Festool ATF 55E User's Manual
Contents
1. Figure 5 5 a Riving Knife The riving knife is a safety feature that prevents the cut from closing and binding on the sawblade This reduces the chances for a kickback See page 4 for more information on kickbacks 5 b Retaining Screw The retaining screw holds the riving knife in position Use this screw when removing or adjusting the riving knife See page 11 for more information on removing and adjusting the riving knife Technical Specifications sisi pie viai rri Only metric sawblades should be used Maximum Depth of Cut 50 mm 90 37 mm Q 45 using the guide rail 1 15 16 in 90 1 7 16 in 45 Certifications IEC 745 UL745 CSA C22 2 745 6 ATF 55E Circular Saw Systainer System Container Every Festool product is shipped in its own unique system container called a Systainer This provides protection and storage for the tool and accessories All Systainers are stackable and can be interlocked together including stacking and locking atop Festool dust extractors Setup and Adjustments Setting up and Adjusting a New Saw PNP INNER Always disconnect the saw from the power supply before making any adjustments to the saw or installing or removing any accessory Follow this sequence of inspections and adjustments before using a new saw It is important that this sequence be followed before cutting the zero clearance splinter guard l With the saw unplugged inspect the b2. v All due care should be practiced while using extension cords with this tool When operating a power tool outside use an outdoor extension cord marked W A or W These cords are rated for outdoor use and reduce the risk of electric shock gt Never use an extension cord that is damaged such as cuts exposed wires or bent missing prongs gt Use only extension cords rated for the purpose Personal Safety Stay alert watch what you are doing and use common sense when operating a power tool Do not use 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 Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Avoid accidental starting Be sure the switch is off before plugging in the power cord Carrying tools with your finger on v v Save These Instructions Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control 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 to carry the tools or pull the plug from an outlet Keep cord away from heat oil sharp edges or moving p
3. cherry and maple Plastic laminate countertops Hard plastics Soft plastics 1 4 Masonry and cementitious hardboard Aluminum 4 6 Figure 19 19 a Plunge Release Lever 19 b Power Switch trigger To prevent unexpected start ups the power switch has an integral safety interlock Before the saw can be started the plunge release must be engaged l Press up on the plunge release lever 2 Pull back on the power trigger Bevel Setting Bevel cuts are made when the blade is tilted with respect to the sole plate Figure 20 20 a Front Locking Knob 20 b Rear Locking Knob 20 c Bevel Setting Gauge Setting the Bevel Angle 1 Loosen the front 20 a and rear 20 b locking knobs 2 Tilt the saw to the desired angle as indicated on the bevel setting gauge 20 c 3 Re tighten the two locking knobs Instruction Manual 13 Dust Extraction Figure 21 21 a Diverter Storage 21 b Dust Port 21 c Retaining Ribs The ATF 55E can be used with the standard dust extraction diverter or with a vacuum system When not in use the diverter is stored on the sole plate of the saw 21 a For best performance a vacuum system is recommended Basic Sawing Intended Use The ATF 55 E is designed exclusively for the sawing of wood wood like materials and plastics With the special saw blades for aluminum offered by Festool this tool can also be used for sawing aluminum This tool should not be used for processing other m
4. cut 6 Move the saw forward until the cut is complete 24 d The leading edge of the guide stop overlaps the saw s sole plate to stop the saw from lifting up causing a kickback during the initial plunge Instruction Manual 15 Troubleshooting 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 Motor does not start and no indicator lights come on 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 Motor does not start but the power The brushes have worn and need replacement When the brushes wear to a indicator Green LED is certain point the saw stops running to prevent damage to the motor illuminated The overload light Red LED The saw may not be getting enough power due to a voltage drop caused by a comes on frequently long or light gauge extension cord Use a heavier gauge cord The wrong blade is being used or the feed rate is too fast The rear of the blade may be too close to the cut Adjust the blade skew setting on page 10 The motor bearings may be worn Send the saw in for service The saw makes a Growling sound This sound is normal and expected It is the result of the gears in the saw s when it is first turned on or i
5. 5 0 6 0 mm Hex Keys T10 T15 T20 Torx Drivers 4 5 mm Straight Blade 2 PoziDrive E ye Y x N M J k 1 3 u A i AIN Rip Fence Item Numbers 483 278 and 484 583 Use the rip fence instead of the guide rail for making a rip using the edge of the workpiece as a reference Y lt q wt 20 ATF 55E Circular Saw Warranty Conditions of 1 2 Warranty You are entitled to a free extended warranty 1 year 2 years 3 years for your Festool power tool Festool shall be responsible for all shipping costs during the first year of the warranty During the second and third year of the warranty Festool Limited Warranty This warranty is valid on the pre condition that the tool is used and operated in compliance with the Festool operating instructions Festool warrants only to the original consumer purchaser that the specified tool will be free from defects in materials and workmanship for a term of one year from the date of procurement Festool makes no other warranty express or implied for Festool portable power tools No agent representative distributor dealer or employee of Festool has the authority to increase or otherwise change the obligations or limitations of this warranty The obligations of Festool in its sole discretion under this warranty shall be limited to the repair or replacement of any Festool portable power tool that is found to be defective as packaged with the User Manual Excluded from
6. M E 19 ERA CES OT K atta D ne eae aa ea ee T O A CRM E eo eee are 20 BOTENG Er Un 20 Ur versab Tool Tote aiii ia 20 VY ALTONILY sata its 21 Conditions or TEZ WA AA A ao 21 Festool Limited Warrants ati 21 able tai E 21 2 ATF 55E Circular Saw General Safety Rules Important Read and understand all instructions listed below Failure to heed instructions may result in personal injury electrocution or fire hazard Work Area Keep your work area clean and well lit Cluttered benches and dark areas invite accidents gt Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes Electrical Safety gt Double insulated tools are equipped with a polarized plug one blade is wider than the other This plug will fit ina polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation eliminates the need for the three wire erounded power cord and grounded power supply system Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Extension Cords
7. This is the scrap side of the cut Figure 9 Igu 11 b After being cut the two halves of the board are placed 10 a Front 90 degree Stop Screw back together to verify that the original cut line is tight 10 b Rear 90 degree Stop Screw not visible 11 c and 11 d After the offcut is flipped end for end the 10 c Bevel Lock knobs one front and one rear bevel error becomes visible Adjustment Procedure Using the guide rail carefully cut a small piece of wood 4 Inspect the joint between the two boards in half If there is no gap then the adjustment is correct gt This is a precision adjustment Make sure the guide rail If the gap is at the top of the two boards 11 c then turn and workpiece are securely clamped the adjustment screws clockwise The piece should be at least 20 mm thick and about 50 If the gap is at the bottom of the two boards 11 d then cm square Y inch thick by 12 inches square turn the adjustment screws counterclockwise The thicker the piece the more accurate the adjustment 5 Loosen the front and rear bevel lock knobs 10 c will be Turn the two stop screws 10 a and 10 b in the direction For best results the material should have a consistent determined in step 4 Make sure to turn both screws the center such as Medium Density Fiberboard MDF same amount plastic or solid lumber Bach turn of the adjustment screw will have the 2 Place the two pieces back together to verify tha
8. 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 Also excluded are wearing parts such as carbon brushes lamellas of air tools rubber collars and seals sanding discs and pads and batteries Festool portable power tools requiring replacement or repair are to be returned with the receipt of purchase to Festool call 800 554 8741 for address details 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 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 2005 TTS Tooltechnic Systems AG amp Co KG ATF 55 E 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
9. for more information The ATF 55 E is fitted with a riving knife All saw work with the exception of plunge cuts should be carried out only with the riving knife installed and correctly set Perform the guide rail gib adjustment procedure described on page 8 Only after all other inspections and adjustments have been completed cut the zero clearance splinter guard as described on page 8 Adjusting the Guide Rail Gibs The guide rail gibs keep the saw s sole plate tightly aligned with the rib of the guide rail system There is one adjustment gib at the front of the saw and one at the rear Both need to be adjusted Figure 8 8 a Adjustment Gib 8 b Adjustment Screw not visible 8 c St Setting the Blade Perpendicular to the Sole plate This adjustment ensures that cuts are made square to the workpiece surface This adjustment is completed at the factory and shouldn t need to be adjusted unless the tool has been modified or serviced The most accurate method for checking the square of the blade is to make a cut with the saw and examine the resulting cut For even greater accuracy the procedure below uses a method that amplifies a small measurement into a larger measurement to make it easier to observe This doubles the accuracy of the adjustment Figure 11 Figure 11 shows three views of a board that has been cut in half with the saw This is used to calibrate the adjustment 11 a Offcut
10. or invoice IN NO EVENT SHALL FESTOOL BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR BREACH OF THIS OR ANY OTHER WARRANTY EXPRESSED OR IMPLIED WHATSOEVER ALL WARRANTIES IMPLIED BY STATE LAW INCLUDING THE IMPLIED WARRANTIES OF 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 apply to you With the exception of any warranties implied by state or province law as hereby limited the foregoing express limited warranty is exclusive and in lieu of all other warranties guarantees agreements and similar obligations of Festool This warranty gives you specific legal rights and you may also have other rights which vary from state to state in the U S and province to province in Canada As hereby limited the foregoing express limited warranty is exclusive and in lieu of all other warranties guarantees agreements and similar obligations of Festool This warranty gives you specific legal rights and you may also have other rights which vary from state to state in the U S and province to province in Canada consequent to your 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 so
11. ATF 55E am d n aa J TEH 1 bi FES TOOL Circular Saw Instruction Manual Important Read and understand all instructions before using this tool Contents Riiie cU cin A e A A E E llas E 3 Dpecitic oalety Rules tor CCU SAWS nadia ica 4 LD yt ol als iaimmerer enema baie ps e Mi tee adis see OS 5 Motor Controls NET 6 Une A O er ee rete err 6 a eval gl eel bre A RO 6 Systamer System Conta A a ens A SAA A tec cies Se eau di 7 Setuprand a Us A A A A 7 Se EIN uprand Adun a NEW SIW ay OAE A O O O 7 Adjustino the Guide Rais arenada ida aci 8 Trim the sp inter Guards ssp uo editi A aia 8 petting the Blade Perpendicular to the Sole Plate sida ii 9 Adus anehe blade POSIIOD es tae yer ces aletas dit et rere 10 Replacing the Splinter UAT eR Em 11 Removine Replace Adjusine the Rivno FoU cerina aeq id 11 Chane ine the Saw Dla di id 12 OPE tato sli eiu eu LM 12 Dette tne Blade Detail irc cdes 12 Speed Bora o o n 13 Lower SW UCU igac ts aescatancceatdeicuesca iste ditacwa A uta aecenalenuatie 13 DeVel A ere ere en E refer ree RUE E Eod e ee ere Disi ee E E E en 13 WDUIG EE XUACTION 9 CEPAP ET na AO 14 Bic Sa Uo A IS A A AA A SAA 14 Makine PIutige Cuisine AA NOA 15 Ghigo bi bles Une plenas A T O tre ore eee ee 16 Mantenga e ep 17 Rounne VNC UIUC AT NCS c REDE DN MN nre 17 Chane me the Motor bruselas llcits 18 ACCES OLC RU RE MN a aa aaa a a 19 DAW Esto Cero PAPER ET EEE T EE EEE PT A E AA AET AA T E PTT A TA
12. arts Replace damaged cords immediately Damaged cords increase the risk of electric shock 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 saw to lose power and damage the saw Extension Cord Ratings Cord Length Size AWG 50 100 Ft 12 100 150 Ft 10 Not recommended 2150 Ft the switch or plugging in tools that have the switch on invites accidents Remove adjusting keys or wrenches before turning the 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 Proper footing and balance enables better control of the tool in unexpected situations Use safety equipment Always wear eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions Ordinary glasses are NOT v proper eye protection Tool Use and Care Use clamps or other practical way to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed Do not use the tool if the switch does not turn it on or off Any tool that cannot be controlled w
13. aterials The saw should not be converted 14 Figure 22 Figure 22 shows the diverter 22 a installed and directing the dust to the side The diverter can be rotated so dust can be directed downward or to the side Connect either the diverter or a vacuum hose by pressing the end into the dust port 21 b of the saw The dust port has two ribs 21 c that hold the extractor in place Tilting the hose slightly to engage one rib first and then the other works best or modified for any other form of use other than as specified in these operating instructions AAN The user is solely responsible for any damage or accident should the machine be used for other than its intended purpose Figure 23 23 a The optional guide rail clamp holds the guide rail to the workpiece 23 b The blade is lowered to cutting depth before entering the cut 23 c The optional cord guide prevents the power cord and vacuum hose from catching on the end of the guide rail ATF 55E Circular Saw Safety Checks Inspect the saw for loose parts and for proper operation During the cut if the Motor Overload light turns on Inspect the area underneath the cutting path to make sure slow down the feed rate of the saw see Motor Controls on you will not cut through other objects page 6 Make sure the power cord is behind the saw and not Push the saw forward to cut Never pull the saw back as within the cutting path this can cause the sa
14. dling heavy duty drivetrain reacting to the speed control of the motor The speed of the motor is controlled by turning the motor On and Off very rapidly This form of speed control is called Pulse Width Modulation PWM and is common in most power tools with a variable speed control When there is no load on the sawblade the pulsations of the motor cause the gears to rapidly engage and disengage called backlash and this is the sound you are hearing The saw makes wavy cuts Make sure the guide rail gibs are properly adjusted Inspect the blade for damage Make sure the sole plate is not rocking on the guide rail It is acceptable if the center of the sole plate is concaved but all four corners should touch the guide rail Keep the blade depth consistent during the cut don t raise and lower the blade Forcing an ATB type blade into the cut too fast can cause the blade to deflect The rear of the blade may be too close to the cut Adjust the blade skew setting on page 10 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 Reduce the motor speed The rear of the blade may be too close to the cut Adjust the blade skew setting on page 10 If possible increase the blade depth Excessive chipping on the lower Make sure to use the correct blade for the type of material and type of cut edge of the cut The rear of t
15. e 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 15 This moderate bevel angle provides 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 Instruction Manual 19 Guide Rail Accessory Kit Universal Tool Toolie Item Number 492 396 Item Number 490 833 Contains Miter Gauge Splinter Guard Guide Stop Cord Guide Guide Rail Connection Bars Guide Rail Clamps Systainer This single tool contains all of the drivers and keys necessary to adjust any Festool tool Exception Note that the arbor bolt on the saw uses a special hex key for changing blades Using the Toolie can damage the arbor bolt Contains 2 5 4 0
16. e matched to an existing saw or guide rail system or To restore the factory default distance prior to replacing the splinter guard Do not install a new splinter guard until after this procedure is complete l Loosen but do not remove the four sole plate adjustment screws 12 a and 12 b the bevel angle pointer screw 12 d and the two bevel locking knobs 12 c 10 ATF 55E Circular Saw 410 02 341 09956 525 025 4 After the cut is complete unplug the saw for safety but and workpiece but two sheets of paper should not fit leave it on the guide rail 6 Ifan adjustment is necessary loosen the rear bevel 9 Lower the sawblade to its maximum depth and examine locking knob and move the back of the saw until the the gap between the blade and the workpiece using a 0 15mm gap is achieved regular piece of paper as a thickness gauge 7 Retighten the bevel locking knobs before removing the gt The front of the blade should be tight to the workpiece saw from the guide rail and then retighten the other You should not be able to slip the paper between the blade screws Set the bevel pointer to zero before tightening and workpiece the screw The rear of the blade should be 0 15mm away from the workpiece The paper should fit loosely between the blade Replacing the Splinter Guard The splinter guard prevents splintering and chipping of the F 14 workpiece by holding the top edge of the workpiece down as the ee teeth
17. etting There is one at the front and one at the rear of the saw 1 g Arbor Access Hole During a blade change the arbor screw can be accessed through this opening h Riving Knife Access Hole The retaining screw for the riving knife is accessible through this opening Single point Entry Instruction Manual Figure 2 2 a Plunge Depth Scale Used with the plunge depth stop 2 b this sets the depth of cut 2 b Plunge Depth Stop This sets the limit on how deep the blade will travel into the cut 2 c 90 degree Stop Screws The screws are for fine adjustment so the blade is at 90 degrees to the sole plate 2 d Sole Plate 2 e Dust Deflector Storage When the saw is used with a vacuum the dust deflector can be stored on top of the rear guide rail gib 2 f Hex Key Storage The hex key for changing the blade is stored here 2 8 Guide Rail Gibs These are adjusted so the saw fits snugly on the guide rail The second gib is not visible underneath the dust deflector 2 e Single point entry means that the sawblade always enters the cut at the same location regardless what the bevel angle is set to The pivot point of the bevel adjustment is located at the bottom edge of the splinter guard 3 a This means that the cut will always be along the splinter guard for any bevel setting Note that this is applicable only when the guide rail is used When the guide rail is not under the saw the bevel cut will move slig
18. f the blade can dig into the top surface of the wood causing objects that can cause kickback the blade to climb out of the kerf and jump back toward the operator When the blade is pinched or bound tightly by the kerf closing down the blade stalls and the motor reaction drives the unit rapidly back toward the operator Kickback is the result of incorrect operating procedures or conditions and can be avoided by taking proper precautions as described below gt Maintain a firm grip with both hands on the saw and position your body and arm to allow you to resist kickback forces Kickback forces can be controlled by the operator if proper precautions are taken If the blade is binding or when interrupting a cut for any reason release the trigger and hold the saw motionless in the material until the blade comes to a complete stop Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur Investigate and take corrective actions to eliminate the cause of blade binding When restarting a saw in the workpiece center the saw blade in the kerf and check that the saw teeth are not engaging the material If the saw blade is binding during a restart it may climb up or kickback from the workpiece gt Do not use a dull or damaged blade Dull or improperly sharpened blades cause excessive friction blade binding and kickback Support large panels to minimize the risk of t
19. he blade may be too close to the cut Adjust the blade skew setting on page 10 A very shallow blade depth can cause chipping on the underside if the teeth are barely protruding below the surface Increase the blade depth Excessive chipping on the top edge Make sure to use the correct blade for the type of material and type of cut of the cut Inspect the splinter guard Make sure it is flush with the cut line for its entire length Materials prone to splintering may splinter more if the blade is set too deep 16 ATF 55E Circular Saw Maintenance Routine Maintenance Any maintenance or repair work that requires opening of the motor or gear housing should be carried out only by an authorized Customer Service Center name supplied by your dealer Maintenance or repair work carried out by an unauthorized person can lead to improper connection of electrical wires or other components which can result in injury To prevent injury or electrocution always unplug the tool from the power supply outlet before performing any maintenance or repair work on the tool Do not use compressed air to clean the motor housing of the tool as you could inject foreign objects into the motor through the ventilation openings Compressed air may be used on other components but personal safety protection should be employed hearing vision and respiratory Certain cleaning agents and solvents are harmful to plastic parts Some of these incl
20. he blade pinching and causing a kickback Large panels tend to sag under their own weight Respiratory Exposure Warning Various dust created by power sanding sawing arsenic and chromium from chemically treated lumber grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemicals are gt lead from lead based paints crystalline silica from bricks and cement and other masonry products and v v v The risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as dust masks that are specially designed to filter out microscopic particles 4 ATF 55E Circular Saw Tool Description Figure 1 l a Plunge Release and Trigger Safety Release Press this lever upward to release the plunge lock and move the sawblade into the work This lever must be pressed before the power trigger can be engaged 1 b Trigger On Off Switch Pull back on the trigger to turn the saw on Release the trigger to turn the saw off 1 c Arbor Lock Press down on this button to stop the arbor from turning during blade changing 1 d Auxiliary Handle 1 e Dust Extraction Port 1 f Bevel Lock Knobs The knobs lock the bevel s
21. htly outward away from the main body of the Saw Motor Controls Figure 4 4 a Speed Control Knob The ATF 55E has electronic variable speed control that maintains a constant speed under varying loads Turn this dial to change speed from 2100 to 5100 RPM 4 b Speed Control Pointer When setting the speed control line up the numbers on the speed control knob with this pointer 4 c Motor Power Green This green LED indicates when the motor is receiving power This LED should be ON during normal cutting operations 4 d Motor Overload Red This red LED indicates when the motor is being loaded within 70 of maximum power When this LED turns ON you should slow the feed rate of your cut Additional Motor Features Soft Start When the motor is first started it will come up to speed Thermal Overload Protection To protect the motor slowly This prevents the saw from jumping during startup This also under excessive loading it is equipped with extends the life of the components within the saw thermal overload protection This prevents the motor from being damaged due to overheating The motor is disabled until it has cooled down Wait 3 to 5 minutes for the overload protection to automatically reset Overcurrent Protection If the motor is loaded to the point where it can no longer maintain its set speed and the current exceeds the safe limitation of the motor it will shut down operation to protect the motor Riving Knif
22. ing of the carbide teeth of a sawblade can result in serious injury to the saw operator Adjust and Inspect the Saw To ensure the saw is in proper working order periodically inspect the operation of the saw and ensure it is properly adjusted Observe the function of the saw during normal operation Unusual sounds are indicative of pending problems A reduction in the cut quality indicates the saw is either improperly adjusted or not functioning properly A reduction in cutting power or speed may indicate a dull blade or a motor problem If any of the safety devices on the saw are inoperable or disabled immediately stop using the saw and have it serviced Periodically inspect the guide rail gibs for wear and proper adjustment If the gibs are worn or misadjusted the saw will not cut straight 17 Changing the Motor Brushes This procedure should be completed only by an authorized Festool service representative Opening the motor cover WILL void your warrantee This procedure is presented as informational only The motor brushes are graphite bars that provide an electrical connection between the motor controller and the rotating armature The brushes wear over time and need to be replaced When the brushes have worn past their useful length spring loaded pins 27 a are exposed that separate the brush from the armature contacts This disables the motor to prevent damage When the brushes are worn the green p
23. ith the switch is dangerous and must be repaired Disconnect the plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the riske p67 Td06 Tc Shc for v v v Instruction Manual Service gt Tool service must be performed only by qualified repair When servicing a tool use only identical replacement parts personnel Service or maintenance performed by unqualified Use of unauthorized parts or failure to follow maintenance personnel could result in a risk of injury instructions may create a risk of electric shock or injury Specific Safety Rules for Circular Saws Risk of personal injury gt Nes hold the piece being cut in your hands or across your eg It is important to support the work properly to minimize Keep hands away from the blade and cutting area Keep body exposure blade binding or loss of control your second hand on the auxiliary handle If both hands Hold the saw by the insulated handles when performing an are holding the saw they cannot be cut by the blade operation in which the sawblade may contact hidden wiring or Keep your body positioned to either side of the saw its own cord Contact with a live wire will make the exposed blade but not in line with the saw blade Kickback could metal parts of the tool live and shock the operator cause the saw to jump backward See Causes and gt When ripping always use a rip fe
24. justment screw Move the riving knife to achieve the clearance from the blade as shown in figure 15 Tighten the adjustment screw pelagi P Instruction Manual 11 Changing the Sawblade Sawblade Checks and Warnings Use only sawblades that are approved for use with the saw and appropriate for the type of material being cut Use only sawblades with a diameter of 160 mm and an arbor bore of 20 mm gt Do not use a sawblade that is bent or warped Do not use a sawblade with missing or damaged teeth gt The hex hey provided with the saw is specifically designed not to cam out and damage the arbor bolt Do not use a standard Allen wrench or hex key Operation Setting the Blade Depth The ATF 55 E is equipped with a plunging depth stop for setting the blade depth 12 Figure 16 16 a Arbor Screw 16 b Arbor Flange Removal Procedure l Unplug the saw 2 Lower the blade until the arbor screw 16 a is accessible as shown 3 Press down on the arbor lock figure 1 c 4 Using the hex key stored on the sole plate figure 2 f unscrew the arbor screw by turning it counterclockwise standard thread and remove the arbor screw 16 a and arbor flange 16 b 5 Remove the sawblade out the bottom of the saw Replacement Procedure l Insert the new blade up through the bottom of the saw and place it on the arbor Make sure the blade teeth are pointing forward as shown 2 Place the arbor f
25. lade for damage and make sure it is properly secured to the arbor Refer to Changing the Sawblade on page 12 for more information Check regularly whether the saw blade is in good condition Saw blades which are cracked damaged or deformed should no longer be used Instruction Manual Figure 6 6 a 6 b 6 c 6 d Carrying Handle The handle folds flat when not in use Cover Latches These secure the cover and also secure one systainer to another as described below Stacking Tabs These are used to lock two systainers together There are four sets of tabs two on the front and two on the sides of each systainer Stacking Latches These are similar to the cover latches but they serve the purpose of latching onto the side stacking tabs of a systainer stacked above the systainer Stacking Systainers Figure 7 Figure 7 shows how the four latches 2 stacking latches and 2 cover latches are repositioned so they will engage the stacking tabs of the upper systainer 2 Place one systainer on top of the other Release all four latches on the lower systainer by pulling back at their top edges step 7 1 Slide all four latches upward step 7 2 as depicted by the two views of figure 7 Snap all four latches back to their flat position step 7 3 so they engage the stacking tabs item 6 c of the upper systainer Verify that the riving knife is properly secured and adjusted refer to page 11
26. lange over the arbor and rotate it until the tabs line up with the slots in the arbor 3 Make sure the arbor and arbor flange are properly seated with one another 4 Insert and tighten the arbor screw Figure 17 17 a Depth Gauge 17 b Pointer 17 c Lock Button 17 d Depth Stop Adjustment Procedure l Determine the optimal blade depth The depth of the blade is determined by the depth gauge in millimeters 17 a For optimal chip free cutting in plywood and hard plastics the sawblade should be slightly below the bottom of the material about 1 2 of a blade tooth For dense hardwoods softer plastics and aluminum where chipping is less of a concern the blade should be set a little deeper At a deeper setting the blade cuts more efficiently 2 Push in on the lock button 17 c and slide the depth stop 17 d to the desired depth Add 5 mm to account for the thickness of the guide rail ATF 55E Circular Saw Speed Control The ATF 55E has electronic speed control so the speed of the blade remains constant regardless how much the motor is loaded The speed of the motor should be set according to the type of material being cut Figure 18 18 a Speed Control Knob 18 b Pointer 18 c Power Indicator Adjustment Settings Turn the speed control knob 18 a so the speed indicator lines up with the pointer 18 b Soft wood products and veneer plywoods Hardwood products prone to burning when cut i e
27. le discretion of Festool without notice All rights reserved Printed in Germany Electronically duplicated in the United States of America Festool is a trademark and service mark of TTS Tooltechnic Systems AG amp Co KG 21
28. nce or straight edge guide Prevention of Kickback below This improves the accuracy of cut and reduces the chance for gt Do not reach underneath the workpiece The blade is blade binding fully exposed under the workpiece Always use blades with the correct size and shape diamond vs Never use a dust extraction system when making round arbor holes Blades that do not match the mounting cuts that can result in sparks such as cutting through of the saw will run eccentrically causing loss of control nails and other ferrous materials Sparks and hot embers Never use damaged or incorrect blade flanges or bolt The blade flanges and bolt were specially designed for your saw for optimum performance and safety of operation can cause a fire or explosion in the dust extraction system Causes and Prevention of Kickback Kickback is a sudden reaction to a pinched bound or misaligned saw Supports must be placed under the panel on both sides blade that causes an uncontrolled saw to lift up and out of the workpiece near the line of cut and near the edge of the panel as toward the operator shown v The bevel adjusting knobs must be fully tightened before making a cut If the blade tilts during a cut it will bind and cause a kickback Use extra caution when making a plunge cut into existing If the blade becomes twisted or misaligned in the cut the teeth at the walls or other blind areas The protruding blade may cut back edge o
29. nnected to the spades on the brushes 31 a Finish the procedure by reversing the remainder of the removal steps Note that during the break in period while the new brushes conform to the shape of the armature contacts the brushes my exhibit more arcing sparking than normal The ribs 27 b on the new brushes are intended to minimize the arcing during the break in period v v v ATF 55E Circular Saw Accessories Sawblades i m k Description Ripping Panther With a low tooth count and a high The high hook angle of the Nd oe died d Purpose hook angle this blade easily cuts Panther blade makes for effortless ae P 8 i results when a single blade is needed through general construction materials ripping without burning the cut n6 MM for crosscutting and ripping Tooth Type ATB 12 teeth ATB 14 teeth ATB 28 teeth Hook Angle 2 ZZ 3 935 9 15 Item Number 439 685 490 516 Description Fine Crosscut With a high tooth count this blade The ultra hard TCG teeth on this The negative hook angle and high provides excellent chip free blade provide chip free cutting of TCG tooth count of this blade crosscutting of lumber and fine laminates and solid surface provides grab free control for cutting cabinet grade plywood materials without dulling aluminum and hard plastic Tooth Type ATB 48 teeth TCG 48 teeth TCG 56 teeth Hook Angle qr Item Number 491 952 489 457 439 686 Purpos
30. of the sawblade move upward against it The splinter guard 14 a Splinter Guard needs to be replaced if it becomes damaged or worn 14 b Alignment Rib Because the splinter guard is trimmed by the sawblade itis important 14 c Friction Strips that the sawblade is properly adjusted before replacing the splinter guard Verify and or perform the Adjusting the Blade Position Replacement Procedure d d ibed 10 bef lacing th lint d PA E ERCE CEDE page dr ca E CE l Peelthe original splinter guard away from the guide rail 2 Asneeded clean residual adhesive and debris from the guide rail 3 Peeloff the plastic backing from the new splinter guard to expose the adhesive 4 Without stretching the rubber carefully place the new splinter guard on the underside of the guide rail tight to the alignment rib 14 b 5 Make sure the splinter guard is firmly pressed down to the guide rail 6 Trim the splinter guard as described on page 8 Removing Replacing Adjusting the Riving Knife The riving knife must be removed before a plunge cut can be made After it is reinstalled it must be adjusted for proper clearance 15 a Riving Knife Figure 15 15 b Adjustment Screw Removal Procedure Unplug the saw 2 Loosen the adjustment screw 15 b 3 Remove the riving knife and retighten the adjustment screw Replacement Adjustment Procedure Unplug the saw Loosen the adjustment screw 15 b Insert the riving knife under the ad
31. ower indicator figure 4 c will illuminate when the saw is powered but the motor will not run For a shorter break in period without excessive arcing new brushes have ribs 27 b that quickly form to the curve of the armature eel E AEI Used Brush NH 5 Spade L 3 zn UNA ANIMES Make sure the power cord is unplugged before beginning this procedure Failure to do so may result in electrocution l Remove the two screws 28 b that secure the access cover 28 a to the motor 2 As necessary cut or remove any labels that may cover the seams between the motor and the access cover 28 c both sides 3 Remove the cover to expose the motor and brushes 4 Liftthe terminal links 29 a and figure 30 straight up off the brushes and out of their sockets 29 c 5 Remove the two screws 29 b that secure the brushes to the motor housing Be careful not to drop the screws into the motor 18 6 The brushes are spring loaded in their brass sleeves During both removal and replacement tilt the brushes as shown in figure 31 to clear the motor housing al Replacement Notes When replacing the brushes tilt them into position as shown in figure 31 and compress the spring loaded brush assembly as you insert them into their mounting slots When replacing the terminal links figure 30 make sure the forked spades 30 a are inserted into the sockets 29 c and the lugs 30 b are co
32. t the following effect turn equals 1 degree of adjustment v original cut line is tight 11 b If the cut line is not tight make a new cut 1 turn equals Y mm of gap between the boards shown 3 Flip the offcut board 11 a end for end so the cut line is above assuming 20 mm Y inch th92 3 still together but the board is upside down Don t flip the board that was under the saw v Instruction Manual 9 Adjusting the Blade Position Adjusting the position of the blade with respect to the guide 2 Slide the sole plate in or out until one of the following rail system consists of two interrelated adjustments Blade conditions is met depending on the need for this Distance and Blade Skew Both of these adjustments are adjustment completed at the factory and should be altered only if the saw For the factory default setting align the tips of the is damaged modified or needs to match other Festool hinge blocks 13 a to be flush with the tips of the products hinge brackets 13 b as show with Figure 12 12 a Sole Plate Rear Adjustment Screws 12 b Sole Plate Front Adjustment Screws 12 c Bevel Locking Knob front knob not visible 12 d Bevel Angle Pointer Screw Blade Distance In most cases only the blade skew needs to be adjusted the second half of this procedure Adjust the blade distance only if any of the following are true The blade is not cutting along the splinter guard Anew saw needs to b
33. ude but are not limited too Gasoline Acetone Methyl Ethyl Ketone MEK Carbonyl Chloride cleaning solutions containing Chlorine Ammonia and household cleaners containing Ammonia To ensure proper cooling of the tool and motor the cooling vents in the motor housing must always be kept clear and clean 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 As a general rule keep the saw clean of all dust and debris Even soft wood dust can be abrasive over time Examine all moving parts for dust and debris Keep the bevel hinges figure 13 clean of dust using compressed air or cotton swabs If the hinges wear due to abrasive particles the saw will not perform optimally Instruction Manual Keep the blade area and dust extraction ports clean of debris Debris can cause wear and reduce the effectiveness of the dust extraction system Keep the Sawblades Sharp Using a dull sawblade can be extremely dangerous and provide poor cut quality Never attempt to sharpen a sawblade manually Special equipment is necessary to properly sharpen a circular sawblade An improperly sharpened sawblade can injure the operator destroy the saw and damage the workpiece The sawblades should be sharpened regularly and only by a qualified sharpening service Improper grind
34. w to jump backward unexpectedly Before beginning the cut make sure the sawblade is at operating speed Operation l Set the plunge depth page 12 6 Plunge the saw down until it reaches the depth stop 2 Set the motor speed page 13 7 Firmly hold the saw with both hands and push it 3 Place the saw on the guide rail and behind the start of through the cut away from your position the cut as shown in figure 23 8 After the cut is complete release the power trigger and 4 Press upward on the plunge release lever and pull back hold the saw steady until the blade comes to a complete on the power trigger stop 9 Wait for the motor to come up to full speed Making Plunge Cuts Figure 24 Operation 24 a Guide Stop This guide rail accessory limits the travel l Remove the riving knife as described on page 11 of the saw and is necessary for safely making plunge 2 Place the saw on the guide rail where the cut should cuts also shown in 25 a begin A mark on the face of the saw indicates the back 24 b Clamping Knob Tighten this knob to secure the stop to ius a an AO the guide rail l mies ee 3 Slide the guide stop 24 a and 25 a up to the sole plate 24 c Direction Arrow This arrow must point forward and lock it down 4 Set the blade speed To avoid burning the wood during the initial plunge set the blade speed lower than normal for the type of material 9 Turn on the saw and slowly plunge the blade into the
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