Harbor Freight 18 Volt 5 1 2 In Cordless Circular Saw With Laser Guide System Product Manual
2015-05-27
: Harbor-Freight Harbor-Freight-18-Volt-5-1-2-In-Cordless-Circular-Saw-With-Laser-Guide-System-Product-Manual-723224 harbor-freight-18-volt-5-1-2-in-cordless-circular-saw-with-laser-guide-system-product-manual-723224 harbor-freight pdf
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Owner’s Manual & Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. 18 VOLT CORDLESS 5-1/2" CIRCULAR SAW WITH LASER GUIDE REV 14h Visit our website at: http://www.harborfreight.com Email our technical support at: productsupport@harborfreight.com When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-888-866-5797 as soon as possible. Copyright© 2011 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. Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL. Table of Contents SAFETY Safety.......................................................... 2 Specifications.............................................. 8 Setup........................................................... 8 Operation.................................................... 10 Maintenance............................................... 13 Parts List and Diagram............................... 14 Warranty..................................................... 16 WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. SETUP Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Addresses practices not related to personal injury. OPERATION IMPORTANT SAFETY INFORMATION General Power Tool Safety Warnings Read all safety warnings and 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 battery-operated (cordless) power tool. Work area safety MAINTENANCE 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 Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. Page 2 For technical questions, please call 1-888-866-5797. Item 68849 Personal safety 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. 6. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves 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 these devices can reduce dust‑related hazards. 8. Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI‑approved and breathing protection must be NIOSH‑approved for the specific hazards in the work area. SAFETY 2. Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. 5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. SETUP 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. 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. 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 blades 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. MAINTENANCE 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. OPERATION Power tool use and care Item 68849 For technical questions, please call 1-888-866-5797. Page 3 Battery tool use and care SAFETY 1. 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. 2. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire. 3. 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. 4. 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. 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. SETUP Circular Saw Safety Warnings 1. DANGER: Keep hands away from cutting area and the blade. If both hands are holding the saw, they cannot be cut by the blade. 2. Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece. 3. Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece. OPERATION 4. Never hold piece being cut in your hands or across your leg. Secure the workpiece to a stable platform. It is important to support the work properly to minimize body exposure, blade binding, or loss of control. 5. Hold power tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a ″live″ wire will also make exposed metal parts of the power tool ″live″ and shock the operator. MAINTENANCE 6. When ripping always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding. 7. Always use blades with correct size and shape (diamond versus round) of arbor holes. Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control. 8. Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation. Page 4 9. Causes and Operator Prevention of 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; • When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator; • If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator. Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below: a. Maintain a firm grip 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, but kickback forces can be controlled by the operator, if proper precautions are taken. b. When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding. For technical questions, please call 1-888-866-5797. Item 68849 Circular Saw Safety Warnings (cont.) e. Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback. 17. Do not use blades made from high-speed steel, abrasive blades, metal-cutting blades or masonrycutting blades. The guards of this saw are not designed to protect against the failure of such blades. f. Blade depth and bevel adjusting locking levers must be tight and secure before making cut. If blade adjustment shifts while cutting, it may cause binding and kickback. 18. Place the larger portion of the saw base on the larger, supported part of the workpiece. This will help maintain balance and control while the cut is completed. g. Use extra caution when making a ″plunge cut″ into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback. 10. Check lower guard for proper closing before each use. Do not operate the saw if lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If saw is accidentally dropped, lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut. 11. Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris. 12. Lower guard should be retracted manually only for special cuts such as ″plunge cuts″ and ″compound cuts.″ Raise lower guard by retracting handle and as soon as blade enters the material, the lower guard must be released. For all other sawing, the lower guard should operate automatically. 13. Always observe that the lower guard is covering the blade before placing saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released. 14. DO NOT USE THIS SAW WITH THE SAW HELD UPSIDE DOWN IN A VISE. The saw is not designed for such use and cannot be used safely in that position. Item 68849 19. Blades must be rated to at least the maximum speed marked on the tool. SAFETY SETUP 16. Wet lumber, green (unseasoned) lumber, and pressure treated lumber all have an increased potential for kickback and should only be cut with a blade for cutting that lumber type. Wear a NIOSH-approved respirator and have appropriate ventilation whenever cutting pressure treated lumber. 20. Maintain labels and nameplates on the tool. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 21. Avoid unintentional starting. Prepare to begin work before turning on the tool. 22. Do not lay the tool down until it has come to a complete stop. Moving parts can grab the surface and pull the tool out of your control. 23. When using a handheld power tool, maintain a firm grip on the tool with both hands to resist starting torque. 24. Do not leave the tool unattended when it is plugged into an electrical outlet. Turn off the tool, and unplug it from its electrical outlet before leaving. OPERATION d. Support large panels to minimize the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel. 15. Do not use to cut logs, tree limbs, or uneven lumber. 25. Use clamps (not included) or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. 26. The battery charger gets hot during use. The charger’s heat can build up to unsafe levels and create a fire hazard if it does not receive adequate ventilation, due to an electrical fault, or if it is used in a hot environment. Do not place the charger on a flammable surface. Do not obstruct any vents on the charger. Especially avoid placing the charger on carpets and rugs; they are not only flammable, but they also obstruct vents under the charger. Place the charger on a stable, solid, nonflammable surface (such as a stable metal workbench or For technical questions, please call 1-888-866-5797. Page 5 MAINTENANCE c. When restarting a saw in the workpiece, center the saw blade in the kerf and check that saw teeth are not engaged into the material. If saw blade is binding, it may walk up or kickback from the workpiece as the saw is restarted. Circular Saw Safety Warnings (cont.) SAFETY concrete floor) at least 1 foot away from all flammable objects, such as drapes or walls. Keep a fire extinguisher and a smoke detector in the area. Frequently monitor the charger and battery while charging. 27. This product is not a toy. Keep it out of reach of children. 28. Verify that there are no utility lines or hardware in or near the workpiece. This is especially critical for plunge cuts. 29. Do not depress the spindle lock when starting or during operation. SETUP 30. 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. • Properly ground power cord. Ground Fault Circuit Interrupter (GFCI) should also be implemented – it prevents sustained electrical shock. 31. 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 and 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.) 32. WARNING: The cord of this product contains 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.) 33. 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. OPERATION 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: MAINTENANCE 1. Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical check‑ups 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 medical or physical symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible. 2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury. 3. Use tools with the lowest vibration when there is a choice. 4. Include vibration-free periods each day of work. 5. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work. 6. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately. SAVE THESE INSTRUCTIONS. Page 6 For technical questions, please call 1-888-866-5797. Item 68849 TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE CONNECTION: Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the power cord plug provided with the Charger. Do not use the Charger if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician. SAFETY Grounding 1. Tools marked “Double Insulated” do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical Code. Outlets for 2-Prong Plug 2. Double insulated tools may be used in either of the 120 volt outlets shown in the preceding illustration. (See Outlets for 2-Prong Plug.) SETUP Double Insulated Tools: Tools with Two Prong Plugs Extension Cords Note: Extension cords must not be used with this item’s Charger. Read the manual before set-up and/or use. Canadian Standards Association WARNING marking concerning Risk of Hearing Loss. Wear hearing protection. WARNING marking concerning Risk of Fire. Do not cover Charger ventilation ducts. Charge on fireproof surface only. WARNING marking concerning Risk of Electric Shock. Properly connect Charger’s power cord to appropriate outlet. WARNING marking concerning Risk of Explosion. Do not puncture, short, or open battery packs and do not charge damaged battery packs. Underwriters Laboratories, Inc. VAC A Volts Alternating Current Amperes n0 xxxx/min. No Load Revolutions per Minute (RPM) WARNING marking concerning Risk of Eye Injury. Wear ANSI‑approved safety goggles with side shields. Item 68849 For technical questions, please call 1-888-866-5797. Page 7 MAINTENANCE Double Insulated OPERATION Symbology Specifications Charger SAFETY Battery Type 120VAC, 60Hz Input 7.2-24VDC Output 1 Hour Charge Time (Item 68859, sold separately) 18V, 1500mAh, NiCd (Item 68860, sold separately) Speed 4000 RPM Cut Depth 1-9/16 IN. @ 90°/1-1/8 IN. @ 45° Arbor 10mm Blade Diameter 5-1/2 IN. AVOID EXPOSURE Laser light is emitted from this opening. LASER LIGHT DO NOT STARE INTO BEAM Max. Output: <1 mW, Wavelength: 650 nm CLASS II LASER PRODUCT This product complies with 21 CFR 1040.10 and 1040.11 Diode Mfr.: Yueqing Dengke Electron Ltd., Xiaxue Industry Area, Shifan Town, Yue Qing City, Zhejiang, China Manufacture Date: ___________, ______ SETUP Setup - Before Use: Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn the Power Switch of the tool off and unplug the tool from its electrical outlet before assembling or making any adjustments to the tool. OPERATION Note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual. Charger Indicator LED’s Green LED: Continuously lit indicates charger is powered. MAINTENANCE Red LED: Flashing indicates that the battery is charging. Continuously lit (not flashing) indicates that the battery has finished charging and should be removed from the charger. Battery Pack Red LED Green LED Page 8 For technical questions, please call 1-888-866-5797. Charger Item 68849 Functions Auxiliary Handle Battery Pack (not included) Bevel Scale SAFETY Battery Button Bevel Adjusting Knob (42) Trigger (36) Plate (50) SETUP Saw Blade (6) Laser Switch (38) Trigger Lock Button (34) Laser Guide (14) Fence Adjusting Knob (45) Depth Gauge MAINTENANCE Depth Adjusting Knob (53) OPERATION Spindle Lock Button (20) Item 68849 For technical questions, please call 1-888-866-5797. Page 9 Operating Instructions Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. SAFETY Tool Set Up TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Release the Trigger and disconnect the Battery Park before making any adjustments to the tool. TO PREVENT SERIOUS INJURY FROM FLYING FRAGMENTS: Do not use blades made from high-speed steel, abrasive blades, or metal- or masonry‑cutting blades. The guards of this saw are not designed to protect against the failure of such blades. Mounting and Removing Blade Adjusting Depth SETUP • Do not install the Battery Pack until AFTER you complete the following steps to set up the Saw for use. 1. Use the Depth Adjusting Knob (53) to adjust the Saw’s cutting depth. • Refer to page 7 for the location of the parts of the Saw for the following steps. 2. Set the Plate (50) flat against the edge of the workpiece. Loosen the Knob, which will allow the Plate to be moved. 1. Hold in the Spindle Lock Button (20) while using the Hex Key (51) to remove the Blade Bolt (1), turning it counterclockwise. See Figure A, below. Blade Bolt (1) Saw Blade (6) 3. Use the scale along the Depth Gauge located behind the main housing to determine depth of cut. To reduce the risk of injury, adjust the depth of cut to just barely clear the workpiece and remove shavings. 4. After adjustment, tighten Depth Adjusting Knob. WARNING! Tighten Depth Adjusting Knob before use. OPERATION Adjusting Bevel Outer Flange (2) 1. Use the Bevel Adjusting Knob (42) to adjust the Saw’s cutting depth. Inner Flange (7) Figure A: Blade Installation 2. Remove the Outer Flange (2). 3. Use the lever on the Lower Guard (10) to raise the Guard and remove the Blade (6). Leave the inner flange in place. 2. Turn the Bevel Adjusting Knob to loosen the Plate, allowing you to adjust angle of cut. 3. Use the Bevel Scale to set the desired angle (anywhere between 0-45°). 4. After adjustment, tighten the Bevel Adjusting Knob. WARNING! Tighten Bevel Adjusting Knob before use. MAINTENANCE 4. Install the new blade, with the directional arrow on the blade pointing the same as the directional arrow on the Upper Guard (5,18). 5. Place the Outer Flange on the spindle, recessed side first. 6. Hold the Spindle Lock Button (20) while using the Hex Key (51) to replace the Blade Bolt (1), turning it clockwise. Page 10 For technical questions, please call 1-888-866-5797. Item 68849 Adjusting Fence 1. Loosen the Fence Adjusting Knob (45) and slide the Fence (53) to the desired setting. Fence Adjusting Knob (45) SAFETY Note: There is a ruler on the fence to show the approximate width of cut. 2. The Fence can be removed entirely, if needed. 3. After adjustment if the Fence is used, tighten the Fence Adjusting Knob. WARNING! Tighten Fence Adjusting Knob before use. Fence (53) Figure B: Fence Adjustment Note: If recharging a newly spent Battery Pack, allow it to cool completely before charging. 2. Examine the Battery Pack. It must be undamaged, and a NiCd type Battery Pack. Do not charge a cracked, open, or leaking Battery Pack, or charge a non‑recommended type of Battery Pack. 3. The Battery Pack’s terminals are designed to fit this Charger specifically. If the Battery Pack does to not fit the Charger properly, do not try to insert it. Do not force a Battery Pack into the Charger. 4. Plug the Power Supply into a grounded, 120VAC, 60Hz receptacle. 5. Connect the Power Supply to the Charger. The green power LED will light, showing that power is supplied to the Charger. 6. Slide the Battery Pack into the charger until the button on the Battery Pack clicks into place. The Red LED will flash to show the Battery is charging and the Green LED will continue to stay lit. Note: The Battery Pack’s capacity will increase somewhat during the first few charging cycles. A fully discharged Battery Pack will take about 1 hour to fully charge. Recharging the Battery Pack for more than 1 hour can damage the battery cells. 7. While charging, the Battery Pack, Charger, and Power Supply may become warm to the touch. This is normal, and does not indicate a problem. 8. The red LED will light continuously when the Battery Pack is charged. Unplug the Charger and disconnect it from the Battery Pack when finished. 9. Allow the Battery Pack to cool completely before using it. 10. Press the Battery Button to release Battery Pack from the Charger. OPERATION 1. Place the Battery Pack on a dry fireproof surface in a room where the temperature is from 50–104° F. SETUP Charging Work Piece and Work Area Set Up a. Work piece must be free of foreign objects and loose knots. b. Do not use to cut logs, tree limbs, or uneven lumber. c. Wet lumber, green (unseasoned) lumber, and pressure treated lumber all have an increased potential for kickback and should only be cut with a blade designed for cutting that lumber. Wear a NIOSH-approved respirator and have appropriate ventilation whenever cutting pressure treated lumber. 2. Designate a work area that is clean and well‑lit. The work area must not allow access by children or pets to prevent distraction and injury. 3. Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working. 4. Secure loose workpieces using a vise or clamps (not included) to prevent movement while working. 5. Verify that there are no utility lines or hardware in or near the workpiece. This is especially critical for plunge cuts. Item 68849 For technical questions, please call 1-888-866-5797. Page 11 MAINTENANCE 1. Work piece selection: General Operating Instructions 1. WARNING! TO PREVENT SERIOUS INJURY, BEFORE OPERATION: a. Remove Battery Pack. SAFETY b. Adjust Blade Depth to extend beyond bottom of workpiece by 1/4 IN. or less. Lock Depth Adjusting Knob (53). c. Make sure that all guards are in place and in proper working order. d. Tighten all knobs/bolts securely. e. Tighten Blade Bolt. (Blade Bolt may loosen during operation.) 2. Install fully charged Battery Pack into base at back of handle. 3. Hold the saw with one hand on the Main Handle and the other hand on the Auxiliary Handle. SETUP 4. Align Saw on cut line with the larger part of the workpiece to the left of the Saw Blade. 5. Press Laser Switch (38) to activate Laser (14). WARNING! Only turn Laser on when Saw is on workpiece. Do not stare directly at the laser beam. Do not aim the beam at any person or object other than the workpiece. WARNING! Do not aim Laser Guide at a workpiece with a reflective surface, such as sheet steel or metal. Bright, shiny reflective sheet metal could direct the beam back at you. 6. Push the Trigger Lock Button (34) and squeeze the Trigger (36). 7. Allow the Blade to come up to full speed before contacting the workpiece. Note: When cutting across the grain, wood fibers can lift and tear. Move the Saw slowly to minimize any tearing. 8. After completing the cut, release the trigger. Make sure that the Movable Guard closes immediately. 9. To prevent accidents, turn off the tool and disconnect the Battery Pack after use. 10. Clean, then store the tool indoors out of children’s reach. Pocket Cut OPERATION 1. WARNING! Verify workpiece is clear of any hidden wiring and utility lines before cutting. 6. Once the Blade starts cutting, release the Blade’s Lower Guard. 2. Draw a line on the workpiece to indicate the cut. Set the Blade’s depth adjustment accordingly and raise the Lower Guard (10). 7. When the Plate is resting flat on the surface being cut, continue to cut forward to the end of the cut. 3. Set the Blade so that it is barely above the workpiece. 4. Start the Saw and allow the Blade to come to full speed. 5. Gradually lower the Blade onto the workpiece, using the front end of the Plate (50) as a pivot point. 8. Allow the Blade to come to a full stop before removing it from the cut. 9. WARNING! Do not pull the Saw back. Doing so will cause the Blade to climb out of the cut, leading to Kickback (see warnings on page 4). 10. Turn the Saw around and finish the cut in a normal manner, sawing forward. Use a jig saw or hand saw (not included) to finish cutting the corners, if needed. Cutting Large Sheets MAINTENANCE 1. Cutting large sheets or boards requires support to prevent sagging. Cutting without leveling and/ or proper support will cause the Blade to bind, leading to kickback (see warnings on page 4). Page 12 2. Use sawhorses to support the board or panel to be cut. For technical questions, please call 1-888-866-5797. Item 68849 Maintenance and Servicing SAFETY Procedures not specifically explained in this manual must be performed only by a qualified technician. TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Release the Trigger and remove the Battery Pack before performing any inspection, maintenance, or cleaning procedures. TO PREVENT SERIOUS INJURY FROM TOOL FAILURE: Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use. Cleaning, Maintenance, and Lubrication 2. AFTER USE, wipe external surfaces of the tool with clean cloth. 3. Ni-Cd BATTERY MUST BE RECYCLED OR DISPOSED OF PROPERLY. Do not short, incinerate or open Battery Pack. 4. Store in clean, dry and safe location out of reach of children. SETUP 1. BEFORE EACH USE, inspect the general condition of the tool. Check for: • leaking, swollen, or cracked battery pack, • loose hardware, • misalignment or binding of moving parts, • cracked or broken parts, and • any other condition that may affect its safe operation. Troubleshooting Likely Solutions 1. Remove Battery Pack, make sure there are no obstructions, reinsert the Battery Pack according to its shape (it should only fit one way), and press firmly until the Battery Pack locks in place. 2. Battery Pack not 2. Make sure Charger is connected and operating properly. properly charged. Give enough time for Battery Pack to recharge properly. 3. Battery Pack burnt‑out. 3. Dispose of old Battery Pack properly or recycle. Replace Battery Pack. 4. Internal damage or wear. 4. Have technician service tool. Tool operates 1. Forcing tool to work too fast. 1. Allow tool to work at its own rate. slowly. 2. Battery Pack power low. 2. Recharge Battery Pack. 3. Battery Pack burnt‑out. 3. Dispose of old Battery Pack properly or recycle. Replace Battery Pack. Performance 1. Blade dull or damaged. 1. Keep cutting Blades sharp. Replace as needed. decreases 2. Battery Pack wearing out. 2. Battery Pack capacity will gradually decrease through use. over time. If symptoms are severe, recycle old Battery Pack (or dispose of properly) and replace it. Excessive noise Internal damage or wear. (Carbon Have technician service tool. or rattling. brushes or bearings, for example.) Overheating. 1. Forcing tool to work too fast. 1. Allow tool to work at its own rate. 2. Blade dull or damaged. 2. Keep cutting Blades sharp. Replace as needed. 3. Blocked motor housing vents. 3. Wear ANSI-approved safety goggles and NIOSH‑approved dust mask/respirator while blowing dust out of motor using compressed air. Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect Battery Pack and Charger power supply before service. Item 68849 For technical questions, please call 1-888-866-5797. Page 13 OPERATION Possible Causes 1. Battery Pack not properly connected. MAINTENANCE Problem Tool will not start. Parts List and Diagram PLEASE READ THE FOLLOWING CAREFULLY SAFETY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR 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 DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, 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. Parts List SETUP Part OPERATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Description Blade Bolt Outer Flange Screw (M4x10) Spring Pad Left Upper Guard Saw Blade Inner Flange Screw (M3x10) Guard Washer Lower Guard Torque Spring Self Tapping Screw (ST3.5x14) Laser Base Laser Wire Plate Screw (M4x14) Rubber Ring Right Upper Guard Connector Pipe Spindle Lock Button Lock Spring Lock Block Shaft Left Housing Gearbox Bearing (6000) Output Shaft Lock Block Qty. 1 1 3 5 1 1 1 10 1 1 1 8 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 Part 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Description Large Gear Small Gear Bearing (606) Gearbox Cover Spring Pad (Ø3) Motor Trigger Lock Button Trigger Spring Trigger Right Housing Laser Switch Laser Switch Frame Rear Housing Self Tapping Screw (ST3x14) Bevel Adjusting Knob Washer (Ø6.5xØ15) Screw Fence Adjusting Knob Nut (M4) Connecting Screw Rod Locknut Screw (M6x95) Plate Hex Key Depth Adjusting Knob Fence Qty. 1 1 1 1 1 1 4 1 1 1 1 1 1 13 2 2 1 1 1 1 1 1 1 1 1 1 MAINTENANCE Record Product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 14 For technical questions, please call 1-888-866-5797. Item 68849 SAFETY 4 5 29 16 6 30 46 16 47 7 8 48 4 31 32 9 SETUP 3 45 10 8 11 12 12 33 8 34 13 35 36 14 15 OPERATION 2 44 52 43 49 50 51 16 17 37 18 19 38 39 41 40 41 23 20 21 22 MAINTENANCE 1 43 24 25 26 27 42 28 Assembly Diagram 53 Page 15 For technical questions, please call 1-888-866-5797. Item 68849 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 • 1-888-866-5797
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