Harbor Freight Tools 91852 User's Manual
Contents
1. 2 21 Bush 1 65 PanHeadScrew 1 22 StatorAssembly 1 66 Elbow Dust Chute 1 MEM 24 BallBearng 1 68 25 BrushHolder 2 69 Nut 26 _ Carbon Brush 2 70 SprngWashe 1 27 jPowrCod 1 1 71 Washer 1 28 CordGumd 1 1 72 Blade Guard 1 29 PanHeadScrew 4 73 jStopperPlate 1 30 PanHeadScrew 6 74 Rivet 1 41 31 Motor Housing 1 75 Spring 1 32 CordClips 1 76 jSafetyCoverGea 1 33 Screw 2 77 SpndeLock 1 34 Inductance 2 78 JjShaftLockGrip 1 35 j Capadto 1 79 Fastener 1 36 Safety Lever amp 1 80 Pn 1 37 Safety Button 1 81 Compressor Spring 1 38 Switch 1 82 jFestenlevr 39 Compressor Spring 1 83 jFrntCovr 1 40 Screw 1 84 PanHeadScew 4 L 41 SwithLever 1 85 Screw 2 42 SafetyLockGrip 1 86 j ReinforredNut 1 43 SafetyLock 1 87 WokTale 1 L 44 PanHeadScrew 7 88 RubberWasher 2 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts 23 Brush Holder Cap 2 67 Compressor Spring Plastic Stop2. o SKU 91852 For technical questions please call 1 800 444 3353 PAGE 23 PARTS LIST CONTINUED Part amp Description Qty Part Description Qty 89 RetainingRing 2 133a Short Bolt 1 90 DustproofCover 4 133b Long Bot 1 91 JFeithing 4 135 JAmmStopPlaie 1 92 Linear Ball Bearing 3 136 LaserSwitch 1 93 _ Slide Bar 1 137 BatteryBoxCap 1 94 LongerSliderBar_ 1 138 Battery AAA Size 2 95 jLokRing 1 139 jBatteryTermnal 1 1 96 WingScrew 2 140 BatteyTerminal2 1 97 Guide Fence 1 141 BatteyTermnal3 1 98 Slide Plate 3 142 Screw 2 99 ClampShaft 1 143 BatteryBox 1 100 Base Complete 1 144 HexHeadBot 1 101 VisePlate 1 145 Torsion Spring 1 102 RubberFoot 5 146 Sleeve tt 108 _ Wing Screw 5 147 Screw 104 BafflePlate 1 148 jLaserAssemby 1 105 Holder 1 2 149 PanHeadScrew 7 106 FlatWasher 4 150 Hex Socket Head Bolt 1 Spring Washer 4 151 KerfBoard 1 108 HexHeadBoltt 4 152 Index 11 109 Clamp Assembly 1 153 FastenKnob 1 110 HexBolt 4 154 ndex
3. 4 to the Baffle Plate and when the desired length of cut is determined lock the Holder in place with the Wing Screw See Figure K 4 Guide Fence Adjustment Loosen all four Bolts 108 on the back side of the Guide Fence 97 Using a square not included make sure that the fence is at a perfect right angle to the blade when the blade is set at 0 angle Also ensure that the blade does not contact the fence in any of the blade s positions Tighten the Bolts 108 to lock the Guide Fence in position CLAMP ASSY 96 99 109 111 WING SCREW CLAMP ASSY 103 Ii 96 99 109 111 BAFFLE PLATE 104 WING SCREW HOLDER 105 BAFFLE PLATE 104 WING SCREW 103 FENCE GUIDE FIGURE K 97 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 15 The Safety Cover 1 The transparent Safety Cover 72 automatically rotates to cover the Saw Blade 4 when the Blade Case 54 is lifted When the Blade Case is lowered the Safety Cover rotates back out of the way See Figure L 2 Do not disconnect or remove the Safety Cover 72 Do not operate the Miter Saw if the Safety Cover is damaged or missing See Figure L d If the transparent Safety Cover 72 becomes so dirty that the Saw Blade 4 cannot be seen clearly disconnect the electrical Power Cord from its electrical outlet and clean the Safety Cover with a soft damp cloth A mild detergent may be used but do not use solvents w
4. FR 8 9 09 REV 07 05 12 05 PAGE 25 For technical questions please call 1 800 444 3353 SKU 91852 ASSEMBLY DIAGRAM CONTINUED kad T re oc gt SE n 26 17 Qe D 2d gn gm H i32 JN R 12 a p Cu wo eg H 9 s 9 E om TH a T A 3 i 1 NOTE Part 143 Battery Box is located on the bottom of the Arm Holder Complete Partt 156 REV 03 06 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 26
5. and as shown in the Battery Box See Figure N 3 To activate the Laser Assembly 148 depress the Laser Switch 136 Align the cut line on the woodstock with the Laser Beam Then turn on the Miter Saw and make the cut NOTE Turn on the Laser only before you are ready to start cut ting and make sure the Laser Assembly is off when not cutting See Figure N BATTERY BOX 143 LASER ASSY 148 FIGURE N REV 03 06 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 17 The Elbow Dust Chute 1 The Elbow Dust Chute 66 exhausts the wood chips and saw dust when the Miter Saw is in operation See Figure O 2 The outside diameter of the Elbow Dust Chute is 1 3 8 Attach Dust Collection Bag 158 to the Elbow Dust Chute or attach vacuum hose not included It is recommended that only a qualified technician attach a vacuum hose See Figure O ELBOW DUST CHUTE 66 OUTSIDE DIAMETER 1 3 8 Fc yw G wd ro KL AUD A SEL m bs wit T M TRE j r a yay nl d n TOP PLATE 435 Xi FISH s B Ras dad FIGURE O Depth Adjustment Parts Closeup Photo Adjust The Cutting Depth 1 A WARNING Prior to performing this procedure make sure the Power Cord 27 of the Miter Saw is unplugged from its electrical outlet The depth of cut may be adjusted to a maximum of 4 at 90 and 1 15 16 at 45 Loosen the Wing Screw 103 and pull the Miter Saw s Motor Housing 31 for w
6. 1 111 Adjusting Knob 1 155 ScalePlate 1 112 SupportFoot 1 156 Amm Complete 1 113 nset 2 157 HexHead Bolt 1 114 LockRing 1 2 158 DustCollection Bag 1 115 RubberRing 2 159 JamNu 2 116 SlideBarSuppot 1 J DQ S 117 HexSocketHeadBolt 2 Z 118 Flat Washer 5 Z o 119 SpringWasher 2 O 120 Shaft 1 o O 121 Spring 1 OO 122 LockLever 1 o O j 123 ShaftLockAssembly 1 2 o o S 124 Knb CT 1 Fo Z Y O 127 Nut 2 Compressor Spring J 1 127 FlatWasher 1 LJ 128 tockPin 1 OT 120 Pin J 114 l 1 1 4 130 jlockNut 1 131 CenterSpinde 1 o Z 132 jArmHolderComplete 1 Z o Z NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts REV 07 05 12 05 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 24 ASSEMBLY DIAGRAM sued 1ueureo2e dai se j enpiaipur ejqe reAe zou 31e pue uo sesodaund uoneasn r 10 UMOUS pue poijsi 31e syed wos 310N UMOUS OU 894 Beg uonoejoo Isna e T OF Gr OS IK G ES
7. 91852 For technical questions please call 1 800 444 3353 PAGE 4 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 10 11 12 13 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 obstructions grease oil trash and other debris Do not use the Miter Saw in areas near flammable chemicals dusts and vapors Do not use this product in a damp or wet location Maintain labels and nameplates on the Miter Saw These carry important information If unreadable or missing contact Harbor Freight Tools for a replace ment Do not force the equipment This Miter Saw will do the work better and safer at the speed and capacity for which it was designed Keep all guards in place and in working order Remove all adjusting wrenches from the Miter Saw before turning it on Do not abuse the Power Cord Do not use the Power Cord to pull its Plug from an electrical outlet Keep the Power Cord away from heat oil sharp edges and moving parts Route the Power Cord safely Protect the Power Cord from being damaged by other equipment in the work area Do not route the Power Cord where it ca
8. 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 91852 For technical questions please call 1 800 444 3353 PAGE 22 PARTS LIST Part amp Description Qty Part amp Description Qty 1 jHexHeadBot 1 45 SpingWasher 7 2 jSpinde Washer 1 46 FlatWasher 7 3 Flange 1 217 1 47 jJPanHeadScew 7 1 4 jSawBlade 1 48 jSpingCover 1 5 Ball Bearing 4 49 Safety Lock Shaft 1 Flange 1 50 Torsion Spring MN 7 jFan 1 51 jHexHeadBot amp 1 8 PanHeadScrew 2 82 Cip 1 1 9 SpringWasher T 2 53 jHexHeadBot 1 10 FlatWasher THR 54 Blade Case Complete 1 11 Bearing Cover 1 55 Nut PA 0 4 12 FanGude 14 56 j CentrCover 30 11 13 Bearing 1 57 Screw 14 BearingBox 1 58 JjGearlinkPlate 1 15 Ger 1 59 j GearPate 1 16 Armature Assembly 1 60 jLinkPlate 1 PanHeadScrew T 2 61 j FlatHeadScrew 3 18 Spnde 1 62 PanHeadScew 3 19 Key 1 1 63 Seew 012 20 RetainingRing 1 64 Bush
9. OPERATING INSTRUCTIONS NOTE For additional references to the parts listed in the following pages refer to the Assembly Diagrams on pages 25 and 26 To Heplace And Install A Saw Blade ZT WARNING Prior to performing any assembly and or adjustment procedures make sure the Power Cord 27 of the Miter Saw is unplugged from its electrical outlet Make sure the unit has completely cooled and wear heavy duty work gloves 2 When replacing the Saw Blade 4 make sure the new Saw Blade has a diam eter of 12 an RPM rating of at least 5000 and an arbor hole of 1 diameter S When installing a Saw Blade 4 make sure the teeth of the Saw Blade point downward and that the direction of the arrow shown on the Saw Blade matches the direction of the arrow shown on the Blade Case 54 See Figure D SKU 91852 For technical questions please call 1 800 444 3353 PAGE 11 BLADE CASE 54 ARROW SAW BLADE 4 ARROW SAW TEETH POINTING DOWNWARD LIN The Lock Pin 128 should always be activated in the locked down position when the Saw is not being used and when the Saw is being transported The Lock Pin should be activated in the locked up position when changing Saw Blades NEVER use the Lock Pin in any cutting operation The Lock Pin allows the operator to lock the Saw Blade in position preventing the Saw Blade from being raised or lowered See Figure E next page 9 Lock the Saw Blade 4 in its upward position To do
10. electrically live terminal See Figure A SKU 91852 For technical questions please call 1 800 444 3353 PAGE 8 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 DOUBLE INSULATED TOOLS TOOLS WITH TWO PRONG PLUGS 4 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 See Figure B 5 Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration See Figure B FIGURE B SKU 91852 For technical questions please call 1 800 444 3353 PAGE 9 EXTENSION CORDS 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 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
11. electricity away from the user D 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 contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation O eliminates the need for the three wire grounded power cord and grounded power supply system 6 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 7 Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock 8 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 9 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 10 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 o
12. ABLE 87 To Adjust The Miter Angle 1 A WARNING Prior to performing this procedure make sure the Power Cord of the Miter Saw is unplugged from its electrical outlet 2 The miter angle of a cut may be adjusted 0 45 degrees to the right or left To do SO loosen the Fasten Knob 153 located at the front of the Work Table 87 See Figure Q 3 Move the Work Table 87 to the right or left until the desired miter angle of cut is indicated by the Miter Scale located on the Base 100 Then retighten the Fasten Knob 153 to lock the Miter Saw in place See Figure Q WORK TABLE 87 FASTEN KNOB 153 FIGURE Q REV 12 05 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 19 To Adjust The Angle Of Cut A 1 Z WARNING Prior to performing this procedure make sure the Power Cord of the Miter Saw is unplugged from its electrical outlet 2 The bevel angle or Saw Blade tilt capacity may be adjusted from 0 45 degrees to the left To do so loosen the Lock Lever 122 located at the rear of the Miter Saw See Figure R 3 Tilt the Arm Holder 132 until the desired bevel angle of cut is achieved as indi cated on the Scale Plate 155 Then retighten the Lock Lever 122 to lock the Arm Holder in place See Figure R LOCK LEVER 122 SCALE PLATE 155 FIGURE R Basic Operation 1 Make sure the Power Cord 27 of the Miter Saw is unplugged from its elec trical outlet The
13. CHICAGO 3I YeiitePower Tools 12 COMPOUND SLIDE MITER SAW Model 91852 ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 9301 1 Visit our Web site at http www harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 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 please call 1 800 444 3353 REVISED MANUAL 04 05 PRODUCT SPECIFICATIONS Electrical Requirements 120 V 60 Hz 1800 Input Watts 66AJ 15 AMPs 4100 RPM Motor Two Prong Polarized Power Cord Plug L LISTED Power Switch Type Single Pull Trigger Type Laser Input Power Two AAA Batteries E105017 Laser Switch Type Push Button Switch Activation Saw Blade Included 12 Diameter Diameter Type 100 Tooth Carbide Tipped 5000 RPM Rated Capacity Crosscut Capacity 12 3 4 x 4 Vertical 9 90 12 3 4 x 1 15 16 Vertical 45 Blade Tilt Capacit 0 45 R amp L Miter O 45 L Compound 0 15 22 5 30 45 L R Miter 0 45 L Bevel Overall Dimensions SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assembly dia
14. N WARNING The warnings precautions and instructions discussed in this manual cannot cover all possible conditions and situations that may occur The operator must understand that common sense and caution are factors which cannot be built into this product but must be supplied by the operator N 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 properly 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
15. Saw Blade to climb out of the kerf and jump toward the operator Kickback is a result of tool misuse and or incorrect operating procedures or conditions and can be minimized by taking proper precautions as given below A Maintain a firm grip with both hands on the Saw and position your body and arm to allow you to resist kickback forces B When the Saw Blade is binding or when interrupting a cut for any rea son release the Power Switch and hold the Saw motionless in the work piece until the Saw Blade comes to a complete stop Never attempt to remove the Saw from the workpiece or pull the Saw backward while the Saw Blade is in motion or kickback can occur C When restarting the Saw in the workpiece center the Saw Blade in the kerf and check that the saw teeth are not engaged into the workpiece If the Saw Blade is binding it may walk up or kickback from the workpiece as the Saw is restarted D Support large panels to minimize the risk of Saw 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 E Do not use a dull or damaged Saw Blade Unsharpened or improperly set Saw Blades produce a narrow kerf causing excessive friction Saw Blade binding and kickback F Make sure all Saw adjustments are tight and secure before making a cut If Saw adjustments shift while cutting it may cause binding and kickba
16. ard as far as it will go Notice whether the edge of the Saw Blade 4 passes completely through the Kerf Board 151 See Figure P next page 4 If the Saw Blade 4 does not pass completely through the Kerf Board 151 lower the Saw Blade slightly by turning the two Bolts 133A 133B counterclock wise See Figure P 5 The rear Short Bolt 133A should be adjusted for maximum allowable depth of cut The forward Long Bolt 133B is used in conjunction with the Arm Stop Plate 135 The Long Bolt 133B can be adjusted for a secondary less deep cut if desired Pivot the Arm Stop Plate 135 outward to use the front stop or push the Arm Stop Plate 135 inward and the Long Bolt 133B will bypass it allowing full depth of cut After making the adjustments to the two Bolts 133A 133B tighten the two Jam nuts 159 to keep the two Bolts 133A 133B from moving See Photo Above 6 After adjusting the two Bolts 133A 133B press down on the Miter Saw and make sure the Saw Blade 4 does not contact the bottom of the Work Table 87 or any other part of the Saw Base See Figure P REV 07 05 REV 12 05 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 18 6 If the Saw Blade 4 touches the Work Table 87 or any other part of the Saw Base turn the two Bolts 133A 133B clockwise to raise the Saw Blade slightly until it clears See Figure P LONG BOLT 133B KERF BOARD 151 FIGURE P SAW BLADE 4 WORK T
17. are located on each side of the Motor Housing 31 To do so remove the two Brush Holder Caps 23 Then remove the two Carbon Brushes from the Brush Holders 25 If the Carbon Brushes are worn down more than 1 2 replace both Carbon Brushes If however the Carbon Brushes are just dirty they may be cleaned by rubbing them with a pencil eraser When installing the Carbon Brushes make sure the carbon portion of the Carbon Brushes contact the Motor Armature and that the springs face away from the Motor Also make sure the springs operate freely After cleaning or replacement replace the Brush Holders NOTE New Carbon Brushes tend to arc or spark when first used until they wear and conform to the Motor s Armature See Assy Diagram 5 NOTE With the exceptions of Steps 1 2 3 and 4 all other mainte nance and servicing should be performed only by a qualified service tech nician PLEASE READ THE FOLLOWING CAREFULLY 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
18. ck NWARNING The Lock Pin 128 should always be activated in the locked down position when the Saw is not being used and when the Saw is being transported The Lock Pin should be activated in the locked up position when changing Saw Blades NEVER use the Lock Pin in any cut ting operation The Lock Pin allows the operator to lock the Saw Blade in position preventing the Saw Blade from being raised or lowered Allow the Saw Blade to spin up to full speed before feeding it into the workpiece Do not force the Saw Blade into the workpiece when cutting Apply moderate pressure allowing the Saw Blade to cut without being forced When turning off the Saw allow the Saw Blade to spin down and stop on its own Do not press against the Saw Blade to stop it Turn off the Saw and allow the Saw Blade to stop on its own if the Saw Blade is to be backed out of an uncompleted cut Industrial applications must follow OSHA requirements SKU 91852 For technical questions please call 1 800 444 3353 PAGE 6 18 19 20 21 22 23 24 25 26 2f 28 The Laser on the Miter Saw is rated as a Class 2 Do not stare directly at the Laser beam A hazard may exist if you deliberately stare into the beam Never aim the Laser beam at any person animal or an object other than the work piece Make sure the Laser beam is aimed at a sturdy workpiece without reflective surfaces Reflective surfaces are not suitable for Lase
19. ect 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 adjustments 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 re paired Check for misalignment or binding of guards and other moving parts breakage of parts cracking or breakage of the Saw Blade 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 maintained tools Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury SKU
20. f inattention while operat ing power tools may result in serious personal injury 11 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 91852 For technical questions please call 1 800 444 3353 PAGE 3 12 13 14 15 16 17 18 19 20 21 22 23 24 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 situa tions Use safety equipment Always wear eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate condi tions TOOL USE AND CARE Use clamps or other practical ways to secure and support the workpiece to a stable platform Holding the work by hand is unstable and may lead to loss of control Only work on a workpiece that is properly secured Do not force the tool Use the correct tool for your application The corr
21. gram 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 Z WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed in the following pages 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 flammables REV 06 05 REV 02 06 SKU 91852 For technical questions please call 1 800 444 3353 PAGE2 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 ELECTRICAL SAFETY 4 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
22. hich may damage the Safety Cover See Figure L ED y SAFETY COVER V CAUTION NRW um X x Never disconnect or remove Safety Cover 72 FIGUREL The Safety Button And Switch Lever 1 Before plugging in the Miter Saw check the operation of the Safety Button 37 and the Switch Lever 41 Do not operate the Miter Saw if either the Safety Button or Switch Lever are not operating properly See Figure M next page 2 Depress the Safety Button 37 with your thumb and squeeze the Switch Lever 41 which will start the Miter Saw Then release the Safety Button See Figure M S To turn off the Miter Saw release the Switch Lever 41 This allows the Safety Button 37 to return to the OFF position See Figure M 4 Do not force the Switch Lever 41 if the Safety Button 37 is not working prop erly This will damage the Switch Lever mechanism See Figure M SKU 91852 For technical questions please call 1 800 444 3353 PAGE 16 SAFETY BUTTON 37 SWITCH LEVER 41 FIGURE M The Laser Assembly 1 The Miter Saw is equipped with a Laser Assembly 148 for improved cutting accuracy and convenience See Figure N 2 The Laser Assembly 148 is powered by two AAA Batteries included To install the Batteries open the Battery Box Cap 137 Insert two AAA Batteries into the Battery Box 143 making sure to match the polarity of the Batteries with the polarity signs
23. 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 9 If 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 6 If you are using an extension cord outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use 7 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 electrician 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 EXTENSION CORD LENGTH AMPERES At Full Load Based on limiting the line voltage drop to five volts at 15096 of the rated amperes FIGURE C SKU 91852 For technical questions please call 1 800 444 3353 PAGE 10 SYMBOLOGY B Paulette Association O emm Laboratories Inc Volts Alternating Ww Ts o d e No Load Revolutions xxxx min Min V UNPACKING When unpacking check to make sure all the parts shown on the Parts Lists on pages 23 and 26 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
24. n if necessary make adjustments to the workpiece Holder 105 Baffle Plate 104 cutting depth and miter angle and or bevel angle 2 Raise the Motor Housing 31 to its full UP position 3 Check to make sure the Safety Button 37 and the Switch Lever 41 are operat ing properly 4 Place the workpiece on the Work Table 87 and against the Guide Fence 97 9 Use the Clamp Assembly 96 99 109 111 to hold the workpiece in place SKU 91852 For technical questions please call 1 800 444 3353 PAGE 20 6 Plug the Power Cord into the nearest 120 volt grounded electrical outlet 7 Depress the Safety Button 37 with your thumb and squeeze the Switch Lever 41 Then release the Safety Button 8 When the Saw Blade 4 is turning at full speed slowly bring down the Motor Housing 31 to complete the cut NOTE Feed the Saw Blade into the work piece gradually Do not force the machine to remove material faster than it was designed to cut 9 When cutting a large workpiece make sure its entire length is properly sup ported If necessary use a roller stand not included with a larger workpiece 10 Never attempt to remove material stuck in the moving parts of the Miter Saw while it is plugged in and running 11 Turn off the Miter Saw if the workpiece is to be backed out of an uncompleted cut 12 When the cut is complete release the Switch Lever 41 This allows the Safety Button 37 to return to the OFF po
25. n be walked on or tripped over Replace a damaged Power Cord immediately Do not use this Miter Saw for cutting metals or brittle materials Do not cut dangerous materials such as asbestos which can cause harmful dust or vapors To avoid accidental injury always wear heavy duty work gloves when changing a Saw Blade Before using the Miter Saw make sure the Saw Blade is properly mounted on the Saw Spindle Make sure the Saw Blade is balanced and is not cracked or bent The Saw Blade will become hot while cutting Allow the Saw Blade to com pletely cool before touching Make sure the workpiece is free from nails and any other foreign objects which can damage the Saw Blade Keep your body positioned to either side of the Saw Blade but not in line with the Saw Blade Kickback can cause the Saw to jump backwards 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 Saw Blade is pinched or bound tightly by the kerf closing down the Saw Blade stalls and the Motor SKU 91852 For technical questions please call 1 800 444 3353 PAGE5 14 19 16 17 reaction drives the tool rapidly toward the operator If the Saw Blade becomes twisted or misaligned in the cut the teeth at the back edge of the Saw Blade can dig into the top surface of the workpiece causing the
26. r applications as the reflective surface may direct the Laser beam back at the operator causing poten tial eye damage Do not attempt to alter the Laser or replace it with a different type Doing so may result in hazardous radiation exposure Never attempt to remove material stuck in the moving parts of the Miter Saw while the machine is plugged in and running Whenever possible use clamps or other safe practical ways to hold and support the workpiece Do not attempt to cut material that does not have a flat surface unless a suitable support is used Always keep hands and fingers away from the spinning Saw Blade Use eye hearing and breathing protection Always wear ANSI approved safety impact eye goggles hearing protectors and dust masks or respirator when working with the Miter Saw Do not use this product if under the influence of alcohol or drugs Read warning labels on prescriptions to determine if your judgement or reflexes are impaired while taking drugs If there is any doubt do not attempt to use this product Maintain this product with care Keep the Miter Saw clean and dry for better and safer performance For your safety service and maintenance should be performed regularly by a qualified technician 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 attachment There are certain applications for which this product wa
27. s 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 in tended Always turn off the Miter Saw and unplug the Power Cord 27 from its electrical outlet before changing accessories or performing inspection maintenance or cleaning procedures SKU 91852 For technical questions please call 1 800 444 3353 PAGE 7 29 A WARNING People with pacemakers should consult their physician s before using this product Operation of electrical equipment in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker 30 ZA 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 Califor nia Health amp Safety Code 25249 5 et seq 31
28. s the Saw Blade 4 See Figure G 15 Reinstall the Screw 62 and retighten the Screw 57 See Figure F 16 Make sure the Blade Guard 72 returns to its original position prior to operating the Miter Saw CAUTION Make sure to pull out on the Knob 124 Turn the Knob 90 degrees Then insert the Knob into the shallow slot in its unlocked posi tion NEVER use the Knob in any cutting operation 17 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 14 To Assemble Adjust Additional Accessories 1 A workpiece Clamp Assembly 96 99 101 109 111 can be installed by inserting the Assembly into the hole located in the Guide Fence 97 Once inserted lock the Assembly in place with a Wing Screw 103 To clamp the workpiece to the Work Table 87 of the Miter Saw turn the Adjusting Knob 111 clockwise See Figure K 2 A workpiece Holder 105 can be inserted into each side of the Base 100 ad justed for the desired length and locked in place with a Wing Screw 103 The Holders should be used as supports when cutting longer length workpieces See Figure K 3 The Baffle Plate 104 can be attached to the workpiece Holder 105 and locked in place with a Wing Screw 103 Once attached and locked in place the Baffle Plate allows you to make repeated cuts of the same length To do so loosen the Wing Screw 103 that holds the Holder 105 in place Measure the distance from the Saw Blade
29. sition 13 Wait until the Saw Blade 4 comes to a complete stop Then raise the Motor Housing 31 to its full UP position 14 Loosen the Clamp Assembly 96 99 109 111 and remove the workpiece and scrap material from the Work Table 87 15 Unplug the Power Cord 27 from its electrical outlet INSPECTION MAINTENANCE AND CLEANING 1 A WARNING Always make sure the Switch Lever 41 is in its OFF position and unplug the Power Cord 27 from its 120 volt electrical outlet before performing any inspection adjustments maintenance or cleaning 2 Before each use inspect the general condition of the Miter Saw Check for loose screws misalignment or binding of moving parts cracked or broken parts damaged electrical wiring loose cracked or bent Saw Blade 4 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 SKU 91852 For technical questions please call 1 800 444 3353 PAGE 21 3 Daily With a soft brush cloth or vacuum remove all dust and debris from the Miter Saw Then use a premium quality lightweight machine oil to lubricate all moving parts except the Saw Blade 4 4 To replace the Motor Carbon Brushes It may become necessary at some time to replace the two Carbon Brushes 26 when the Motor performance de creases or stops working completely The Carbon Brushes
30. so pull out on the Knob 124 Raise and hold the body of the Miter Saw fully upward Turn the Knob 90 degrees Then insert the Knob into the deep slot in its locked position See Figure E 6 Loosen the Screw 57 that holds the Center Cover 56 in place Then remove the Screw 62 See Figure F next page 7 Hotate the Center Cover 56 up and out of the way See Figure G next page SKU 91852 For technical questions please call 1 800 444 3353 PAGE 12 RAISED POSITION Iar we N N E b d 8 Depress the Spindle Lock 77 to keep the Saw Blade 4 from turning See Figure H CENTER COVER SPINDLE LOCK 77 FIGURE G FIGURE H SKU 91852 For technical questions please call 1 800 444 3353 PAGE 13 9 Unscrew and remove the Hex Head Bolt 1 Then remove the Spindle Washer 2 and Flange 3 See Figure I SPINDLE WASHER 2 HEX HEAD BOLT 1 FLANGE FIGURE 3 10 Release pressure on the Safety Lock Grip 42 See Figure H 11 Wearing heavy duty work gloves to avoid accidental cuts remove the old Saw Blade 4 See Figure J SAW BLADE 4 FIGURE J 12 Install the new Saw Blade 4 making sure the teeth of the Saw Blade are point ing downward See Figure D 13 Reassemble the Flange 3 Spindle Washer 2 and Hex Head Bolt 1 firmly See Figure l 14 Swing the Center Cover 56 back in place making sure the Blade Guard 72 cover
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