lower the bevel lock lever a d LR pl a UL K Bevel Adjust ment Knob sayin VEI A WA sm LC wn Lock 13 Setting the Depth Limit The depth limit is used for making partial cuts that do not cut all the way through the workpiece such as making dados When the depth limit is engaged the sawblade s vertical travel is limited from going below the preset height The height is easily adjustable by turning the depth limit knob Turning the knob clockwise turn raises the sawblade by approximately 1 mm 0 040 and turning it counterclockwise lowers the sawblade To engage the depth limit pull the knob forward To disengage the depth limit push the knob back Using the Tall Miter Latch The tall miter latch is used for cutting boards in the vertical position such as mitering baseboard material In this cutting position the height of the cut is maximized The miter latch holds the saw head slightly forward from its normal position and also increases the maximum depth that the saw can plunge downward WARNING To reduce the risk of injury from loss of control never cut tall boards without the auxiliary fence installed The workpiece can tip if not properly supported D Note The bevel position must be at zero degrees before you can engage the tall miter latch The latch will not engage if the saw head is tilte
9. dust or fumes gt Keep children and bystanders away while operating a power tool Distractions can cause you to lose control gt If operating a power tool in a damp location is unavoidable use a ground fault circuit interrupter GFCI protected supply Use of a GFCI reduces the risk of electric shock Never use an extension cord that is damaged including cuts exposed wires or bent missing prongs Damaged extension cords increase the risk of fire or electric shock Use only extension cords rated for the purpose gt Use only extension cords rated for the amperage of this tool and the length of the cord Using too small of an extension cord can cause the cord to overheat Extension Cord Ratings Cord Length Size AWG lt 25 Ft 25 50 Ft 50 100 Ft gt 100 Ft Not recommended have the switch on invites accidents gt Remove adjusting key or wrench before turning the power tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury Do not overreach Keep proper footing and balance at all times This enables better control of the tool in unexpected situations Dress properly Do not wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts If devices are provided for the connection of dust extraction and collection facilities ensure these a
10. of a crown the moulding regardless how long the tails of the moulding is the compliment of its Spring Angle the moulding may extend see image below spring angle is measured relative to the wall and the slope ER is measured relative to the ceiling The two common Projection i spring slope angles of crown moulding are 38 52 and 45 45 The reason why these angles are represented by dual numbers is because the actual angle depends on which direction the moulding is oriented For example turned one way the slope is 38 degrees but turned the other way the slope is 52 degrees Note that the sum of these two angles is always 90 degrees For mouldings that are not the standard 38 52 or 45 45 you will need to measure the moulding to determine its Slope This is very similar to measuring the Drop and This is NOT Projection of a pyramid but more care needs to be taken to ensure the measurements are taken from the correct locations Important The slope of a moulding does not mmm e Ae mm Drop the slope Calculating Compound Angles There are two separate equations for calculating a If you don t know the slope angle but you know the Drop compound angle One equation is for calculating the miter and Projection then use the following to calculate the setting of the saw and the other equation is for calculating slope the bevel setting of the saw Drop CornerAngle Slope ArcTan Miter ArcTan
11. unauthorized use and reproduction is prohibited Written and Illustrated by Rick Christopherson 2008 TTS Tooltechnic Systems AG amp Co KG All rights reserved Printed in the United States of America and Germany 2 misuse of this equipment Festool USA assumes no liability for incidental special or consequential damage of any kind Equipment specifications applications and options are subject to change at the sole discretion of Festool USA without notice Festool USA is a division of Tooltechnic Systems LLC Festool is a trademark and service mark of TTS Tooltechnic Systems AG amp Co KG Kapex and FastFix are registered trademarks of TTS Tooltechnic Systems AG amp Co KG MiterFast is a trademark of TTS Tooltechnic Systems AG amp Co KG www festoolusa com Kapex KS120 Miter Saw Contents Limited Warranty ni 2 Power Trigger and Plunge Releaee 11 30 Day Money Back Guarantee 2 Using the Hold Down Camp 12 1 2 Limited Warranty nen 2 Setting the Miter Ange 12 Conditions of 1 2 Limited Warranty 2 Setting the Bevel Angle cccc cece cece ee eeees 13 BEE he eh ee Kee eege 2 Using the Auxillary Fence nenn 13 Re een een 2 Setting the Depth Limit cece cece eee eens 14 Liability Statement 2 Using the Tall Miter Latch eee eens 14 Proprietary Notce en 2 Using the MiterFast Tool 15 About This Manual uuuuu00000nnnn nun nn nn nun nun nun 3 Using the Bed Extensions and Cr
12. Arcsin WidthLeft WidthRight 4 Length Width Right 0 300 0 000 If the answer is a negative number Right side wider than Left side then your saw is cutting too much to the left of center If the answer is a positive number your saw is cutting too much to the right of center Built in Electronic Calculator Supplemental User s Manual Adjusting the Saw 1 Using the hex key stored on the cord reel slightly loosen the two adjusting screws located behind the cord reel shown below 2 You may find it easier to move the entire saw head instead of just the bevel plate To move the entire saw head leave the bevel lock lever see page 13 in the locked position To move just the bevel plate move the bevel lock lever to the unlocked position 3 Carefully adjust the bevel angle to account for the error calculated previously 4 Retighten the two screws and repeat the procedure to verify the results 5 When the calibration is correct torque the two screws to 18 ft Ibs 25 Nm e Gaz g Ke ye away to show screw locations RK Adjustment Screws 21 Calibrating the Lasers In order to calibrate the lasers you will need to puncture the decal on the side of the saw The 2 5mm adjustment screw openings are identified by the small circles on the decal _ The 2 5 mm hex key is shipped with the saw and is located in the Styrofoam packing material Lef
13. FESTOO Kapex KS 120 Miter Saw Sliding Dual Compound Miter Saw Supplemental User s Manual A WARNING To reduce the risk of serious or fatal injury read and understand all safety precautions and instructions in this manual before using this tool Limited Warranty 30 Day Money Back Guarantee We are so confident that you will thoroughly enjoy our tools that we offer a 30 day money back guarantee If you are not 1 2 Limited Warranty Festool USA offers a 3 year limited warranty one of the longest in the industry This warranty is valid on the pre condition that the tool is used and operated in compliance with the Festool Conditions of 1 2 Limited Warranty You are entitled to a free extended limited warranty 1 year 2 years 3 Years for your Festool power tool Festool USA is responsible for all shipping costs during the first year of the warranty During the second and third year of the warranty the customer is responsible for shipping the tool to Festool Festool will pay for return shipping to the customer using UPS Ground Service All warranty service is valid 3 years from the date of purchase on your receipt or invoice Excluded from the coverage under this warranty are normal wear and tear damages caused by misuse abuse or neglect damage caused by anything other than defects in material and workmanship This warranty does not apply to accessory items such as circular saw blades drill bits router bits jig
14. Festool recommends using a 36 mm hose A IA 10 Kapex KS120 Miter Saw Basic Operation Setting the Motor Speed The Kapex saw has electronic speed control with soft start circuitry The electronic controller will maintain the motor speed even as the load changes The speed control is infinitely variable from 1400 to 3400 RPM The optimal speed of the saw is predominately determined by the type of material being cut 3 6 Material Soft wood products and veneer plywoods Hardwood products Plastic laminate countertops Hard plastics Soft plastics Aluminum Using the Laser Guides A The Kapex saw contains a low power solidstate laser system that scans across the path of the sawblade to indicate to the user where the blade will cut the workpiece The laser does not cut the workpiece CAUTI ON Laser Radiation Do not look directly into the laser beam The two laser beams shine down on the workpiece on either side of the sawblade The sawblade will cut the workpiece between the two laser lines To turn on the laser press the On Off button on the rear of the motor near the speed control dial Pressing the button a second time will turn the laser off The laser will also automatically shut off if left on for more than approximately 30 minutes Power Trigger and Plunge Release The power trigger turns on the saw but also releases the motor head to plunge downward To help prevent accidental starting of the sa
15. Tan 7 x Cos Slope Projection 2 The most common error in calculating compound angles is using the wrong Corner Angle As a CornerAngle double check to your calculations for nearly all The only time the angle should be significantly larger than 90 is either for a 3 sided box ora wall corner with a sharp edge i i the C Angle should be less than 100 Bevel ArcSin Sin x Sin Slope cases the Corner Angle should be less than 2 Compound Angle Calculator A compound angle calculator has been built into this Adobe Acrobat PDF file If you do not have an original electronic version of this manual visit the http www festoolusa com website to download a copy Slope Angle Options Note If you are unsure about the corner angle you have entered check the calculated MiterFast Tool Angle value This number should be no more than 60 degrees for Sharp corners but C Arc MiterFast otherwise it should O nn 0 Tool Angle always be less than 45 degrees for most corners If it is significantly Results greater than 45 degrees i then you probably have Miter Setting the wrong Corner Calculate ee Supplemental User s Manual 21 Crown Moulding There are several methods for cutting crown moulding and each method has its benefits depending on the specific application The most common method for cutting crown moulding is to use a standard miter cut where the mou
16. calculating the error is shown below however the electronic version of this manual also contains a built in calculator To use the calculator enter your measurements in either mm or inches in the boxes and click on the Calc Error button The calculated error angle is displayed to the right of the button WidthLeft WidthRight Error D x Arcsin 4 Length Built in Electronic Calculator Width Left Width Right 0 500 jenn 180 Cale Error 0 000 If the answer is a negative number Right side wider than Left side then your saw is cutting too much to the left of center If the answer is a positive number your saw is cutting too much to the right of center Adjusting the Saw 1 With the miter handle out of the way loosen only the middle screw on the miter gauge and then move the miter handle back to zero 2 Engage the miter lock by pressing down on the lock handle see page 12 This locks the miter gauge to the miter handle and prevents the gauge from moving until you are ready to move it 3 Loosen the remaining two screws on the miter gauge and gently tap sideways on the miter handle to move the gauge as needed 4 Retighten all three screws 5 Repeat the calibration procedure to verify the results Mounting Screws Move this way for Negative Error J Move this way for Positive Error 25 Calibrating the Bevel Angle Calibrating the bevel angle uses the same 4 cut meth
17. ch as the dado example shown on page 19 Installation 1 Place the bed extension in the V max channel of the saw Wy i bb i d amp 1 4 u Ki X e u h be T To install the bed extension place the edge into the V channel of the Kapex bed position the extension forward or back as needed and then tighten the clamping knob see image to the right Setting up the Crown Stop The crown stop is used for cutting crown moulding and holds the moulding at the desired angle against the fence of the saw so that it can be cut using a standard miter cut refer to the Crown Moulding discussion on page 22 The stop slides forward or back depending on the size of the moulding and clamps in place to serve as a secondary fence KA N To set up the crown stop place the moulding against the Tighten the 2 fence and bed of the saw as shown in the lower left image clamping knob slide the crown stop up against the moulding and tighten x the clamping knob Use the hold down clamp to secure the e moulding while cutting as shown in the lower right image Moulding Crown Stop 16 Kapex KS120 Miter Saw Cutting Techniques There are three basic cutting techniques for sliding miter Saws but only two are proper and authorized These are Chop Cut Push Cut and the improper method is a Pull Cut Chop Cut A chop cut is used for cutting narrow or tall stock where the front edge of the workp
18. chment to do a job for which it was not designed Never use this saw for cutting ferrous metals Never use saw blades that are damaged or deformed Never use a dull sawblade A dull sawblade places undue stress on the saw and the workpiece and can increase the risk of kickback gt Make sure the sawblade is securely installed and is not backward The arrow on the blade should match the direction of the arrow marked on the tool y Respiratory Exposure Safety Warnings Substantial or repeated inhalation of dust and other airborne contaminants in particular those with a smaller particle size may cause respiratory or other illnesses Various dusts created by power sanding sawing grinding drilling and other construction activities contain chemicals or substances known to the State of California and others to cause cancer birth defects or other reproductive harm Some examples of these chemicals substances are gt lead from lead based paints crystalline silica from bricks cement and other masonry products Tool Description Technical Specifications Motor Speed 1400 3400 RPM no load Max Blade Size 260 mm 10 25 dia 2mm sa thick Max Depth std 88 mm 3 46 arsenic and chromium from chemically treated lumber and some wood dusts especially from hardwoods but also from some softwoods such as Western Red Cedar The risk from these exposures varies depending on how often
19. d Engaging the Tall Miter Latch 1 Pull the saw head away from the fence 2 While holding the latch lever down push the saw head back toward the fence until the tall miter latch locks into the back of the saw head Ka ru Miter Latch Release Lever 14 Limit Knob a Releasing the Tall Miter Latch While pressing down on the release lever See previous Image pull the saw head away from the fence The tall miter latch will spring to the vertical position when it releases Cutting the Workpiece Stand the workpiece up against the fence and plunge the saw head down into the cut Kapex KS120 Miter Saw Using the MiterFast Tool The MiterFast angle transfer tool converts a corner angle 4 Place the MiterFast tool on the saw with one of the measurement into a miter setting The miter line in the arms up against the fence center of the tool is always at the midpoint of the two angle arms and when lined up with the saw s laser provides the proper miter angle for the measured corner 5 Turn on the laser for the saw Refer to Using the Laser Guides on page 11 6 Adjust the miter angle of the saw refer to Setting the Measure the Comer Miter Angle on page 12 until either of the laser beams l line up with the miter line on the MiterFast tool For measuring an outside corner extend the extension arms as shown in the image below 7 Lock the miter setting on the saw
20. d agent of the laser manufacturer Never attempt to replace the laser on this tool with a different type of laser A tipping workpiece can lift up and contact the spinning sawblade or bring the operator s hand upward into the blade For proper control never pull the saw through the cut always chop or push cut See page 17 of this manual gt Cut only one workpiece at a time Multiple workpieces cannot be adequately clamped or braced and may bind on the blade or shift during cutting Keep workpieces firmly against the rear fence when cutting Never cut workpieces that do not lay flat or are curved in any way A curved workpiece can be grabbed by the blade and propelled back against the fence gt Inspect workpieces for nails or foreign objects Make sure there are no tools or foreign objects on the saw gt Do not cut round stock unless it is clamped in such a way as to prevent rotation Round stock will tend to roll while it is being cut gt Use only sawblades recommended by the manufacturer and designed for use with the saw with a 30mm arbor bore a 260mm diameter and a maximum thickness of 2mm Be sure that the speed marked on the saw blade is at least equal to the speed marked on the saw Do not use high speed steel saw blades Select the correct saw blade for the material to be cut Do not use the saw to cut materials other than those recommended by the manufacturer Never force the tool or atta
21. e changing blades 1 Push in and rotate the FastFix arbor lock clockwise This prevents the arbor from turning and also disables the motor 2 Loosen the clamping screw on the arbor bolt guard and rotate the guard away from the arbor bolt The combination hex key is stored on the back of the saw by the power cord FastFix Arbor Lock Wa Q x x L E FESTOOL KS 120 E6 mn nanim A ERA i X 3 Unscrew the arbor bolt by turning it clockwise The arbor bolt is a left hand thread and turns the opposite of a standard screw Supplemental User s Manual 4 Without pushing down on the trigger lock pull up on the trigger to release the blade guard 5 Raise the blade guard out of the way and remove the outboard arbor flange and sawblade from the arbor 6 Inspect the friction lining on the two arbor flanges If the lining is damaged replace the flanges as this can cause the sawblade to wobble Note The friction lining on the arbor flanges grips the blade but also permits the blade to slip Slightly in the event of a binding condition Inboard Arbor Flange Outboard Arbor Flange and Arbor Bolt Mhirsa Friction Lining WARNI NG When installing a new blade make sure the arbor bolt is properly tightened and the rotation direction of the sawblade matches the rotation direction indicated on the saw see image below AN 7 Make sure the blade is oriented correctly and
22. ee eeees 11 CrOWwWD SUC E 31 Using the Laser Guides 11 About This Manual Save These Instructions It is important for you to read and understand this manual The Tool Sym bols information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS The symbols below are used to help you recognize this information V Volts W Watts Indicates a potentially hazardous Hz Hertz WARNING situation which if not avoided could Al aac AC result in death or serious injury ternating Current AC No load Speed Diameter Class Il Double Insulated Indicates a potentially hazardous CAUTION Situation which if not avoided could result in minor or moderate injury mean This symbol is used on the machine and in this manual to signify the possibility of laser radiation Laser Radiation Designated Danger Zone Avoid positioning hands fingers or arms in the area designated by this symbol Indicates a potential situation which if NOTICE not avoided can result in property damage or damage to the tool Indicates information notes or tips for Note l improving your success using the tool Supplemental User s Manual 3 General Power Tool Safety Warnings A WARNI NG Read all safety warnings and instructions Failure to follow the warnings and instructions may result in electric shock fire and serious or fatal injury Work Area Safety gt gt Keep your work area clean and
23. eral setting 3 Reinstall the lens before making adjustments to the until the laser is against the edge of the kerf lasers 8 Raise the saw back to the top and adjust the tilt setting so the laser remains against the edge of the SZ kerf at the same position as the previous step Clear 9 Verify the tilt adjustment by raising and lowering the RER saw and check that the laser remains the same ead alien distance away from the kerf 10 Finally adjust the lateral position to line up with the edge of the saw cut 4 Clamp a smooth piece of scrap wood to the saw and It is a matter of your own personal preference as using the depth limit see page 14 make a shallow to whether the laser lines split the edge of the kerf cut across the board kerf or if they remain just outside of the kerf gt This kerf cut will help you aim the lasers where the ER thet yeu DIEIEE Saw actually cuts 28 Kapex KS120 Miter Saw Troubleshooting Symptom Possible Causes Motor does not start gt Check that the cord is properly plugged into an outlet Make sure the outlet has power Check the circuit breaker or try another outlet gt If used with a Festool dust extractor make sure the selector switch is pointing to Auto The auxiliary outlet on the dust extractor has power only when the selector 1s at Auto Inspect the power cord including extension cords for damage or missing prongs The motor brushes may have worn and need replacemen
24. ersonal Injury and damage to the saw A dado is a special type of cut where the depth of the cut does not go all the way through the workpiece One common example of this type of cut is for making half lapped joints which is shown to the right and described below In a half lap joint material is removed from the intersection of both workpieces comprising the joint When the joint is assembled the pieces overlap creating a strong joint but unlike a full lap joint the thickness of the joint is equal to just the thickness of the workpieces Depth Setting For making a half lap joint it is necessary to set the saw s cutting depth to be exactly in the center of the workpiece thickness The most accurate way of finding the center of a board is to trim from both sides until the two cuts meet Use a piece of scrap wood that is the same thickness as the actual workpiece Starting with a depth setting that you know to be less than half the workpiece thickness make a cut from the top side and then flip the piece over and make a second cut as shown below by the Red color Gradually lower the depth of cut and repeat these two cuts until the two cuts meet and the spine reaches a zero thickness This is exactly the center of the workpiece Keep trimming until the spine thickness reaches zero Fence Spacer The center of the sawblade is 50 mm 2 forward of the Saw s fence which results in the curved ramp at the rear o
25. ex work support table is specifically designed for use with the Kapex saw It is slightly shorter than a standard MFT 3 and also has additional mounting holes for placing the saw The saw may be positioned close to the front edge close to the rear edge more to the left or more to the right The height of the MFT 3 Kapex is lower so the Kapex is at a more comfortable working height This height also coincides with the height of a standard MFT 3 which can be used as workpiece support tables Bolt Down Clamping Kit 494 693 The bolt down kit includes bolts and threaded knobs for quickly securing the Kapex saw to a Multi Function Table Crown Stop 494 369 The crown stop is used to support the forward edge of crown moulding when cutting the moulding tilted against the fence for making non compound miter cuts Supplemental User s Manual 31 32 Kapex KS120 Miter Saw
26. f the cut shown in the image below To account for this and remove the radius at the end of the cut add a 50mm 2 spacer in front of the fence and clamp it in place with the Kapex hold down clamp as shown to the right Supplemental User s Manual Half Lap J oint Clamping It is important that both the fence spacer and workpiece are securely clamped to the saw for cutting Use the Kapex Hold Down Clamp see page 12 to clamp the fence Spacer and use an auxiliary clamp such as a Festool Quick Clamp or Screw clamp See page 16 to secure the workpiece Cutting the Dado Before cutting the dado mark the right and left sides of the cut to indicate how wide the dado needs to be Then make successive kerf cuts between the lines until all the material between the lines is removed The closer together each of these successive cuts are the smoother the bottom of the dado will be For best results clean the bottom of the dado with a sharp chisel 19 Compound Miter Cuts Compound miter cuts are where the saw is both in a miter position and a bevel position at the same time There are several applications for compound miter cuts but cutting crown moulding and sloped miters are common examples The example below shows a very simple birdfeeder roof Top View The greatest challenge with compound miters is determining the proper saw settings to achieve the desired miter angle These saw settings can be found in look up
27. ft or right side of the sawblade 3 Place the scrap on the saw with the number 1 against the fence A WARNI NG This procedure involves cutting small workpieces To reduce the risk of injury always clamp the workpiece to the saw 4 Cut approximately 1 4 inch off the board so that there is at least a 1 8 inch offcut This offcut ensures that the sawblade will be stable because there is wood on both sides of the blade during the entire cut 5 Rotate the board with side 2 against the fence and repeat the same cut Note that the side previously cut is now against the fence for each of the four cuts described below 6 Rotate the board to side 3 against the fence and repeat the same cut 7 Rotate the board to side 4 against the fence but this time make the cut a little wider so that the offcut is large enough to handle without breaking it approximately 1 4 to 1 2 inch wide 8 Discard the first three offcuts but the fourth offcut is the calibration offcut 9 Measure the length of the fourth offcut The accuracy of this measurement is not critical so a standard tape measure or ruler will suffice Supplemental User s Manual 10 Measure the width of the fourth offcut at both ends as labeled Right and Left These two measurements are critical so use the best method you can Measure the Length Measure the Width at Each End Calculating the Enor The equation for
28. has three settings The first setting 0 45 limits the bevel travel between 0 degrees and 45 degrees to the left The second setting 45 limits the bevel travel between 45 degrees to the left and 45 degrees to the right The last setting 47 limits the bevel travel to the full extent of the saw which is 47 degrees to the left and to the right 3 H NOTICE These settings are not hard limits and turning the bevel adjustment knob into one of the limit settings will cause the spring loaded limit to be bypassed However it should be noted that doing so can cause premature wear to the bevel limits 1 Release the bevel lock by lifting the lever 2 As necessary turn the bevel range selector to the desired range Ce y E A 4 His Bevel Lock Lever Bevel Range selector Using the Auxiliary Fence The auxiliary fence provides support for taller workpieces The two halves of the fence can be slid toward or away from the blade or removed completely Performing beveled cuts requires the auxiliary fence to be moved away from the blade area To move the auxiliary fence lift the locking lever slide the fence then lower the locking lever To remove the auxiliary fence lower the limit screw by turning it clockwise then slide the fence out of the retaining slot Supplemental User s Manual 3 Rotate the bevel adjustment knob until the bevel index pointer is pointing to the desired angle
29. he miter angle is one half of the corner angle So for a 90 corner for example the miter angle is 45 Miter Angles for Polygons Number of sides Corner Angle Miter Angle 3 Triangle 120 60 4 Square 90 45 5 Pentagon 72 36 6 Hexagon 60 30 7 Heptagon 514 257 For even the most experienced woodworkers cutting accurate and tight fitting miters can be problematic The following are some tips for making accurate miters Clamp the workpiece down Because the sawblade is cutting at an angle with the workpiece edge and fence it will tend to move the workpiece sideways in the direction of the cut as the cut progresses This can result in a cut that is not straight or the angle of the cut may be off Cut slowly Cutting too rapidly can cause the sawblade to deflect as it encounters varying densities in the woodgrain Use a chop cut only for narrow miters When in doubt use a push cut v Bevel Cuts Bevel cuts are used when a board needs to be cut at an angle across its thickness The most common application for a bevel cut is for constructing a box or similar structure The following are tips for making accurate bevel cuts Clamp the workpiece down If the workpiece is not held firmly the blade will tend to pull the workpiece into the cut and up the blade For best results use only a push cut Take care not to deflect the saw head sideways Because the saw head is
30. iece is behind the center of the sawblade For this type of cut the saw head is brought Straight down into the cut Push C ut A push cut is used for cutting wider boards but is also usable in most situations where a chop cut could be used For this type of cut the saw head is pulled out toward the operator plunged downward and the primary cutting of the workpiece occurs as the saw head is being pushed back toward the rear of the saw as shown in the picture below Pull C ut Improper Method WARNING To reduce the risk of injury from loss of control never use the pull cut technique The third type of cut called a pull cut or climb cut should be avoided for both safety reasons and for cutting performance reasons This type of cut is made by plunging the saw head down and then pulling it forward The danger of this type of cut is that the sawblade wants to self feed Into the cut called climb cutting and this can cause the saw head to jump forward unexpectedly The reason this type of cut results in a poor quality cut is because it is using two different actions for the same cut It starts out with a plunge cut and then finishes with a climb cut This means that the sawblade is cutting the wood in two different manners and there will frequently be a rough edge at the transition from one type of cut to the other Tips for Succ essful C uting gt For more accurate cuts mark your cutting length with a thin pencil line
31. install the blade onto the inboard arbor flange 8 Replace the outboard arbor flange tighten the arbor bolt and then unlock the FastFix arbor lock Blade Rotation A Pty T Indicator Arrow Ce FESTOOL Transporting the Saw When The Kapex miter saw is collapsed for transport it is very well balanced and easily carried using the integrated carrying handles 1 Unplug the saw and coil the power cord on the reel at the rear of the saw Cord Reel Head Loc Se Knob 4 Set the miter angle to 60 and push down on the miter lock lever 5 Pick up the saw from the rear by grasping the two handle points as shown below Carrying Handle WARNING To reduce the risk of unexpectedly Starting the saw make sure the saw Is unplugged 2 Pull the power trigger without depressing the trigger lock and lower the motor head down When the head is in the down position push in on the Head Lock Knob see the picture to the upper right 3 Push the motor head all the way to the rear of the saw and tighten the Slide Lock Knob Dust Extraction The Kapex saw can be connected to a dust extractor to substantially reduce dust during operation The dust port swivels to either side and accepts either a 27 or 36 mm Festool hose The 27 mm hose fits inside the dust port or the 36 mm hose fits over the outside of the dust port Extractor Note For optimal dust extraction performance
32. ion threshold is 0 16 but this calibration procedure is capable of measuring errors as low as 0 001 which is nearly impossible to obtain in actual practice The basis for this procedure is to make four successive cuts where each new cut references from the previous cut As a result any angular error in the miter angle will propagate and be compounded with each cut The final cutting error will have 4 times the actual error of the saw In the diagram to the right you can see that each successive offcut has a slightly larger angle than the previous offcut You may have heard of this method referred to as the 5 cut Calibration Method but as long as you start out with a straight edge on the board only 4 cuts are required Furthermore any additional cuts made after the fourth cut will not increase the accuracy and it will remain at 4 times the original error Getting Started You will need a piece of scrap wood that is between 6 and 12 inches on a side The scrap does not need to be perfectly square but at least the first edge must be Straight The larger the piece the more accurate your final measurement will be The material can be anything but Medium Density Fiberboard MDF will give you the cleanest cuts and therefore the easiest to measure High density plywood such as Baltic birch will also give very accurate results Low grade plywood may have rough edges depending on the quality and
33. justments located in the Styrofoam packing material Take care not to lose it Note You may want to save the original box and packing material in case you ever need to send in the saw for service o es The KS120 miter saw is ready to use right out of the box but there are several placement options available depending on the intended use These options include For truly portable use the KS120 may be used directly on a jobsite floor The height of the cutting bed was specifically designed to coincide with the height of a Festool 1 Systainer which can be used as an outfeed Ste support The Kapex saw was specifically designed to be compatible for operation on a Festool Multi Function Table MFT The four feet under the saw coincide with the hole spacing of an MFT tabletop to keep the saw firmly in position and the optional bolt kit permits quick mounting z for Support e gt The KS120 can also be used on a level and stable jobsite work table The saw must be securely clamped to the table to help prevent it from tipping or falling off If you clamp at the feet you must clamp each corner Note When clamping or bolting the Kapex to a work table take care not to over tighten the clamps or bolts as this may distort the saw base 8 Kapex KS120 Miter Saw Changing Sawblades WARNING To reduce the risk of injury from f contact with a moving part always unplug the saw befor
34. lding is tilted against the fence of the saw For unusual situations or when the moulding is too large to fit against the fence compound miters are used In some applications inside corners are made using a method called coping Each of these methods will be described briefly Standard Miter A standard miter cut is the easiest and most common method for cutting crown moulding The Kapex miter Saw has an optional auxiliary crown moulding fence also called the Crown Stop specifically for making this type of cut The fence holds the moulding at the correct angle so it can be cut with a normal miter cut For this type of cut you place the moulding on the Saw as it would normally rest in the installed position The edge that normally faces the ceiling is the edge that should be on the base of the saw Crown Moulding amp Tilted Against the Fence Auniliary Crown Fence Compound Miter A compound miter cut is used when the moulding is too tall to use the standard miter method This can also be used for a higher level of accuracy when the tails of the moulding are not perfectly perpendicular with each other a common problem with most mouldings Place the moulding on the saw with the flat back face on the base Coped Cut A coped cut is sometimes used for making inside corners so there is no visible gap between the two pieces of moulding A coped cut requires the use of a coping saw a thin bladed handsaw for c
35. ly to you This warranty gives you specific legal rights and you may also have other rights that vary from state to state in the U S and from province to province in Canada With the exception of any warranties implied by state or province law as limited above the foregoing express limited warranty is exclusive and in lieu of all other warranties guarantees agreements and similar obligations of Festool USA Festool USA makes no other warranty express or implied for Festool portable power tools No agent representative distributor dealer or employee of Festool USA has the authority to increase or otherwise change the obligations or limitations of this warranty hats t shirts or other wearables may be returned Also contact our Service Department at the telephone number listed above if you have any questions about warranty claim procedures If you need to return your Festool tools for any reason please return it to the dealer from which you originally bought the tool Liability Statement This product has been built to the high standards of Festool Please do not attempt to operate or repair this equipment without adequate training Any use operation or repair in contravention of this document is at your own risk By acceptance of this system you hereby assume all liability consequent to your use or Proprietary Notice All drawings and information herein are the property of Festool TTS Tooltechnic Systems AG amp Co KG All
36. nt handles can cause the saw and or workpiece to move unexpectedly gt Always unplug the saw before servicing or changing the sawblade gt Never remove or disable the blade guard Inspect the blade guard before use Repair or replace a damaged or improperly functioning blade guard before further use gt Keep hands out of the path of the sawblade Never cross your hand over intended line of cutting Supporting the workpiece cross handed e g holding the left side of the workpiece with your right hand is very dangerous Do not reach in back of the moving saw blade with either hand to remove wood scraps hold down or support the workpiece or for any other reason The proximity of the spinning saw blade to your hand may not be obvious and you may be seriously injured Use clamps to support workpiece whenever possible Do not use this saw to cut pieces that are too small to be securely clamped gt Clamp the offcut side of the workpiece when using a length stop An unsecured offcut can bind between the length stop and the saw blade If securing the workpiece by hand you must always keep hands outside of No Hand area as marked with a symbol on the base Your hand if placed inside the No Hands region can easily slip or be pulled into the blade Support long workpieces to prevent them from tipping y Any repairs to the laser must be carried out by the laser manufacturer or by an authorize
37. nto the blade This is especially true for miters and bevels where the blade tends to pull the workpiece into the blade Reduce the motor speed Saw cuts are wavy Do not make plunge then pull type cuts as this can lead to uneven cuts Make sure to keep the workpiece firmly clamped in position especially for miter and bevel cuts Don t change the feed rate during the cut Keep a constant and steady feed rate Bent or damaged sawblade such as missing teeth The Tall Miter Latch won t Make sure the bevel setting is at zero degrees The tall miter latch will not engage engage if the saw head is tilted Supplemental User s Manual 29 Optional Accessories Sawblades Combination Blade Hook Angle Ir Item Number 494 604 Description This is the standard blade that comes with the saw With a moderate tooth count and ATB tooth grind this blade provides good results when a single blade is needed for general purpose cutting The blade incorporates asymmetrical tooth spacing to reduce harmonic vibration Fine Crosscut Blade Description With a high tooth count and ATB tooth grind this blade provides excellent chip free crosscutting of lumber and fine cabinet grade plywood The blade incorporates asymmetrical tooth spacing to reduce harmonic vibration Fine Laminate Blade Tooth Type Flat tipped ATB 64 teeth tem Number 494606 Description The ultra hard flat tipped FT ATB teeth on this blade reduces chipping
38. od described in the Calibrating the Miter Angle procedure on page 24 Refer to the discussion on page 24 for an explanation of the method Except for cutting tall miters the bevel setting accuracy is generally less critical than the miter setting accuracy Take care not to attempt to over calibrate this setting Getting Started You will need a piece of scrap wood that is between 4 and 4 3 4 inches on a side The scrap does not need to be perfectly square but at least the first edge must be Straight The larger the piece the more accurate your final measurement will be but 4 3 4 is the maximum size that can be cut using the Tall Miter Setting See page 14 The material can be anything but Medium Density Fiberboard MDF will give you the cleanest cuts and therefore the easiest to measure gt High density plywood such as Baltic birch will also give very accurate results Low grade plywood may have rough edges depending on the quality and therefore may provide the lowest accuracy Solid wood can also be used but you may experience burning on the rip cuts if you are using a fine tooth blade You will need a ruler to measure the length of the final offcut and optionally a dial caliper to accurately measure the difference in the width of the offcut at both ends This width measurement is the most critical so a dial caliper is recommended It does not matter whether your measurements are in metric units o
39. of laminates and solid surface materials without dulling The FT ATB grind results in the performance of an ATB grind with the longevity of a TCG grind Aluminum and Plastic Blade TCG 68 teeth Hook Angle 5 Item Number 494 607 Description The high tooth count TCG grind of this blade provides long lasting Sharpness and good control for cutting aluminum and hard plastic Notes ATB Alternate Top Bevel The ATB type blade slices through wood fibers first on one side and then on the other for clean cuts in natural and manmade materials TCG Triple Chip Grind The TCG type blade is designed to cut through hard materials The trapezoidal tooth cuts the center of the kerf and the flat raker tooth cuts the edges This type of blade design is more resistant to dulling 26 a Bevel Angle All of the ATB type blades shown above have a bevel angle of ATB ICG 15 This moderate bevel angle helps provide good chip free cutting without rapidly dulling 26 b Hook Angle The higher the hook angle the more the tooth grabs the material and pulls it into the cut Ripping blades have a very high hook angle to cut aggressively Lower hook angles are used for harder materials where greater control is needed Tooth Count The more teeth a blade has the smoother it will cut Conversely blades with fewer teeth cut more aggressively 30 Kapex KS120 Miter Saw MFT 3 Kapex Table 495 565 The MFT 3 Kap
40. own Stops 16 TOO oni nei EE 3 Cutting Techniques ue eeuugseeugeg egeuEeS Ek NeEEe 17 General Power Tool Safety Warnings s555 Miter Cute nenn ann nnn anne 18 Work Area Gate 4 B Ver CULS arena 18 Electrical Safety cccccceeseeeeeeeeeeeseeeeeeenees 4 Depth Limited Dado Half Lap Cuts 19 Personal Gatetv nennen nen 4 Compound Miter Cute en nennen 20 Power Tool Use and Care 4 Calculating Compound Angles 21 SOVICE are era 5 Compound Angle Calculator 2222222220 21 Specific Safety Rules for Miter Gawe 5 Crown Mouldmg nennen ennne nennen nen 22 Respiratory Exposure Safety Warnings 5 Adding Auxiliary Fencetaces nn 23 Tool Description enee eu NENNEN ENEE ENEE EEN 5 Making a Zero Cearancelnsert eee es 23 Technical Specifications ccc cece cece cece nn Rn 5 Calibration and Adjustment uuuuuuunnnnnnnnnnnn 24 Huewel WEE 6 Calibrating the Miter Ange 24 Functional Description 6 Calibrating the Bevel Ange 26 EEN 8 Calibrating the Lasere eee eeeeeees 28 Setting Up a New Miter Gau 8 Troubleshooting uuuuuuununnnnnnnnnnnnnnnnnnnnnnnnnn 29 Changing Gawllades ee nn nennen nenn 9 Optional Accessories e 30 Transporting the Gaw 10 Sawblades 222222ssssesnnnnennnnen nennen nennen nn 30 AIR ge ge een 10 MFT 3 Kapex Table nn 3l Basic Operation enee NENNEN nun nn nun nun nnnnnnn 11 Bolt Down Clamping Km 3l Setting the Motor Gpeed cece e
41. r imperial units Dial Caliper Before adjusting the saw you first need to measure whether it is accurately calibrated to begin with The factory calibration threshold is 0 5 If you attempt to exceed this calibration threshold you may end up actually making the saw less accurate Measuring the Enor 1 Number the sides of the scrap piece of wood from 1 to 4 starting with the best edge gt If you cut the wood on the left side of the blade as shown in this example then number the sides in a counterclockwise direction as shown If you cut the wood on the right side of the blade then number the sides in a clockwise direction gt Note that this is the opposite from the miter calibration numbering 26 A Workpiece Here d On the 1 side which will eventually become the final calibration offcut label it Left and Right as shown Do this regardless whether the cut is made on the left or right side of the sawblade Lock the saw in the Tall Miter position Refer to page 14 Make sure that both auxiliary fences are in place and supporting the workpiece Refer to page 13 Place the scrap on the saw with the number 1 facing down against the base of the saw WARNING This procedure involves cutting small workpieces To reduce the risk of injury always clamp the workpiece to the saw Cut approximately 1 4 inch off the board so that there Is at least a 1 8 inch offcut This offc
42. re connected and properly used Use of dust collection can reduce dust related hazards Maintain power tools 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 gt Keep cutting tools sharp and clean Properly maintained 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 Kapex KS120 Miter Saw Service gt To reduce the risk of serious or fatal injury never open the motor housing Have your power tool serviced only by a qualified repair person using only identical replacement parts Specific Safety Rules for Miter Saws gt To reduce the risk of serious or fatal injury never alter or misuse the power tool gt Be certain the miter saw is mounted or securely placed on a level firm work surface before using A level and firm work surface reduces the risk of the miter saw becoming unstable or tipping gt Make sure all controls and clamping handles are secured before starting any operation Unsecured clamps or adjustme
43. saw blades Sanding belts and grinding wheels Also excluded are wearing parts such as carbon brushes lamellas of air tools rubber collars and seals sanding discs and pads batteries and Festool gear hats and t shirts The obligations of Festool USA in its sole discretion under this warranty shall be limited to repair or replacement or a refund of the purchase price for any Festool portable power tool that is found to have a defect in materials or workmanship during the Repairs If your Festool power tools require repair you must contact our Service Department at 800 554 8741 for authorization and address details No collect shipments will be accepted No Festool Returns completely satisfied your full purchase price will be refunded excluding all freight charges operating instructions Festool USA warrants that the specified tool will be free from defects in materials and workmanship for a term of 3 years from the date of purchase warranty period FESTOOL USA SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES REGARDLESS OF THE THEORY OF LAW ON WHICH THE CLAIM IS BASED ALL WARRANTIES IMPLIED BY STATE LAW INCLUDING THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY LIMITED TO THE DURATION OF THREE YEARS Some states in the U S and some Canadian provinces do not allow the limitations on how long an implied warranty lasts so the above limitation may not app
44. t Lasers do not work The lasers turn off automatically f the saw is not used for a period of time Press the Laser On Off button to turn the lasers back on Check that the cord is properly plugged into an outlet Make sure the outlet has power Check the circuit breaker or try another outlet If used with a Festool dust extractor make sure the selector switch is pointing to Auto The auxiliary outlet on the dust extractor has power only when the selector is at Auto Inspect the power cord including extension cords for damage or missing prongs Inspect the laser dust lens for excessive dust see page 28 Excessive tearout on the This can occur with plunging and or pulling cuts see page 17 bottom edge of the cut Too fast of a feed rate through the cut Too coarse of a blade for a crosscut operation Excessive tearout on the top This can occur with a push cut especially with thicker materials side of the cut Too fast of a feed rate through the cut Too coarse of a blade for a crosscut operation Excessive tearout at the rear This is common for plunge cuts and slightly less prominent with push cuts of the cut gt Too fast of a feed rate through the cut Use a backing board or auxiliary fence Saw cuts are burning Make sure to use the correct blade for the material Make sure the blade is sharp Make sure the blade is installed correctly not turning backward Keep the workpiece clamped to prevent it from moving i
45. t Laser Adjustments gt The Tilt adjustment is used to ensure the lasers are pointing parallel to the sawblade so they trace out the same line regardless whether the saw is raised or lowered gt The Yaw adjustment rotates the laser as viewed from above the saw so it remains parallel with the path of the Saw cut front to rear The lateral adjustment moves the laser toward or away from the saw cut sawblade Right Laser Adjustments v Setup 1 Before beginning remove the laser dust lens and clean You can use any wood that has a relatively smooth it To remove the lens loosen the retaining screw surface The white melamine board shown below push in and down on the ribbed surface to release the provides a good contrast between the board surface locking tabs and then slide the lens out of the saw and the kerf cut Retaining Screw_ Shallow Kerf Cut Melamine Coated gt Particleboard gt Push in then down to release 5 Turn on the laser 6 Begin by adjusting the yaw settings so both lasers are parallel with the saw cut Make sure to remove the hex key from the screw before gauging your progress The pressure of the hex key is enough to deflect the laser 2 Wipe off any dust and debris from the lens with a soft 7 Next lower the sawblade down into the kerf touching cotton cloth or rinse it with water and mild soap the wood and temporarily adjust the lat
46. the back of each mounting screw Option 2 Using a tablesaw or chisel back cut the lower rear of the fence to clear the fixed portion of the factory fence gt After mounting the auxiliary fence faces to the Saw use the saw to trim the ends for a zero clearance fit Trim one side at a time table To make the countersunk holes for the mounting screws first use a small forstner bit to drill the countersunk holes and then a regular drill bit to drill a through hole for the screw s shank After the insert is installed and screwed down to the saw s table cut the kerf opening with the saw using a standard push cut Calibration and Adjustment The Festool Kapex miter saw comes fully calibrated from the factory and should not require further calibration out of the box or after normal use The following calibration saw is knocked out of alignment such as can happen during frequent or unsecured transport Use these procedures only when your saw needs service techniques should only be necessary in the event that your Calibrating the Miter Angle The calibration method described here is based on compounding an error by a factor of four This makes it easier to detect extremely small calibration errors However care should be taken in over using this calibration procedure because it has such a fine accuracy that it could be easy to get carried away and try to over calibrate the saw The factory calibrat
47. therefore may provide the lowest accuracy Solid wood can also be used but you may experience burning on the rip cuts if you are using a fine tooth blade 24 Fourth Offcut First Offcut Be Second Calibration Oticut 89 89 _ Third Offcut You will need a ruler to measure the length of the final offcut and optionally a dial caliper to accurately measure the difference in the width of the offcut at both ends This width measurement is the most critical so a dial caliper is recommended It does not matter whether your measurements are in metric units or imperial units Dial Caliper Kapex KS120 Miter Saw Measuring the Enor Before adjusting the saw you first need to measure whether it is accurately calibrated to begin with If you attempt to exceed the factory calibration threshold you may end up actually making the saw less accurate 1 Number the sides of the scrap piece of wood from 1 to 4 starting with the best edge gt If you cut the wood on the left side of the blade as shown in this example then number the sides in a clockwise direction as shown below gt If you cut the wood on the right side of the blade then number the sides in a counterclockwise direction 2 On the 1 side which will eventually become the final calibration offcut label it Left and Right as shown Do this regardless whether the cut is made on the le
48. tilted to the side it can be 18 gt When marking the length of the workpiece use a sharp pencil to draw a thin line The thicker the line the more difficult it will be to cut accurately on the line When marking a workpiece length to match a wall or other structure use a utility knife to mark the cut with a small nick This is more accurate than a pencil line Mark the cut by placing a small nick with a utility knife e G Nie tge gt Ifa utility knife is used to mark the cut you can use a method called Sneaking up on the cut This is where you make an initial cut longer than needed and continually make very small re cuts until the cut line splits through the center of the nick you made with the utility knife v easy to inadvertently push the saw head down or pull it up as you feed the saw into the cut This will result in a crooked cut Place the workpiece on the saw with the best side down Because of the angle of the blade teeth exiting the workpiece on the top side of the cut there will be slightly more tearout on the top especially on the sharper edge PW Use a push cut when making ZAbord cuts Kapex KS120 Miter Saw Depth Limited Dado Half Lap Cuts A WARNI NG Never attempt to install or use a dado blade in the Kapex saw Using either a stacked dado or wobble dado blade will exceed the capacity of the arbor and the blade may impact the saw s guards resulting in p
49. tting smaller workpieces The term zero clearance means that there is no gap between the Sawblade and the fence This is achieved by cutting the auxiliary fence to final length after it is installed Making the Auxiliary Fences The auxiliary fences can be made from solid wood composite wood such as particle board or soft non brittle plastic Cut your fence blanks to basic size They can be wider or narrower taller or shorter than the actual fence Size them to best suit your needs Drill and countersink two 11 64 holes for 10 mounting 2 Screws 3 If desired trace the shape of the factory fence onto the auxiliary fence and then cut the auxiliary fence with a band Saw or coping saw 4 To permit the fence to slide left or right it is necessary to have a space between the auxiliary fence and the fixed portion of the factory fence Use one of the options listed Making a Zero Clearance Insert A zero clearance insert is helpful when cutting small pieces to prevent the offcuts from falling under the standard pair of inserts The insert can be made from any hard wood For best results the insert should be custom fit to your Saw so use the dimensions shown below as a Starting guideline Adjust the thickness to be flush with the saw s 13 7 8 352mm 127 8 327mm 6 7 16 163mm 3 11 16 49mm 0 3 7 5mm Thick 1 7 16 36 5mm Supplemental User s Manual Option 1 Place a washer on
50. ust mask non Skid safety shoes hard hat or hearing protection used for appropriate conditions will reduce the risk of personal Injuries Eye protection must comply with ANSI Z87 1 Prevent unintentional starting Ensure the switch is in the off position before connecting to power source picking up or carrying the tool Carrying power tools with your finger on the switch or energizing power tools that Power Tool Use and Care gt 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 is 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 before making any adjustments changing accessories transporting or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally Store idle tools out of 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 Class II laser Do not look directly into the laser beam CAUTION Laser Radiation This product contains a Power lt 1mW Wavelength 640 to 660 nm Save all warnings and instructions for future reference or dust Power tools create sparks which may ignite the
51. ut ensures that the sawblade will be stable because there is wood on both sides of the blade during the entire cut Clamp the mm 1 n enden m Rotate the board with side 2 against the base and repeat the same cut Note that the side previously cut is now against the base for each of the four cuts described below Rotate the board to side 3 against the base and repeat the same cut Rotate the board to side 4 against the base but this time make the cut a little wider so that the offcut is large enough to handle without breaking it approximately 1 4 to 1 2 inch wide Discard the first three offcuts but the fourth offcut is the calibration offcut Kapex KS120 Miter Saw 11 Measure the length of the fourth offcut The accuracy of this measurement is not critical so a standard tape measure or ruler will suffice 12 Measure the width of the fourth offcut at both ends as labeled Right and Left These two measurements are critical so use the best method you can Measure the Length Measure the Width at Each End Calculating the Enor The equation for calculating the error is shown below however the electronic version of this manual also contains a built in calculator To use the calculator enter your measurements in either mm or inches in the boxes and click on the Calc Error button The calculated error angle is displayed to the right of the button Error 1 x
52. utting 22 curves but the initial cut is made with a miter saw The first piece of moulding does not get a miter and butts into the adjacent wall The second piece of moulding gets a coped cut to match the profile of the first piece To make a coped cut cut the second piece of moulding with a miter just as though it was going to be a mitered joint Then use a coping saw to cut along the edge of the resulting miter Original Finished Miter Cut Cope Cut Use this edge to guide the p cope cut General Notes gt If you are mitering both ends of a piece of moulding make the more difficult cut first because it does not need to be at the exact length For example a right handed operator may want to cut the left hand miter first This makes it easier cutting the second miter to exact length When installing crown moulding around a room with walls that may not be square use a piece of off cut scrap moulding to test fit the miters and lengths It is mathematically impossible to make a mitered joint that changes two directions at the same time such as putting crown moulding around a vaulted ceiling You must either make a double miter joint or use a corner block v Horizontal Segment Kapex KS120 Miter Saw Adding Auxiliary Fence Faces Auxiliary fence faces can be added to the Kapex fence One of the primary benefits of adding fence faces is to create a zero clearance fence opening for cu
53. w the trigger lock must be pushed to release the trigger to power the saw gt To start the saw activate the sawblade press the trigger lock and squeeze the trigger The saw head can then be plunged downward gt To plunge the saw head down without starting the saw squeeze the power trigger but do not press the trigger lock Supplemental User s Manual Turn the speed control dial to the number shown in the table to the left The speeds listed in the table are just rough guidelines and actual results may vary Speed i s 15 ae E Control Power Trigger and Plunge Release 11 Using the Hold Down Clamp The hold down clamp fits in a socket on either the left or right sides of the saw To insert or remove the clamp rotate it to the rear to unlock it from the socket as shown in the first image below To lock the clamp in its socket rotate it to the forward position as shown in the center h d amp d A Ge A A Setting the Miter Angle A mitered cut is where the saw head is rotated side to side The Kapex saw Is capable of mitering 50 to the left and 60 to the right Positive stops are located at 0 22 30 and 45 degrees The miter gauge pointer also includes 1 degree vernier indices for accurately setting the miter angle to half degree values Also refer to Using the MiterFast Tool described on page 15 1 Release the miter lock by lifting up on the handle d
54. well lit Cluttered or dark work areas invite accidents Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases Electrical Safety gt Power tool plugs must match the outlet Never modify the plug in any way Do not use any adapter plugs with 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 for outdoor use reduces the risk of electric shock Personal Safety gt Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while 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 d
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