Biscuit joiner 38648 Set up and Operating Instructions Distributed exclusively by Harbor Freight Tools. 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our website at: http://www.harborfreight.com Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright 2001 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. For technical questions or replacement parts, please call 1-800-444-3353. Cover Revised 09c
SPECIFICATIONS Motor Speed 10,000 RPM (No Load) Power Rating 120 V~ / 60 Hz / 6 A Blade 4 Diameter Spindle Bearing Mounted Fence Adjustment Max. Depth: 1-1/8 Max. Angle: 45 Preset Depth Stops 0, 10, 20 Power Cord 18 AWG, 3-Prong Plug SAVE THIS MANUAL You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference. 1. GENERAL SAFETY WARNINGS AND PRECAUTIONS KEEP WORK AREA CLEAN AND DRY. Cluttered, damp or wet work areas invite injuries. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle this product. 3. STORE IDLE EQUIPMENT. When not in use, tools and equipment should be stored in a dry location to inhibit rust. Always lock up tools and equipment and keep out of reach of children. 4. DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF AL- COHOL OR DRUGS. Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is 5. any doubt, do not attempt to use this product. USE EYE, HEARING, AND BREATHING PROTECTION. Wear ANSI-approved safety impact eye glasses, ANSI approved hearing protection, and dust mask or respirator when using this product. ANSIapproved safety impact eye glasses, hearing protection, and dust masks and respirators are available from Harbor Freight Tools. 6. DRESS SAFELY. Non-skid footwear or safety shoes should be used when working with this product. Do not wear loose clothing or jewelry as they can become caught in moving parts. Wear a protective hair covering to prevent long hair from becoming caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up above elbows. 7. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS. 8. DO NOT OVERREACH. Keep proper footing and balance at all times to prevent tripping, falling, back injury, etcetera. 9. STAY ALERT. Watch what you are doing at all times. Use common sense. Do not use this product when you are tired or distracted from the job at hand. 10. CHECK FOR DAMAGED PARTS. Before using this product, carefully check that it will operate properly and perform its intended function. Check for damaged parts and any other conditions that may affect the operation of this product. Replace or repair damaged or worn parts immediately. SKU 38648 For technical questions, please call 1-800-444-3353. Page 2
11. 1 REPLACEMENT PARTS AND AC- CESSORIES. When servicing, use only identical replacement parts. Only use accessories intended for use with this product. Approved accessories are available from Harbor Freight Tools. MAINTAIN THIS PRODUCT WITH CARE. Keep this tool clean and dry, and keep saw blades clean and sharp for better and safer performance. 13. MAINTENANCE: For your safety, service and maintenance should be performed regularly by a qualified technician. 14. USE THE RIGHT PRODUCT FOR THE RIGHT JOB. There are certain applications for which this product was designed. Do not use small equipment, tools or attachments to do the work of larger industrial equipment, tools or attachments. Do not use this product for a purpose for which it was not intended. SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS 1. GROUND THIS PRODUCT. The electrical power cord for this tool is equipped with a grounded 3-prong plug. Never remove the grounding prong or modify the plug in any way. Do not use adapter plugs with this product. When in use, make sure this product is always plugged into a grounded 3-hole electrical receptacle with an appropriate breaker switch in-line. MAKE SURE THE POWER SWITCH IS IN THE OFF POSITION BE- FORE PLUGGING IN THE POWER CORD. DO NOT ABUSE THE POWER CORD. Do not use the cord to pull the 3-prong plug from a power outlet. Keep cord away from heat, oil, sharp edges, and moving parts. Replace damaged cord immediately. Route the power cord safely. Protect it from being damaged by other equipment in the shop. Do not route the cord where it can be walked on or tripped over. SKU 38648 For technical questions, please call 1-800-444-3353. Page 3 3. 4. 5. RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT) NAMEPLATE AMPERES (at full load) 25 EXTENSION CORD LENGTH 50 75 100 150 0 0 18 18 18 18 16 1 3.4 18 18 18 16 14 3.5 5.0 18 18 16 14 12 5.1 7.0 18 16 14 12 12 7.1 10 18 14 12 10-11 16.0 14 12 10 - - 16.1 20.0 12 10 - - - TABLE A * Based on limiting the line voltage drop to five volts at 150% of the rated amperes. IF YOU USE AN EXTENSION CORD, MAKE SURE TO USE ONLY UL APPROVED CORDS HAV- ING THE CORRECT GAUGE AND LENGTH. (SEE TABLE A.) MAINTAIN A SAFE WORK ENVI- RONMENT. Do not use this tool in or near damp or wet areas. Do not expose this tool to rain. Keep work area well lit. Make sure there is adequate surrounding work space. Use
6. 7. 8. 9. 10. 11. 1 this product in a well ventilated area. Do not operate this product in the presence of flammable liquids, gases, or dust. To avoid accidental electric shock, do not let your body come in contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. DO NOT FORCE THE EQUIPMENT. This tool will do the work better and safer at the speed and capacity for which it was designed. KEEP ALL GUARDS IN PLACE AND IN WORKING ORDER. REMOVE ALL ADJUSTING WRENCHES FROM THE TOOL BE- FORE TURNING ON THE BISCUIT JOINER. MAKE SURE THAT WHEN IN- STALLING THE CUTTING BLADE (61) THE SAW TEETH POINT TO- WARD THE RIGHT SIDE OF THE BISCUIT JOINER. (See figure E in OPERATION section.) AVOID UNINTENTIONAL START- ING. Make sure you are prepared to begin work before turning the START switch on. DO NOT USE THIS TOOL FOR CUTTING METALS OR BRITTLE MATERIALS. Do not cut dangerous materials, such as asbestos which can cause harmful dust or vapors. Some woods contain preservatives such as copper chromium arsenate (CCA) which can be toxic. When cutting these materials, extra care should be taken to avoid inhalation and minimize skin contact. 13. 14. 15. 16. 17. 18. 19. BEFORE USING THE BISCUIT JOINER, MAKE SURE THE CUT- TING BLADE IS PROPERLY MOUNTED ON THE BLADE SPIN- DLE. Make sure the Cutting Blade (61) is balanced, securely mounted and is not bent or cracked. ALLOW THE CUTTING BLADE TO SPIN UP TO FULL SPEED BEFORE FEEDING WOOD INTO IT. When turning it off, allow the Cutting Blade (61) to spin down and stop on its own. Do not press against the saw blade to stop it. DO NOT FORCE THE CUTTING BLADE INTO THE MATERIAL BE- ING CUT. Apply moderate pressure, allowing the Cutting Blade (61) to cut without being forced. NEVER ATTEMPT TO REMOVE MATERIAL STUCK IN THE MOVING PARTS OF THE BISCUIT JOINER WHILE IT IS PLUGGED IN AND RUNNING. THE CUTTING BLADE WILL BE- COME HOT WHILE CUTTING. Allow the Cutting Blade (61) to completely stop and cool before touching. WHENEVER POSSIBLE, USE CLAMPS OR OTHER SAFE, PRAC- TICAL WAYS TO HOLD AND SUP- PORT THE WORKPIECE. ALWAYS DISCONNECT TOOL FROM ITS ELECTRICAL SUPPLY SOURCE WHEN NOT IN USE OR BEFORE PERFORMING ANY SER- VICES OR MAINTENANCE such as leaving the work area, moving the tool from one location to another, changing the saw blade, cleaning sawdust from the unit, etcetera. SKU 38648 For technical questions, please call 1-800-444-3353. Page 4
20. 21. 2 People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure. In addition, people with pacemakers should: Avoid operating alone. Do not use with power switch locked on. Properly maintain and inspect to avoid electrical shock. Any power cord must be properly grounded. Ground Fault Circuit Interrupter (GFCI) should also be implemented it prevents sustained electrical shock. WARNING: Some dust created by power sanding, sawing, 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: Lead from lead-based paints Crystalline silica from bricks and cement or other masonry products Arsenic and chromium from chemically treated lumber Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. (California Health & Safety Code 25249.5, et seq.) WARNING: Handling the cord on this product will expose you to lead, a chemical known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. (California Health & Safety Code 25249.5, et seq.) The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. SKU 38648 For technical questions, please call 1-800-444-3353. Page 5 23. 1. Vibration Safety This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury: Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical checkups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud s Disease should not use this tool. If you feel any symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury. REV 09c
3. 4. 5. 6. 7. Wear suitable gloves to reduce the vibration effects on the user. Use tools with the lowest vibration when there is a choice. Include vibration-free periods each day of work. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately. Save these instructions. REV 09c SKU 38648 For technical questions, please call 1-800-444-3353. Page 6
UNPACKING When unpacking, make sure the product is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at 1-800-444-3353 as soon as possible. OPERATING INSTRUCTIONS NOTE: All parts below refer to the parts listed and shown in the parts list and diagram near the end of this manual. To Attach The Dust Bag: Remove both Allen Screws (67) on the front of the Joiner Base (43), using the Hex Wrench provided. Slide the Adjustable Fence (64) backward onto the Joiner Base and secure the Adjustable Fence with the two Allen Screws. (See Figures C and D.) To Attach The Spacer: Turn the Biscuit Joiner upside down. Simply push the 2 Spacers (60) into the holes in the bottom of the Biscuit Joiner; one Spacer fits across the front and the other Spacer fits across the back (see Assembly Diagram). To Set The Depth Stops: FIGURE B 1. Insert the Dust Bag Adapter (75) into the small opening of the Dust Bag (45). Then, slide the Dust Bag Adapter onto the Dust Porthole located at the rear of the Joiner until it snaps into place. (See Figure B.) 3. To remove the Dust Bag (45), pull the release tab located on the right side of the Dust Porthole and slide the Dust Bag off. To empty the Dust Bag (45), hold the Dust Bag over a trash can and slide the plastic clip off the end of the Bag Clamp (63). NOTE: For efficient dust pickup, empty the Dust Bag (45) frequently. To Attach The Adjustable Fence: Figure C The biscuit joiner has 3 settings for rapid adjustment to size 0, 10, or 20 biscuits. The Preset Depth Adjustment Dial (48) is located on the adjusting screw at the rear of the base plate, and has 3 pair of notches marked 0, 10, and 20. An arrow is molded into the base to the left of the dial at the 9 o clock position. The number next to the arrow is the selected biscuit size. To change the setting, pull the dial out, the rotate it to the desired size. (See Figure C) Rev 02e SKU 38648 For technical questions, please call 1-800-444-3353. Page 7
Adjusting Cutter Depth To Change The Cutting Blade: The jointer should be pre-set at the factory for the included biscuits. The depth of the cut should be one half the width of the biscuits you are using. If further adjustment is necessary, proceed as follows. Note: Any change made will affect all 3 preset positions. 1. Unplug the Joiner. 1. 3. 4. 5. Unplug the Joiner. Position the preset dial to the biscuit size you are adjusting. Turn the joiner upside down, bracing the handle against a solid surface. Grasp the front of the base plate, and pull rearward until it stops. Rotate the exposed blade so that one carbide tip is at maximum travel from the face of the base plate. FIGURE E FIGURE F Figure D 6. Use a small scale to measure this distance, then turn Depth Adjustment Dial (48) adjusting screw as needed. The amount of exposed cutter should be one half of the biscuit width. (See Figure D.) Turn the Biscuit Joiner upside down and remove both Allen Screws (67) on the Adjustable Fence (64), using the Hex Wrench provided. Remove the Adjustable Fence by sliding it forward. (See Figures E and F.) Rev 02e SKU 38648 For technical questions, please call 1-800-444-3353. Page 8
Note: Be aware of the sharp blade; handle with care. 7. 8. Replace the Blade Bolt (62) and tighten clockwise until secure. Reassemble the Adjustable Fence (64) to the Joiner Base (43) using the two Allen Screws (67). To Use The Locking On/Off Switch: NOTE: The Biscuit Joiner Switch (35) is located under the Hold Covers (28, 29). The orange Switch Lock Button on the left side of the Cover locks the Switch in the ON position for long cutting operations. (See Assy. Drawing.) FIGURE G 3. Place a Crescent Wrench on the Spindle (1) and firmly hold to prevent the Spindle from rotating. (See Figure G.) 4. Place the Arbor Wrench (included accessory) on the Blade Bolt (62) and loosen counterclockwise to remove the Blade Bolt. (See Figure G) Note: Be aware of the sharp blade; handle with care. 1. 3. To turn the Biscuit Joiner on without locking it in the ON position, press and hold the Switch (35) in. When pressure is released, the Switch snaps back to the OFF position. To lock the Switch (35) in the ON position, press and hold the Switch in. Then, press in the orange Switch Lock Button on the left Hold Cover (28). To unlock the Switch (35) from the ON position, press and release the orange Switch Lock Button. 5. 6. Slide the Cutting Blade (61) out, noting the direction of the Blade Teeth. Install the new Cutting Blade (61) onto the Spindle (1), making sure the Blade Teeth are facing toward the right of the Biscuit Joiner. (See Figure F.) Rev 02e SKU 38648 For technical questions, please call 1-800-444-3353. Page 9
FIGURE H To Mark Slot Locations For Standard Cuts: FIGURE I 1. Always begin with the Joiner Base (43) cutting into the end of the wood, rather than the side. (See Figures H and I.) Mark the center of the slot at a point at least 2-1/2 from the outer edge of the board. face to be cut, pull the Biscuit Joiner back and turn the power OFF. To Mark Slot Locations For Other Types Of Cuts: NOTE: When making preparations for cutting slots for T-butt, miter, edge-toedge, leg and rail, and square pattern joints, there are two important steps to ensure proper alignment of the joints: a. Align all boards as you want them to appear when finished, then mark the center line for the slots on all boards at the same time. b. Set the plate depth before making the cuts. NOTE: Allow at least 1 between slots in multiple plate applications for best results. Mark all slots on both boards at the same time to assure proper alignment. 3. 4. Align the center line on the Adjustable Fence (64) with the pencil mark on the wood. (See Figures B and C.) Hold the Biscuit Joiner firmly with both hands. Turn the power ON and push the Biscuit Joiner forward slowly and smoothly. 5. When the Joiner Base (43) has butted completely against the wood sur- Rev 02e SKU 38648 For technical questions, please call 1-800-444-3353. Page 10
CLEANING, INSPECTION, AND MAINTENANCE CAUTION: Always disconnect the Biscuit Joiner from its electrical power supply source before performing any cleaning, inspection, or maintenance. 1. 3. 4. 5. Do not introduce water into the electric motor through the motor vents. Do not use solvents to wipe off the Biscuit Joiner, as damage may result. With a brush or soft cloth, remove all the sawdust from the Biscuit Joiner. If necessary, wipe with a damp cloth. You may use a mild detergent. Once clean, lubricate all moving parts with a light oil. PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEI- THER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBU- TOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UN- DERTAKEN BY CERTIFIED AND LICENSED TECH- NICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. 6. 7. 8. When storing, keep the Biscuit Joiner in a box, or cover with a cloth cover. Before each use, inspect the general condition of the Biscuit Joiner. Inspect switch, power plug and cord assembly, and extension cord (if used) for damage. Check for loose screws, misalignment, binding of moving parts, improper mounting, broken parts, loose or damage Cutting Blade and any other condition that may affect its safe operation. If abnormal noise or vibration occurs, turn off the Biscuit Joiner immediately and have the problem corrected before further use. Do not use damaged equipment. Included in the Biscuit Joiner kit are two additional Motor Carbon Brushes (23). In the event the old Carbon Brushes need replacing, it is recommended that only a qualified technician perform this service. SKU 38648 For technical questions, please call 1-800-444-3353. Page 11
Part Description Qty 1 Spindle 1 2 Straight Key 4 x 12 1 3 Circlips for Hole 1 4 Ball Bearing 80101 1 5 Screw M4 x 14 4 6 Washer M4 8 7 Packing Gland 1 8 Plate 2 9 Gear 1 10 Spindle Ring 1 11 Spindle Sleeve 1 12 Tapping Screw 4 13 Gear Cover 1 14 Nut M6 1 15 Washer M6 1 16 Pinion 1 17 Ball Bearing 80100 1 18 Clamp 1 19 Armature Assembly 1 20 Ball Bearing 80018 1 21 Hoop 1 22 Stator Assembly 1 23 Carbon Brush 2 24 Spring 2 25 Brush Hold Assembly 1 26 Rubber Gauge Washer 1 27 Housing Assembly 1 28 Hold Cover 1 29 Hold Cover 1 30 Tapping Screw 2 31 Washer M4 8 32 Wire Assembly 2 33 Name Plate 1 34 Tapping Screw 4 35 Switch 1 36 Cord Armor 1 37 Cord Clip 1 PARTS LIST Part Description Qty 38 Tapping Screw 2 39 Cord Assembly 1 40 Spring 1 41 Lock Pin 1 42 Washer 1 43 Joiner 1 45 Dust Bag 1 46 Depth Adjust. Screw 1 47 Spring 1 48 Depth Adjusting Dial (preset) 1 49 Square Nut 1 51 Bolt M6 4 52 Washer M6 2 53 Top Handle 1 54 Allen Screw M10 2 60 Spacer 2 61 Cutting Blade 1 62 Blade Bolt 1 63 Bag Clamp 1 64 Adjustable Fence 1 65 L-shaped Guide 2 66 Mounting Brackets 2 67 Allen Screw M5 2 68 Washer M5 2 69 Nut M5 4 70 Nut M6 2 75 Dustbag Adapter 1 Accessories Assorted Biscuits: 0, 10, 20 gauge Carbon motor brush set 4 mm Hex wrench Arbor wrench Glue bottle Rev 02e SKU 38648 For technical questions, please call 1-800-444-3353. Page 12
ASSEMBLY DIAGRAM Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 38648 For technical questions, please call 1-800-444-3353. Page 13
LIMITED 90 DAY WARRANTY Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. This warranty is expressly in lieu of all other warranties, express or implied, including the warranties of merchantability and fitness. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 3491 Mission Oaks Blvd. PO Box 6009 Camarillo, CA 93011 (800) 444-3353 REV 09c SKU 38648 For technical questions, please call 1-800-444-3353. Page 14