WEN Cordless 6.5-Inch Track Saw Instruction Manual

1. Introduction

This manual provides essential information for the safe and effective operation, maintenance, and troubleshooting of your WEN Cordless 6.5-Inch Track Saw, Model 20691. Please read this manual thoroughly before using the tool to ensure proper handling and to prevent injury or damage.

The WEN Track Saw is designed for precise, straight cuts in various wood materials, offering the accuracy of a table or panel saw in a portable format. It is ideal for tasks such as ripping plywood, trimming doors, building furniture, and other applications requiring long, accurate cuts.

2. Important Safety Information

WARNING: Read all safety warnings, instructions, illustrations, and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury.

General Power Tool Safety Warnings

• Work Area Safety: Keep work area clean and well lit. Cluttered or dark areas invite accidents. 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. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
• Electrical Safety: 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. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. Do not abuse the cord. Never use the cord for carrying, pulling, or unplugging the power tool. Keep cord away from heat, oil, sharp edges, or moving parts. Damaged or entangled cords increase the risk of electric shock. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
• Personal Safety: 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. Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. 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 energizing power tools that have the switch on invites accidents. 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. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
• Power Tool Use and Care: 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. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. Disconnect the plug from the power source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventative safety measures reduce the risk of starting the power tool accidentally. 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. Maintain power tools and accessories. 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. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. Use the power tool, accessories, and tool bits, etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. Keep handles and grasping surfaces dry, clean, and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
• Battery Tool Use and Care: Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire. When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws, or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire. Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns. Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion, or risk of injury. Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265°F (130°C) may cause explosion. Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.
• Service: 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. Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

3. Product Components

Familiarize yourself with the various parts of your WEN Cordless Track Saw before operation.

Figure 3.1: The WEN Cordless 6.5-Inch Track Saw, including the main saw unit, two 20V Max 4.0 Ah lithium-ion batteries, and a dual charger. This image shows the complete package as it would appear out of the box.

• Track Saw Unit: The main body of the saw, housing the motor, blade, and controls.
• 6.5-inch Blade: A 48-tooth carbide-tipped blade for efficient cutting.
• Depth Gauge: Allows adjustment of cutting depth from 0 to 2.1 inches.
• Bevel Adjustment: Enables angle cuts from -1 to 47 degrees.
• Dust Port: Located at the rear for connection to a dust collection system.
• Blade Settings Lever: For switching between scoring cuts, full plunge cuts, and blade change mode.
• Base Plate: 12 x 6.75-inch base with precision grooves for track compatibility.
• 20V Max 4.0 Ah Lithium-Ion Batteries (x2): Provide cordless power to the saw. Feature onboard LED charge gauges.
• Battery Charger: For recharging the 20V Max batteries.

4. Setup and Assembly

4.1 Charging the Batteries

Before first use, fully charge both 20V Max 4.0 Ah lithium-ion batteries. Insert the batteries into the charger, ensuring they click into place. The charger's indicator lights will show the charging status. Once fully charged, remove the batteries from the charger.

Figure 4.1: The WEN 20V Max Battery System, showing the two 4.0Ah batteries and the dual charger. These components are essential for the cordless operation of the track saw.

4.2 Installing the Blade

1. Ensure the saw is disconnected from any power source and batteries are removed.
2. Set the blade settings lever to the blade change position.
3. Use the provided wrench to loosen the blade arbor nut.
4. Carefully remove the old blade (if applicable) and install the new 6.5-inch 48-tooth carbide-tipped blade, ensuring the teeth are oriented correctly for cutting.
5. Tighten the arbor nut securely.
6. Return the blade settings lever to the desired cutting position.

Figure 4.2: A detailed view of the WEN Track Saw's 6.5-inch 48-tooth carbide-tipped blade and its base, highlighting the precision grooves designed for track compatibility. Proper blade installation is crucial for safe and accurate cuts.

4.3 Attaching Batteries

Insert the two charged 20V Max batteries into the designated battery ports on the saw. Ensure they are fully seated and locked into place. The saw requires two batteries for operation, combining to power the 40V motor.

Figure 4.3: The WEN Track Saw with two 20V batteries inserted, demonstrating how the dual battery system fuels the powerful 40V motor. This setup enables cordless operation for various cutting tasks.

4.4 Connecting Dust Collection

For optimal dust control, connect a dust collection system to the back-mounted dust port. The dust port adapter allows the unit to remain flush against walls, which is beneficial for flooring trim cuts.

5. Operation

5.1 Adjusting Cutting Depth

The depth gauge allows you to set the cutting depth from 0 to 2.1 inches. Adjust the gauge to the desired depth for your material. For scoring cuts, set the depth to 1/8-inch.

5.2 Setting Bevel Angle

The saw can make bevel cuts from -1 to 47 degrees. Loosen the bevel adjustment knob, set the desired angle, and tighten the knob securely before cutting.

Figure 5.1: A close-up of the WEN Track Saw's base, illustrating the bevel adjustment mechanism that allows cuts from -1 to 47 degrees, along with the depth gauge for precise control over plunge depth (0 to 2.1 inches).

5.3 Using the Track (Optional)

For long, precise cuts, align the WEN Track (models CT9502, CT9110, not included) along your desired cut line. The saw's base is designed to glide smoothly along the track, ensuring straight and accurate results. Secure the track to your workpiece if necessary to prevent movement.

5.4 Plunge Cutting

The saw can be used as a plunge saw, relying on its flat base for stability. To make a plunge cut, position the saw on the workpiece, engage the plunge mechanism, and slowly lower the blade into the material while maintaining control.

Figure 5.2: The WEN Track Saw in action, demonstrating its capability as a plunge saw. The image shows the saw's flat base providing maximum stability and precision during a cut on a wooden workpiece.

5.5 Blade Settings

The saw features a lever to switch between three blade settings:

• Scoring Cuts: For shallow cuts (approx. 1/8-inch deep) to prevent tear-out on delicate materials.
• Full Plunge Cuts: For standard through-cuts.
• Blade Changes: Positions the blade for easier and safer replacement.

Figure 5.3: An illustration of the WEN Track Saw's versatile blade settings, including options for scoring cuts (1/8-inch deep), full plunge cuts, and a dedicated mode to simplify blade changes. This feature enhances both precision and user convenience.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your WEN Track Saw.

6.1 Cleaning

• After each use, disconnect the batteries and clean the saw thoroughly.
• Remove sawdust and debris from the blade guard, base plate, and motor vents using a brush or compressed air.
• Wipe down external surfaces with a clean, damp cloth. Do not use harsh chemicals or solvents.

6.2 Blade Care

• Inspect the blade regularly for sharpness and damage. A dull or damaged blade can cause kickback and poor cut quality.
• Replace the blade when it becomes dull or damaged. Refer to Section 4.2 for blade installation instructions.

6.3 Battery Care

• Store batteries in a cool, dry place away from direct sunlight and extreme temperatures.
• Do not store fully discharged batteries for extended periods. Recharge them periodically if not in use.
• Avoid exposing batteries to water or moisture.

7. Troubleshooting

This section addresses common issues you might encounter with your WEN Track Saw.

If you encounter issues not listed here or if problems persist, please contact WEN customer support for assistance. Do not attempt to repair the tool yourself unless you are a qualified technician.

8. Product Specifications

9. Warranty and Support

9.1 Two-Year Limited Warranty

Your WEN Cordless 6.5-Inch Track Saw (Model 20691) is backed by a two-year limited warranty. This warranty covers defects in material and workmanship under normal use. For specific terms and conditions, please refer to the warranty card included with your product or visit the official WEN website.

9.2 Customer Support

For technical assistance, parts, or warranty claims, please contact WEN customer support. WEN maintains a nationwide network of skilled service technicians and a friendly customer helpline to assist you with any questions or issues you may have.

Please have your model number (20691) and purchase date available when contacting support.

For more information, visit the WEN Store on Amazon.