Harbor Freight Tools 91938 User's Manual
Contents
1. 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 com plaint 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 exp2. W in Canada to indicate it is acceptable for outdoor use T Make sure your extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified elec trician before using it 8 Protect your extension cords from sharp objects excessive heat and damp or wet areas RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 VOLT NAMEPLATE AMPERES EXTENSION CORD LENGTH At Full Load 25 FEET 50 FEET 75 FEET 100 FEET 150 FEET 18s 138 14 14 k 5 1 7 0 ts et 12 __ 7 1 12 0 CC e 121 16 0 14 12 10 J gt gt 16 1 20 0 12 10 FIGURE C Based on limiting the line voltage drop to five volts at 150 of the rated amperes A SYMBOLOGY Double Insulated Canadian Standards Association Underwriters Laboratories Inc Amperes No Load Revolutions per Minute RPM SKU 91938 For technical questions please call 1 800 444 3353 Page 10 UNPACKING When unpacking check to make sure all the parts shown on the Parts List on page 15 are included If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible ASSEMBLY AND OPERATING INSTRUCTIONS NOTE For additional information regarding the parts listed in the following pages refer to the Assembly Diagram on page 16 To Remove or Install a Cut Off Wheel Warning Prior to performin
3. 1 Maintain labels and nameplates on the Cut Off Saw These carry important information If unreadable or missing contact Harbor Freight Tools for a replace ment 2 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Always keep the work area free of ob structions grease oil trash and other debris Do not use a power tool in areas near flammable chemicals dusts and vapors Do not use this product in a damp or wet location 3 Avoid unintentional starting Make sure you are prepared to begin work before turning on the Cut Off Saw 4 Do not force the Cut Off Saw This tool will do the work better and safer at the speed and capacity for which it was designed 5 Always keep the extension cord away from moving parts on the tool 6 Keep hands and fingers away from the cutting area and the Cut Off Wheel Keep one hand on the handle and the other on the motor housing If both hands are holding the saw you hands and fingers cannot be cut by the Cut Off Wheel T Do not reach under the base of the Cut Off Saw The Swing Guard 53 cannot protect you from the Cut Off Wheel below the base SKU 91938 For technical questions please call 1 800 444 3353 Page 5 10 11 12 13 14 15 16 Check Swing Guard 53 for proper closing before each use Do not operate the Saw if the Swing Guard does not move freely and close instantly Never clamp or tie the Swi
4. and conform to the Motor Armature 85 FIGURE 8 Carbon Brush Cover 68 Carbon Brush Cover 68 SKU 91938 For technical questions please call 1 800 444 3353 Page 14 Description Description PARTS LIST Description Screw M6x14 Binding Ring Motor Housing Lock Nut Washer Spring Dust Cover Pin Binding Ring Screw M5x12 Screw M10x20 Cross Pin Lock Nut M6 Lock Washer Screw 2 M5x10 Nut M10 Washer Block Nut M10 Screw M10x20 Binding Ring Binding Ring Lock Washer Cross Pin Washer Washer Screw Nut M8 Check Nut M5 Bearing Screw 4 M6x24 Bar Armature Rubber Foot Lock Nut M6 Bearing Base Straight Bar Middle Cover Bracket Spring Bearing Ring Nut M8 Screw Binding Ring Depth Adjustment Bolt Swing Guard Gear Screw Bolt Front Cover Lock Nut M6 Outer Flange Bearing Screw 2 M5x10 Cut Off Wheel Half Washer Spring Holder Inner Flange Gasket Ring Lock Down Pin Screw Binding Ring Rubber Gasket Lock Washer Flange Washer Rubber Gasket Fixed Guard Nut M6 Binding Ring Arbor Screw M6x10 Lock Ball Spring Nut M4 Roll Pin Lock Pin Left Handle Thread Bar Screw 2 M5x54 Nut M5 Vise Handle Lock Washer Capacitor Roll Pin Carbon Brush Holder T
5. 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 See Figure B D Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration See Figure B FIGURE B EXTENSION CORDS 1 Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord 2 As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage See Figure C next page 3 The smaller the gauge number of the wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord See Figure C 4 When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required See Figure C 5 lf you are using one extension cord for more than one tool add the nameplate amperes and use the sum to determine the required minimum cord size See Figure C SKU 91938 For technical questions please call 1 800 444 3353 Page 9 6 If you are using an extension cord outdoors make sure it is marked with the suf fix W A
6. up against the workpiece Then tighten the Vise Handle 28 When releasing loosen the Vise Handle 28 a few turns lift up the Quick Release 31 and pull the Vise Handle 28 open 2 To cut at various angles up to 45 degrees adjust the Angle Scale 35 by loos ening the two Screws 41 amp 44 as shown in FIGURE 5 Adjust the Angle Scale to the desired setting and then tighten the Screws 41 amp 44 3 To reposition the Angle Scale 35 remove both of the Screws 41 amp 44 and reattach the Angle Scale at the upper two screw holes See FIGURE 4 FIGURE 4 FIGURE 5 Quick Place Workpiece Here Upper Two Screw Holes Release 31 Screws 41 amp 44 Vise Handle 28 SKU 91938 For technical questions please call 1 800 444 3353 Page 12 Operation Warning Make sure the Swing Guard 53 and the Fixed Guard 60 are in place whenever operating the Saw Keep your hands and fingers away from the Cut Off Wheel 56 1 Make sure the Saw is in the upright position as shown in FIGURE 6 below 2 Using the clamps secure your workpiece and if necessary adjust the angle of the cut See Clamp and Angle Scale page 12 3 Plug the Power Cord Plug 107 into the nearest 120 volt grounded electrical outlet Slide the Trigger Lock Switch 103 and pull it to start the Saw Allow the Cut Off Wheel 56 to attain full soeed See FIGURE 7 FIGURE 6 FIGURE 7 Handle 100 109 Base 13 Trigger Lock Switc
7. 38 For technical questions please call 1 800 444 3353 Page 3 12 13 14 15 16 17 18 19 20 21 22 Avoid accidental starting Be sure the Power Switch is off before plugging in Carrying power tools with your finger on the Power Switch or plugging in power tools with the Power Switch on invites accidents Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations Use safety equipment Always wear ANSI approve eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions TOOL USE AND CARE Use the included clamp or other practical ways to secure and support the workpiece to the Base 13 Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed Do not use the power tool if the Power Switch does not turn it on or off Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced Disconnect the Power Cord Plug from the power source before making any adju
8. CHICAGO Yeyiifea POWer Tools 14 HEAVY DUTY CUT OFF SAW Model 91938 ASSEMBLY AND OPERATING INSTRUCTIONS Distributed Exclusively by HARBOR FREIGHT ANIH ios TOOLS mi TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com Copyrighte 2004 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 For technical questions and replacement parts please call 1 800 444 3353 PRODUCT SPECIFICATIONS Electrical Requirements 120V 60HZ 15 AMP s Rated L LISTED 3500 RPM E105017 Maximum Cut Off Wheel Diameter Recommended Cut Off Wheel 14 Cut Off Wheel for Metal SKU 44814 Types included 14 Cut Off Wheel for Masonry SKU 44815 7 1st Setting 9 1 2 2nd Setting SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly op erating inspection maintenance and cleaning procedures parts list and assem bly diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY RULES WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to
9. ations for which this product was designed It will do the job better and more safely at the rate for which it was intended Do not modify this product and do not use this product for a purpose for which it was not intended A WARNING Some dust created by power sanding sawing grinding drilling and other construction activities contain chemicals known to the State of Califor nia to cause cancer birth defects or other reproductive harm Some examples of these chemicals are lead from lead based paints crystalline silica from bricks and cement or other masonry products arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as those dust masks that are specially designed to filter out microscopic particles California Health amp Safety Code 25249 5 et seq A WARNING People with pacemakers should consult their physician s be fore using this product Electromagnetic fields in close proximity to a heart pace maker could cause interference to or failure of the pacemaker SKU 91938 For technical questions please call 1 800 444 3353 Page 7 WARNING Improperly connecting the grounding wire can result in the risk of electric shock Check with a qualified electrician if you are in doubt as to whether the outlet is proper
10. ense 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 e PO Box 6009 Camarillo CA 93011 800 444 3353 SKU 91938 For technical questions please call 1 800 444 3353 Page 17
11. follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA 1 Keep your work area clean and well lit Cluttered benches and 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 bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed REV 09 04 SKU 91938 For technical questions please call 1 800 444 3353 Page 2 10 11 ELECTRICAL SAFETY Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user Double insulated tools are equipped with 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 contac
12. g any assembly procedures make sure the Power Cord Plug 107 of the Cut Off Saw is unplugged from its electrical outlet Make sure the Cut Off Wheel has cooled and be sure to wear heavy work gloves while replacing it 1 Push in the Lock Pin 63 as shown in FIGURE 1 and move the Swing Guard 53 out of the way Rotate the wheel until the Lock Pin 63 slides into place 2 While continuing to hold down the Lock Pin 63 use the Wrench 111 to loosen the Bolt 54 See FIGURE 2 3 Remove the Bolt 54 the Flange Washer 96 the Outer Flange 55 and the Cut Off Wheel 56 4 Replace with a new Cut Off Wheel 56 and reassemble the parts listed above in number 3 While holding the Lock Pin 63 tighten the Bolt 54 with the wrench not included FIGURE 1 FIGURE 2 g Lock Pin 63 a Bolt 54 Swing Guard 53 SKU 91938 For technical questions please call 1 800 444 3353 Page 11 Locking Down the Saw FIGURE 3 1 To lock down the Saw push the Saw down as far as it will go and then push the Lock Ball 25 in 2 To raise the Saw push down on the Saw and pull out the Lock Ball 25 Lock Ball 25 Depth Adjustment To adjust the depth either up or down adjust the ae q Depth Adjustment Bolt 16 shown in FIGURE 3 Depth Adjustment Bolt 16 Clamp and Angle Scale 1 To use the Quick Release 31 put the Quick Release 31 tab in the position shown in FIGURE 4 and push the Vise Handle 28
13. g parts cracked or broken parts dam aged electrical wiring and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment Daily while wearing gloves use a soft brush cloth or vacuum to remove all dust and debris from the Saw Then use a high quality lightweight machine oil to lubricate all moving parts except the Cut Off Wheel 56 Note If the motor performance decreases or stops it may be necessary to replace the Carbon Brushes 67 Refer to FIGURES 8 and 9 The Carbon Brushes 67 are located on each side of the Motor Housing see FIGURE 8 To replace the Carbon Brushes 67 use a standard screwdriver not included to open the two Carbon Brush Covers 68 Remove the Carbon Brush es 67 If they are less than half their original size replace them If replacing you must replace both at the same time If they are larger than half their original size they can be cleaned by rubbing them with a pencil eraser When returning them to their compartment make sure the carbon portions of the Carbon Brush es 67 contact the Motor Armature 85 and the springs face away from the Motor Also make sure the springs operate freely After cleaning or replacement replace the Carbon Brush Covers 68 and tighten securely DO NOT OVER TIGHTEN Note New Carbon Brushes 67 tend to arc or spark when first used until they wear
14. h 103 Vise Handle 28 4 With one hand on the Handle See FIGURE 6 slowly bring the Saw down onto the Base 13 letting the Saw do the work Do not apply excessive force If the Cut Off Wheel 56 does not cut all the way through the workpiece raise the Saw and release the Trigger Lock Switch 103 Unplug the unit Wait until the unit comes to a full stop Remove the workpiece Set the depth adjustment to a deeper setting see Setting Depth Adjustment on page 12 After adjusting the depth bring the Saw all the way down to make sure the Cut Off Wheel 56 doesn t contact the Base 13 If it does contact any part of the Base 13 re adjust the depth so it doesn t 5 Repeat the cutting process starting with number 1 above SKU 91938 For technical questions please call 1 800 444 3353 Page 13 T Once the cut is completed turn off the Saw by releasing the Trigger Lock Switch 103 and unplug the unit Do not attempt to remove the workpiece until the Cut Off Wheel 56 has stopped moving Lock down the Saw see Locking Down the Saw on page 12 INSPECTION MAINTENANCE AND CLEANING 1 N WARNING Make sure the Power Switch 103 of the Saw is in its OFF position and that the tool is unplugged from its electrical outlet before performing any inspection maintenance or cleaning procedures BEFORE EACH USE inspect the general condition of the Saw Check for loose screws misalignment or binding of movin
15. heels only use them on materials that the manufacturer recommends To avoid accidental injury always wear heavy duty work gloves and work bib when changing a Cut Off Wheel Before using the Cut Off Saw make sure the Cut Off Wheel is properly mounted on the saw spindle Make sure the Cut Off Wheel is balanced and is not broken or bent Always unplug the Cut Off Saw from its electrical outlet before perform ing any inspection maintenance or cleaning procedures SKU 91938 For technical questions please call 1 800 444 3353 Page 6 17 18 19 20 21 22 23 24 The Cut Off Wheel will become hot while cutting Allow the Cut Off Wheel to completely cool before touching Allow the Cut Off Wheel to spin to full speed before feeding it into the workpiece When turning off the Saw allow the Cut Off Wheel to spin down and stop on its own Do not press against the Cut Off Wheel to stop it Do not force the Cut Off Wheel into the workpiece when cutting Apply moderate pressure allowing the Cut Off Wheel to cut without being forced Industrial applications must follow OSHA requirements Always locate the Cut Off Saw on a level flat work surface capable of sup porting the solid weight of the saw workpiece and related tools Always use the right tool or attachment for the right job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool or attach ment There are certain applic
16. ly grounded Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool 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 GROUNDED TOOLS TOOLS WITH THREE PRONG PLUGS 1 Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of elec tric shock See Figure A 2 The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool The green wire in the cord must be the only wire connected to the tool s grounding system and must never be attached to an electrically live terminal See Figure A 3 Your tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See Figure A FIGURE A SKU 91938 For technical questions please call 1 800 444 3353 Page 8 DOUBLE INSULATED TOOLS TOOLS WITH TWO PRONG PLUGS 4 Tools marked Double Insulated do not require grounding They
17. ng Guard 53 into the open position If the saw is acci dently dropped the Swing Guard 53 may be bent Raise the Swing Guard 53 and make sure it moves freely and does not touch the Cut Off Wheel or another part in all depths of cut The Swing Guard 53 should be retracted manually only for special cuts such as Pocket Cuts and Compound Cuts Raise the Swing Guard 53 only enough to begin the cut As soon as the Cut Off Wheel enters the material the Swing Guard 53 must be released For all other sawing the Swing Guard 53 should be allowed to operate automatically The Saw is not to be used for any cutting in the locked down position The Saw should be locked down position only for carrying and storage Always use Cut Off Wheels with a 14 diameter 1 arbor hole and rated at a minimum of 3750 RPM Cut Off Wheels that do not match the mounting hard ware of the Saw or that are rated at less than the Saw s maximum RPM may fly off the Saw or may run eccentrically causing loss of control Never use damaged or incorrect Cut Off Wheel washers or bolts The Cut Off Wheel s washers and bolts were specially designed for your Saw for opti mum performance and safety of operation Do not use the included Cut Off Wheel to cut aluminum copper brass or other non ferrous metals The included Cut Off Wheel is designed to cut only ferrous iron containing metals such as steel alloys and cast iron If using other Cut Off W
18. rigger Lock Switch Clamp Base Carbon Brush Screw Quick Release Carbon Brush Cover Wire Board Lock Washer Screw 2 M5x10 Sheathing Screw Cover Power Cord Plug Sliding Jaw Screw 2 M5x10 Screw Angle Scale Screw M4x10 Right Handle Straight Pin Lock Washer Screw 3 M5x50 Washer Washer Wrench 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 SKU 91938 For technical questions please call 1 800 444 3353 Page 15 ASSEMBLY DIAGRAM _ Wrench 111 not shown 2 NOTE Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 91938 For technical questions please call 1 800 444 3353 Page 16
19. stments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users Maintain tools with care Keep cutting tools sharp and clean Properly maintained tools with a sharp cutting edge are less likely to bind and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly main tained tools SKU 91938 For technical questions please call 1 800 444 3353 Page 4 23 Use only accessories that are recommended by the manufacturer of your model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE 24 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 25 When servicing a tool use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury SPECIFIC SAFETY RULES
20. t a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation A eliminates the need for the three wire grounded power cord and grounded power supply system Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock Do not abuse the Power Cord Never use the Power Cord to carry the tools or pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immedi ately Damaged Power Cords increase the risk of electric shock When operating a power tool outside use an outdoor extension cord marked W A or W These extension cords are rated for outdoor use and reduce the risk of electric shock PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when oper ating a power tool Do not use a power tool while tired or under the influ ence of drugs alcohol or medication A moment of inattention while operat ing power tools may result in serious personal injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts SKU 919
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