WEN CT1065 6.5-INCH TRACK SAW

Instruction Manual

Need Help? Contact Us! ?

Have product questions? Need technical support? Please feel free to contact us:

800-232-1195 (Mon-Fri 8AM-5PM CST)

techsupport@wenproducts.com ?

IMPORTANT: Your new tool has been engineered and manufactured to WEN's highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.

For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM ?

Specifications

Introduction

Thanks for purchasing the WEN Track Saw. We know you are excited to put your tool to work, but first, please take a moment to read through the manual. Safe operation of this tool requires that you read and understand this operator's manual and all the labels affixed to the tool. This manual provides information regarding potential safety concerns, as well as helpful assembly and operating instructions for your tool.

⚠️ Safety Alert Symbol: Indicates danger, warning, or caution. The safety symbols and the explanations with them deserve your careful attention and understanding. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury. However, please note that these instructions and warnings are not substitutes for proper accident prevention measures.

ℹ️ NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. WEN reserves the right to change this product and specifications at any time without prior notice.

Keep this manual available to all users during the entire life of the tool and review it frequently to maximize safety for both yourself and others.

To purchase accessories for your tool, visit WENPRODUCTS.COM ?

• 100-inch Track with Adapters (Model No. CT9502)
• 4-piece Track Adapter Set (Model No. CT9011)
• Pair of Track Clamps (Model No. CT992F)

ℹ️ NOTE: The rubber strip (Part No. CT9502-001) and foam strips (Part No. CT9502-002) on your track may wear down with use. This is normal and not covered under the two-year warranty. These parts are available for purchase on wenproducts.com, just search their part numbers.

General Safety Rules

Safety is a combination of common sense, staying alert and knowing how your item works. SAVE THESE SAFETY INSTRUCTIONS. ?

⚠️ WARNING: Read and understand all warnings, cautions and operating instructions before using this tool. Failure to follow all instructions listed below may result in personal injury, electric shock, fire and/or tool damage.

Work Area Safety

1. KEEP WORK AREA CLEAN AND WELL LIT. Cluttered or dark areas invite accidents.
2. 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. ?
3. KEEP CHILDREN AND BYSTANDERS AWAY WHILE OPERATING A POWER TOOL. Distractions can cause you to lose control. ?

Electrical Safety

1. 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.
2. 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.
3. DO NOT EXPOSE POWER TOOLS TO RAIN OR WET CONDITIONS. Water entering a power tool will increase the risk of electric shock.
4. 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. ?
5. 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.
6. IF OPERATING A POWER TOOL IN A DAMP LOCATION IS UNAVOIDABLE, USE A GROUND FAULT CIRCUIT INTERRUPTER (GFCI) PROTECTED SUPPLY. Use of a GFCI reduces the risk of electric shock.

Personal Safety

1. 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.
2. USE PERSONAL PROTECTIVE EQUIPMENT. ALWAYS WEAR EYE PROTECTION. Protective equipment such as a respiratory mask, non-skid safety shoes and hearing protection used for appropriate conditions will reduce the risk of personal injury. ?
3. 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. ⚡
4. 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. ?
5. DO NOT OVERREACH. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. ?
6. 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. ?
7. 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. ?

Power Tool Use and Care

1. 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.
2. 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. ❌
3. 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. ?
4. 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. ?
5. 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.
6. KEEP CUTTING TOOLS SHARP AND CLEAN. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. ?
7. 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.
8. USE CLAMPS TO SECURE YOUR WORKPIECE TO A STABLE SURFACE. Holding a workpiece by hand or using your body to support it may lead to loss of control. ?️
9. KEEP GUARDS IN PLACE and in working order. ✅

Service

1. 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. ?️

California Proposition 65 Warning

⚠️ CALIFORNIA PROPOSITION 65 WARNING

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities may contain chemicals, including lead, known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling. ? Some examples of these chemicals are:

• Lead from lead-based paints.
• Crystalline silica from bricks, cement, and 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 with approved safety equipment such as dust masks specially designed to filter out microscopic particles.

Specific Safety Rules for Your Track Saw

⚠️ WARNING: Do not operate the track saw until you have read and understood the following instructions and the warning labels.

Saw Blade Safety

1. Always wear protective gloves when handling saw blades.
2. Only use blades with correct size and type for both your track saw and your workpiece.
   
   • The rated diameter of the saw blade is 6.5" with a 20mm arbor.
   • The no-load speed of the track saw is 5500 RPM. The maximum permissible speed of your saw blade should always be higher than the no-load rotational speed of the saw.
3. Never use damaged or deformed saw blades. Only use sharp blades.
4. Install the saw blade in the correct orientation indicated in the instructions (see "Changing the Saw Blade", page 18).
5. Keep hands out of path of saw blade. Never use your hands to remove sawdust, chips or workpiece near the saw blade or the cutting path of the saw.
6. Never reach around saw blade or reach in back of the saw blade.
7. Do not use blades made from high-speed steel, abrasive blades, metal-cutting blades or masonry-cutting blades. The guards of this saw are not designed to protect against the failure of such blades.
8. 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.
9. Do not use to cut metal, logs, tree limbs, or uneven lumber. Inspect the workpiece and remove all nails and other embedded objects prior to starting work.
10. Wet lumber, green (unseasoned) lumber, and pressure treated lumber all have an increased potential for kickback and should only be cut with a blade specifically designed for that lumber type. Wear a NIOSH-approved respirator and have appropriate ventilation whenever cutting pressure treated lumber.

Personal Safety

1. Operate in a well ventilated area. Keep the floor area around the track saw level and free of slippery substances or other tripping hazards.
2. Wear ANSI-approved safety goggles to protect your eyes from sparks and saw dust. Use hearing protection to protect yourself from hearing loss.
3. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to pacemakers could cause pacemaker interference or pacemaker failure.
4. Wear work gloves when handling saw blades. DO NOT wear gloves while operating the saw.
5. Sawdust is harmful to your health. Use NIOSH-approved dust masks or other respiratory protection during operation and cleaning.
6. Always turn off and unplug the track saw before making any adjustments or repair tasks. Never adjust the track saw or the workpiece while the saw is running.

Preparing the Track Saw

1. When transporting the track saw, carry it by either the handle or the base. Never carry the device by its guards or its accessories. Make sure that the blade is fully covered by the blade cover and not exposed.
2. Securely slide the track saw onto the track before operating.
3. Examine the track saw for any damaged or missing parts. Replace or repair damaged parts before operation. Periodically check that all nuts, bolts and other fasteners are properly tightened.

Secure Your Workpiece

1. To avoid blade binding or loss of control, always secure the workpiece to a stable platform, ensuring that body exposure is minimized. Use clamps to secure the workpiece. Never perform any operation freehand.
2. Ensure that work is correctly supported. Large panels may sag under their own weight and bind the saw blade. Supports must be placed under the panel on both sides, close to the line of cut and near the edge of the panel.
3. For accuracy of cut, and to avoid blade binding, always use a rip fence or straight edge guide.
4. Never hand-hold a workpiece that is too small to be clamped, as it can be launched away and cause injury. Use proper support and guides to secure the small workpiece.

During Cutting Operations

1. Always stand to one side when operating the saw. Never have any part of the body in line with the path of the saw. Never hold a workpiece in your hand or across your legs while cutting.
2. Ensure hands are away from the cutting area and blade. Keep one hand on the rear handle, and the other on the front grip. If both hands are holding the tool they cannot be cut by the blade.
3. Feed work into the blade against the direction of rotation of the blade only.
4. If you are interrupted when operating the saw, complete the process and switch the saw off before looking up.
5. Power tools must always be held by the insulated gripping surfaces when performing an operation, ensuring protection if the cutting tool makes contact with its own cord or hidden wiring. Contact with a `live' wire will make exposed metal parts of the power tool `live' and shock the operator if the insulated gripping surfaces are not used.
6. Do not use the track saw unless all guards are in place. Do not operate with any guard disabled, damaged, or removed. Moving guards must move freely and close instantly.
7. Turn on the track saw and let it reach full speed, then slowly slide the saw into the workpiece. This will help produce safer and cleaner cuts.
8. Always push the saw blade forwards and away from you. Do not pull the saw towards you, or move the saw backwards while cutting. Do not apply any sideways or twisting force to the blade while cutting.
9. Never cut more than one piece at a time. Do not stack workpieces together. Do not attempt to cut material thicker than specified on page 2 of this manual. Adjust the cutting depth to the thickness of the workpiece (less than a full tooth of the blade should be visible below the workpiece).
10. If a cut does not extend to the edge of the workpiece, or if the blade binds in the cut, allow the blade to come to a complete stop and lift the saw out of the workpiece.
11. Turn off tool and wait for saw blade to stop before moving workpiece or changing settings. Do not slow or stop a blade with a piece of wood. Let the blade come to rest naturally. Do not attempt to free a jammed blade while the machine is still running and connected to power.
12. Always raise the blade to be covered by the blade guard after use.

Reducing Kickback

Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator, increasing the chances of serious personal injury. Do not rely on the safety devices built into the saw. Track saw users should take as many precautions as possible to minimize on-site accidents. Kickback is the result of tool misuse and/or incorrect operating procedures. These conditions can be minimized with the following steps:

1. Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade but not in line with the blade. Kickback could cause the saw to jump backwards, however, if proper precautions are taken, kickback forces can be controlled by the operator. Do not let go of the track saw.
2. If the blade is binding, or interrupting a cut for any reason, release the trigger and hold the saw motionless in the workpiece 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. Investigate and take corrective action to eliminate the cause of blade binding.
3. When restarting a saw within an incomplete cut, center the saw blade in the kerf and check that the saw teeth are not engaged into the material (a binding saw blade may `propel upwards' or kickback from the workpiece as the tool is restarted).
4. A large workpiece should be supported close to the line of the cut, and at the edge of the panel, to prevent sagging. This will minimize the risk of blade pinching and kickback.
5. Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding, and kickback.
6. Blade depth and bevel adjusting locking levers must be tight and secure before making a cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
7. Use extra caution when making a `plunge cut' into existing walls or other blind areas. The protruding blade may cut objects causing kickback.
8. Do not use abrasive wheels, doing so will void the warranty.

Electrical Information

Double-Insulated Tools

The tool's electrical system is double insulated where two systems of insulation are provided. This eliminates the need for the usual three-wire grounded power cord. Double insulated tools do not need to be grounded, nor should a means for grounding be added to the product. All exposed metal parts are isolated from the internal metal motor components with protecting insulation.

IMPORTANT: Servicing a double-insulated product requires extreme care and knowledge of the system, and should be done only by qualified service personnel using identical replacement parts. Always use original factory replacement parts when servicing.

1. Polarized Plugs. To reduce the risk of electric shock, this equipment has a polarized plug (one blade is wider than the other). This plug will fit in a 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 proper outlet. Do not modify the machine plug or the extension cord in any way.
2. Ground fault circuit interrupter protection (GFCI) should be provided on the circuit or outlet used for this power tool to reduce the risk of electric shock.
3. Service and repair. To avoid danger, electrical appliances must only be repaired by qualified service technician using original replacement parts.

Guidelines and Recommendations for Extension Cords

When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The table below shows the correct size to be used according to cord length and ampere rating. When in doubt, use a heavier cord. The smaller the gauge number, the heavier the cord.

AMPERAGE

REQUIRED GAUGE FOR EXTENSION CORDS

1. EXAMINE EXTENSION CORD BEFORE USE. Make sure your extension cord is properly wired and in good condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it.
2. DO NOT ABUSE EXTENSION CORD. Do not pull on cord to disconnect from receptacle; always disconnect by pulling on plug. Disconnect the extension cord from the receptacle before disconnecting the product from the extension cord. Protect your extension cords from sharp objects, excessive heat and damp/wet areas.
3. USE A SEPARATE ELECTRICAL CIRCUIT FOR YOUR TOOL. This circuit must not be less than a 12-gauge wire and should be protected with a 15A time-delayed fuse. Before connecting the motor to the power line, make sure the switch is in the OFF position and the electric current is rated the same as the current stamped on the motor nameplate. Running at a lower voltage will damage the motor.

Unpacking & Transportation

⚠️ WARNING: Do not plug in or turn on the tool until it is fully assembled according to the instructions. Failure to follow the safety instructions may result in serious personal injury.

Unpacking

Thanks for taking the plunge and buying this saw. With the help of a friend or trustworthy foe, carefully remove the track saw from the packaging. Make sure to take out all contents and accessories. Do not discard the packaging until everything is removed. Check the packing list below to make sure you have all of the parts and accessories. If any part is missing or broken, please contact our customer service at 1-800-232-1195.

Packing List

• A. Track Saw (1)
• B. Carbon Brushes (2)
• C. Dust Port Adapter (1)
• D. 5mm Hex Wrench (1)

The tools listed below are not included but are required for either assembly or adjustment:

• Flat-head Screwdriver
• Phillips-head Screwdriver

The items listed below are not included, but are commonly bought with the this saw and made specifically for this track saw (Model Number: CT1065). These items can be purchased at wenproducts.com; to easily find the items on our website, search their model numbers:

• 100-inch Track with Adapters (Model Number: CT9502)
• 4-piece Track Adapter Set (Model Number: CT9011)
• Pair of Track Clamps (Model Number: CT992F)

Transporting the Track Saw

Before transporting your track saw, make sure that the blade is fully retracted inside the blade guard. Only lift the saw by the handles.

Know Your Track Saw

Tool Purpose

Track Saws allow you to easily make miter cuts and rough cuts on large sheets of material. Refer to the following diagrams to become familiarized with all the parts and controls of your track saw. The components will be referred to later in the manual for assembly and operation instructions.

Parts Identification (Diagrams not included, descriptions follow):

• A. Front Grip
• B. Depth Scale
• C. Bevel Scale
• D. Track Compensation Lever
• E. Depth Adjustment Knob
• F. Front Bevel Lock Knob
• G. Front Fine Adjustment Knob
• H. Track Lock Knob
• I. Anti-Kickback Knob
• J. Rear Fine Adjustment Knob
• K. Base Plate
• L. Rear Bevel Lock Knob
• M. Rear Handle
• N. Power Trigger
• O. Plunge Lock Button
• P. Spindle Lock
• Q. Dust Port
• R. Mode Selector
• S. Slot for Parallel Guide
• T. Saw Blade
• U. Track Slot
• V. Carbon Brush Cover

Assembly & Adjustments

⚠️ WARNING: Do not plug in or turn on the tool until it is fully assembled according to the instructions. Read through and become familiarized with the following procedures of handling and adjusting your track saw. Failure to follow the safety instructions may result in serious personal injury.

Dust Collection (Figure 1)

A dust collection bag (not included) or vacuum system should be used at all times. The inner diameter of the dust port adapter is 35mm; the outer diameter is 39.5mm.

1. Locate the dust port on the track saw.
2. Insert the dust port adapter into the dust port. Position the adapter so the dust hose or bag will not interfere with your work.
3. Securely attach a dust bag or vacuum to the end of the dust port adapter. If using a vacuum, make sure to turn it ON before starting your cut.

Mode Selection (Figure 2)

The mode selector switch enables fast and easy setting of major functions by simply rotating the switch to the desired mode of operation. The functions include:

1. Blade changing (see page 18 for instructions)
2. Free plunge, for general cutting
3. Scribe cut, for a scribe cut 2.5 mm (0.1 in) deep

B. Free Plunge Mode (Figure 3)

The cutting depth can be set between 0" - 2-3/8" (0 mm - 59 mm). ℹ️ NOTE: Always maintain an appropriate blade-depth setting. The blade teeth should never protrude more than 1/8" below the material being cut, as excessive blade depth increases the chances of saw kickback or contact with hidden surfaces beneath the workpiece.

1. Turn the mode selector switch to the free-plunge setting (Figure 2). Unplug your track saw. Loosen the depth adjustment knob and slide it up or down so the indication arrow points to the desired depth on the depth scale.
2. If you are using the saw with the track, turn the track compensation lever clockwise to the lower position to compensate for the thickness of the track. If you are using the saw without the track, turn the track compensation lever counterclockwise to the upper position.
3. Tighten the depth adjustment knob to lock it into place. Test the depth setting on a piece of scrap material to make sure it is correct before plugging the saw back in.

C. Scribe Cuts

1. Turn the mode selector switch to the scribe cut function; see "Mode Selection" on page 13.
2. Press the plunge lock button (Figure 4) and plunge the saw downwards. It will stop at a 2.5 mm (0.1 in) depth of cut.

ℹ️ NOTE: An initial scribe cut (before additional cuts) helps prevent friction on the blade, particularly when deep plunge cuts are required. It is also helpful for initial cuts on veneered or melamine laminates.

Adjusting the Bevel Angle (Figures 5 & 6)

The saw can be beveled between 0° - 45°.

1. Unplug your track saw. Loosen both bevel lock knobs (Figure 5). Bevel the saw so that the indication arrow is pointing to the desired angle on the bevel scale.
2. Tighten both bevel lock knobs to lock the bevel angle into place.
3. Make a test cut in a piece of scrap material. Measure the angle of the cut to confirm that the bevel angle is properly set. If necessary, re-adjust the bevel angle before cutting the actual workpiece.

ℹ️ NOTE: The bevel indication arrow should be properly adjusted at the factory. If you find that it is inaccurate, adjust it using the steps below.

1. Make a test cut. Measure the bevel angle.
2. Loosen the Phillips-head screw on the bevel indication arrow. Adjust the arrow so that it points to the angle of the cut. Tighten the screw.

Line-of-Cut Indicators (Figure 7)

Two line-of-cut indicators can be found on the base of the track saw. These notches help you to align your cuts.

1. Mark your cut on your workpiece. Locate the line-of-cut indicators on the front and back of the base plate.
2. Follow step "2.1" if you are using the track, follow step "2.2" if you are not using the track.
   2.1) When using the saw with the track, always align position A (the "0" mark on the base plate) with your marked cutting line.
   2.2) When using the saw without the track, align position A (the "0" mark on the base plate) with your marked cutting line for straight cuts. Align position B (the "45" mark on the base plate) with your marked cutting line for 45° bevel cuts.

ℹ️ NOTE: Since blade thicknesses vary, it is necessary to make test cuts along a guide line on a piece of scrap material to determine the proper alignment of the guideline within the notch. This will help to obtain an accurate cut with blades of various thicknesses.

Setting Up the Track

ℹ️ NOTE: You will need to remove the protective sleeves from the ends of each track before using the track. To help your saw glide smoothly along the track, do not allow dust, shavings, or other debris to build up on the track.

1. Each track adapter assembly is made up of 6 pieces: a spacer, a sleeve, and four hex screws. Assemble the track adapter by fitting the spacer into the sleeve, opposite the hex screws. See Figure 8.
2. Slide the track adapter assembly into the groove on the front face of the track. Half of the adapter should be in the groove and half should hang off the track. The hex screws should be accessible. Tighten the two hex screws that are within the track with a 3mm hex wrench (Figure 9).
3. Repeat step 2 with the second adapter and the groove on the underside of the track. Be sure to tighten the two hex screws that are within the track.
4. Guide the two free halves of the track adapters onto another piece of track (Figure 10) and tighten the hex screws on the face side and the underside (Figure 11).
5. Align the track along the workpiece, the right-hand (flat) side of the track is where the actual cut will occur. Clamp down the track to the work surface so the track is secure.
6. Place the saw onto the track. Make sure the blade will contact the workpiece as intended.
7. Use the fine-adjustment cams to line up the track's edge and the saw's cutting path with one another. Refer to page 17.

Cutting the Rubber Strip

The rubber strip running along the edge of the track comes in its uncut original state. This rubber strip has two main applications. Firstly, it acts as a straightedge, allowing users to visualize the exact location of the cut. Secondly, it helps prevent dust from flying up during sawing operations. Because of the precision required for these two applications, users must cut this rubber strip themselves before using the track saw on any workpieces. This ensures every track perfectly complements a particular track saw.

1. Turn the mode selector switch to the free-plunge setting, see "Mode Selection" on page 13. Set the depth stop to 1/2", limiting the blade's maximum cutting depth.
2. Clamp the track into place so that you can cut the full length of the track in one go.
3. Position the saw onto the end of the track with the back two-thirds of the saw hanging off. The goal should be to maximize the amount of the saw's base that is on the track while still being able to plunge the full 1/2" downwards without yet contacting the rubber strip with the blade (Figure 12).
4. Start the saw and then plunge downwards, making sure to not yet contact the rubber strip. Once the saw has reached full speed and is plunged the full 1/2", progress forward along the track so that the blade makes contact with the rubber strip.
5. Cut the rubber strip along the full length of the track. Once you have made it all the way down the track, the strip should be precision-cut to meet the specifications of your particular track saw.

Using the Track Lock (Figure 13)

The track lock is an added measure to prevent the track saw from separating from the track during operation.

1. Pull upwards on the track lock knob and rotate it counterclockwise (so the arrow on the knob points to the 0 on the base), then set the track saw onto the track.
2. Once the saw is sitting properly on the track, pull upwards on the track lock knob and rotate it clockwise (so the arrow on the knob points to the 1 on the base). This hooks a small plate on the base of the saw under the lip of the track, preventing the saw from separating from the track.

Using the Fine-Adjustment Cams (Figures 14 & 15)

There are two fine-adjustment cams on the base of the saw to help eliminate play between the track guide rail and the track slot on the base of the saw.

1. Loosen the fine-adjustment cam knobs, then move the lever on the cam all the way to the left or the right. Tighten the knobs.
2. Set the track saw on the track, ensuring that the track rail enters the slot in the saw base.
3. Loosen the knobs and move the lever on each cam to take any play out of the track saw's movement. The saw base should be snug against the track rail. Tighten the knobs to lock the cams in place.
4. Move the saw forward along the track, ensuring its movement is smooth. Repeat step 3, if necessary, if adjustments are needed.

ℹ️ NOTE: Some tracks' rails may be wide enough that the saw cannot be placed on the track without removing the cams. If this is the case, unscrew the knobs and remove the cams.

Anti-Kickback Cam (Figure 15)

For your safety, an anti-kickback cam is included on the base of the saw. The cam is designed to prevent backwards movement of the saw along the track, and therefore kickback that can result from this movement. If you are not making a cut and need to easily slide the saw backwards along the track, turn the cam knob so the arrow points to the 0 (disengaged) position on the base, hold it in this position, then slide the saw backwards. ℹ️ NOTE: The cam is spring-loaded and should return to the 1 (engaged) position automatically.

Changing the Saw Blade

DANGER! Never try to use a blade larger than the stated capacity of the saw. Do not use a blade thicker than 1.9mm. It will prevent the blade screw from properly securing the blade on the arbor. Install the suitable blade for your cutting operation. See page 2 and page 6 for specifications and saw blade safety.

❗ CAUTION: Always wear gloves while handling blades to prevent cuts and injuries.

1. Unplug your track saw. Turn the mode selector switch to the blade changing setting (p. 13, Figure 2).
2. Press and hold the plunge lock button (Figure 16) and plunge the saw downwards until the arbor screw is visible in the blade guard window. Release the plunge lock button; the saw should now be locked in place and unable to be plunged or raised.
3. Press and hold the spindle lock (Figure 16), then use the included 5mm hex wrench to loosen the arbor screw (turn it counterclockwise).
4. Remove the screw and outer flange (Figure 17). Slide the blade off the arbor and downwards until it is clear of the blade guard.
5. Install the new blade on the arbor. Ensure that the blade rotation direction is correct ➡️. Install the outer flange and arbor screw. Press and hold the spindle lock button, then use the hex wrench to tighten the arbor screw.
6. Press and hold the plunge lock button to release the saw, then raise it.

Operation

⚠️ WARNING: Do not plug in or turn on the tool until it is fully assembled according to the instructions. Read through and become familiarized with the following procedures of handling and adjusting your track saw. Failure to follow the safety instructions may result in serious personal injury.

⚠️ WARNING: Always let the blade reach full speed before guiding the saw into the workpiece. The blade coming into contact with the workpiece before reaching full speed, could cause your saw to KICKBACK towards you resulting in serious personal injury.

⚠️ WARNING: If, while operating the saw, the cord hangs up on the workpiece or some other object during a cut, release the switch trigger immediately. Unplug the saw and reposition the cord to prevent it from hanging up again.

Starting/Stopping the Saw (Figure 18)

1. Plug in the tool.
2. To start the saw, press and hold the plunge lock button, then pull the power trigger. Once the saw reaches maximum speed, plunge the saw downwards.
3. To stop the saw, release the power trigger. Allow the blade to come to a complete stop.

ℹ️ NOTE: Do not remove your saw from the workpiece while the blade is still moving.

Operating the Saw (Figure 19)

1. Hold the tool firmly with both hands, using both the front grip and the rear handle. Avoid placing your hand on the workpiece while making a cut.
2. Place the workpiece with the "good" side down.
3. Set-up and support the workpiece so the cut is always on your right side. The larger (left) side of the saw's base should be on the part that does not fall off when a cut is made.
4. Securely clamp the workpiece so it will not move during the cut. If you are cutting with the track, use two clamps to clamp the track to the workpiece. If you are cutting without the track, place a clamp as close to the base of the saw as possible to support the workpiece. Make sure the clamp is as close to the cut as possible without getting in the way of the saw's line of motion.
5. Draw a guideline along the desired path of the cut before starting your saw or the cut. Set up the track to meet the needs of your particular guide line (see "Setting Up the Track" on page 15).
6. Keep the cord away from the cutting area. Position the cord to prevent it from hanging up on the workpiece and stop you from standing or tripping on the cord during operation. Start the saw and make your cut.

❗ CAUTION: To make sawing easier and safer, be sure to move the tool forward gently in a straight line. Never force or twist the saw during operation. Forcing or twisting the tool will result in overheating the motor and will increase the chances of dangerous kickback, possibly causing severe personal injury. Do not pull the saw towards you, or move the saw backwards, while cutting.

Cross-cutting and Rip Cutting

Cutting directly across the grain of a piece of wood is called crosscutting. Cutting wood lengthwise, or with the grain, is referred to as rip cutting (or simply "ripping"). Both types of cuts are performed in the same manner with the exception of the methods used to support and secure the workpiece for cutting. After you have secured the workpiece in position, positioned the cord so it won't be cut or hung up, performed the saw set-up adjustments, made the necessary measurements, drawn a straight guide line, and put on your personal protection, you can begin the cutting operation.

1. Hold the tool firmly with both hands, using both the front grip and the rear handle. Avoid placing your hand on the workpiece while making a cut.
2. Set the front portion of the saw's base on the workpiece to be cut without the blade making any contact. Align the line-of-cut indicator notch on the right side of the base with your guideline. Turn the saw on and wait until it reaches full speed.
3. Ease the tool forward over the workpiece surface, keeping it flat and advancing smoothly while following your guideline until sawing is completed.
4. Once the cut is complete, release the power trigger. Wait for the blade to completely stop. Raise the saw. Now you can safely remove the saw from the workpiece and set it out of the way.
5. To achieve clean cuts, keep your sawing line straight while smoothly advancing forward. Do not force the saw forward too quickly in order to try and hurry up the process. Let the tool work at its own pace.
6. If the cut fails to properly follow your intended cut line, do not attempt to turn or force the tool back to the cut line. Doing so may bind the blade and lead to dangerous kickback and possible serious injury. Do not pull the saw towards you, or move the saw backwards, while cutting. Instead, release the switch trigger, wait for the blade to stop, and then remove the tool. Realign saw on a new cut guide line and start the cut again.
7. Position yourself in a way that allows you to avoid the wooden chips and dust being ejected from the saw.

Bevel Cutting

For instructions on how to bevel the saw blade, see "Adjusting the Bevel Angle" on page 14. Bevel cuts are made using the same technique as crosscuts and ripping described in the previous section. The difference is that the blade is set at a tilted angle between 0° - 45°. A bevel cut made at an angle to the edge of a board is called a compound miter.

There are tools better suited for bevel and compound cuts than the track saw. Although the inner line-of-cut indicator notch aids the operator in following the cut's guideline, the tilted motor housing sometimes obstructs the operator's ability to see the blade, making accurate cuts difficult. Before taking on a project with numerous compound or bevel cuts, it is suggested that inexperienced saw users spend time making practice cuts in scrap material to become familiar with and overcome difficulties associated with compound/bevel cutting.

ℹ️ NOTE: Keep in mind that bevel cutting may cause misalignment or alter the rubber strip along the edge of your track.

⚠️ WARNING: Always let the blade reach full speed before guiding the saw into the workpiece. The blade coming into contact with the workpiece before reaching full speed, could cause your saw to KICKBACK towards you resulting in serious personal injury.

Plunge Cuts (Figure 20)

A plunge cut is a cut that must be made inside the area of the workpiece, rather than starting from an outside edge and working inward.

1. Adjust the bevel setting to zero; see "Adjusting the Bevel Angle" on page 14.
2. Turn the mode selector switch to the free-plunge setting, see "Mode Selection" on page 13.
3. Set the blade to the correct blade depth setting and position it where you would like your cut to occur. You will find two notches along the blade cover. The notches indicate the maximum points that the saw's blade will reach (Figure 20).
4. Press the plunge lock button (Figure 21) to allow the saw to plunge downwards, while not allowing the blade to actually contact the workpiece.
5. Power the saw on by pulling the trigger switch (Figure 21). Allow it to reach full speed.
6. Once the blade has reached its maximum speed, lower the blade down into the workpiece until the set cutting depth has been reached. Once the saw cannot be lowered anymore, move the saw along the desired cut line in an even and steady motion.

Flush Cutting (Figure 22)

Your track saw can perform cuts close to walls or other obstructions (for example, when removing hardwood flooring). ℹ️ NOTE: The minimum distance between the cut line and wall is 16 mm (5/8").

1. Turn the mode selector switch to the scribe-cut or free-plunge setting, see "Mode Selection" on page 13.
2. Adjust the bevel angle to 0 degrees, see "Adjusting the Bevel Angle" on page 14.
3. If using the free-plunge setting, set the desired plunge depth and ensure that the track compensation mechanism is properly adjusted, see "B. Free Plunge Mode" on page 13. If using the scribe-cut setting, the cutting depth is pre-set at 2.5 mm (0.1").
4. Plunge the saw downwards and complete the cut, see "Operating the Saw" on page 19. After completing the cut, release the power trigger (Figure 21) and allow the blade to come to a complete stop before removing the saw from the workpiece.

Troubleshooting Guide

⚠️ WARNING: Stop using the tool immediately if any of the following problems occur. Repairs and replacements should only be performed by an authorized technician. For any questions, please contact our customer service at (800) 232-1195, Mon-Fri 8-5 CST or email us at techsupport@wenproducts.com.

Maintenance

Routine Inspection

Before each use, inspect the general condition of the tool. If any of these following conditions exist, do not use until parts are replaced or the saw is properly repaired.

• Loose hardware,
• Misalignment or binding of moving parts,
• Damaged cord/electrical wiring,
• Cracked or broken parts, and
• Any other condition that may affect its safe operation

⚠️ WARNING: To avoid accidents, turn OFF and unplug the tool from the electrical outlet before cleaning, adjusting, or performing any maintenance work.

⚠️ WARNING: Any attempt to repair or replace electrical parts on this tool may be hazardous. Servicing of the tool must be performed by a qualified technician. When servicing, use only identical WEN replacement parts. Use of other parts may be hazardous or induce product failure.

ℹ️ NOTE: Electric tools used on fiberglass material, wallboard, spackling compounds, or plaster are subject to accelerated wear and possible premature failure because the fiberglass chips and grindings are highly abrasive to bearings, brushes, commutators, etc. Consequently, we do not recommend using this tool for extended work on these types of materials. However, if you do work with any of these materials, it is extremely important to clean the tool using compressed air after operation.

Cleaning & Storage

1. Keep the ventilation openings free from dust and debris to prevent the motor from overheating.
2. Wipe the tool surfaces clean with a clean cloth. Make sure water does not get into the tool.

❗ CAUTION: Most plastics are susceptible to damage from various types of commercial solvents. Do not use any solvents or cleaning products that could damage the plastic parts. Some of these include but are not limited to: gasoline, carbon tetrachloride, chlorinated cleaning solvents, and household detergents that contain ammonia.

3. Store the tool in a clean and dry place away from the reach of children. Store in temperatures between 41°F to 86°F.
4. Cover the track saw in order to protect it from dust and moisture. It is preferable to store it in its original packaging with the instruction manual and all accessories.

Lubrication

The bearings of your track saw are permanently sealed and require no extra lubrication. The gearbox is also sufficiently lubricated from the factory and requires no additional lubrication.

Product Disposal

Used power tools should not be disposed of together with household waste. This product contains electronic components that should be recycled. Please take this product to your local recycling facility for responsible disposal and to minimize its environmental impact.

Please recycle the packaging where facilities exist.

Carbon Brush Replacement

The wear on the carbon brushes depends on how frequently and how heavily the tool is used. To maintain maximum efficiency of the motor, we recommend inspecting the two carbon brushes every 60 hours of operation or when the tool stops working. Your track saw comes with a carbon brush replacement set.

ℹ️ NOTE: Replacement carbon brushes (Part No. CT1065031) can be ordered at wenproducts.com. Only genuine WEN replacement brushes designed specifically for your tool should be used. Carbon brushes are not covered under the two-year warranty.

1. Unplug the saw. To access the carbon brushes, remove the carbon brush cover (Figure 23) with a flat-head screwdriver (not included).
2. Carefully remove the old carbon brushes using pliers. Keep track of which orientation the old carbon brushes were in to prevent needless wear if they will be reinstalled.
3. Measure the length of the brushes (Figure 23). Install the new set of carbon brushes if either carbon brush length is worn down to 3/16" or less. Reinstall the old carbon brushes (in their original orientation) if your brushes are not worn down to 3/16" or less. Both carbon brushes should be replaced at the same time.
4. Replace the carbon brush cover.

ℹ️ NOTE: New carbon brushes tend to spark for a few minutes during the first use as they wear down.

Exploded View & Parts List

Warranty Statement

WEN Products is committed to building tools that are dependable for years. Our warranties are consistent with this commitment and our dedication to quality.

Limited Warranty of WEN Products for Home Use

GREAT LAKES TECHNOLOGIES, LLC ("Seller") warrants to the original purchaser only, that all WEN consumer power tools will be free from defects in material or workmanship during personal use for a period of two (2) years from date of purchase or 500 hours of use; whichever comes first. Ninety days for all WEN products if the tool is used for professional or commercial use. Purchaser has 30 days from the date of purchase to report missing or damaged parts.

SELLER'S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the replacement of parts, without charge, which are defective in material or workmanship and which have not been subjected to misuse, alteration, careless handling, misrepair, abuse, neglect, normal wear and tear, improper maintenance, or other conditions adversely affecting the Product or the component of the Product, whether by accident or intentionally, by persons other than Seller. To make a claim under this Limited Warranty, you must make sure to keep a copy of your proof of purchase that clearly defines the Date of Purchase (month and year) and the Place of Purchase. Place of Purchase must be a direct vendor of Great Lakes Technologies, LLC. Purchasing through third party vendors, including but not limited to garage sales, pawn shops, resale shops, or any other secondhand merchant, voids the warranty included with this product. Contact techsupport@wenproducts.com ? or 1-800-232-1195 ? with the following information to make arrangements: your shipping address, phone number, serial number, required part numbers, and proof of purchase. Damaged or defective parts and products may need to be sent to WEN before the replacements can be shipped out.

Upon the confirmation of a WEN representative, your product may qualify for repairs and service work. When returning a product for warranty service, the shipping charges must be prepaid by the purchaser. The product must be shipped in its original container (or an equivalent), properly packed to withstand the hazards of shipment. The product must be fully insured with a copy of the proof of purchase enclosed. There must also be a description of the problem in order to help our repairs department diagnose and fix the issue. Repairs will be made and the product will be returned and shipped back to the purchaser at no charge for addresses within the contiguous United States.

THIS LIMITED WARRANTY DOES NOT APPLY TO ITEMS THAT WEAR OUT FROM REGULAR USAGE OVER TIME, INCLUDING BELTS, BRUSHES, BLADES, BATTERIES, ETC. ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO TWO (2) YEARS FROM DATE OF PURCHASE. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY.

THIS LIMITED WARRANTY APPLIES ONLY TO ITEMS SOLD WITHIN THE UNITED STATES OF AMERICA, CANADA AND THE COMMONWEALTH OF PUERTO RICO. FOR WARRANTY COVERAGE WITHIN OTHER COUNTRIES, CONTACT THE WEN CUSTOMER SUPPORT LINE. FOR WARRANTY PARTS OR PRODUCTS REPAIRED UNDER WARRANTY SHIPPING TO ADDRESSES OUTSIDE OF THE CONTIGUOUS UNITED STATES, ADDITIONAL SHIPPING CHARGES MAY APPLY.