Porter-Cable 3802 User's Manual
Contents
1. Use proper extension cords Make sure your extension cord is in good condition When using an extension cord be sure to use one heavy enough to carry the current of the saw An undersized cord will cause a drop in line voltage resulting in loss of power and overheating Fig 1 shows the correct gauge to use depending on the cord length If in doubt use the next heavier gauge The smaller the gauge number the heavier the cord 0 6 0 6 0 6 0 6 6 10 6 10 6 10 6 10 10 12 10 12 10 12 10 12 120 120 120 120 120 120 120 120 120 120 120 120 up to 25 25 50 50 100 100 150 up to 25 25 50 50 100 100 150 up to 25 25 50 50 100 100 150 18 AWG 16 AWG 16 AWG 14 AWG 18 AWG 16 AWG 14 AWG 12 AWG 16 AWG 16 AWG 14 AWG 12 AWG 12 16 120 up to 25 14 AWG 12 16 120 25 50 12 AWG 12 16 120 GREATER THAN 50 FEET NOT RECOMMENDED Fig 1 OPERATING INSTRUCTIONS FOREWORD Porter Cable Model 3802 Type 2 is a high capacity 12 compound miter saw designed to cut wood and non ferrous metals It can crosscut 8 x 2 and 7 x 3 miter at 45 both left and right 5 x 2 bevel at 45 left 6 x 214 and 8 x 1 and compound 45 x 45 5 x 2 1 2 and 4 x 2 It has positive miter stops at O 15 22 5 31 62 and 45 degrees both left and right and bevel stops at O and 45 degrees left POWER CONNECTIONS A separate electrical circuit should be used for your tools If an extension cord is used make sure the condu2. 597 5000 Fax 248 597 5004 MINNESOTA Minneapolis 55429 4315 68th Avenue North Phone 612 561 9080 Fax 612 561 0653 MISSOURI North Kansas City 64116 1141 Swift Avenue P O Box 12393 Phone 816 221 2070 Fax 816 221 2897 St Louis 63119 7574 Watson Road Phone 314 968 8950 Fax 314 968 2790 NEW YORK Flushing 11365 1595 N Y C 175 25 Horace Harding Expwy Phone 718 225 2040 Fax 718 423 9619 NORTH CAROLINA Charlotte 28270 9129 Monroe Road Suite 110 Phone 704 841 1176 Fax 704 708 4625 OHIO Columbus 43214 4560 Indianola Avenue Phone 614 263 0929 Fax 614 263 1238 Cleveland 44125 8001 Sweet Valley Drive Unit 19 Phone 216 447 9030 Fax 216 447 3097 PENNSYLVANIA Willow Grove 19090 520 North York Road Phone 215 658 1430 Fax 215 658 1433 TENNESSEE Nashville 37214 2262 Lebanon Pike Phone 615 882 0320 Fax 615 882 0051 TEXAS Carroliton 75006 Dallas 1300 Interstate 35 N Suite 112 Phone 972 446 2996 Fax 972 446 8157 Houston 77055 West 10 Business Center 1008 Wirt Road Suite 120 Phone 713 682 0334 Fax 713 682 4867 WASHINGTON Renton 98055 Seattle 268 Southwest 43rd Street Phone 425 251 6680 Fax 425 251 9337 Authorized Service Stations are located in many large cities Telephone 800 487 8665 or 901 541 6042 for assistance locating one Parts and accessories for Porter Cable products should be obtained by cont
3. 1 When cutting flat pieces first check to see if the material is bowed If it is make sure the material is positioned on the table as shown in Fig 39 2 If the material is positioned the wrong way as shown in Fig 40 the workpiece will pinch the blade near the completion of the cut CONSTRUCTING WORK SUPPORT EXTENSIONS Fig 41 One of the unique features of the miter saw is the ease of constructing work supports Fig 41 illustrates the miter saw mounted to two standard 2 x 4 s A Fasten the grooves in the two mounting legs B to the 2 x 4 s using four screws through the four holes in the mounting legs The length of the 2 x 4 s A can vary depending on preference The distance from the top of the 2 x 4 s A to the compound miter saw table 3 1 4 Standard 2 x 4 s C can then be fastened to the top of the 2 x 4 s A The top of the 2 x 4 s C will then be the same height as the miter saw table or minor adjustments can easily be made depending on the height of the 2 x 4 s This method will provide support for long workpieces using standard 2 x 4 s instead of constructing an expensive complicated work support 16 CUTTING CROWN MOULDING One of the many features of the saw is the ease of cutting crown moulding The following is an example of cutting both inside and outside corners on 52 38 degree wall angle crown moulding NOTE The following procedure for inside or outside crown molding corners is
4. 204 633 9259 G2E 5E2 Fax 403 735 6144 Fax 204 632 1976 Phone 418 877 7112 BRITISH COLUMBIA ONTARIO Fax 418 877 7123 8520 Baxter Place 505 Southgate Drive 1447 Begin Burnaby B C Guelph Ontario St Laurent Montr al Qu bec V5A 4T8 N1H 6M7 H4R 1V8 Phone 604 420 0102 Phone 519 836 2840 Phone 514 336 8772 Fax 604 420 3522 Fax 519 767 4131 Fax 514 336 3505 QUEBEC 1515 Ave ALBERTA The following are trademarks of PORTER CABLE Corporation Las siguientes son marcas registradas de PORTER CABLE S A Les marques suivantes sont des marques de fabriquant de la PORTER CABLE Corporation BAMMER LASERLOC OMNIJIG POCKET CUTTER PORTA BAND PORTA PLANE PORTER CABLE QUICKSAND SANDTRAP SAW BOSS SPEED BLOC SPEEDMATIC SPEEDTRONIC STAIR EASE THE PROFESSIONAL EDGE THE PROFESSIONAL SELECT TIGER CUB TIGER SAW TORQ BUSTER VERSA PLANE WHISPER SERIES DURATRONIC FRAME SAW INNOVATION THAT WORKS JETSTREAM MICRO SET MORTEN NETWORK RIPTIDE TRU MATCH WOODWORKER S CHOICE Trademarks noted with are registered in the United States Patent and Trademark Office and may also be registered in other countries Las Marcas Registradas con el signo de son registradas por la Oficina de Registros y Patentes de los Estados Unidos y tambi n pueden estar registradas en otros paises Marques d pos es indiqu es par la lettre sont d pos
5. Thread locking stud into threaded hole in fence slide support B 9 Position lock handle M Fig 7J on stud and replace screw and spring L that were removed in STEP 7 NOTE Lock handle M is spring loaded and can be repositioned by lifting up on handle ATTACHING DUST BAG Depress spring clips A Fig 8 of dust bag B and clip dust bag B onto end of dust chute FASTENING MACHINE TO SUPPORTING SURFACE Before operating your compound miter saw firmly mount it to a workbench or other supporting surface Four holes A Fig 9 are provided for fastening the saw to a supporting surface When frequently moving the saw from place to place mount the saw to a 3 4 piece of plywood The saw can then be easily moved from place to place and the plywood can be clamped to the supporting surface using C clamps STARTING AND STOPPING MACHINE To start the machine depress switch trigger A Fig 10 To stop the machine release the switch trigger This saw is equipped with an automatic electric blade brake As soon as the switch trigger A Fig 10 is released the electric brake is activated and stops the blade in seconds PORTER CABLE Fig 10 DANGER A TURNING SAW BLADE CAN BE DANGEROUS AFTER COMPLETING CUT RELEASE SWITCH TRIGGER A FIG 12 TO ACTIVATE BLADE BRAKE KEEP CUTTINGHEAD DOWN UNTIL BLADE HAS COME TO A COMPLETE STOP WARNING THE TORQUE DEVELOPED DURING BRAKING MAY LOOSEN THE ARBO
6. es au Bureau des brevets d invention et marques d pos es aux Etats Unis et pourraient tre d pos es aux autres pays
7. for identification and use in assembling the saw Extension table Fence slide Fence slide support Dust bag Arbor and fence wrench Ya wrench Open end wrench Lock handle for slide fence Yq flat washer 14 lock washer 11 14 18 x 1 1 4 long hex head screw 2 12 14 18 x 3 4 long hex head screws 2 h O O O Y O 0 E ON ASSEMBLY WARNING FOR YOUR OWN SAFETY DO NOT CONNECT THE MITER SAW TO THE POWER SOURCE UNTIL THE MACHINE IS COMPLETELY ASSEMBLED AND YOU HAVE READ AND UNDERSTOOD THE ENTIRE OWNER S MANUAL MOVING CUTTINGHEAD TO THE UP POSITION 1 Pull out cuttinghead lockpin A Fig 4 and move the cuttinghead B to the up position 2 Fig 5 illustrates the lockpin A pulled out and the cuttinghead B in the up position MOVING TABLE TO THE O DEGREE CUT OFF POSITION 1 Rotate locking knob A Fig 6 counter clockwise as far as it will go to unlock Depress lever B and rotate table C to the O degree straight cut off position release lever B and tighten locking knob A 2 Fig 7 illustrates the table C in the O degree straight cut off position 3 For proper operation and adjustment of the table refer to sections ROTATING TABLE FOR MITER CUTTING ADJUSTING CLAMPING ACTION OF TABLE LOCKING MECHANISM and ADJUSTING SLIDING FIT BETWEEN MOVABLE TABLE AND BASE ATTACHING EXTENSION TABLE AND FENCE SLIDE Fig 7A Fig 7B 1 Attach flat washers to the two 3 4 sc
8. practical 14 DON T OVERREACH Keep proper footing and balance at all times 15 MAINTAIN TOOLS IN TOP CONDITION Keep tools sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories 16 DISCONNECT TOOLS before servicing and when changing accessories such as blades bits cutters etc 17 USE RECOMMENDED ACCESSORIES The use of improper accessories may cause hazards or risk of injury to persons 18 dos THE RISK OF UNINTENTIONAL STARTING Make sure switch is in OFF position before plugging in power cord 19 deri STAND ON TOOL Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted 20 CHECK DAMAGED PARTS Before further use of the tool a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function Check for alignment of moving parts binding of moving parts breakage of parts mounting and any other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated elsewhere in this instruction manual Have defective switches replaced by authorized service center Do not use tool if switch does not turn it on and off 21 DIRECTION OF FEED Feed work into a blade or cutter against the direction of rotation of the blade or cutter only 22 NEVER LEAV
9. the same with the exception that the bevel position will always be at 30 degrees and the miter position will be 35 1 4 degrees to the right or left 1 Move the table to the 31 5 8th degree right miter position and lock the table in position NOTE A positive stop is provided to find this angle quickly 2 Tilt the saw blade to the 33 7 833 7 8 degree left bevel position and tighten bevel lock handle NOTE A triangle indicator is provided on the bevel scale to find this angle quickly 3 Place the crown moulding on the table with the CEILING EDGE of the moulding against the fence and make the cut as shown in Fig 42 NOTE The piece of crown moulding used for the outside corner will always be on the right hand side of the blade as shown at A Fig 42 The piece of crown moulding used for the inside corner will always be on the left hand side of the blade as shown at B Fig 42 Note that the accessory work clamp E is being used to hold the workpiece in position 4 To make the matching halves of the inside and outside corners simply rotate the table to the 31 5 8 degree left miter position NOTE A positive stop is provided to find this angle quickly The saw blade is already tilted to the 33 7 8 degree bevel position from the previous cut 5 Place the crown moulding on the table with the WALL EDGE of the crown moulding against the fence and make the cut Again the piece of crown moulding used for the outside corner
10. will always be on the right side of the blade as shown at C Fig 43 The piece of crown moulding used for the inside corner will always be on the left side of the blade as shown at D Fig 43 Again the accessory work clamp E is being used to hold the workpiece in position 6 Fig 44 illustrates the two outside corner pieces 1 being the piece cut at D Fig 43 and 2 being the piece cut at C Fig 43 7 Fig 45 illustrates the two inside corner pieces 1 being the piece cut at B Fig 42 and 2 being the piece cut at A Fig 42 Fig 44 Fig 45 17 MAINTENANCE CHANGING THE BLADE Fig 46 Fig 47 WARNING USE ONLY CROSS CUTTING SAW BLADES DO NOT USE BLADES WITH DEEP GULLETS AS THEY CAN DEFLECT AND CONTACT GUARD 1 Use only 12 diameter blades with 1 arbor holes that are rated for 4200 RPM or higher 2 DISCONNECT MACHINE FROM THE POWER SOURCE 3 Loosen screw A Fig 46 with wrench B provided 4 Rotate arbor cover C Fig 47 and lower guard D Fig 47 to the rear exposing arbor screw E 5 Remove arbor screw E Fig 47 by turning screw clockwise with wrench supplied while at the same time pressing in on arbor lock F Fig 48 to keep the arbor from turning Remove outside blade flange G Fig 47 and saw blade H Fig 46 DO NOT REMOVE INSIDE BLADE FLANGE 6 Attach the new saw blade MAKING CERTAIN TEETH OF SAW BLADE ARE POINTING DOWN AT THE FRONT and attach outside blad
11. E TOOL RUNNING UNATTENDED TURN POWER OFF Don t leave tool until it comes to a complete stop 23 DRUGS ALCOHOL MEDICATION Do not operate tool while under the influence of drugs alcohol or any medication 24 MAKE SURE TOOL IS DISCONNECTED FROM POWER SUPPLY while motor is being mounted connected or reconnected 25 WARNING SOME DUST CREATED BY POWER SANDING SAWING GRINDING DRILLING AND OTHER CONSTRUCTION ACTIVITIES contains chemicals known to cause cancer birth defects or other reproductive harm Some examples of these chemicals are e lead from lead based paints e crystalline silica from bricks and cement and other masonry products and e 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 SAVE THESE INSTRUCTIONS Refer to them often and use them to instruct others ADDITIONAL SAFETY RULES FOR COMPOUND MITER SAWS 1 WARNING USE ONLY CROSS CUTTING SAW BLADES DO NOT USE BLADES WITH DEEP GULLETS AS THEY CAN DEFLECT AND CONTACT THE GUARD 2 WARNING Do not operate the miter saw until it is completely assembled and installed according to the instructions 3 IF YOU ARE NOT thoroughly familiar with the operation of compound miter saw
12. Instruction Manual ESPA OL P GINA 21 FRANCAISE PAGE 41 12 Compound Miter Saw To learn more about Porter Cable visit our website at http www porter cable com JRTER CABLE PROFESSIONAL POWER TOOLS Copyright 2000 PORTER CABLE Corporation MODEL 3802 IMPORTANT Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations The Model and Serial No plate is located on the main housing of the tool Record these numbers in the spaces below and retain for future reference Model No Type Serial No Part No 900988 11 30 00 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS This tool was designed for certain applications DO NOT modify or use it for any application other than for which it was designed If you have any questions relative to its application do not use the tool until you have written Porter Cable and we have advised you Technical Service Manager Porter Cable Corporation 4825 Highway 45 North Jackson TN 38305 WARNING FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL INJURY 1 FOR YOUR OWN SAFETY READ INSTRUCTION MANUAL BEFORE OPERATING THE TOOL Learn the tool s application and limitations as well as the specific hazards peculiar to it 2 KEEP GUARDS IN PLACE and in working order 3 GROUND ALL TOOLS If tool is equipped with thr
13. R SCREW THE ARBOR SCREW SHOULD BE CHECKED PERIODICALLY AND TIGHTENED IF NECESSARY LOCKING SWITCH IN THE OFF POSITION IMPORTANT When the miter saw is not in use the switch should be locked in the OFF position using a padlock B Fig 11 with a 3 16 diameter shackle to prevent unauthorized use of the saw ROTATING TABLE FOR MITER CUTTING 1 Your compound miter saw will cut any angle from a straight O degree cut to 47 degrees right and left Rotate locking knob A Fig 12 depress lock lever B and rotate table to desired position 2 The compound miter saw is equipped with positive stops at the O degree cut off position and at the 15 22 5 31 62 and 45 degree left and right positions 3 The center line C Fig 13 on the cursor indicates the actual angle of cut Each scale line B represents one degree In effect when the center line C is moved from one line to the next on the scale the angle of the cut is changed by one degree 4 The pointer is provided with two additional lines D and E Fig 15 This allows movement of the control arm exactly1 2degree For example assume the center line C is pointing to the 10 degree mark on the scale as indicated and and the angle of cut is 1 2 degree to the right Move the control arm until the right line E lines up with the next line on the scale The angle of cut will then be changed 1 2 degree to the right If you change the angle of cut 1 2 degree to the lef
14. able Locations ou vous trouverez les pieces de rechange n cessaires ainsi qu un service d entretien ARIZONA Tempe 85282 Phoenix 2400 West Southern Avenue Suite 105 Phone 602 437 1200 Fax 602 437 2200 CALIFORNIA Ontario 91761 Los Angeles 3949A East Guasti Road Phone 909 390 5555 Fax 909 390 5554 San Leandro 94577 Oakland 3039 Teagarden Street Phone 510 357 9762 Fax 510 357 7939 COLORADO Denver 80216 5855 Stapleton Drive North Suite A 140 Phone 303 370 6909 Fax 303 370 6969 FLORIDA Davie 33314 Miami 4343 South State Rd 7 441 Unit 107 Phone 954 321 6635 Fax 954 321 6638 Tampa 33609 4538 W Kennedy Boulevard Phone 813 877 9585 Fax 813 289 7948 GEORGIA Forest Park 30297 Atlanta 5442 Frontage Road Suite 112 Phone 404 608 0006 Fax 404 608 1123 ILLINOIS Addison 60101 Chicago 311 Laura Drive Phone 630 628 6100 Fax 630 628 0023 Woodridge 60517 Chicago 2033 West 75th Street Phone 630 910 9200 Fax 630 910 0360 MARYLAND Elkridge 21075 Baltimore 7397 102 Washington Blvd Phone 410 799 9394 Fax 410 799 9398 MASSACHUSETTS Braintree 02185 Boston 719 Granite Street Phone 781 848 9810 Fax 781 848 6759 Franklin 02038 Boston Franklin Industrial Park 101E Constitution Blvd Phone 508 520 8802 Fax 508 528 8089 MICHIGAN Madison Heights 48071 Detroit 30475 Stephenson Highway Phone 248
15. able Service Center or Authorized Service Station Proof of purchase may be required This warranty does not apply to repair or replacement required due to misuse abuse normal wear and tear or repairs attempted or made by other than our Service Centers or Authorized Service Stations ANY IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WILL LAST ONLY FOR ONE 1 YEAR FROM THE DATE OF PURCHASE To obtain information on warranty performance please write to PORTER CABLE CORPORATION 4825 Highway 45 North PO Box 2468 Jackson Tennessee 38302 2468 Attention Product Service THE FOREGOING OBLIGATION IS PORTER CABLE S SOLE LIABILITY UNDER THIS OR ANY IMPLIED WARRANTY AND UNDER NO CIRCUMSTANCES SHALL PORTER CABLE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state 19 NOTES 20 PORTER CABLE SERVICE CENTERS CENTROS DE SERVICIO DE PORTER CABLE CENTRE DE SERVICE PORTER CABLE Parts and Repair Service for Porter Cable Power Tools are Available at These Locations Obtenga Refaccion de Partes o Servicio para su Herramienta en los Siguientes Centros de Porter C
16. acting any Porter Cable Distributor Authorized Service Center or Porter Cable Factory Service Center If you do not have access to any of these call 888 848 5175 and you will be directed to the nearest Porter Cable Factory Service Center Las Estaciones de Servicio Autorizadas estan ubicadas en muchas grandes ciudades Llame al 800 487 8665 6 al 901 541 6042 para obtener asistencia a fin de localizar una Las piezas y los accesorios para los productos Porter Cable deben obtenerse poni ndose en contacto con cualquier distribuidor Porter Cable Centro de Servicio Autorizado o Centro de Servicio de Fabrica Porter Cable Si no tiene acceso a ninguna de estas opciones llame al 888 848 5175 y le dirigir n al Centro de Servicio de Fabrica Porter Cable m s cercano Des centres de service agr s sont situ s dans beaucoup de grandes villes Appelez au 800 487 8665 ou au 901 541 6042 pour obtenir de l aide pour en rep rer un Pour obtenir des pi ces et accessoires pour les produits Porter Cable s adresser a tout distributeur Porter Cable centre de service agr ou centre de service d usine Porter Cable Si vous n avez acces a aucun de ces centres appeler le 888 848 5175 et on vous dirigera vers le centre de service d usine Porter Cable le plus proche DELTA SERVICE CENTERS MANITOBA Bay 6 2520 23rd St N E 1699 Dublin Avenue Calgary Alberta Winnipeg Manitoba St Jean Baptiste T2E 8L2 R3H 0H2 Qu bec Qu bec Phone 403 735 6166 Phone
17. c parts They could possibly dissolve or otherwise damage the material CAUTION WEAR SAFETY GLASSES WHILE USING COMPRESSED AIR FAILURE TO START Should your tool fail to start check to make sure the prongs on the cord plug are making good contact with the outlet Also check for blown fuses or open circuit breakers in the line SERVICE AND REPAIRS All quality tools will eventually require servicing or replacement of parts due to wear from normal use These operations should ONLY be performed by either an AUTHORIZED PORTER CABLE SERVICE STATION or a PORTER CABLE SERVICE CENTER All repairs made by these agencies are fully guaranteed against defective material and workmanship We cannot guarantee repairs made or attempted by anyone other than these agencies Should you have any questions about your tool feel free to write us at any time In any communication please give all information shown on the nameplate of your tool model number type serial number etc PORTER CABLE LIMITED ONE YEAR WARRANTY Porter Cable warrants its Professional Power Tools for a period of one year from the date of original purchase We will repair or replace at our option any part or parts of the product and accessories covered under this warranty which after examination proves to be defective in workmanship or material during the warranty period For repair or replacement return the complete tool or accessory transportation prepaid to your nearest Porter C
18. ck handle H Fig 28 Loosen locknut B and turn adjusting screw C with wrenches provided until blade is 90 degrees to the table Tighten locknut B and bevel lock handle H 5 When the blade is 90 degrees to the table adjust the pointer to line up with the O degree mark on the bevel scale 6 Loosen bevel lock handle H Fig 28 and move cuttinghead all the way to the left bevel position and tighten bevel lock handle 7 Use a square A Fig 29 to see if the blade is at 45 degrees to the table 8 If an adjustment is necessary loosen the bevel lock handle Loosen the locknut E Fig 30 and turn the adjusting screw F with wrenches provided until the blade is 45 degrees to the table Tighten locknut E and bevel lock handle 9 These positive stops enable you to rapidly position the blade at the most common bevel angles to the table 90 and 45 degrees ADJUSTING SLIDING FIT BETWEEN TRUNNION AND BEVEL BRACKET After a long period of time it may become necessary to adjust the sliding fit between the trunnion A Fig 30 and the bevel bracket B by tightening adjusting nut C Fig 31 located underneath the bevel lock A Fig 31 and collar B Fig 31 13 Fig 30 Fig 31 Correct adjustment provides for a good snug sliding fit between these two parts This adjustment should not be so tight that it restricts the tilting movement of the trunnion A when bevel cutting or so loose that it affe
19. ctor size is large enough to prevent excessive voltage drop which will cause loss of power and possible motor damage For distances up to 100 feet use 12 wire For distances up to 150 feet use 10 wire If an extension cord is to be used outdoors it must be marked with the suffix W A following the cord type designation For example SJTW A indicates that it is acceptable for outdoor use Replace damaged or worn cords immediately Before connecting the motor to the power line make sure the switch is in the OFF position and be sure that the electric current is of the same characteristics as stamped on motor nameplate UNPACKING 1 Carefully remove the machine from the carton Retain all packing materials until you have inspected and satisfactorily operated the machine WARNING Do not connect the machine to the power source until you have read and understood this entire instruction manual 2 Place the machine on a firm level surface with extra room for handling and proper support of the workpiece 3 Familiarize yourself with all features and controls as explained in this manual 4 The machine is shipped with the cuttinghead locked in the down position and the table rotated to 45 degrees left Fig 2 To release the head and move it to the operating position see MOVING CUTTINGHEAD TO THE UP POSITION and MOVING THE TABLE TO THE 90 DEGREE CUT OFF POSITION in this section 5 Unassembled items are shown in Fig 3
20. cts the accuracy of the saw cut ADJUSTING THE TENSION OF CUTTINGHEAD RETURN SPRING The tension of the cuttinghead return spring has been adjusted at the factory in order that the cuttinghead returns to the up position after a cut has been made To re adjust the spring tension turn adjusting screw A Fig 32 clockwise to increase or counterclockwise to decrease the spring tension ADJUSTING SLIDING FIT BETWEEN CUTTINGHEAD ARM AND TRUNNION After a long period of time it may become necessary to adjust the sliding fit between the cuttinghead arm B Fig 32 and the trunnion C by tightening nut D Correct adjustment is a good snug sliding fit between these two parts This adjustment should not be so tight that it restricts the sliding movement of the cuttinghead arm B or so loose that it affects the accuracy of the saw cut Fig 32 Fig 33 ADJUSTING DOWNWARD TRAVEL OF SAW BLADE 1 DISCONNECT THE SAW FROM THE POWER SOURCE 2 The downward travel of the saw blade can be limited to prevent the saw blade from contacting any metal surfaces of the machine This adjustment is made by loosening locknut A Fig 33 and turning adjusting screw B in or out until other end of screw B contacts stop C at the full downward travel of the saw blade 3 When making this adjustment MAKE SURE THE MACHINE IS DISCONNECTED FROM THE POWER SOURCE and lower the blade as far as possible Rotate the blade by hand to make certain the teeth do not contac
21. e When miter cutting blade set 90 degrees to the table and at an angle to the right or left the fence should be set all the way toward the blade Fig 25A When bevel cutting however blade tilted at an angle to the table the fence A Fig 25B should be moved away from the blade to allow for proper clearance for the saw blade and guard Fig 25B To accomplish this movement loosen the lock handle B and slide the fence A to the desired location Tighten the lock handle B NOTE Lock handle B is spring loaded and can be repositioned Pull up on handle to reposition it on the serrated nut located underneath handle Fig 25A ADJUSTING CHIP DEFLECTOR 1 DISCONNECT THE SAW FROM THE POWER SOURCE 2 Achip deflector A Fig 26 is supplied to help prevent scrap or cut off pieces from entering the upper blade guard The chip deflector A should be adjusted so that it is almost touching the side of the blade by loosening screw B adjusting chip deflector A and tightening screw B 12 ADJUSTING 0 AND 45 DEGREE BEVEL POSITIVE STOPS 1 DISCONNECT THE SAW FROM THE POWER SOURCE 2 Adjust saw so that both bevel and miter pointers are set at O degrees Tighten bevel lock handle and lock cuttinghead in down position 3 Place one end of a square A Fig 27 on the table and the other end against the blade The blade should be set at 90 degrees to the table 4 lf an adjustment is necessary loosen bevel lo
22. e flange G Fig 47 Check to see that the flats on outside blade flange are engaged with flats on arbor shaft 7 Thread arbor screw E Fig 47 into saw arbor by turning screw E counterclockwise as far as possible by hand Then tighten arbor screw E with wrench supplied while at the same time pressing in on arbor lock F Fig 48 to keep arbor from turning 8 Rotate arbor cover C Fig 47 and lower guard D to the front and tighten screw A that was loosened in STEP 3 a 18 BRUSH INSPECTION AND REPLACEMENT Fig 49 Fig 50 CAUTION BEFORE INSPECTING BRUSHES DISCONNECT THE MACHINE FROM THE POWER SOURCE Brush life varies depends on the load on the motor Check the brushes after the first 50 hours of use of a new machine or after a new set of brushes has been installed After the first check examine them after about 10 hours of use until replacement is necessary The brush holders A Fig 49 are located on the motor housing opposite each other Fig 50 illustrates one of the brushes removed for inspection When the carbon on either brush B is worn to 3 16 in length or if either spring or shunt wire C is burned or damaged in any way replace both brushes lf the brushes are found serviceable after removing reinstall them in the same position KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air Clean all plastic parts with a soft damp cloth NEVER use solvents to clean plasti
23. ed to clean plastic parts 22 DISCONNECT SAW from power source and clean the machine before leaving it 23 MAKE SURE the work area is cleaned before leaving the machine 24 ADDITIONAL INFORMATION regarding the safe and proper operation of this product is available from the National Safety Council 1121 Spring Lake Drive Itasca IL 60143 3201 in the Accident Prevention Manual for Industrial Operation and also in the Safety Data Sheets provided by the NSC Please also refer to the American National Standard Institute ANSI 01 1 Safety Requirements for the Woodworking Machinery and the U S Department of Labor OSHA 1910 213 Regulations 25 SOME WOOD CONTAINS PRESERVATIVES WHICH CAN BE TOXIC Take extra care to prevent inhalation and skin contact when working with these materials Request and follow any safety information available from your material supplier 26 DON T ABUSE CORD Never carry tool by cord or yank it to disconnect from receptacle Keep cord from heat oil and sharp edges Have damaged or worn power cord and strain reliever replaced immediately DO NOT ATTEMPT TO REPAIR POWER CORD 27 WEAR EAR PROTECTION to safeguard against possible hearing loss 28 AVOID CUTTING NAILS AND KNOTS Inspect for and remove all nails from lumber before cutting Try to do layout cuts between knots 29 NEVER USE LIQUID COOLANT To do so could present electrical shock hazard 30 KEEP CLEAR OF SAWDUST EJECTION CHUTE Sawdust and chips are expel
24. ee prong plug it should be plugged into a three hole electrical receptacle If an adapter is used to accommodate a two prong receptacle the adapter lug must be attached to a known ground Never remove the third prong 4 REMOVE ADJUSTING KEYS AND WRENCHES Form habit of checking to see that keys and adjusting wrenches are removed from the tool before turning it on 5 KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents 6 DON T USE IN DANGEROUS ENVIRONMENT Don t use power tools in damp or wet locations or expose them to rain Keep work area well lighted 7 KEEP CHILDREN AND VISITORS AWAY All children and visitors should be kept a safe distance from work area 8 MAKE WORKSHOP CHILDPROOF with padlocks master switches or by removing starter keys 9 DON T FORCE TOOL It will do the job better and be safer at the rate for which it was designed 10 USE RIGHT TOOL Don t force tool or attachment to do a job for which it was not designed 11 WEAR PROPER APPAREL No loose clothing gloves neckties rings bracelets or other jewelry to get caught in moving parts Nonslip footwear is recommended Wear protective hair covering to contain long hair 12 ALWAYS USE SAFETY GLASSES Wear safety glasses must comply with ANSI Z87 1 Everyday eyeglasses only have impact resistant lenses they are not safety glasses Also use face or dust mask if cutting operation is dusty 13 SECURE WORK Use clamps or a vise to hold work when
25. kpiece Faan O o Rune 3 To clamp the workpiece F Fig 22 tightly against the table lower cam lever G After cut is complete lift lever G to release the clamp TILTING CUTTINGHEAD FOR BEVEL CUTTING CAUTION DISCONNECT THE MACHINE FROM THE POWER SOURCE IMPORTANT MOVE THE SLIDING FENCE TO THE LEFT TO PROVIDE CLEARANCE FOR THE BLADE AND GUARD THE DEGREE OF TILT DETERMINES Fig 22 HOW FAR TO MOVE THE SLIDING FENCE REFER TO THE SECTION ADJUSTING SLIDING FENCE 11 1 The cuttinghead of your compound miter saw can be tilted to cut any bevel angle from a 90 degree straight cut off to a 45 degree left bevel angle by loosening bevel lock handle A Fig 23 tilting cuttinghead B to the desired angle and tightening lock handle A 2 Positive stops are provided to rapidly position the saw blade at 90 and 45 degrees to the table Refer to the section of this manual titled Adjusting 90 and 45 degree bevel positive stops The bevel angle of the cutting arm is determined by the position of the pointer C Fig 24 on scale D 3 In addition a marked indicator is provided on the bevel scale 33 9 degrees for cutting crown moulding Refer to the CUTTING CROWN MOULDING section of this manual Fig 23 Fig 24 ADJUSTING SLIDING FENCE The high sliding fence A Fig 25A provides support for extra large workpieces used with your saw and should always be set as close as possible to the saw blad
26. led out the ejection chute at rear of saw Do not allow anyone in this area while saw is in operation 31 WHEN THE MITER SAW IS NOT IN USE the switch should be locked in the OFF position to prevent unauthorized use of the saw REPLACEMENT PARTS When servicing use only identical replacement parts 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 the proper outlet Do not change the plug in any way MOTOR Many Porter Cable tools will operate on either D C or single phase 25 to 60 cycle A C current and voltage within plus or minus 5 percent of that shown on the specification plate of the tool Several models however are designed for A C current only Refer to the specification plate on your tool for proper voltage and current rating CAUTION Do not operate your tool on a current where the voltage is not within correct limits Do not operate tools rated A C on a D C current To do so may seriously damage the tool RECOMMENDED EXTENSION CORD SIZES FOR USE WITH STATIONARY ELECTRIC TOOLS MINIMUM GAUGE EXTENSION CORD RECOMMENDED SIZES FOR USE WITH STATIONARY ELECTRIC TOOLS EXTENSION CORD SELECTION Ampere Volts Total Length of Gauge of Rating Cord in Feet Extension Cord
27. n order to limit the possibility of personal injury or blade guard damage an auxiliary wood fence can be mounted to your saw as follows Holes are provided in the fence to attach an auxiliary fence A and B Fig 36 This auxiliary fence is constructed of straight wood approximately 1 4 thick by 3 4 high by 16 inches long as shown at B and 1 2 thick by 5 high by 17 long A Fig 36 NOTE The auxiliary fence A is used only with the saw blade in the O degree bevel position 90 degrees to the table The auxiliary fence must be removed for all bevel cuts blade tilted CUTTING ALUMINUM Aluminum extrusions aluminum screens and storm windows can easily be cut with your miter saw When cutting aluminum extrusions or other sections that can be cut with a saw blade and are within the capacity of the machine position the material so the blade is cutting through the smallest cross section as shown in Fig 37 The wrong way to cut aluminum angles is illustrated in Fig 38 Be sure to apply a stick wax similar to Johnson s stick wax 140 to the blade before cutting any aluminum stock This stick wax is available at most industrial mill supply houses The stick wax provides proper lubrication and keeps chips from adhering to the blade NEVER APPLY LUBRICANT TO THE BLADE WHILE THE MACHINE IS RUNNING 15 ENCE gt BLADE Fig 37 CUTTING BOWED MATERIAL Fig 39 Fig 40
28. rew assemblies A Fig 7A and thread into the threaded holes on left side of the saw NOTE Turn the screws only a few threads into the holes at this time 2 Attach the table extension B Figs 7A and 7B to left side of saw table making sure groove of table extension B is inside flat washers C as shown in Fig 7B Fig 7C Fig 7D 3 Usea oor edge C Fig 7C to make the extension table B even with saw table D and tighten the two screws A Fig 7B 4 Attach the fence slide UPP Fig 7D to the extension table B by using the two 1 1 4 long hex head screws 5 16 lockwashers and 5 16 flat washers F Bring screws up through the two holes in table extension and thread them into the two threaded holes H on bottom of fence slide support NOTE Do not completely tighten screws at this time Fig 7E Fig 7F 5 Use a straight edge C Fig 7E to level the fence slide support E with saw fence J and tighten the two 6 Position the fence slide K Fig 7F in position on top of saw fence J and fence slide support E Slide fence slide K back and forth several times to check alignment of fence slide suppor E Make any necessary final adjustments to fence slide support Fig 7G Fig 7H 7 Remove screw and spring L Fig 7G and lock handle M from lockina stud N 8 PLace 1 4 flat washer O Fig 7G onto locking stud N and insert locking stud N Fig 7H through slot in fence slide
29. s G adjusting cursor F and tightening screws G Fig 16 Fig 17 TABLE HAZARD AREA WARNING THE AREA INSIDE THE TWO RED LINES A FIG 17 ON THE TABLE IS DESIGNATED AS A HAZARD ZONE NEVER PLACE YOUR HANDS INSIDE THIS AREA WHILE THE TOOL IS BEING OPERATED 10 Fig 18 ATTACHING OPTIONAL WORK CLAMP The work clamp is an important accessory After purchase the work clamp can be attached to any one of the four holes A Fig 18 provided on the base of the machine three of which are shown 1 Thread lock knob B Fig 19 into threaded hole where the clamp will be inserted Place post C of work clamp down through hole as far as possible Tighten lock knob B An additional lock knob B is supplied and can be threaded into one of the other three holes TIP Thread the two lock knobs into the two holes where the work clamp will be used most frequently USING THE OPTIONAL WORK CLAMP 1 The height of the work clamp A Fig 20 can be adjusted by loosening lock knob B and moving post C up or down or depressing lock lever D and sliding clamp body E up or down After height of clamp A is adjusted tighten lock knob B and or release lock lever Y D 2 During operation lower clamp A Fig 21 by depressing lock lever D until the bottom of the clamp A lightly contacts the top of the workpiece F IMPORTANT Cam lever G should be in UP position when the clamp is lowered on the wor
30. s obtain advice from your supervisor instructor or other qualified person 4 BE SURE blade is sharp runs freely and is free of vibration 5 ALLOW the motor to come up to full speed before starting cut 6 KEEP motor air slots clean and free of chips 7 ALWAYS MAKE SURE rotating table is tight before cutting even if the table is positioned in one of the positive stops 8 BE SURE blade and flanges are clean and that arbor screw is tightened securely 9 USE ONLY blade flanges specified for your saw 10 NEVER apply lubricants to the blade when it is running 11 ALWAYS CHECK the blade for cracks or damage before operation Replace cracked or damaged blade immediately 12 ALWAYS KEEP the lower blade guard in place and operating properly 13 MAKE SURE blade is not contacting workpiece before switch is turned on 14 NEVER LOCK the switch in the ON position 15 IMPORTANT After completing cut release power switch and wait for coasting blade to stop before returning saw to raised position 16 DO NOT remove jammed or cut off pieces until blade has stopped 17 NEVER cut ferrous metals or masonry 18 NEVER recut small pieces 19 PROVIDE ADEQUATE SUPPORT to the sides of the saw table for long workpieces 20 NEVER use the miter saw in an area with flammable liquids or gases 21 NEVER USE SOLVENTS TO CLEAN PLASTIC PARTS Solvents could possibly dissolve or otherwise damage the material Only a soft damp cloth should be us
31. t use the left line D in the same manner ADJUSTING SLIDING FIT BETWEEN MOVABLE TABLE AND BASE CAUTION DISCONNECT THE MACHINE FROM THE POWER SOURCE To adjust the sliding fit between the movable table and the base turn nut A Fig 14 clockwise to increase the sliding fit opposite to decrease the fit This adjustment should not be so tight that it restricts the rotating movement of the table or so loose that it affects the accuracy of the saw ADJUSTING FENCE 90 DEGREES TO BLADE IMPORTANT BEFORE MAKING THIS ADJUSTMENT SET THE BLADE AT O DEGREES TO THE TABLE SEE SECTION ADJUSTING 0 AND 45 DEGREE BEVEL POSITIVE STOPS 1 CAUTION DISCONNECT THE MACHINE FROM THE POWER SOURCE 2 Rotate the movable table so that the blade is 90 degrees to the fence and the positive stop is set for O degrees 3 Place one end of a framing square A against the front of the fence B and the other end against the blade C with the blade locked in the down position The fence should be 90 degrees to the blade 4 If an adjustment is necessary the fence B Fig 15 can be adjusted by loosening four screws two of which are shown at D that attach the fence to the base Use the wrench supplied Adjust the fence B and tighten the four screws D 5 When the fence is 90 degrees to the blade adjust the cursor F Fig 16 so the pointer is aligned with the 0 degree mark on the scale by loosening two screw
32. t any metal surfaces and adjust if necessary After adjustment is completed tighten locknut A Fig 33 ADJUSTING BLADE GUARD After an extended period of time the movable blade guard A Fig 34 might become sloppy and move erratically when the cuttinghead is lowered This can be easily corrected by slightly tightening nut B until the lower blade guard A moves smoothly 14 TYPICAL OPERATIONS AND HELPFUL HINTS 1 Before cutting make certain the cutting arm and table area are at their correct settings and firmly locked in place 2 Before cutting determine that the workpiece is the right size for the saw 3 Place the workpiece on the table and hold or clamp it firmly against the fence Fig 35 illustrates the optional work clamp A being used to clamp a workpiece to the fence and table 4 WARNING If the workpiece causes your hand to be inside the table hazard area see section TABLE HAZARD AREA clamp the workpiece in place before making the cut as shown in Fig 35 5 For best results cut at a slow even cutting rate 6 Never attempt any freehand cutting wood that is not held firmly against the fence and table AUXILIARY WOOD FENCE When performing multiple or repetitive cut off operations that result in small cut off pieces one inch or less the saw blade can catch the cut off pieces and project them out of the machine or into the blade guard and housing possibly causing damage and or injury I
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