909 LS1620 Instruction Manual - User Manual

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Code:

LS1620

Date:

110224

Edition:

Op:

DCR

INSTRUCTION MANUAL

LS1620

125W 50mm

VARIABLE SPEED SCROLL SAW

WITH WORK LIGHT

CONTENTS

Warranty Power Tools

For full details please visit us at www.909.com

Introduction

Environmental protection

Description of symbols

Specifications

General safety instructions

Additional safety rules for scroll saws

Accessories

Unpacking

Assembly

Know your product

Mounting the saw to a workbench

Blades

Selecting the correct blade

Removing blades

Installing blades

Setting the table for horizontal or bevel cutting

Aligning the degree scale pointer

Turning on and off

Sawdust blower

Flexible worklight

Mitre gauge

Adjusting the speed

Selecting the correct speed

Scroll saw operation

Oiling the arm bearings

Cleaning

General inspection

Repairs

Description of symbols

The rating plate on your tool may show symbols.

These represent important information about the

product or instructions on its use.

Wear hearing protection.

Wear eye protection.

Wear breathing protection.

Conforms to relevant standards

for electromagnetic compatibility.

For safe operation read instruction manual.

Specifications

Nominal voltage:

230–240Vac ~ 50Hz

Power:

S2 5 min 125W

Speed:

550–1600 SPM

Maximum Depth of cut: 50mm

Stroke length:

20mm

Blade Type:

Pinned or Plain

Blade length:

Pinned: 128mm between pins

Flat: 127mm

Blade change:

Pinned: Tool-free

Plain: Hex Key Clamp

Bevel angle:

0° to 45° left

Throat depth:

405mm

Light:

12Volt 10W

Introduction

Your new 909 power tool will more than satisfy

your expectations. It has been manufactured under

stringent 909 Quality Standards to meet superior

performance criteria.
You will find your new tool easy and safe to operate,

and, with proper care, it will give you many years

of dependable service.

CAUTION.

Carefully read through this entire Instruction

Manual before using your new 909 Power Tool. Take

special care to heed the Cautions and Warnings.
Your 909 power tool has many features that will make

your job faster and easier. Safety, performance, and

dependability have been given top priority in the

development of this tool, making it easy to maintain

and operate.

Environmental protection

Recycle unwanted materials instead

of disposing of them as waste. All tools,

hoses and packaging should be sorted,

taken to the local recycling centre and

disposed of in an environmentally safe way.

General safety rules

WARNING.

Read all safety warnings and all instructions.

Failure to follow the warnings and instructions may result in

electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

The term “power tool” in the warnings refers to your mains-

operated (corded) power tool or battery-operated (cordless)

power tool.

1) Work area safety
a) Keep work area clean and well lit.

Cluttered or dark

areas invite accidents.

b) 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.

c) Keep children and bystanders away while operating a

power tool.

Distractions can cause you to lose control.

2) Electrical safety
a) Power tool plugs must match the outlet. Never modify

the plug in any way.

Do not use any adapter plugs with

earthed (grounded) power tools. Unmodified plugs and

matching outlets will reduce risk of electric shock.

b) 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.

c) Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of

electric shock.

d) Do not abuse the cord. Never use the cord for

carrying, pulling or unplugging the power tool.

Keep cord away from heat, oil, sharp edges or

moving parts.

Damaged or entangled cords increase

the risk of electric shock.

e) When operating a power tool outdoors, use an

extension cord suitable for outdoor use.

Use of a cord

suitable for outdoor use reduces the risk of electric shock.

f) To reduce the risk of electric shock, the manufacturer

recommends the use of a residual current device

with a rated residual current of 30mA or less at

all times.

3) Personal safety
a) Stay alert, watch what you are doing and use

common sense when operating a power tool. Do not

use a power tool while you are tired or under the

influence of drugs, alcohol or medication.

A moment

of inattention while operating power tools may result in

serious personal injury.

b) Use personal protective equipment. Always wear eye

protection.

Protective equipment such as dust mask,

non-skid safety shoes, hard hat, or hearing protection used

for appropriate conditions will reduce personal injuries.

c) Prevent unintentional starting. Ensure the switch

is in the off-position before connecting to power

source and/or battery pack, picking up or carrying

the tool.

Carrying power tools with your finger on the

switch or energising power tools that have the switch

on invites accidents.

d) Remove any adjusting key or wrench before

turning the power tool on.

A wrench or a key left

attached to a rotating part of the power tool may result

in personal injury.

e) Do not overreach. Keep proper footing and balance

at all times.

This enables better control of the power tool

in unexpected situations.

f ) Dress properly. Do not wear loose clothing or

jewellery. Keep your hair, clothing and gloves away

from moving parts.

Loose clothes, jewellery or long hair

can be caught in moving parts.

g) If devices are provided for the connection of dust

extraction and collection facilities, ensure these are

connected and properly used.

Use of dust collection

can reduce dust-related hazards.

4) Power tool use and care
a) Do not force the power tool. Use the correct power

tool for your application.

The correct power tool will

do the job better and safer at the rate for which it was

designed.

b) 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.

c) Disconnect the plug from the power source and/or

the battery pack from the power tool before making

any adjustments, changing accessories, or storing

power tools.

Such preventive safety measures reduce

the risk of starting the power tool accidentally.

d) Store idle power tools out of the reach of children

and do not allow persons unfamiliar with the power

tool or these instructions to operate the power tool.

Power tools are dangerous in the hands of untrained users.

e) Maintain power tools. Check for misalignment or

binding of moving parts, breakage of parts and any

other condition that may affect the power tool’s

operation. If damaged, have the power tool repaired

before use.

Many accidents are caused by poorly

maintained power tools.

f ) Keep cutting tools sharp and clean.

Properly

maintained cutting tools with sharp cutting edges are

less likely to bind and are easier to control.

g) Use the power tool, accessories and tool bits etc.

in accordance with these instructions, taking into

account the working conditions and the work to be

performed.

Use of the power tool for operations different

from those intended could result in a hazardous situation.

h) This appliance is not intended for use by persons

(including children) with reduced physical, sensory

or mental capabilities, or lack of experience and

knowledge,

unless they have been given supervision or

instruction concerning use of the appliance by a person

responsible for their safety.

i) Children should be supervised to ensure that they do

not play with the appliance.

5) Service
a) Have your power tool serviced by a qualified repair

person using only identical replacement parts.

This

will ensure that the safety of the power tool is maintained.

Additional safety rules for scroll saws

•

Do not alter or misuse the tool. These tools are precision

built. Any alteration or modification not specified is misuse

and may result in dangerous conditions.

•

For your own safety, do not operate your scroll saw until

it is completely assembled and installed according to the

instructions and until you have read and understood all of

the instructions.

•

Your scroll saw must be bolted securely to a stand or

work bench. In addition, if there is any tendency for the

scroll saw to tip over or move during certain operations,

such as cutting long, heavy boards, bolt your scroll saw

stand or workbench to the floor.

•

This scroll saw is intended for indoor use only.

•

To avoid being pulled into the blade, do not wear loose

fitting gloves, loose clothing, neck ties or jewellery. Tie

back long hair and roll long sleeves above elbows.

•

Do not cut pieces too small to hold by hand. When making

a small cutout always secure the workpiece to a scrap

piece of plywood with double sided tape. This way the work

is supported and your fingers are away from the blade.

•

Never turn your scroll saw on before clearing the

table of all objects (tools, scraps of wood, etc.) except

for the workpiece.

•

Avoid awkward hand positions where a sudden slip could

cause a hand to move into the blade.

•

Always adjust the drop foot to just clear the workpiece to

protect the operator, keep blade breakage to a minimum

and provide maximum support for the blade.

•

Always adjust blade tension correctly.

•

The scroll saw should cut on the down stroke. Always

make sure blade teeth are oriented downward towards

the table.

•

When cutting a large piece of material make sure it is

supported at table height.

•

Hold the work firmly against the table.

•

Do not feed the material too fast while cutting. Only feed

the material fast enough so that the blade will cut.

•

Use caution when cutting off material which is irregular in

cross section as it could pinch the blade before the cut is

completed. A piece of moulding, for example, must lay flat

on the table and not be permitted to rock whilst being cut.

•

Use caution when cutting off round material such as

dowel rods or tubing. They have a tendency to roll while

being cut causing the blade to bite.

•

Never leave the scroll saw running unattended. Always

turn the saw off, make sure that it has come to a

complete stop, and then remove plug from the power

supply before leaving the work area.

•

Do not perform layout, assembly or setup work on the

table while the cutting tool is operating.

•

Turn saw off and remove plug from power supply outlet

before installing or removing blades.

WARNING.

We recommend the use of a residual current

device with a residual current rating of 30mA or less.

Wear safety goggles
Wear ear protection
Wear a breathing mask

Accessories

The 909 LS1620 Scroll Saw is supplied with the following

accessories as standard:

•

15 TPI saw blade

•

18 TPI saw blade

•

Plain blade adaptors

•

Hex key

•

Instruction manual

Unpacking

Due to modern mass production techniques, it is unlikely

that your 909 Power Tool is faulty or that a part is missing.

If you find anything wrong, do not operate the tool until the

parts have been replaced or the fault has been rectified.

Failure to do so could result in serious personal injury.
The scroll saw you have purchased is ideal for numerous

projects including making toys, puzzles, games, artwork

and jewellery, and due to its cutting capacity is a handy

do-it-yourself tool. It cuts wood up to 50mm thick as well

as plastics.

Assembly

The 909 LS1620 scroll saw is packed with some minor

assembly work required to fit the front guard assembly.

Know your product

Before using the tool,

familiarise yourself with all

the operating features and

safety requirements.

Use the tool and accessories

only for the applications

intended. All other

applications are expressly

ruled out.

1. On/off switch

2. Variable speed dial

3. Sawdust blower

4. Flexible light

5. Drop foot

6. Drop foot locking knob

7. Table

8. Table insert

9. Blade tension knob

10. Plain blade adapters

11. Plain blade setting holder

12. Blade

13. Bevel adjustment scale

14. Table lock lever

15. Blade storage tray

16. Front guard

17. Mitre Gauge

18. Dust Extraction Port

8
7

Mounting the saw to a workbench

It is recommended that the scroll saw is secured to a

work bench to gain maximum stability and reduce noise

and vibration.
1. Using the base of the scroll

saw as a template mark

the holes on the workbench

through the holes in the

casting.

2. Drill the holes through the

workbench using an 8mm

drill bit.

3. Bolt the saw to the workbench

using bolts, washers and nuts.

Note.

The fasteners are not supplied with the machine.

Note.

A soft foam pad or carpet (not supplied) can be placed

between the scroll saw and the work bench to further reduce

noise and vibration.

Blades

The scroll saw accepts 128 mm pin type and flat blades.
A set of flat adaptors are supplied, along with a setting

fixture on the top of the scroll saw arm

Selecting the correct blade

1. The scroll saw accepts a wide variety of blade widths

and thicknesses for cutting wood and other wood-

based materials.

2. The blade width, thickness, and number of teeth per inch

will be determined by the material and size of the radius

being cut.

3. Select a blade that allows at least three teeth to be

in contact with the workpiece at all times.

4. Very fine, narrow blades should be used for curve cutting

in thin wood (6 mm or less).

5. To cut thicker wood, use wider blades with fewer teeth

per inch.

6. When cutting wood thicker than 25 mm, guide the

workpiece into the blade slowly and take care not

to bend or twist the blade whilst cutting.

7. Most blade packages state the size or thickness of

wood which that blade is intended to cut, and the radius

(size of curve) which can be cut with that blade.

8. Wider blades cannot cut curves as tight or small as

thinner blades.

9. Blades wear faster when:
    a. Cutting plywood which is very abrasive
    b. Cutting wood that is thicker than 19 mm
    c. Cutting hardwood
    d. Side pressure is applied to the blade
10. This saw uses either pin-type or flat blades

of 128 mm length.

Removing blades

CAUTION.

Always ensure that the

saw is switched off and unplugged

from the mains supply before

removing or installing a blade.

Note.

It is suggested to lift the

front guard and foot assy to

provide more access to the table

insert and lower blade attachment.
1. Loosen the blade tension knob (9) by turning in an anti-

clockwise direction to reduce the blade tension.

2. Remove the table insert (8) by raising it with a

screwdriver and passing the blade through the blade slot.

3. Gently apply a small pressure to the moving top saw arm.
For pinned blades, unhook the pinned blade from the arm

holder and withdraw the blade through the small slot.

For plain blades mounted in the blade adaptors, lift and

unhook the adaptor from the top saw arm.

4. Remove the blade from the

bottom arm attachment the

same as performed for the

top arm.

Installing blades

CAUTION.

Always ensure that the saw is switched

off and unplugged from the mains supply before

removing or installing a blade.
1. Rotate the tension knob in an anti clockwise direction

to reduce the tension on the blade.

2. Remove the table insert (8) by raising it with a

screwdriver and sliding the insert off the blade

through the exit slot.

4. In order to cut effectively and avoid uncontrollable lifting

of the workpiece, the teeth of the scroll saw blade must

always point in a downward direction.

3. For pinned blades, pass the

blade through the centre hole

in the table, pass the blade

through the bottom arm slot

with the pin on the underside

of the arm attachment.

Apply a slight upward

pressure on the blade to

ensure the blade is locked

in place.

5. With the lower pined blade

securely attached to the lower

arm, keeping a slight upward

pressure on the blade, insert

the blade through the upper

arm locating slot with the pin

above the locating plate on

the arm.

Note.

A slight downward

pressure on the top moving arm may be required

to allow the blade to enter the slot with the pin above

the locating plate
6. Increase the tension on the

blade by turning the rear

tension knob in a clockwise

direction.

The tension of the blade should

then be adjusted when the

cutting operation is undertaken.

Higher tensions will be required

for tight curves etc. to reduce

blade deflection.

Over tensioning will reduce

blade life. Blade should be

tensioned so the blade is

straight, and deflection during

use is kept to a minimum.

Over tension will load the

motor excessively and will

prematurely break the blade.

7. Replace the table insert and

reset the foot and guard height.

Setting a plain blade in the adaptors.

1. Fit the plain blade into one of the adaptors so the small

grub screws align with the sides of the blade and the teeth

of the blade are in the same direction as the single hole in

the front of the adaptor.

2. With the blade inserted so as to

enter just past the grub screws,

tighten the grub screws on

to the blade so it is clamped

centrally in position

3. Fit the second adaptor on the

other end of the blade with the

same orientation as the first

and then locate the two adaptors and the blade into the

holder on top of the machine arm as shown in the picture.

The second adaptor has not been tightened so it can slide

on the blade so as the adaptors can locate.

4. Loosen the grub screws on the first adaptor and centrally

locate the blade between the adaptors by sliding the blade

one way or another.

5. When central, lock the grub screws of both adaptors on to

the blade.

6. Prepare the scroll saw as per points 1–-3 for installing the

blade.

7. With the teeth of the blade downward and towards the front

of the saw, pass the adaptor and end of blade through the

hole in the table and locate the pin on the adaptor over the

wide hook on the front of the lower arm.

8. Apply a slight upward pressure on the blade to ensure the

blade is locked in place.

9. With the lower blade adaptor securely attached to the

lower arm, keeping a slight upward pressure on the

blade, hook the top blade adaptor over the wide front

hook section of the top arm.

Note.

A slight downward pressure on the top moving arm

may be required to allow the blade adaptor to locate.
10. Proceed to tension the blade as per point 6 as detailed

in the pinned section of installing the blades

11. Replace the table insert and reset the foot and guard

height.

Setting the table for horizontal

or bevel cutting

CAUTION.

Always ensure that the saw is switched off

and unplugged from the mains supply before making any

adjustments.
1. Loosen the table lock lever

(14) to allow the saw table to

be tilted to the left. The table

can be locked at any angle

from a 0º horizontal cutting

position up to a 45º angle to

the left for bevel cutting.

3. A bevel adjustment scale (13)

is positioned under the work

table to assist in setting the

appropriate table angle for

bevel cutting. When greater

precision is required, make

a practice cut first and then

adjust the table as necessary

for your requirements.

Note.

When bevel cutting, the drop

foot (5) can be tilted so it’s parallel

to the table and rests flat against

the workpiece. To tilt the drop foot,

loosen the screw at the front of

the drop foot assembly and then

tilt the foot so that it’s parallel to

the table, re-tighten the screw to

secure the drop foot in place.

The bevel locking lever is a spring loaded lever which can

be orientated at various positions. To adjust the angle of the

lever so as not to make contact with the dust extraction port,

or the underside of a tilted table, PULL the lever outwards

and rotate to the desired position, and release.

Aligning the degree scale pointer

1. Loosen the table lock lever (14) and move the table (7) to

position the table at a right angle to the blade.

2. Place a small square on the table next to the blade

to check if the table is at a 90º angle to the blade. If

adjustment is needed, change

the bevel angle until the

table is at approximately 90º to

the blade and securely tighten

the table lock lever (14).

3. Loosen the Phillips head

screw holding the degree

scale pointer and move the

pointer to the 0º position.

Securely tighten the screw.

Note.

The degree scale is a convenient guide but

should not be relied upon for precision. Always make

a practice cut in scrap wood to determine if your angle

settings are correct.

Turning on and off

1. To turn on the scroll saw press the green On (I) button (1).
2. To turn off the scroll saw press the red Off (O) button (1).

Sawdust blower

Your scroll saw features a

sawdust blower (3) to help keep

the work area clean for more

accurate scroll cuts. The blower

tube is fully adjustable and can

be directed as required.

Flexible worklight

The flexible light will illuminate

the work area for greater visibility

of the cutting line.
1. The light will illuminate when

ever the saw is turned on by

pushing the green button (1).

The light cannot be operated

without the saw running

Mitre gauge

The table of the saw is provided

with a guide slot for the operation

of a mitre gauge.
The gauge can be set between

0° and 45°, left or right
1. To adjust, loosen the locking

screw and rotate the gauge

to the desired angle. Lock the

screw at the correct angle.

Note.

Always take a trial cut to ensure the angle is the

correct angle required as the scale is only a guide.
The mitre gauge is particularly suited for cutting angles

which are required to be straight. However, it should be

noted that the cutting action of the blade will not provide

a perfectly flat surface and should be considered on two

mating surfaces.

Adjusting the speed

The speed can be adjusted to suit the workpiece being cut.

The variable speed dial (2) is located on the lower front

panel of the saw, next to the

On/Off buttons, for convenient

adjustment of the speed.
1. Turn the saw on.
2. Turn the dial in a clockwise

direction for a faster speed

and in an anti-clockwise

direction to reduce the speed.

3. Determine the optimum speed by making a trial cut in a

scrap piece of material.

Note.

Using the correct speed for the job increases the life

of the saw blade.

Selecting the correct speed

The below table shows the suggested blade and speed to

be used for different materials and applications.

Scroll saw operation

1. Ensure that the table insert is in place and flush with

the table.

2. Start saw.
3. Adjust the speed to suit the workpiece being cut.
4. To begin the cut guide the wood into the moving saw

blade, the blade teeth cut only on the down stroke.

5. The saw will not cut wood by itself, you allow the saw to

cut wood by guiding the wood into the blade as it moves.

6. The drop foot (5) should always be lowered until it just

rests on top of the workpiece to prevent your workpiece

from lifting during operation but not so much that the

workpiece drags. To lower or raise the drop foot loosen

the drop foot locking knob (6) and position the drop foot

so it rests on top of the work piece. Retighten the drop

foot locking knob.

7. Ensure that you feed the wood into the blade slowly

because the teeth of the blade are very small and

they can only remove wood when they are on the

down stroke.

8. The blade will flex backwards when applying feed

pressure. Too much feed pressure will cause blade

breakage.

9. Best results are achieved when cutting wood less than

25 mm thick.

10. When cutting wood thicker than 25 mm, the user must

feed the wood into the blade very slowly, increase blade

tension and take extra care not to bend or twist the

blade while cutting in order to maximise blade life.

11. Teeth on scroll saw blades wear quickly and as a result

must be replaced frequently for best cutting results.

Scroll saw blades generally stay sharp for 30 minutes

to 2 hours of cutting.

12. Once finished, turn off the saw and unplug the tool from

the power point to prevent unauthorised use.

Oiling the arm bearings

The saws arm bearings should be lubricated after every

50 hours of use. Ensure plug is removed from the mains

power supply.
1. Turn the saw on its side.
2. Squirt a generous amount of

SAE 20 oil around the shaft

end and bronze bearings.

3. Let the oil soak in overnight in

this position.

4. Next day repeat the above

procedure for the opposite

side of the saw.

Blade Teeth

per Inch

Width

Thickness Strokes

per Minute Material and Application

6 - 10

2.8mm

0.5mm

1200–1600 Hard and soft woods from 5mm to 50mm thick

plastics, paper, felt

10 - 15

2.8mm

0.5mm

600–1200

Wood, plastics, extremely thin cuts in materials

2.5mm to 13mm thick

15 - 18

2.4mm

0.3mm

550–600

Tight radius work in thin materials 2.5mm to 3mm thick.

Wood, veneer, fiber, plastic.

Cleaning

1. Keep the tool’s air vents unclogged and clean at all times.
2. Remove dust and dirt regularly. Cleaning is best done

with a brush or a rag.

3. Re-lubricate all moving parts at regular intervals.
4. Never use caustic agents to clean plastic parts.

CAUTION.

Do not use cleaning agents to clean the plastic

parts of the tool. A mild detergent on a damp cloth is

recommended. Water must never come into contact with

the saw.

General inspection

Regularly check that all the fixing screws are tight.

They may vibrate loose over time.

Repairs

Only an authorised service centre should replace the cordset

or effect other repairs. If the cordset is damaged or worn,

have it repaired or replaced by an authorised service centre.

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