Jigsaw Supplemental User`s Manual
Contents
1. ccsseeceeeesseenees 13 Power Tool Use and Care cc ccccseeseneeneeenseeens 4 Turning on the SAW ssnsssssssssnrnnsnsnrnernenrnennne 13 SVIC E E ee ee ee ree 5 Sawblade Selection cccccceesscseesnerereesseenes 14 Specific Safety Rules for Reciprocating Saws D OP SAlON sissisveccnisrisevannicaunsccensnenerasunsuusiseneunen 15 Specific Safety Rules for Battery Powered Tools 5 Using DUST Extracto c setsstetaaresnaesatnanieniss teens 15 Respiratory Exposure Safety WarningS ssss0 5 Using the Jigsaw with a Guide Rail 08 15 Functional DeSCFriptiONn ssssssseeeeencccensnennnneeeees 6 Using the Trammel to Cut Circles ccceeeeeee 16 Intended 0 te 7 Making Bevel CUtS c sexiesessseetaanrrisiesiananesieees 17 Technical Specifications ccccccceceeeeeeeeeeseeeeees 7 Maintenance and Adjustment ccccccesesnnnnnes 18 SETUP nesenrereetneeeieanes 8 Routine Maintenance asc cxcscansssis deasstaveawecwmeieenees 18 Changing the Sawblade siscassecsineesseiissaieeseiawan 8 PSU VIC HES a isnrecyagaadey ete ser aasauda aie savisassaneeeeress 18 Adjusting the Blade Guide cccccceeseneeneeeseeeene 8 Programming the LED light Function 18 Changing Base Inserts ssc scsenicinvescsseieaiasasengonaats 9 TFOUDIGCSNOOUNG issccccsecsieracsacssunesccewirrsamsereneews 19 Installing Removing the Dust Collection Port 9 Changing the Main BaSe ccssseeceeesesceenenens2. 10 About This Manual Save These Instructions It is important for you to read and understand this manual The information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS The symbols below are used to help you recognize this information WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a potential situation which if not avoided can result in property damage or damage to the tool GD Note Indicates information notes or tips for improving your success using the tool Tool Symbols V Volts W Watts Hz Hertz Alternating Current AC n No load Speed Class II Double Insulated Supplemental Owner s Manual 3 General Power Tool Safety Warnings WARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury AN Work Area Safety gt Keep your work area clean and well lit Cluttered or dark work areas invite accidents gt Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power Electrical Safety gt Power tool plugs must match the outlet Never modify the plug in any way Do not use any adapter
3. battery is being charged at its maximum charging rate gt Green Slow Flash The battery is approaching full charge and is being charged at a reduced charging rate After the battery has been fully charged the intelligent Green Steady The battery is fully charged charger will switch to a maintenance mode to maintain a gt Red Flashing General fault indication such as faulty full charge on the battery The battery may be left in the battery pack or faulty connection to battery charger until needed However it is not recommended to leave a battery in the charger for t gt Red Steady The battery temperature is too high to v Li rger for long term storage safely charge Charging will commence when the tempera For infrequently used batteries overall battery life will ture returns to a lower level be improved if they are stored with a partial charge and recharged only before needed Supplemental Owner s Manual 11 Connecting the Plug It Power Cord The corded Carvex jigsaws PS 420 EBQ and PSB 420 EBQ come equipped with a removable Plug It power cord The cord can be removed for easier storage of the tool The Plug It port on the PS 420 EBQ model can also be rotated when used inverted under a workpiece or for fitting in tighter corners To install the power cord insert the cord into the inlet port on the tool with the key and keyway aligned and twist the locking ring 4 turn until it clicks Reverse the pr
4. has been printed courtesy of TOOLNUT SINCE 1994 for our Festool customers
5. of the saw is somewhat subjective but is predominately determined by the type of material being cut The actual speed that delivers the best results for a specific cut may depend on other factors such as blade type work piece brittleness desired smoothness of cut etc The table to the right provides a general guideline for blade speeds but your actual speeds may vary A indicates maximum Speed Turning on the Saw All saw models have power switches on the left and right To use the variable speed trigger on a D handle model side of the main housing The D handle saws also have a press in on the trigger release and pull up on the trigger variable speed trigger in the handle gt The speed of the saw will be controlled by how much the To use the power switches on the barrel slide either switch trigger is pulled but the speed control dial determines the forward to start the saw and then release the switch The maximum available speed Saw will continue to run until you slide either of the switches gt It is not necessary to continue to hold the trigger release forward again button but it is necessary to continue to hold the trigger gt The speed of the saw will be determined by the speed depressed for the saw to run contro dial described above gt The automatic speed control function is not available when gt It is not necessary to hold the switch forward while the the trigger is used saw is running Tr
6. 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 gt Use the power tool accessories and tool bits etc in accor dance with these instructions taking into account the working Carvex PS420 Series conditions and the work to be performed Use of the power gt To reduce the risk of serious injury never alter or misuse the tool for operations different from those intended could result power tool in a hazardous situation Service gt Have your power tool serviced by a qualified repair person the safety of the power tool is maintained using only identical replacement parts This will ensure that Specific Safety Rules for Reciprocating Saws gt Keep hands away from the blade and cutting area Do not gt Hold the saw by the insulated handles when performing an reach underneath the workpiece The blade is fully exposed operation in which the sawblade may contact hidden wiring or under the workpiece its own cord Contact with a live wire will make the exposed gt Never hold the piece being cut in your hands or across your metal parts of the tool live and shock the operator leg It is important to support the work properly to minimize Never use a dust extraction system when making cuts that body exposure blade binding or loss of control can result in sparks unless a spark trap is instal
7. the blade gt Note that for thinner workpieces the blade guides can be set fairly wide without adversely affecting the cut quality gt Make sure to use the correct blade for the desired cut gt Saw blades with a wide set to the teeth will cut more aggressively faster but will leave more scratches in the side of the cut gt Saw blades with fewer teeth will cut more aggressively but may be more prone to chipping in some woods gt Saw blades with a wider shank front to rear cut better in a straight line but are more difficult for cutting tight curves gt Don t force the saw through the cut Let the blade work at the speed it was intended gt Use the correct blade speed Too slow of a speed may result in rough cuts Too fast can burn the workpiece gt If the speed of the saw is set to 1 and the saw is not yet cutting it may not draw enough power from the dust extractor to activate the auto start function The extractor should start once the saw begins drawing more power during a cut gt The saw s power cord must be plugged into the extractor s auxiliary outlet The auto start feature will not function with battery powered jigsaws Supplemental Owner s Manual 19 FES TOOL Tools for the toughest demands Festool USA 400 N Enterprise Blvd Lebanon IN 46052 www festoolusa com Service Questions 800 554 8741 Application Questions 888 337 8600 This Festool Supplemental Manual
8. EB and PSBC 420 EB use a removable BPC series 18V Lilon battery pack for their power However if needed the saw may also be powered using any BPC or BPS series battery from 12 to 18 volts However performance may be reduced when using a smaller battery a jigsaw from your tool belt or waistband The saw can start unexpectedly causing serious personal gt injury If a battery has the battery clip installed it is Release recommended to remove the clip to prevent it from Button catching on objects during operation WARNING Do not use any battery clips to hang To install the battery slide it into the receptacle on the rear of the saw until it clicks into place To remove the batter press in on both left and right release buttons and slide the battery out of the receptacle Charging the Battery Battery equipped Carvex saws include a TRC 3 intelligent battery charger This charger may be used to charge any Festool BPC Lilon or BPS NiCd NiMH series battery The charger is microprocessor controlled and will detect the type of battery being charged as well as the condition of the battery To charge a battery slide it onto the battery slot until it is fully seated The status light will change when the charger detects the presence of the battery fully seated The meanings of the status light indications are listed below gt Yellow Steady Charger is ready no battery present gt Green Rapid Flash The
9. FES T OOL PRODUCTS COM The Festool Carvex PS420 Series Pendulum Jigsaws Jigsaw Supplemental User s Manual Models PS420EBQ PSB420EBQ PSC420EB amp PSBC420EB 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 Buy with confidence If you are not completely satisfied return your tool to the selling dealer within 30 days and you will receive a refund of either your purchase price or the lowest retail price at which the same item has been offered since your date of purchase Freight charges are not refundable 1 2 Limited Warranty Festool offers a 3 year limited warranty one of the strongest in the industry This warranty is valid on the pre condition that the tool is used and operated in compliance with the Festool operat ing instructions Festool 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 Conditions of 1 2 Limited Warranty All customers receive a free extended limited warranty 1 year 2 years 3 Years on new Festool power tools purchased from an authorized retailer Festool is responsible for all ship ping costs during the first year of the warranty During the second and third year of the warranty the customer is respon sible for shipping the tool to Festool Festool w
10. Systainer cutter blade power cord etc Liability Statement This product has been built to the high standards of Festool Please do not attempt to operate or repair this equipment with out adequate training Any use operation or repair in contra vention of this document is at your own risk By acceptance of this system you hereby assume all liability consequent to your Proprietary Notice All drawings and information herein are the property of Festool TTS Tooltechnic Systems AG amp Co KG All unauthorized use and reproduction is prohibited Written and Illustrated by Rick Christopherson 2013 TTS Tooltechnic Systems AG amp Co KG All rights reserved Printed in the United States of America and Germany 2 The obligations of Festool 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 warranty period FESTOOL 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 lim
11. an be operated using any Festool BPC or BPS class battery pack from 10 8 volts to 18 0 volts The TRC 3 battery charger is capable of charging any Festool BPC or BPS class battery pack from 7 2 volts to 18 0 volts Input voltage Output Voltage Rapid Charge Rate Maintenance Charge Rate oe eee Permitted charging Temperature Available Batteries Voltage Capacity Weight Supplemental Owner s Manual Setup Changing the Sawblade The Carvex jigsaw features tool free blade changing Used blades can be ejected from the saw without touching the potentially hot blade New blades are inserted into the holder with just a simple twist Choosing the correct sawblade for the task is important for optimal results Refer to Sawblade Selection on page 14 WARNING Always disconnect the saw from the A power supply power cord or battery before making any adjustments to the saw or installing or remov ing the blade may be hot Take care not to touch the sawblade CAUTION After prolonged use the used sawblade until it has cooled m Unplug the saw or remove the battery This procedure may require you to touch the blade with your fingers so make sure the saw cannot start unexpectedly 2 If the splinter guard is installed remove it as described on page 12 3 Slide the blade release lever forward until the blade is ejected from the spring loaded holder 4 Place the new blade into the diagonal slot on the bla
12. at the LED light function is correctly programmed as described on page 18 O The LEDs have 3 programmable options for steady on stroboscopic and off gt The LEDs will turn off if the saw is inverted or tilted slightly past the vertical position This is to prevent the lights from shining into the operator s eyes The LEDs will resume nor mal operation the next time the saw is turned on while in the normal horizontal position Make sure you have removed the splinter guard before attempting to eject the blade The blade cannot rotate with the splinter guard in place gt Make sure to use the correct sawblade identified for use with a Carvex jigsaw Some blades may be too thick or have too much paint on the shank to easily slide out If a thick blade rotates to the eject position but does not come out try to gently pull it out with pliers gt Inspect the blade holder to make sure it is in the Park position fully retracted If the blade holder is not in the Park position unplug the saw and press the tip of the blade against a work surface to retract it Additional symptoms may include bluish discoloration of the metal sparks emanating from the blade guide area the blade bends backward even under a light cutting speed gt The blade guides are set too close for the thickness of the saw blade Readjust the blade guides gt The guides should barely contact the blade without restricting the movement of
13. be returned Also contact our Service Department at the telephone number listed above if you have any questions about warranty claim procedures Returns If you need to return your Festool tools for any reason please return it to the dealer from which you originally bought the tool use or misuse of this equipment Festool 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 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 Plug It and Systainer are registered trademarks of TTS Tooltechnic Systems AG amp Co KG www festoolusa com Carvex PS420 Series Contents About This Manual sssssssnnunnnnnnnnnnnnnnnnnnnnnnnnn 3 Setting the Pendulum Stroke ccceeeesseeneee 10 TOO SYR OONS rrara aeea 3 Installing Removing the Battery cceesseeseee 11 General Power Tool Safety Warnings A Charging the Battery sssssnsssnnnnsrnerenererrene 11 Work Area Safety sssssssssrsersnrrrrnrenrrrrerenn 4 Connecting the Plug It Power Cord sssssessssssn 12 Electrical Safely isceriesrsrdsinteeropik snik ieren 4 Installing the Splinter Guard s sessssssssnssrsrens 12 Personal Safety sssssssnsnrrrenrnnrnrenrnrrnrrrrnrno 4 Setting the Variable Speed
14. beeps release both power switches 5 Press and release the right hand power switch to cycle through the 3 programming options gt The LED lights will indicate the current program mode They will flash if in stroboscopic mode They will be steady on for steady on mode They will be off for the off mode 6 When the desired program mode is selected Pres and release the left hand power switch to exit program mode Carvex PS420 Series Troubleshooting Motor does not start corded models Motor does not start cordless models LED work lights not functioning properly The saw blade will not eject Saw blade burns on the rear of the blade shank away from the teeth Poor cut quality Dust extractor will not auto start when the saw starts gt Check that the cord is properly plugged into an outlet gt Make sure the Plug it connector is properly inserted and fully tightened gt 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 is at Auto gt Inspect the power cord including extension cords for damage or missing prongs gt Make sure the battery is properly charged and correctly installed on the saw If possible try a different battery to determine if the problem persists gt Verify th
15. blade Take care not to over tighten the adjustment screw If the jaws are too tight to the blade you will have exces sive wear on the jaws and it may even prevent proper pendulum action If the jaws are too loose the blade won t be well guided in the cut gt For optimal adjustment you should be able to wiggle the blade side to side just a little bit b Adjustment Screw Carvex PS420 Series Changing Base Inserts The standard Carvex base can be fitted with one of 5 optional base inserts shown below Each base insert is described below gt Standard Insert This is a general purpose insert that is supplied with the saw and may be used in all applications gt Felt Insert The felt insert provides a soft felt surface to the base of the jigsaw for mar free cutting on finished materials The bottom of the felt insert has a tight hook amp loop surface that holds the replaceable disposable felt pads in place Standard Insert Dimpled Insert NOTE The optional Base Accessory Kit may include r20 a small key and lanyard This is for a European configuration to lock the power button and is not used in North America 1 Remove the dust collection port as described below The release tab on the base insert cannot be pressed in when the dust collection port is in place 2 Either remove the main base from the saw as described on page 10 or remove the sawblade described o
16. cause part of the sawblade never extends below the sole plate of the jigsaw the blade length must be greater than the thickness of the workpiece to be cut The length of a jigsaw blade is specified by the length of the body that contains teeth but does not include the upper shank that fits inside the blade holder The example below shows a 75 mm blade The usable length of this blade is approximately 54 mm 2 s8 which is 75 mm minus the 19 mm that does not extend below the saw s sole plate minus the distance of the lowest tooth from the tip of the blade Usable Length Approx 54 mm Tooth Type Saw blades will have different types of teeth depending on the purpose of the blade and the type of material it is expected to cut gt Angle ground teeth are the most common type of teeth for wood cutting applications These teeth have sharpened sides as well as sharp points to provide effective side cut ting of the teeth and not just the tips gt Straight ground teeth are more typical for plastic and metal cutting blades but some wood cutting blades may also have straight ground teeth The tips of the teeth are the primary cutting edges for the blade gt Carbide tipped blades provide for longer blade life Carbide is a harder metal that does not dull as quickly as 14 other metals used for the blade bodies gt Tungsten carbide abrasive blades are used for cutting very hard materials such as ceramics Thes
17. d against a table to allow the sawblade to cut into the splinter guard as it slides the rest of the way on the base For added life as the splinter guard wears you can push it farther back into the base until the gap is gone Carvex PS420 Series Setting the Variable Speed The speed of the saw can be varied from 1500 to 3800 strokes per minute The two D handle models have a broader speed range of 1000 to 3800 strokes per minute Soft wood products and veneer plywoods when the variable speed trigger is utilized Hard wood products The Carvex jigsaws also include an automatic speed setting Plastic laminate countertops designated with an A on the speed dial In this setting the Saw will operate at maximum speed during a cut but will Operate at a reduced speed before the blade makes contact Soft plastics with the workpiece This reduced speed makes it easier to Plaster and cementitious hardboard line up the sawblade with your cut line at the beginning of your cut Hard plastics Aluminum Ceramic To set the speed of the saw rotate the speed dial to the steel desired setting from 1 to A The speed may be adjusted while the saw is running Trigger For the D handle models the speed control dial acts as a maximum speed limit when the variable trigger is used The more you press in on the variable trigger the faster the saw will operate until it reaches the speed setting of the speed dial The optimal speed
18. d until the clamp is clear of the main base 3 Lift the main base off the bottom of the saw Setting the Pendulum Stroke A conventional jigsaw moves the blade up and down ina Use a larger orbit higher number for aggressive cutting in straight line A pendulum jigsaw moves the blade in an softer materials Use a smaller orbit or no orbit for harder orbital motion On the downstroke the blade is guided materials such as harder woods metals ceramics etc or away from the cut and on the upstroke the blade is guided when smoother cuts are desired Also when cutting thinner toward the cut materials a lower orbit setting may produce better results The pendulum stroke should be set to zero when using a The Carvex jigsaw has 4 settings for the pendulum stroke tungsten carbide blade ranging from a wide orbit to no obrbit straight up and down Because a jigsaw cuts only on the upstroke Down Clearing Stroke Up Cutting Stroke this orbital type of motion is more efficient The orbital motion allows the saw to cut more aggres sively and improves the life of the blade However the larger the orbit and more aggressive the cut the rougher the cut may be rotate the lever to settings O off through 3 maximum orbit The lever setting may be changed regardless whether the Saw is running or not 10 l Carvex PS420 Series Roller Installing Removing the Battery i The battery powered Carvex jigsaws PSC 420
19. de holder press it fully in and rotate the blade until it locks into place If the blade does not rotate easily it is not pressed in far enough The small tabs on the side of the blade must be inside the blade holder 5 Adjust the blade guide as described below Adjusting the Blade Guide The Carvex jigsaw features a lower blade guide to ensure that the blade stays straight and true in the cut If the blade was guided only by the blade holder like many other jigsaws the upper half of the blade could flex which would make it more likely that the blade wouldn t be perpendicular to the workpiece For longer life the blade guide is carbide tipped to reduce wear power supply power cord or battery before making any adjustments to the saw or installing or remov ing the blade WARNING Always disconnect the saw from the 1 Unplug the saw or remove the battery This procedure may require you to touch the blade with your fingers so make sure the saw cannot start unexpectedly 2 Install a blade in the saw 3 Remove the Main Base as described on page 10 4 Using the provided 2 5 mm hex key loosen the adjust ment screw enough to ensure the blade fits loosely between the jaws of the blade guide 5 Carefully push back on the blade to ensure it is fitting between the parallel faces of the blade guide jaws 6 While wiggling the blade back and forth tighten the adjustment screw until the jaws are almost touching the
20. e picking up or carrying the tool Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents gt Remove adjusting key or wrench before turning the power 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 gt 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 gt Disconnect the plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally gt Store idle tools out of reach of children and do not allow persons unfamiliar with the power tool or these instructions A Save all warnings and instructions for future reference tools create sparks which may ignite the 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 gt Never use an extension cord that is damaged including cuts exposed wires or bent missing prongs Damaged extens
21. e types of blades cut in an abrasive or filing type of action Serrated blades are used for cutting very soft materials such as building foam The blade functions much like a knife in its cutting action ee Se Angle Ground tere ree ee ee ew ee ee ee wie W E E AT AE Straight Ground Carbide Tipped F ma E pe a he a i r anG M q S a j EE a ra ik r perk eAleee Se Sa ia a Serrated Tooth Set The term tooth Set refers to whether the teeth of the blade extend out past the body of the blade This permits the kerf of the blade s cut to be wider than the body of the blade which reduces the likelihood of the blade binding in the cut or overheating due to friction gt Conical ground blades also called tapered or trapezoidal blades do not have any set in their teeth but the body of the blade is ground to be narrower that the width of the teeth These blades provide very smooth cuts because the teeth are not set side to side from the body of the blade but the body of the blade still has some clearance within the saw kerf Side Set teeth are when each individual tooth is alter nately bent to the left or right of the blade body This results in the kerf width to be wider than the blade body and also makes these blades more aggressive in their cut ting action However the wider the tooth set the rougher the cut surface will be y Wavy set teeth are used almost exclu
22. igger Release aa ee gt Either switch may be used to turn the saw on or off A rea ape thy f Left Power mi 4 Switch C y me ms a Ei Supplemental Owner s Manual 13 Sawblade Selection Festool sawblades are designed for optimal performance in a variety of applications Choosing the correct sawblade is important for obtaining the best cuts and optimal blade life There are several factors that determine which blades are best suited for the operation Some of the important parameters for choosing the best blade are length tooth shape tooth spacing tooth set and type of metal used for the blade body and teeth Blade Usage The shank of Festool sawblades are color coded according to their general usage intention These colors are listed below The specialty blades are an exception in that each blade will have its own special purpose and material type These include carbide tipped blades ceramic cutting blades and serrated foam blades Metal NY Specialty Wood Plastic Blade Length NOTICE Always use a saw blade that is long enough to fully cut through the workpiece Never attempt to make a partial depth cut with a jigsaw Attempting to make a cut with a saw blade that is too short to fully cut the workpiece will likely damage the blade and possibly the saw itself It is important to use a saw blade that is the correct length for the material being cut Be
23. ill pay for return shipping to the customer using UPS Ground Service All war ranty service is valid 3 years from the date of purchase on your receipt or invoice Proof of purchase may be required 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 jigsaw blades sanding belts and grinding wheels Operating a tool at a voltage or frequency different from the tool s rating will void the warranty This includes the usage of the tool in combination with a transformer Festool does not condone nor support the use of any non Festool engineered designed and manufac tured accessories or consumables with Festool products Use of any non Festool products may affect performance or void the warranty Festool is not responsible for any damages or losses incurred and user assumes all risk and responsibility with non Festool derived products Also excluded are wearing parts such as carbon brushes lamellas of air tools rubber collars and seals sanding discs and pads and Festool gear hats and Shirts 1 The following is an exemplar Festool limited warranty The actual warranty that comes with your power tool is controlling 2 Tool must be returned in complete and whole condition as supplied to include
24. ion cords increase the risk of fire or electric shock gt 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 50 Ft 50 100 Ft gt 100 Ft Not recommended tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury gt Do not overreach Keep proper footing and balance at all times This enables better control of the tool in unexpected situations gt 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 gt If devices are provided for the connection of dust extrac tion and collection facilities ensure these are connected and properly used Use of dust collection can reduce dust related hazards gt Always wear safety glasses complying with ANSI Z87 1 Ordinary glasses are not proper protection to operate the power tool Power tools are dangerous in the hands of untrained users gt 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
25. itation may not apply 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 prov ince law as limited above the foregoing express limited war ranty is exclusive and in lieu of all other warranties guarantees agreements and similar obligations of Festool Festool makes no other warranty express or implied for Festool portable power tools This warranty policy is only valid for tools that are purchased in the US and Canada Warranty policies of other countries may vary when obtaining warranty service outside the US and Canada Some countries do exclude warranty for prod ucts bought outside their territory Festool reserves the right to reject the repair of any tool that is not part of the US Canada product line No agent representative distributor dealer or employee of Festool has the authority to increase or otherwise change the obligations or limitations of this warranty Repairs If your Festool power tools require repair you must contact our Service Department at 800 554 8741 613 363 0169 Canada for authorization and address details To expedite the repair please fill out and enclose the Repair Order Form Download the form at www festoolusa com www festoolcanada com No collect shipments will be accepted No Festool hats shirts or other wearables may
26. l Owner s Manual S Functional Description Right Side PSC 420 EB PSBC 420 EB PS 420 EBQ Item Name or Description Item Name or Description _ Ref Page s A Chip Guard 5 H Plug It Power Cord Port 12 B Base nset 9 I Speed Control __ 8B Pendulum Lever 10 J Trigger Release _ __ B D MainBase 10 K Variable Speed Trigger 13 E Left amp Right Power Switch 13 18 F Blade Release Lever 8 M Battery o n G Dust Collection Port 915 N LED Work Lights 18 6 Carvex PS420 Series Intended Use The Carvex jigsaw is designed for sawing of wood wood as specified in these operating instructions Using the tool like materials and plastics With special saw blades offered in contravention to this manual will void your warranty and by Festool the saw may also be used for cutting aluminum may lead to injury The user shall be responsible and liable steel non ferrous metals and ceramic The tool should for damages and accidents resulting from misuse or abuse not be altered or used for any other purpose other than of this saw Technical Specifications Jigsaws PT pg 420 EBQ PSB 420 EBQ PSC 420 EB PSBC 420 EB Barrel Grip D Handle Barrel Grip D Handle Corded Corded Battery Battery 1500 3800 1000 3800 1500 3800 10 8 18 0 VDC 26 mm 1 02 Arete aldneas tle with appropriate blade Bevel Angle Batteries and Charger Description The battery powered jigsaws c
27. led such as cutting through nails and other ferrous materials Sparks and heck that th i i a eee eee eee A hot embers can cause a fire in the dust extraction system the reciprocating saw blade If the saw blade strikes another object it may cause a kickback gt Always check the saw blade to make sure it does not have p gt Never cut material that is thicker than the length of the saw missing teeth or is bent Do not use a damaged saw blade blade gt Do not touch the saw blade after prolonged cutting The saw blade may be hot and cause burns Specific Safety Rules for Battery Powered Tools gt Remove the battery before adjusting the tool or changing gt When the battery pack is not in use keep it away from metal saw blades Failure to do so may result in the tool starting objects like paper clips coins keys nails screws or other unexpectedly small metal objects that can make a connection from one terminal to another Shorting the battery terminals together gt Use only battery packs specifically designated for use with the fica ese Dune Or itr power tool Use of any other battery packs may create a risk of injury and fire gt Under abusive conditions liquid may be ejected from the bat tery avoid contact If contact accidentally occurs flush with water If liquid contacts eyes additionally seek medical help Liquid ejected from the battery may cause irritation or burns gt Recharge the battery only with
28. lockwise raises the bevel feet Rotating the knob counterclockwise lowers the bevel feet The best way of setting the bevel angle is to set the angle between the left and right bevel feet The angle between the bevel feet will be twice the bevel angle Hint A digital angle finder is ideal for this operation In the example below the angle finder was reset to zero when the two arms were pointing in opposite directions 180 The reading on the display 45 is twice the actual bevel angle 22 5 For setting the approximate angle the angle base includes a built in angle indicator that shows the angle between the base and the blade ot F il i Indicator E Lines Supplemental Owner s Manual 17 Maintenance and Adjustment AN WARNING Any maintenance or repair work that requires opening of the motor or gear hous ing should be carried out only by an authorized Customer Service Center see your dealer for information on locating a service center WARNING To reduce the risk of electrocution or other personal injury always unplug the tool from the power supply outlet or remove the battery before performing any maintenance or repair work on the tool AN Routine Maintenance Keep the Saw Clean Dust and debris from some materials can be extremely abrasive and cause components within the saw to wear prematurely It is important to keep moving parts cleared of abrasive dusts Adjust
29. ments Programming the LED light Function AN WARNING The stroboscopic function of the LED light may make it difficult to determine the blade position or give the appearance that the blade is not moving WARNING Never look directly into the LED lights A The lights are very bright and may damage your vision The LED work lights have 3 programmable settings These are stroboscopic steady on and off To reduce the likeli hood of the bright LED lights from shining in the operator s eyes the lights will automatically turn off any time the saw is rotated slightly past vertical toward the upside down posi tion These three operating modes are described below Stroboscopic The stroboscopic function means that the LEDs will operate in unison with the speed of the sawblade stroke This synchronous operation will make the sawblade appear stationary instead of a blur of motion The purpose of this stopped motion appearance is to make it easier to follow a pencil line The stroboscopic effect is active only when the blade speed is above approximately 2100 strokes per minute This means the frequency range of the light is 35 to 63 Hertz Steady On In the steady on mode the LED lights will be active and steady on anytime the saw is operating except when the saw is turned upside down Off In this mode the LED lights are disabled WARNING Do not perform this adjustment with a sawblade installed in the jigsaw This adjustme
30. n page 8 3 Press down on the back of the release tab and slide the base insert forward about 1 2 inch 4 Lift the base insert off the main base to remove it Felt Insert w Replaceable Felt gt Phenolic Insert This insert provides a smooth hard and low friction base for abrasive environments that could scratch softer inserts gt Dimpled Insert This insert is designed to provide smooth operation on rough surfaces such as rough sawn lumber The dimples rounded studs glide over and between the rough features of the workpiece surface gt Stainless Steel Insert This insert is ideal for working on steel aluminum and other very hard materials that would scratch even the phenolic insert Phenolic Insert Stainless Steel Insert Installing Removing the Dust Collection Port The dust port is used to connect a dust extractor to the jigsaw Refer to Using Dust Extraction on page 15 It may be used with the standard base or the guide rail base However the dust port cannot be used with the angled base See page 10 for more information on the different bases gt To remove the dust port from the base press down on the release tab and slide the port out from the base gt To install the dust port slide it into the base until the release tab clicks into place Supplemental Owner s Manual Changing the Main Base Three bases are available for the Carvex jigsaw The bases Festo
31. nt may result in the saw starting unexpectedly 1 Remove the sawblade from the saw as described on page 8 2 Hold the saw in such a manner that when the LED lights turn on they will not shine directly into your eyes 18 NOTICE Do not use compressed air to clean the motor housing of the tool as you could inject for eign objects into the motor through the ventilation openings NOTICE Certain cleaning agents and solvents are harmful to plastic parts Some of these include but are not limited to Gasoline Acetone Methyl Ethyl Ketone MEK Carbonyl Chloride cleaning solutions containing Chlorine Ammonia and household clean ers containing Ammonia gt As a general rule keep the saw clean of all dust and debris Even soft wood dust can be abrasive over time gt Examine all moving parts for dust and debris gt Keep the blade area and dust extraction port clean of debris Debris can cause wear and reduce the effective ness of the dust extraction system 3 Simultaneously press and hold both left and right barrel power switches until the saw beeps gt If the saw turns on turn it back off and try again The saw may turn on if both switches are not pressed simultaneously gt It will take approximately 10 seconds for the saw to beep from the time you first pressed the two switches gt The LED lights may or may not come on after the saw beeps depending on the previous program mode 4 When the saw
32. nto the electrical down receptacle on the front of the dust extractor and turn the E E power switch to Auto Dust Collection Port gt When the power switch is in the manual or off position the electrical outlet will not have any power 5 For cordless models turn the power switch to manual Saw s Power Switch Power Cord Set to Auto Dust Collection Port Using the Jigsaw with a Guide Rail When the optional guide rail base see page 10 is 5 Place the jigsaw base over the rear T slot of the guide rail installed on the jigsaw the saw may be used with a Festool and perform the cut as normal guide rail for performing straight cuts In this configura tion the distance from the rear edge of the guide rail to the center of the blade is approximately 13s 35mm 1 Install the optional guide rail base as described on page 10 2 Position the guide rail parallel to the desired cut line and 13s 35mm away from the center of the cut Note you will need to subtract 12 the thickness of the blade to set the distance to the edge of the cut instead of the center of the cut 3 Clamp the guide rail to the workpiece NOTE The body of the jigsaw does not press down on the guide rail To reduce the chance of slipping it D a Guide Rail is recommended to clamp the guide rail lt p SA 4 For best results it is recommended to use a blade with a wide tooth side set such as the FSG blades S
33. ocedure to remove the cord Locking Ring Installing the Splinter Guard The clear plastic splinter guard serves as a zero clearance l throat along the blade to reduce splintering of the topside of the workpiece The splinter guard is a consumable com ponent that is replaced when it wears or when blades of different thicknesses are used A 12 WARNING This procedure requires the saw to be 4 powered and in operation during a portion of the installation procedure Care must be taken to pre vent personal injury Remove the battery or unplug the saw when instructed to do so NOTICE Make sure to fully tighten the plug it cord a full quarter turn until it clicks If the plug is not fully locked the socket and cord can overheat and be damaged NOTE The 18 gauge plug it cord is interchangeable with other tools that use the same size cord but it cannot be used with larger tools such as routers and saws The plug has an extra key to prevent it from being used on a larger tool that would otherwise damage the cord Larger cords may be used with smaller tools but not the reverse Port rotates on PS 420 EBQ model Unplug the saw or remove the battery to prevent accidental starting 2 Rotate the pendulum stroke lever to the zero position 3 Slide the plastic splinter guard onto the ribs on the main base but not far enough to touch the blade Turn the saw on and press the front of the splinter guar
34. ol guide rail or the Festool trammel for cutting can be installed and removed without tools circles The guide rail base can be used with or without dust collection For more information refer to Using the Jigsaw with a Guide Rail on page 15 or Using the Trammel to Cut Circles on page 16 Standard Base The Carvex saw comes equipped with the standard base and standard base insert The standard base is used to mount any of the optional base inserts described on page 9 The standard base can be used gt Angle Base The angle base is used for making bevel cuts with or without dust collection with the jigsaw The two pads can be angled from 45 to gt Guide Rail Base The guide rail base also called the cea information refer to Making Bevel Cuts adapter base is used to guide the saw using either a Standard Base Guide Rail Base Angle Base NOTE Make sure the guide rail base is installed par allel with the blade by wiggling it side to side before closing the release lever If it is installed with a slight skew to the saw blade it may cause the saw to drift off the cutting line when using the saw with a guide rail or trammel power supply power cord or battery before making any adjustments to the saw or installing or remov ing the blade WARNING Always disconnect the saw from the Unplug the saw or remove the battery to prevent acci dental startup 2 Rotate the base release lever outwar
35. plugs with earthed grounded power tools Unmodified plugs and matching outlets will reduce risk of electric shock gt 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 gt Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock gt Do not abuse the cord Never use the cord for carrying pull ing 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 gt 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 gt Use personal protective equipment Always wear eye pro tection Protective equipment such as dust mask non skid safety shoes hard hat or hearing protection used for appro priate conditions will reduce personal injuries gt Prevent unintentional starting Ensure the switch is in the off position before connecting to power sourc
36. s for clockwise rotation and the other for counterclockwise rotation Use the trammel point that is directly across from the sawblade when the circle cutter is mounted to the jigsaw Install the desired sawblade into the saw If the radius diameter of the cut is small use a scrolling sawblade For larger diameter circles the high side set teeth of the FSG blades will probably work best Install the guide rail base on the saw as described on page 10 If you are cutting a full circle you will need a starting point for the sawblade that lines up with your circle a Using a pencil and the cutting indicator trace out a portion of the circle where you will manually begin cutting b Drill a hole on the waste side of your circle large enough to insert the sawblade into c Use this starting hole to manually begin cutting the circle just enough to get the sawblade lined up with the cut Place the jigsaw onto the circle cutter and continue with the cut 10 Before completing the cut make sure that both the waste piece and the saved piece are supported Carvex PS420 Series Making Bevel Cuts Bevel cuts may be made with the optional angle base The angle base provides bevel angles up to 48 to the left and to the right It can also function on both inside and outside corners for edge registration To adjust the bevel angle rotate the adjustment knob on the rear of the angle base Rotating the knob c
37. sively for fine tooth blades such as metal cutting or fine scroll blades The teeth are so close together that it is not possible to put a set on each tooth separately so the teeth are set in groups with a waving pattern down the length of the body Carvex PS420 Series Operation Using Dust Extraction The Carvex jigsaw can be used with or without a dust 3 Slide the vacuum hose over the dust collection port The extraction system For best results however a dust extrac outside diameter of the port is approximately 27 mm tion system such as the Festool CT 22 shown below should be used Festool dust extractors have the added features of variable speed and sensing when the corded model saw b w is turned on When a corded model saw is plugged into the electrical outlet on the vacuum the vacuum will automati cally start when the saw is turned on and will remain run ning for a couple of seconds after the saw turns off to clear the remaining dust NOTE A battery operated saw will not activate the automatic function of the vacuum The vacuum will have to be activated manually NOTE The Angled Base see page 10 does not permit the dust collection port to be installed Therefore dust collection will not be available 1 To use the dust extraction system install the dust collec tion port as described on page 9 2 For improved air flow of the vacuum slide the chip guard 4 For corded models plug the jigsaw i
38. the charger specified by the manufacturer A charger that is suitable for one type of bat tery pack may create a risk of fire when used with another battery pack gt Do not place batteries near fire or heat This will reduce the risk of explosion and possibly injury Respiratory Exposure Safety Warnings Substantial or repeated inhalation of dust and other airborne dusts especially from hardwoods but also from some soft contaminants in particular those with a smaller particle size woods such as Western Red Cedar may cause respiratory or other illnesses Various dusts created by power sanding sawing grinding drilling and other construc The risk from these exposures varies depending on how often tion activities contain chemicals or substances known to the you do this type of work To reduce your exposure to these State of California and others to cause cancer birth defects or chemicals work in a well ventilated area and use a properly other reproductive harm Some examples of these chemicals functioning dust extraction system When the inhalation of substances are lead from lead based paints crystalline silica dust cannot be substantially controlled i e kept at or near the from bricks cement and other masonry products arsenic and ambient background level the operator and any bystanders chromium from chemically treated lumber and some wood should wear a respirator approved by NIOSH for the type of dust encountered Supplementa
39. upplemental Owner s Manual 15 Using the Trammel to Cut Circles The optional circle cutter trammel permits the jigsaw to cut circular holes in a workpiece from the minimum and maximum sizes shown in the table below The optional circle cutting trammel attachment mounts to the underside of the optional guide rail base see page 10 The circle cutting attachment contains the following features gt Built in tape guide showing the cutting radius from 46 mm to 1500 mm gt Clamping knob to lock the trammel at the desired radius gt Index pointers and trammel points for either right or left hand mounting to the jigsaw base gt Trammel points for either clockwise or counterclockwise cutting directions gt Trammel point pin with on tool storage location Trammel Point Pin Storage Clockwise Trammel Point Counterclockwise Trammel Point Cutting Indicator 16 Identify the location of the center of the arc or circle you wish to cut 2 Drill a 4mm 5 32 hole at the center of the arc or circle 3 Loosen the clamping knob and extend the tape measure until the index pointers are pointing to the desired radius The radius is 1 2 the diameter of a circle Retighten the clamping knob Insert the trammel point pin through the trammel point of the circle cutter and into the hole you drilled into the workpiece above gt There are 2 trammel points on the circle cutter One i
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