Operator's Manual CRRFTSMRN° 3 HP (Max. Developed) 10" Blade 4800 R.P.M. MULTI-MITER TM COMPOUND MITER SAW Model No. 137.242760 CAUTION: • Safety Instructions • Installation Before using this Miter Saw, read this manual and follow • • Operation Maintenance all its Safety Rules and Operating Instructions • Parts List Customer Help Line 1-800-843-1682 Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A. Visit our Craftsman webslte: www.sears.comlcraftsman PaN No. 137242760001 SECTION PAGE Warranty ........................................ Product Specifications ....................... Power Tool Safety ............................ Compound Miter Saw Safety ............... Electrical Requirements and Safety ...... Accassodes and Attachments .............. Tools Needed For Assembly................ Carton Contents .............................. SECTION Know Your Miter Saw ........ Glossary of Terms ............................ Assembly and Adjustments................. Operation....................................... Maintenance ................................... Troubleshooting Guide....................... Parts List......................................... 2 2 3 4 4-5 6 6 7 PAGE 8 9 10 17 24 25 26 FULL ONE YEAR WARRANTY If this tool fails due to a defect in material or workmanship within one year of date of purchase, Sears will at its option repair or replace it free of charge. Return this tool to a Sears Service Center for repair, or to place of purchase for replacement. This warranty gives you specific legal rights, and you may also have other rights which may vary from state to state. Seam, Roebuck and Co., Dept. 817 WA, Hoffman Estates, IL 60179 U A WARNING ] Some dust created by power sanding, sawing, grinding, dHIlinQ and other construction activities contains chemicals known (to the State of Ca.fornie) to cause cancer, bnrth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints • Crystalline silica from bricks, cement and other masonry products • Arsenic and chromium from chemically treated lumber Your Hak 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 aquipmantsuch as dust masks that are specially des gned to fi tar out microscop c part c es. MOTOR Pov_r Source..................... Horsepower........................ Speed................................. Brake................................. DoubleInsulated.................... MITER SAW Cutting Capacity: Crosscut............................ Miter45° R.&L..................... Bevel45=L........................ 45° Miterand 45° Bevel......... Rotating Table: Diameter .............................. Miter Detent Stops.................. 120VAC, 60HZ, 15 Amp 3HP (Max. Developed) 4800 RPM (No load) Electric Yes Bevel Positive Stops............... Base Dimensions................... Dust Collection...................... Extension Table ..................... Net Weight ........................... 12-5/8" 0, 15, 22-1/2, 31.6, 450 R. & L. 0, 450 19-7/8" x 16-3/8" Yes Yes 51.25 Lbs 2-5/8"x 5-1/2" 2-5/8"x 3-1/2" 1-1/2"x 5-1/2" 1-1/2"x 3-1/2" IA WARNONGI To avoid electrical hazards, fire hazards or damage to the tool, use proper circuit protection. This tool Is wired st the factory for 110-120 Volt operation. It must be connected to a 110-120 Volt 1 15 Ampere time delay fuse or circuit breaker. To avoid shock or firs, replace power cord Immediately if it is worn, cut or damaged in any way. Before using your tool, it is cdtlcal that you read and understand these safety rules. Failure to follow these rules could result in serious injury to you or damage to the tool. 2 12.ALWAYS WEAR EYE PROTECTION. Any power tool can throw foreign objects into the eyes and ,,,*,,_ could cause permanent eye damage. ALWAYS wear Safety Goggles (not glasses) that comply with ANSI Safety standard Z87.1 Everyday eyeglasses have only impact -resistance lenses. TheyARE NOT safety glasses. Safety Goggles are available at Sears. NOTE: Glasses or goggles not in compliance with ANSI Z87.1 could seriously injure you when they break. GENERAL SAFETY INSTRUCTIONS BEFOREUSINGTHISPOWERTOOL Safety is a combination of common sense, staying alert and knowing how to use your power tool. A WARNING I To avoid mistakes that could cause serious injury, do not plug the tool in until you have read and understood the following. 13.WEAR A FACE MASK OR DUST MASK. Sawing operation produces dust. 1. READ and become familiar with the entire Operators Manual. LEARN the tool's application, limitations and possible hazards. 14.SECURE WORK. Use clamps or a vise to hold work when practical. It's safer than using your hand and it frees both hands to operate the tool. 2. KEEP GUARDS IN PLACE and in working order. 3. REMOVE ADJUSTING KEYS AND WRENCHES. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning ON. 15.DISCONNECT TOOLS FROM POWER SOURCE before servicing, and when changing accessories such as blades, bits and cutters. 4. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. 16.REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in the OFF position before plugging the tool in. 5. DON'T USE IN DANGEROUS ENVIRONMENTS. Don't use power tools in damp locations, or expose them to rain or snow. Keep work area well lighted. 17.USE RECOMMENDED ACCESSORIES. Consult this Operators Manual for recommended accessories. The use of improper accessories may cause risk of injuryto yourself or others. 6. KEEP CHILDREN AWAY. All visitors and bystanders should be kept a safe distance from work area, 18.NEVER STAND ON THE TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionallycontacted. 7. MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys. 19.CHECK FOR 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 functioncheck 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 propedy repaired or replaced. 8. DON'T FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed. 9. USE THE RIGHT TOOL. Do not force the tool or an attachment to do a job for which it was not designed. 10.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 your product will draw. An undersized cord will result in a drop in line voltage and in loss of power which will cause the tool to overheat. The table on page 5 shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord. 20.NEVER LEAVE THE TOOL RUNNING UNAI-rENDED. TURN THE POWER "OFF". Don't walk away from a running tool until the blade comes to a complete stop & unplug the unit. 2t .DON'T OVERREACH. Keep proper footing and balance at all times. 11 .WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair. 22.MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructionsfor lubricating and changing accessodes. 23. WARNING: Dust generated from certain materials can be hazardous to your health. Always operate saw in well-ventilated area and provide for proper dust removal. 3 SPECIFIC SAFETY INSTRUCTIONS THIS COMPOUND MITER SAW 17.NEVER reach around the sew blade. FOR 18.MAKE SURE the blade is not contactingthe workpiece before the switch is turned ON. 1. USE ONLY CROSS-CUTTING SAW BLADES. When using carbide tipped blades, make sure they have a negative hook angle. IMPORTANT: DO NOT USE THIN KERF BLADESthey can deflect and contact guard and can cause possible injury to the operator. 19.IMPORTANT: After completing the cut, release the power switch and wait for the blade to stop before returningthe saw to the raised position. 20.MAKE SURE the blade has come to a complete stop before removing or securing the workpiece, changing the workpiece angle, or changing the angle of the blade. 2. DO NOT operate the miter saw until it is completely assembled and installed according to these instructions. 21 .NEVER cut ferrous metals or masonry with this tool. 3. IF YOU ARE NOT thoroughly familiar with the operation of miter sews, seek guidance from your supervisor, instructor,or other qualified person. 22.NEVER cut small pieces.. If the workpiece being cut would cause your hand or fingers to be within 7-1/4 inches of the saw blade the workpiece is too small. 4. ALWAYS hold the work firmly against the fence and table. DO NOT perform any operation free hand (use clamp wherever possible). 23.PROVIDE adequate support to the sides of the saw table for long work pieces. 5. KEEP HANDS out of the path of the saw blade. If the workpiece you are cutting would cause your hands to be within 6-1/2" inches of the saw blade, the workpiece should be clamped in place before making the cut. 24.NEVER use the mitersaw in an area with flammable liquids or gases. 25.NEVER use solvents to clean plastic parts. Solvents could possiblydissolve or otherwise damage the matedaL 6. BE SURE the blade is sharp, runs freely, and is free of vibration. 26,SHUT OFF the power before servicing or adjusting the tool. 7. ALLOW the motor to come up to full speed before starting a cut. 27,DISCONNECT the saw from the power source and clean the machine when finished using. 8. KEEP THE MOTOR AIR SLOTS CLEAN and free of chips or dust. 28.MAKE SURE the work area is clean before leaving the machine. 9. ALWAYS MAKE SURE all handles are tight before cutting, even if the table is positioned in one of the positive stops, 29.SHOULD any part of your miter saw be missing, damaged, or fail in any way, or any electrical component fail to perform propedy, shut off the switch and remove the plug from the power supply outlet. Replace missing, damaged, or failed parts before resuming operation. tO.BE SURE both the blade and the coUarare clean and the arbor bolt is tightened securely. 11.USE only blade collars specified for your saw. 12. NEVER use blades'larger or smaller in diameter than 10oinches. POWER 13. NEVER apply lubricants to the blade when it is running. SUPPLY AND MOTOR SPECIFICATIONS The AC motor used in this sew is a universal, nonreversible type. See "MOTOR" in the "PRODUCT SPECIFICATIONS" section on page 2. To avoid electdcal hazards, fire hazards, or damage to the tool, use proper circuit protection.Your saw is wired at the factory for 120V operation. Connect to a 120V, 15 Amp circuit and use a 15 amp. time delay fuse or circuit breaker. To avoid shock or fire, if power cord is worn or cut, or damaged in any way, have it replaced immediately. t4. ALWAYS check the blade for cracks or damage before operation. Replace a cracked or damaged blade immediately. 15. NEVER use blades recommended for operation at less than 4800 RPM 16.ALWAYS keep the blade guards in place and use at all times. 4 4. FUSES may "blow" or circuit breakers may tdp frequently if: a. MOTOR is overloaded - overloading can occur if you feed too rapidly or make too many start/stops in a short time. b. LINE VOLTAGE is more than 10% above or below the nameplate voltage rating. For heavy loads, the voltage at motor terminals must equal the voltage specified on the nameplate. c. IMPROPER or dull saw blades are used. 5. Most motor troubles may be traced to loose or incorrect connections, overload, low voltage or inadequate power supply wiring. Always check the connections, the load and supply circuit if the motor doesn't run well. Check minimum gauge for the length of cord you are using on the chart below. ELECTRICAL REQUIREMENTS - cont'd DOUBLE INSULATED  The power tool is double insulated to provide a double thickness of insulation between you and tool's electricel system. All exposed metal parts are isolated from the internal metat motor components with protecting insulation. Replacement parts - When servicing use only identical replacement parts. Polarized plugs - This saw has a plug that looks like the one shown below: / GUIDELINES FOR EXTENSION CORDS Use a proper extension cord. 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 your product will draw. An undersized cord will cause a drop in line voltage, resulting in loss of power and cause overheating. The table below shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord. -i;222 To reduca the risk of electrical shock, this saw 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. [A WARN,NG ] Be sure your extension cord is properly wired and in good condition.Always replace a damaged extension cord or have it repaired by a qualified person before using it. Protect your extension cords from sharp objects, excessive heat and damp or wet areas. Double insulationdoes not take the place of normal safety precautions when operating this tool. To avoid electrocution: 1. Use only identical replacement parts when servicing a tool with double insulation. Servicing should be performed by a qualified technician. 2. Do not use power tools in wet or damp locations or expose them to rain or snow. Use a separate electrical circuit for your tools. This circuit must not be less than # 12 wire and should be protected with a 15 Amp time delay fuse. Before connecting the tool to the power line, make sure the switch is in the OFF position and the electric current is rated the same as the current stamped on the motor nameplate, running at a lower voltage will damage the motor. MOTOR SAFETY PROTECTION IMPORTANT: To avoid motor damage, the motor should be blown out or vacuumed frequently to keep sawdust from interfering with the motor ventilation. 1.CONNECT this saw to a 120V, 15 amp. circuit with a 15 amp. time delay fuse or circuit breaker. Using the wrong size fuse can damage the motor. 2. If the motor won't start, release the trigger switch immediately. UNPLUG THE SAW. Check the saw blade to make sure it turns freely. If the blade is free, try to start the sew again. If the motor still does not start, refer to the "TROUBLESHOOTING GUIDE" 3. If the tool suddenly stalls while cutting wood, release the trigger switch, unplug the tool, and free the blade from the wood. The saw may now be started and the cut finished. lltd I _I liVdlllvJ1¢f_,_1[€t =1 :re] _.i =);,4111:1 _k.'f[e] _I[o(I] :| J_l f:VlvL_! (When using 120 volts only) Rating Total length of cord in feet _mpere _ore fJlen not more I_n 25' 50' 6 18' 16' t00' 16' 150' 14' 10 18' 16' 14' 12' I0 12 16' 16' 14' 12' 12 16 14' 12' not recommended CAUTION: In all cases make certain the receptacle in question is properly grounded. If you are not sure have a certified electrician, check the receptacle. 5 RECOMMENDED ACCESSORIES IA, WARNING] Blade wrench (supplied) Adjustable wrenCh Use only accessories recommended for this miter saw. Follow instructions that accompany accessories. Use of improper accessories may cause hazards. Phillips screwdriver • The use of any cutting tool except 10 inch saw blades which meet the requirements under recommended accessories is prohibited. Do not use accessobes such _ver Combination square as shaper cutters or dado sets. Ferrous metal cutting and the use of abrasive wheels is prohibited. • Do not attempt to modify this tool or create COMBINATION SQUARE MUST BE TRUE accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible Draw a light line serious injury. on a board along Straight edge or this edge. ,-a 3/4" board, this ACCESSORIES s_J edge must be Visit your Sears Hardware Department or see the Sears perfectly straight Power and Hand Tool Catalog to purchase recommendec accessories for this power tool. • ===J [A WARNING I To avoid the risk of personal injury, do not modify this power tool or use accessories not recommended by Sear I,A WARNING] Should not gap or overlap when square is flipped over in dotted position Read warnings and conditionson your CARBIDE TIPPEr SAW BLADE. Do not operate the saw without the proper saw blade guard in place. Carbide is a very hard but brittle material. Care should be taken while mounting, using, and storing carbide tipped blades to prevent accidental damage. Slight shocks, such as striking the tip while handling, can seriously damage the blade. Foreign objects in the workpiece, such as wire or nails, can also cause tips to crack or break off. Before using, always visually examine the blade and tips for bent teeth, cracks, breakage, missing or loose tips, or other damage. Do not use if damage is suspected. Failure to heed safety instructionsand warnings can result in serious bodily injury. I 6 UNPACKING YOUR MITER SAW . 3. IA WARNING I To avoid injury from unexpected starting or electrical shock, do not plug the power cord into a source of power during unpacking and assembly. This cord must remain unplugged whenever you are adjusting/assembling the saw. 1, Place the saw on a secure stationary work surface. Separate all parts from the packing material. Check each one with the illustration below to make certain all items are accounted for, before discarding any packing material. I,_b. WARNING I If any part is missing or damaged, do not attempt to assemble the miter saw, or plug in the power cord until the missing or damaged part is correctly replaced. To avoid electric shock, use only identical replacement parts when servicing double insulated tools. Remove the miter saw from the carton. IMPORTANT: Do not lift the miter saw by the switch handle or miter table handle. It may cause misalignment. LIFT ONLY BY THE BUILT-IN CARRYING HANDLE LOCATED AT THE TOP OF THE MACHINE. V Dust Collector Extension Wing Elbow Locking Screw Extension Table Miter Table Handle Blade Wrench Dust Bag Safety Hold-down Clamp I ,I Bottom (short) Stand Legs bracket Top (short) Bottom (long) bracket 7 leg bracket Top (long) leg bracket Stand Mounting Hardware Bag Safety Lock-OFFButton ' Handle ON I OFF Trigger Switch Handle Locking Lever Motor Arbor Lock Base ExtensionTable Mounting Holes Miter Scale Cutting Head Handle Upper Blade Guard Lower Blade Guard Saw Blade Fence Fence Extension StopBlock MiferSpdng Lock Extension Table Quick-Cam Miter Table Lock M_rHa_le CRAFTSMAN COMPOUND STOP LATCH - MITER SAW TERMS Locks the miter saw in the lowered positionfor compact storage and transportation. ARBOR LOCK - Allows the user to keep the blade from rotating while tightening or loosening the arbor locking bolt during blade replacement or removal. SWITCH HANDLE - The cutting head handle contains the trigger switch and a safety lock-off slide switch. The blade is lowered into the workpiece by pushing down on the handle. The saw will return to its upright position when the handle is released. BASE - Supports the table, holds accessories and allows for workbench or leg set mounting. BEVEL LOCKING HANDLE - Locks the miter saw at a desired bevel angle. WARNING LABELS - Read and understand for your own safety. Always make certain these are in place & legible. BEVEL SCALE - To measure the bevel angle of the saw blade 0° to 45 ° left. WRENCH STORAGE - Convenient storage to prevent misplacing the blade wrench. COVER PLATE SCREW - Loosen this screw and rotate the plate for access to the blade arbor locking bolt. WOODWORKING TERMS DUST CHUTE - Exhausts debds away from the user. ARBOR - The shaft on which a blade is mounted, EXTENSION TABLE - Extends the width of the work table for support while cutting long work pieces. They can be used with or without a stop block as an additional side fence. BEVEL CUT - An angle cut made through the face of the workpiece. FENCE - Helps to keep the workpiece from moving when sawing. Scaled to assist with accurate cutting. CROSS CUT - A cut made across the width or grain of the workpiece. COMPOUND CUT -A simultaneous bevel and miter cut. FREEHAND - Performing a cut without using a fence (guide), hold down or other proper device to prevent the workpiece from twisting during the cutting operation. HAND HOLD - For moving the saw when unplugged. SAFETY LOCK-OFF SLIDE SWITCH - Yellow button on handle must be pushed forward to activate the trigger switch. GUM -A sticky sap from wood products. HEEL- LOWER BLADE GUARD - Helps protect your hands from the blade in the raised position, it retracts as the blade is lowered. Misalignment of the blade. KERF - The amount of material removed by blade cut. MITER CUT - An angle cut made across the width or grain of the workpiece. MITER HANDLE - Used to lock and unlock the miter table, and to rotate the saw to a right or left cutting position. RESIN -A stickysap that has hardened. MITER SCALE - To measure the miter angle 0° to 45 ° left, 0° to 45 ° dght. REVOLUTIONS PER MINUTE (RPM) - The number of turns completed by a spinningobject in one minute. MITER SPRING LOCK - Used in combination with the miter handle, it locks the miter saw at a preset positive stop for the desired miter angle. SAW BLADE PATH - The area of the workpiece or table top directly in line with the travel of the blade Or the part of the workpiece which will be cut. MOUNTING HOLES - To mount the miter saw to a stable surface. SET - The distance between two saw blade tips, bent outward in opposite directions to each other. The further apart the tips are, the greater the set. ON/OFF TRIGGER SWITCH - To prevent the tdgger from being accidentally engaged, a lock-off slide switch is provided. To start the tool, push the lock-off slide switch forward and squeeze the trigger. Release the tdgger to stop the miter saw. WORKPIECE - The item being cut. The surfaces of a workpiece are commonly referred to as faces, ends, and edges. 9 ASSEMBLY INSTRUCTIONS IA WARNING I To avoid injury, do not connect this miter saw to the power source until it is completely assembled and adjusted, and you have read and understood this Operators Manual. ASSEMBLE STAND (Fig. A) 1. Unpack all parts and group by type and size. Refer to the parts list on page 32 for correct quantities. 2. Attach one long upper support (4) to top of leg (1) using one carriage bolt (2) and nut (5). NOTE: Do not tighten bolts until stand is propedy aligned (see step #8). 3. Attach other end of long upper support to the top of another leg using one carriage bolt and one nut. 4. Attach one long bottom support (3) to the center of each leg using carriage bolt and nut. This completes the front frame section. 5. Assemble the rear frame section in exactly the same manner. 6. Join the front and rear frame assemblies using two short upper supports (11) and two short bottom supports (10), carriage bolts and nuts. 7. Place all four rubber feet (7) onto each leg. 8. Place the stand on a level surface and adjust it so all legs are contactingthe floor and are at similar angles to the floor. Tighten all bolts. NOTE: Stand should not rock after all bolts are tightened. ASSEMBLE MITER SAW TO STAND 1. Carefully place the miter saw on top of stand. 2. Line up the three mounting holes in the saw base to the stand. 3. Fasten the saw to the stand using the three mounting bolts (12), three washers (13) and three nuts (14). NOTE: Place a washer on each bolt before inserting it into the saw base and through the support, then thread the nut onto the bolt (see Fig. A) 4. Tighten all three nuts. NOTE: DO NOT OVER TIGHTEN THE LOCK NUTS HOLDING SAW TO THE STAND. THIS COULD DAMAGE THE SAW BASE. 12 Fig. A 11 14 5 10 1 ]0 INSTALLING THE MITER HANDLE (FIG. B) 1,Thread the miter handle (1) into the hole (2) located at the front of the miter table. Fig. D Fig. B 2 1 SAW BLADE WRENCH (FIG. C) 1. For convenient storage and prevention of loss, there is a slot (1) in the rear of the cutting head handle (2) for storing the blade wrench (3) when not in use. Fig. C 2 1 Locking When transporting or storing the miter saw, the cutting head should always be locked in the down position. 1. Push the cutting head (3) down to its lowest position, 2, Push the stop latch (2) into the locking hole (4). IMPORTANT: To avoid damage, never carry the miter saw by the switch handle, the cutting arm, or the miter table handle, ALWAYS use the designated carrying handle located on the top of the machine. THE DUST COLLECTION SYSTEM (FIG. E, F) INSTALLING THE DUST COLLECTION ELBOW (FIG. E) 1. Install the larger end of the elbow (1) onto the exhaust port (2). Note: The elbow can be used to attach either the dust bag or a vacuum hose to remove sawdust from the work area. 3 Fig. E CUTTING HEAD (FIG. D) Raising 1. Push down slightly on the cutting handle (1). 2. Pull out the stop latch knob (2). 3.Allow the cutting head (3) to raise to the up position. IA WA ,NGI To avoid injuryand damage to the saw, transport or store the miter saw with the cutting head locked in the down position. Never use the stop latch to hold the cutting head in a down position for cutting operations. IIIIIlllllll 1 2 INSTALLING THE DUST BAG (FIG. F) 1. Squeeze the metal collar wings (2) of the dust bag (1). 2, Place the dust bag neck opening around the exhaust port (3), and release the metal collar wings, Fig. F 2 3 !_ Fig. H INSTALLING THE EXTENSION TABLE (FIG. G) [,_ WARNING 1 To avoid injury or possible damage to the tool, support long work pieces by installingthe extension table to extend the work support surface. IA WARNING I When using extension and stop block on the right side, hold down clamp must also be in right side. Using hold down clamp on the left side during this operation can cause kick-back and serious injury to the operator. NOTE: The extension table is assembled at the factory to be installed on the left side of the saw. If you wish to attach the extension table on the right side, please skip to page 14, Adjusting Extension Table Figure O. 1. Place the table extension rods into the two holes (1) provided in the miter saw base. 2. Insert one Phillips head screw (2) into the hole (3) and tighten to hold the extension table. 3. Loosen the locking knob (4), slide the stop block assembly (5) to the desired location, re-tighten the locking knob (4). Fig. G 2 5 3 7. Locate the arbor lock (5) on the motor, below the miter saw switch handle. (Fig. I) 8. Press the arbor lock, holding it in firmly while turning the blade wrench clockwise. The arbor lock will then engage and lock the arbor. Continue to hold the arbor lock, while turning the wrench clockwise to loosen the arbor bolt. 4 Fig. I 5 REMOVING OR INSTALLING THE BLADE ['_ WARNING I 1. Only use a 10-inch diameter blade. 2. To avoid injury from an accidental start, make sure the switch is in the OFF position and plug is not connected to the power source outlet. REMOVING (Fig. H, I, J) IA WARNING I 1. Unplug the saw from the outlet. 2. Raise the miter saw to its' upright position, 3. Raise the lower clear plastic blade guard (1) to the updght position. (Fig. H) 4, Loosen the cover plate screw (2) with a Phillips screwdriver. 5. Rotate the cover plate (3) to expose the arbor bolt (4). 6. Place the blade end wrench over the arbor bolt. _ I1, . rJ" I!'! 12 IIII INSTALLING THE HOLD-DOWN CLAMP (Fig. K) REMOVING - cont'd 9. Remove the arbor bolt and washer (4), the outer blade collar (6), and the blade (7). Do not remove the inner blade collar. (Fig. J) NOTE: Pay attention to the pieces removed, notingtheir position and direction they face. Wipe the blade collars clean of any sawdust before installinga new blade. I_1, WARNING I When using the stop block on the extension tabte, place the hold down clamp on the same side. Using the clamp on the opposite side can cause kick-back and serious injuryto the operator. 1. Place the Hold-down Clamp (1) on the desired clamp hote (2). Fig. K Fig J _____ INSTALLING A BLADE (Fig. H, I, J) IA WARNING I Un-plug the miter saw before changing/installingthe blade. 1. Install a 10" blade, making sure the rotation arrow on the blade matches the clockwise rotation arrow on the upper guard, and the blade teeth are pointing downward. 2. Place the outer blade collar (6) against the blade and on the arbor. Thread the arbor bolt (4) on the arbor. (Fig. J) IMPORTANT: make sure the fiats of the blade collars are engaged with the flats on the arbor shaft. Also, the fiat-side of the arbor collar must be placed against the blade. 3. Place the blade wrench on the arbor bolt. 4. Press the arbor lock (5), holding it in firmly while turning the blade wrench counterclockwise. When it engages, continue to press the arbor lock in, while tightening the arbor bolt securely. (Fig. I) 5. Rotate the cover plate (3) back to its original position until the slot in the cover plate engages with the cover plate screw (2). Tighten the screw with a Phillips screwddver. (Fig. I) 6. Lower the blade guard (1). (Fig. J) 7. Be sure the arbor lock is released so the blade turns freely by spinning the blade until the arbor lock disengages. ADJUSTMENTS I_lk WARNING To avoid injuryfrom an accidental start, make sure the switch is in the OFF positionand the plug is not connected to the power source outlet. ADJUSTING FENCE SQUARENESS (Fig. L) 1. Loosen the four fence locking screws (1). 2. Position the cutting head in the lower locked position. Using a square, lay the heel of the square against the blade, and the rule against the fence (2) as shown. Check to see if the fence is 90 ° to the blade. 3. Adjust the fence 90° to the blade and re-tighten the four fence locking screws. CAUTION: If the saw has not been used recently, recheck blade squareness to the fence and readjust if needed. IA WARN,NG I Fig. L • Always make sure the unit is unplugged. To avoid injury, never _Jsethe saw without the cover plate secure in place. It keeps the arbor bolt from falling out if it accidentally loosens, and helps prevent the spinning blade from coming off the saw. • Make sure the collars are clean and properly arranged. Lower the blade into the lower table and check for any contact with the metal base or the turn table by spinningthe blade manually. '11 n I 13 I- r MITER SCALE (FIG. M) The miter scale on the table has nine of the most common angle settings with positive stops at 0°, 15°, 22.5°, 31.6° and 45°. These positive stops positionthe blade at the desired angle quickly and accurately. Miter Angle Pointer Adjustment (Fig. M): 1. Place the miter table at the zero position making sure the positive stop locking lever snaps into position. 2. Loosen the miter angle indicator screw (3) and adjust the indicator to the "0" mark on the miter scale. 3. Tighten miter angle indicator screw. Positive Stop Miter Angle Adjustment: 1. Unlock the miter table by pressing down on the positive stop locking lever (1). 2. While holding the positive stop lockinglever down, grasp the miter handle (2) and move the miter table left or dght to the desired angle. 3. Release the positive stop locking lever. ADJUSTING AUXILIARY FENCE (Fig. N) 1.First make sure the miter saw fence is square to the blade (see Adjustments Fig. L} and adjust if necessary. 2. Loosen the two fence screws (1). 3. Using a square, lay the heel of the square against the blade, and the rule against the auxiliary fence (2) as shown. Check to see if the fence is 90 ° to the blade. 4.Adjust the auxiliary fence 90 ° to the blade and in line with the Miter Saw Fence, retighten the two fence screws (1). CAUTION: If the saw has not been used recently, recheck blade squareness to the fence and readjust if needed. Fig. N Quick-Cam Miter Table Lock Operation: If miter angles required are NOT one of the nine positive stops noted above, the miter table can be locked at any angle between these positive stops by using the Miter Quick-Cam table lock. 1. Unlock the miter table by pressing down on the positive stop locking lever (1). 2. While holdingthe positive stop locking lever down, grasp the miter handle (2) and move the miter table left or right to the desired angle. 3. Release the positive stop lockinglever. 4. Press down on the Miter Quick-Cam lockinglever (4) until it locks the miter table in place. NOTE: The miter Quick-Cam locking lever should lock the table and prevent it from moving. If adjustment is needed, see next step below. Quick-Cam Miter Table Lock Adjustment: 1. Press down and lock the Quick-cam locking lever (4). This provides room to fit the wrench into position. 2. Loosen the Quick-Cam lock nut (5) using a 13 mm wrench and release the Quick-cam lock. 3. Turn the adjusting screw (6) either in or out until the locking lever firmly locks the miter table in place. 4. Tighten Quick-Cam lockingnut. 1 ADJUSTING EXTENSION TABLE (FIG. O) If the extension table is not flush with the miter table, adjust the four knobs (1) accordingly until it is level with the table. NOTE: To reverse the placement of the side extension table: 1. Loosen and remove the locking knob (2) & tab (3). 2. Remove and rotate 180 ° the entire extension rod assembly & replace into position. 3. Reassemble the locking knob and tab, re-tighten in position. Fig. O Fig. M 6 5 _ !l!11 II!ll ....... 4 2 14 IIII CUTTING ARM TRAVEL (FIG. P) Cutting head downward travel adjustment - Cont'd Cutting arm pivot adjustment 4 Fig. Q The up and down pivot movement of the cutting arm should be free of side-to-side movement for accurate miter cuts. It should be tight enough to prevent side-to-side movement while still allowing the arm to move freely up and down when cutting. 1. Before attempting this adjustment, move the sliding fence as far to the LEFT as possible(See "SLIDING FENCE" on Page 20). 2. If cutting arm (1) is too loose, turn the cutting arm adjusting nut (2) clockwise using a 19 mm wrench. 3. If cutting arm is too tight, turn the cutting arm adjusting nut counter clockwise. Fig. P BEVEL STOP ADJUSTMENT (Fig. R & S) Before each cutting operation, check the position of the blade to make sure it does not contact any metal surface. If it contacts any metal surface, the depth of movement can be adjusted. [A To avoid injury from unexpected starting or electrical shock, turn the switch OFF and remove the power cord from the power source. 90° CUTTING HEAD DOWNWARD TRAVEL ADJUSTMENT 1. (Fig. Q) Before each cutting operation, check the position of the blade to make sure it does not contact any metal surface. If it contacts any metal surface, the depth of movement can be 2. adjusted. IAw...,.GI 3. To avoid injury from unexpected starting or electrical shock, turn the switch OFF and remove the power cord from the power source. 1. Before attempting this adjustment, move the sliding fence as far to the LEFT as possible (see "SLIDING FENCE" on Page 20). 2. Lower the blade as far as possible. 3. Loosen lock nut (3) using a 10 mm wrench. 4. Bevel adjustment (Fig. R) Loosen the bevel lock handle (1) and tilt the cutting arm completely to the dght. Tighten the bevel lock handle. Place a combination square (2) on the miter table with the rule against the table and the heel of the square against the saw blade. If the blade is not square with the miter table, loosen the bevel lock handle, turn the bevel angle adjusting screw (3) in or out with a 10mm wrench from underneath the table until the blade is square with the table. Tighten bevel lock handle. Tum the adjusting screw (4) IN to lower the maximum cuffing depth and OUT to raise the maximum cutting depth. 4. . 6. Lower the blade to the new maximum depth and manually rotate the blade with a wooden block to make sure it does not contact any metal surface. NOTE: Repeat adjustment if the blade is contact any metal surface. Fig. R Tighten lock nut. 15 II t MOUNTING THE MITER SAW (Fig. T) NOTE: Use this for reference if you are not mounting saw to the stand provided. BEVEL STOP ADJUSTMENT (Fig. R & S) - Cont'd 90 ° Bevel indicator (Fig. S) 5. When the blade is exactly 90 ° to the table loosen the LEFT bevel indicator screw (5) using a Phillips screwdriver. To avoid injury from unexpected saw movement: • Before moving the saw, disconnectthe power cord from the outlet, and lock the cutting arm in the lower position using the stop latch. 6. Adjust the LEFT bevet indicator (6) to the "0" mark (7) on the bevel scale and retighten the screw. NOTE: The stop latch is for carrying or storing the tool. It is NOT to be held when cutting. 45 ° Bevel adjustment • Never carry the miter saw by the power cord or by the switch handle. Carrying the tool by the power cord could 7. Unlock the bevel lock handle and tilt the cutting arm as cause damage to the insulationor wire connections far to the left as possible. resulting in electric shock or fire. • To avoid injuryfrom flying debris, do not allow visitors to 8. Using a combination square, check to see if the blade stand behind or around the saw. angle is 45 ° to the table. • Place the saw on a firm, level work-surface where there is room for handling and properly supporting the workpiece. 9, If the blade is not at 45 ° to the miter table, turn the bevel • Bolt or clamp the saw to its support. angle adjusting screw (4) in or out with a 10mm wrench Place the saw in the desired location, either on a work from underneath the table until the blade is at 45° to the bench or recommended leg set. The base of the saw has miter table. three mounting holes (1). For stationary use, fasten the saw to a workbench. 10. Tighten the bevel lock handle. For portable use, fasten the saw to a 3/4" piece of plywood. This mounting board can then be clamped to a secure 45 ° Bevel indicator (FIG. S) surface. 11. When the blade is exactly 45 ° to the table, loosen the RIGHT bevel indicator screw (8) using a #2 Phillips screwdriver. Fig. T 12. Adjust RIGHT bevel indicator (9) to the 45° mark (10) on the bevel scale and retighten the screw, Fig. S 9 lO stationary tJse,_ (1) \ (_) I_! __ _..,, 16 .......... 'l IIIIII _ I_1II"'llllll 11 W SAFETY INSTRUCTIONS OPERATION Keep all guards in place, in working order and proper adjustment. If any part of this miter saw is missing, bent damaged or broken in any way, or any electrical parts don't work, turn the saw off and unplug it. Replace damaged, missing, or defective parts before using the sew again. FOR BASIC SAW BEFORE USING THE MITER SAW WARN'NG 1 To avoid mistakes that could cause sedous, permanent injury, do not plug the tool in until the following steps are completed: • • • • • Completely assemble and adjust the saw, following the instructions. (ASSEMBLY AND ADJUSTMENTS) Learn the use and functionof the ON/OFF switch, lock-off switch, upper and lower blade guards, stop latch, bevel lock handle, and cover plate screws. Review and understand all safety instructionsand operating procedures in this Operator's Manuai.(SAFETY & OPERATIONS) Review the MAINTENANCE and TROUBLESHOOTING GUIDE for your miter saw. To avoid injuryor possible death from electrical shock: Make sure your fingers do not touch the plug's metal prongs when plugging or unplugging your miter saw. (ELECTRICAL REQUIREMENTS AND SAFETY) Maintain tools with care. Keep the miter saw clean for best and safest performance. Follow instructions for lubricating. Don't put lubricants on the blade while it's spinning. • USE ONLY RECOMMENDED ACCESSORIES • Consult the ACCESSORIES and ATTACHMENTS section of this Operators Manual for recommended accessories. Follow the instructionsthat come with the accessory. The use of improper accessories may cause risk of injuryto persons. • Compare the direction of rotation arrow on the guard to the direction arrow on the blade. The blade teeth should always point downward st the front of the saw. Choose the correct 10 inches diameter blade for the material and the type of cutting you plan to do. Do not use Thin Kerf blades, Make sure the blade is sharp, undamaged and properly aligned. With the saw unplugged, push the cutting arm all the way down. Hand spin the blade and check for clearance. Tilt the miter head to a 45 ° bevel and repeat the test. BEFORE EACH USE Inspect your saw, • Disconnect the miter saw. To avoid injuryfrom accidental starting, unplug the saw before any adjustments, including set-up and blade changes. Remove all adjusting wrenches from the tool before turning it on. • Make sure the blade and arbor collars are clean. • Make sure all clamps and locks are tight and there is no excessive play in any parts. KEEP YOUR WORK AREA CLEAN Cluttered areas and benches invite accidents. Tighten the arbor bolt. Tighten the cover plate screw. Check for damaged parts. Check for: • Alignment of moving parts • Damaged electdc cords • Bindingof moving parts • Mounting holes • Function of arm return spdng and lower guard: Push the cutting arm all the way down. then let it dse until it stops. The lower guard should fully close. Follow instructions in TROUBLESHOOTING GUIDE for adjustment. • Other conditions that may affect the way the miter saw works. [_IL WARNING I To avoid burns or other fire damage, never use the miter saw near flammable liquids,vapors, or gases. • Plan ahead to protect your eyes, hands, face and ears. • Know your miter saw. Read and understand the Operator's Manual and labels affixed to the tool. Leam its application and limitations as well as the specific potential hazards peculiar to this tool. To avoid injuryfrom accidental contact with moving parts, don't do layout, assembly, or setup work on the miter saw. • Avoid accidental starting Make sure the switch is OFF before plugging the miter saw into a power outlet. PLANYOURWORK • Use the right tool. Don't force a tool or attachment to do a job it was not designed to do. Use a different tool for any workpiece that can't be held in a solidly braced, fixed position. • • • CAUTION: This machine is not designed for cutting ferrous metals (steel, iron, and iron-based metals.) Use this miter saw to cut only wood, wood-like products, or soft metals like aluminum. Other material may shatter, bind the blade, or create other dangers. Remove all nails that may be in the workpiece to prevent sparking that could cause a fire. Make sure there are no gaps between the workpiece, fence and table that will let the workpiece shift during the cut. Keep the cut off piece free to move sideways after it is cut off. Otherwise, it could get wedged against the blade and thrown, possiblycausing injury. Only the workpiece should be on the saw table. Secure work. Use clamps or a vise to help hold the work when it's practical USE EXTRA CAUTION WITH LARGE OR ODD SHAPED WORKPIECES. • DRESS FOR SAFETY • Any power tool can throw foreign objects into the eyes. This can result in permanent eye damage. Everyday eyeglasses have only impact resistant lenses and are not safety glasses. Glasses or goggles not in compliance with ANSI Z87.1 could seriously injure you when they break. • Do not wear loose clothing, gloves, neckties or jewelry (rings, watches). They can get caught and draw you into moving parts. • Wear non-slip footwear. • Tie back long hair. • Roll long sleeves above the elbow. • Noise levels vary widely. To avoid possible hearing damage, wear ear plugs when using any miter saw. • For dusty operations, wear a dust mask along with safety goggles. • • INSPECT YOUR WORKPIECE Make sure there are no nails or foreign objects in the part of the workpiece being cut. Plan your work to avoid small pieces that may bind, or that are too small to clamp and get a solid grasp Use extra supports (tables, sawhorses, blocks, etc.) for workpieces large enough to tip. Never use another person as a substitute for a table extension, or as an additional supportfor a workpiece that is longer or wider than the basic miter saw table, or to help feed, support, or pull the workpiece. Do not use this sew to cut small pieces. If the workpiece being cut would cause your hand or fingers to be within 7-1/4 inches of the saw blade the workpiece is too small. Keep hands and fingers out of the "no hands zone" area marked on the saws table. When cutting odd shaped workpieces, plan your work so it will not bind in the blade and cause possible injury. Molding, for example, must lie fiat or be held by a fixture or jig that will not let it move when cut. Properly support round material such as dowel rods, or tubing, which have a tendency to roll when cut, causing the blade to "bite". To avoid injury,follow all applicable safety instructions, when cutting non-ferrous metals: • Use only saw blades specificallyrecommended for non-ferrous metal cutting. • Do not cut metal workpieces that must be hand held. Clamp workpieces securely. • Cut non-ferrous metals only if you are under the supervision of an experienced person. on. Plan the way you will grasp the workpieca from start to finish. Avoid awkward operations and hand positions. A sudden slip could cause your fingers or hand to move into the blade, DON'T OVER-REACH WHEN SAW IS RUNNING IAW,.N,NO 1 Keep good footing and balance. Keep your face and body to one side, out of the line of a possible kickback. NEVER stand in the line of the blade. Don't allow familiarityfrom frequent use of your miter saw to result in a careless mistake. A careless fraction of a second is enough to cause a severe injury. Never cut freehand: • Brace your workpiece firmly against the fence and table stop so it will not rock or twist during the cut. • Make sure there is no debris between the workpiece and the table or fence. Before cutting, if the sew makes an unfamiliar noise or vibrates, stop immediately. Tum the saw OFF Unplug the sew. Do not restart until finding and correcting the problem. 18 BODY AND HAND POSITION (FIG. U) Proper positioningof your body and hands when operating the miter saw will make cutting easier and safer. Never place hands near the cutting area. Place hand at least 7-1/4" away from the path of the blade. Hold workplece firmly against the fence to prevent movement toward the blade. Keep hands in position until the trigger has been released and the blade has completely stopped. Before making a cut, with the power switch in the OFF position bring the saw blade down to the workplece to see the cutting path of the blade. • Keep children away. Keep all visitors a safe distance from the miter saw. Make sure bystanders are clear of the miter saw and workplece. • Don't force the tool. It will do the job better and safer at its designed rate. Feed the saw into the workpiece slowlywith a firm downward motion. Before freeing jammed TURNING THE SAW ON (FIG. V) To reduce the likelihoodof accidental starting, a thumb activated lock-OFF switch is located on top of the switch handle. The lock-OFF switch (1) must be pushed forward before the trigger switch (2) can be activated and the miter saw started. IAw'R"'NGI Make the switch child-proof. Insert a padlock through the hole (3) in the trigger switch and lock it. This will prevent children and other unauthorized users from turning the switch ON. THREE POSITION ROTATING HANDLE (FIG. V) The handle of the miter saw has been designed to rotate and lock at three different positive stops; 0°, 45 °, and 90 ° for operator convenience. To rotate the handle: 1. Unlock the handle looking lever (4) by pulling it toward you. 2. Pull the handle lockinglatch (5) toward you and hold in position. 3. Rotate the handle to 0°, 45 ° or 90° and release the handle locking latch. NOTE: After releasing the handle locking latch, rotate the handle left and right to make sure the latch engages intothe positive locking position. 4. Lock the handle locking lever by pushing it IN toward the rear of the handle. NOTE: The tightness of the carry handle can be adjusted by the followingsteps: 1. Loosen the four screws (6), and remove the handle seat (7). 2. If the rotating handle (8) is too loose or tight, adjust the nut (9) clockwise or counter clockwise with a 13mm wrench. material: • Turn switch OFF. • Unplug the miter saw. • Wait for all moving parts to stop. After finishing a cut: • Hold the upper cutting head down. • Release the switch, and wait for all moving parts to stop before moving your hands. • if the blade doesn't stop within 6 seconds, unplug the saw and follow the instructionsin THE TROUBLESHOOTING GUIDE section before using the saw again. Fig. U Fig. V 6 6t/2" 61/2" 19 SLIDING FENCE (FIG. W) BEVEL CUT (Fig. Y) I_ WARNING] The sliding fence must be fully extended to the left when making any miter or bevel cuts other than 0 °. Failure to fully extend the sliding fence will not allow enough space for the blade to pass through, which could result in serious injury. At extreme miter or bevel angles the saw blade may also contact the fence. The sliding fence must be fully extended to the left when making any compound cuts. Failure to fully extend the sliding fence will not allow enough space for the blade to pass through, which could result in serious injury. Failure to extend the fence may cause the saw blade to make contact with the fence. When a bevel cut is required, loosen the bevel lock handle (1). Tilt the cutting head to the desired angle as shown on the bevel scale (2). The blade can be positioned at any angle, from a 90 ° straight cut (0° on the scale) to a 45 ° left bevel. Tighten the lock handle (I) to lock the cutting head in position. Positive stops are provided at 0° and 45 °, 1. Unlock the fence cam locking lever (1) by pushing it toward the rear of the machine. 2. Fully extend the fence by sliding it out as far as possible (2). 3. Lock the fence cam rock by pushing it IN toward the fence. NOTE: When transporting the saw, always secure the sliding fence in the collapsed position (toward the saw blade). Fig. Y Fig, W ==_2 COMPOUND CUT (Fig. Z) I MITER CUT (Fig. X) 1. 2. 3. WARNINGI The sliding fence must be fully extended to the left when making any compound cuts. Failure to fully extend the sliding fence will not allow enough space for the blade which could result in serious injury. At extreme compound angles the saw blade may also contact the fence. 1. Fully extend the fence by sliding it out as far as possible, See "SLIDING FENCE" on this page. Set the desired bevel angle using the bevel lock handle (1) see "BEVEL CUT" above. Set the desired miter angle using the positive stop locking lever (3) or the Quick-Cam table lock. See "MITER CUT" on this page. Unlock the miter table by pressing down on the positive stop locking lever (2). While holdingthe positive stop locking lever down; grasp the miter handle (1) and move the miter table left or dght to the desired angle. Release the positive stop locking lever, making sure it engages the positive stop. Slight movement of the miter handle left or rightwill ensure positive stop engagement. NOTE: Positive stops at provided at 0°, 15°, 22,5 °, 31.6° and 45 ° right and left. NOTE: If the miter angle required is NOT one of the positive stops noted above, the miter table can be locked at any angle between these positive stops by using the Quick-Cam table lock (see Page 14). Fig. Z 2O CUTTING BOWED MATERIAL (Fig. AA) A bowed workpiece must be positionedagainst the fence before cutting. Do not position workpiece incorrectly or try to cut the workpiece without the support of the fence, This will cause the blade to bind and could result in personal injury. Fig. AA IA WAR.I.GI When making multiple or repetitive cuts that result in cot-off pieces of one inch or less, it is possible for the saw blade to catch the cut-off piece and throw it out of the saw or into the blade guard and housing, possibly causing damage or injury.To minimize this risk, turn off the machine, wait until the blade comes to a complete stop, unplug the unit & remove the cut pieces. AUXlLARY WOOD FENCE (Fig. CC) Holes are provided in the saw fence to attach an auxiliary wood fence (this provides additionaldepth of cut). This fence should be constructed of straight auxiliary wood approximately 3/4 inch thick by 2-1/2 inches high by 18-1/2 inches long.Attach the wood fence securely and make a full depth cut to make a blade slot. Check for interference between the wood fence and the lower blade guard. Adjust if necessary. WORKPIECE SUPPORT (Fig. BB) Long pieces need extra support. The support should be placed under the workpiece. Keep your hand holdingthe workpiece positioned 7-1/4" or more away from the blade. The support must let the workpiece lay flat on the work table during the cutting operation. NOTE: When mounted on a fiat surface, the miter saw table is 3-1/8 inches high. Fig. CC Fig. BB Cutting capacity with auxiliaryfence Crosscut Miter 45°R. & L, 3-1/8" . 21 IIII _-1/2"x 3-1/2" _-1/2"x 2" Bevel 45°L 2"x 3-112" Compound 45°L.,45°R & L 2"x 2" cu'n'ING BASE MOLDING (Fig. FF) Base moldings and many other moldings can be cut on a compound miter saw. The setup of the saw depends on molding characteristics and applications, as shown. Perform practice cuts on scrap material to achieve best results: 1.Always make sure moldings rest firmly against the fence and table. Use hold-down or C-clamps, whenever possible, and place tape on the area being clamped to avoid marks. 2. Reduce splinteringby taping the cut area prior to making the cut. Mark the cut line directly on the tape. 3. Splinteringtypically happens due to an incorrect blade application or use of thin kerf blades. CUTTING A DIMENSIONAL 4X4 WITH ONE CUT (Fig. DD) A dimensional 4x4 may be cut in half with one cut by attaching an auxiliary wood fence of 3/4 inch thick board. See =AUXILIARY WOOD FENCE" fig. CC on page 21. Fig. DD Auxiliary fence 14_..... 3.1/,2"._._..._1 Mitre s_t _ _ "_--1F2" Fig. FF Mitre saw table I Miter saw table VERTICAL MITER CUTTING (Fig. EE) To make a miter cut in a 2x4 workpiece (1-5/8" x 3-1/2") in the vertical position on edge, a spacer such as the auxiliary wood fence described in the "AUXILIARY WOOD FENCE" figure CC on page 21 is required. Miler at 45°, bevel at O° Fig. EE '1 3-1!2" Mitre sa_ I Mitre saw table I 22 J Miter saw table Miler at 0o, bevel at 45° CUTTING CROWN MOULDING (Fig. GG, HH) Your compound miter saw is suited for the difficult task of cutting crown molding. To fit properly,crown molding must be compound-mitered with extreme accuracy. The two surfaces on a piece of crown molding that fit fiat against the ceiling and wall are at angles that, when added together, equal exactly 90". Bevel/Miter Settings KEY REVEL MITRE SETT NG SETT NG Inside comer-Left side IL 33.9* 31Right 6° 2. table RIGHTagainst° 31,6. 1. Miter fence.P°siti°n topset of at molding 3. LEFT side is finished piece. Inside comer-Right side IR 33.9 = 31Left 6° 2. Mitre table set atofLEFT 31.6 °. 1. against PositiOnfence.bOttom molding 3. LEFT side s finished piece. Outside corner-Left side OL 33.9 = 31 Left "6° OR 33.9 ° 31.6 ° Right 2. Mitre table set atofLEFT 31.6*. 1. against Positionfence, bottom molding 3. RIGHT side is finished piece. Outside comer-Right side 1. Position top of molding against fence. 2. Mitre table set at RIGHT 31.6". 3. RIGHT s de s finished piece. Most crown moldings have a top rear angle (the section that fits flat against the ceiling) of 52° and a bottom rear angle (the section that fits fiat against the wall) of 38 °. In order to accurately cut crown molding for a 90 ° inside or outside corner, lay the molding with its broad back surface fiat on the saw table. When setting the bevel and miter angles for compound miters, keep in mind that the angles for crown molding are very precise and difficultto set exactly. Since it is very easy for these angles to shift slightly,all settings should be tested on scrap molding. Fig. GG TYPE OF CUT __ F e n c e Miter saw table Fig. HH Settings for standard crown molding lying fiat on compound miter saw table i1=111 Compound cut crown moldings IIII IIIII23 I!1 LOWER BLADE GUARD MAINTENANCE Do not use the saw without the lower blade guard, The lower blade guard is attached to the saw for your protection. Should the lower guard become damaged, do not use the saw until the damaged guard has been replaced, Develop a regular check to make sure the lower guard is working properly.Clean the lower guard of any dust or buildup with a damp cloth. DANGER Never put lubricants on the blade while it is spinning. IAWARNING I To avoid fire or toxic reaction, never use gasoline, naphtha acetone, lacquer thinner or similar highly volatile solvents to clean the miter saw. CAUTION: Do not use solvents on the guard. They could make the plastic "cloudy"and brittle. IAWAR.,.G I J,WARN,NG J To avoid injuryfrom unexpected starting or electrical shock, unplug the power cord before working on the saw, When cleaning the lower guard, unplug the saw from the power source receptacle to avoid unexpected startup. IA W NINGI SAWDUST Periodically,sawdust will accumulate under the work table and base. This could cause difficultyin the movement of the worktable when setting up a miter cut. Frequently blow out or vacuum up the sawdust. For your safety, this saw is double-insulated. To avoid electrical shock, fire or injury,use only parts identicalto those identified in the parts list. Reassemble exactly as the original assembly to avoid electrical shock. REPLACING CARBON BRUSHES (FIG. II) The carbon brushes furnished will last approximately 50 hours of runningtime, or 10,000 ON/OFF cycles. Replace both carbon brushes when either has less than 1/4" length of carbon remaining, or if the spring or wire is damaged or burned. To inspect or replace brushes, first unplug the saw. Then remove the black plastic cap (1) on the side of the motor (2). Remove the cap cautiously, because it is spring-loaded. Then pull out the brush and replace. Replace the other side in the same manner. To reassemble, reverse the procedure. The ears on the metal end of the assembly go in the same hole the carbon part fits into. Tighten the cap snugly, but do not overtighten. NOTE: To reinstall the same brushes, first make sure the brushes go back in the way they came out. This will avoid a break-in period. Fig. II 14WARN,NG I If blowing sawdust, wear proper eye protection to keep debris from entering eyes. LUBRICATION All the motor bearings in this tool are lubricated with a sufficient amount of high grade lubricantfor the life of the unit under normal operating conditions; therefore, no further lubrication is required. Lubricate the Following as Required: Chop pivoP.,light machine oil or aerosol will penetrate from the ends of the junction points.A qualified service technician can remove the pivot upstop to relieve tension, and the 2 metric set screws holdingthe shaft, in order to drive the shaft about 3/4" right. Exposed surfaces are lubricated with automotive type oil. Central pivot of plastic guard: Use light household oil (sewing machine oil ) on metal-to-metal or metal-to-plastic guard contact areas as required for smooth, quiet operation. Avoid excessive oil, to which sawdust will cling. 2 Link: (which actuates the lower guard movement) may be oiled at the rear pivot, greased at ball bearing contact, and oiled where the link actuates the acetyl roller of the lower guard, if the down chop motion is hard to start. ......... III 24 i_ WARNING I To avoid injury from accidental starting, always turn the switch OFF and unplugthe tool before moving, replacing the blade or making adjustments. Consult your Sears Sewice Center if for any reason the motor will not run. TROUBLESHOOTING GUIDE - MOTOR PROBLEM PROBLEM CAUSE SUGGESTED CORRECTIVE ACTION Brake does not stop blade within 6 seconds. 1. Motor brushes not sealed or lightly sticking. 2. Motor brake overheated from use of defective or wrong size blade or rapid ON/OFF cycling. 3. Arbor screw loose. 4. Other. 1. Fuse 2. Brush worn. 3. Other. 1. Brushes Worn/Damaged I. Inspect / clean / replace brushes, See MAINTENANCE section. Motor does not start Brush spark when switch released. TROUBLESHOOTING 2. Use a recommended blade. Let cool down. 3. Retighten. 4. Contact Sears Service Center. 1.15-Amp time delay fuse, or circuit breaker. 2. See MAINTENANCE section. 3, Contact Sears Service Center. 1. Replace Brushes (See Maintenance). GUIDE - SAW OPERATION PROBLEM PROBLEM CAUSE SUGGESTED CORRECTIVE ACTION Blade hits table. 1. Miselignment. 1. See ADJUSTMENT section. Angle of cut not accurate. Can't adjust miter. 1. Miter table unlocked. 1. Loose pivot points. 1. Use Miter Quick Look. See OPERATION Section. 2. Vacuum or blow out dust, WEAR EYE PROTECTION. 1. See ADJUSTMENT Section. 1. 2. 1. Contact Sears Service Center. 2. Contact Sears Service Center. Cutting arm wobbles. Cutting arm won't fully raise, or blade guard won't fully close. Blade binds, jams, bums wood. Sew vibrates or shakes. 2. Sawdust under table. Part failure. Pivot spring not replaced propedy after service. 3. Sawdust build-up. 1. Improper operation. 2. Dull blade. 3. Improper blade size. 4. Warped blade. 1 .Saw blade not round. 2.Saw blade damaged. 3.Saw blade loose. 4.Other. 3. Clean and lubricate moving parts. 1. See BASIC SAW OPERATION section. 2. Replace or sharpen blade. 3. Replace with 10" diameter blade. 4, Replace blade. 1 .Replace blade, 2.Replace blade. 3. Tighten arbor bolt, 4,Contact Sears Service Center. 25 10" MITER SAW PARTS LIST MODEL NO. 137.242760 When servicing use only CRAFTSMAN replacement parts. Use of any other parts may create a HAZARD or cause product damage. Any attempt to repair or replace electrical parts on this mitre saw may create a HAZARD unless repair is done by a qualified service technician. Repair service is available at your nearest Sears Service Centre. Always order by I.D. Number PARTS LIST FOR SCHEMATIC A I.D. No. 0KOW 0810 0813 Description Size HEX. HD. SC REVV & WASHER M6X1.0-25 ARM-MITER COIL SPRING Qt,/ I.D, NO. Description Size 2 OJ7K FLAT WASHER 1 1 0KQZ NUT CHUCK 10X20-2 M10X1,5 T=10 1 OJ4R FLAT WASHER 10X20-3 1 LOCKING HANDLE ASS_( 0KCX CR. RE, PAN HD. SCREW MSX0 B*10 4 0CQH 0J5A FLAT WASHER 5X16-2 4 0K2N HEX.SOCKET 082G ASSIST-FENCE HD.CAP SCREWS Qty 1 1 M8X1,25-25 1 1 0817 TABLE 1 0819 LOCKING HANDLE ASS'Y 1 20S3 LOCKING HANDLE ASS"( 081A PLASTIC SLEEVE 1 0K2W HEX SOC HD. CAP BOLT 1 0S2V LOCKING HANDLE ASS"( 1 1 082W CAUTION LABEL 1 3 0JAF TOOTH WASHER 1 0JBH 22SX DISC SPRING WASHER HANDLE 1 1 22SP PLATE 2 22SL AUXILIARY TABLE 1 22SW ASSIST-FENCE 1 22SR SUPPORT ROD 2 22SN LOCKING TAB 1 22T3 STOP BLOCK 1 20X3 KNOB 4 0KDL CR. RE. PAN HD, SCREW M5xB,B*18 1 0KTF CR. RE. ROUND WASHER HD. SCREW M5x0.B*8 4 0JPD HEX. HD. BOLT M6x1.0-16 1 0J4U FLAT WASHER _6x1B*l.5 1 21DZ KNOB 0K7K CR. RE ROUND WASHER HD. SCREW 0KDR CR, RE. PAN HD. SCREVV 081D N_nl 0KCX M5XO.5-10 F POINTER CR, RE. PAN HD SCREW MSX0 8-8 081G FOLLOWER PLATE 3 081J TABLE INSERT 1 0KB5 CR. RE. PAN HD. TAPPING SCREW M4X18-10 TILTING SCALE 1 203Y BASE 1 SHAFT 01(24 HEX. SOC. HD CAP SCREW 081V SUPPORT 1 MSX1.25-35 2 1 0JTR FLAT WASHER 112X1o3164 1 0KR0 NUT CHUCK M12Xl.75 1 0D7Z T=12 KNOB*HANDLE 1 OKMS HEX. NUT M6X1.0 T=5 1 0JPE HEX. HD BOLT M6X1.0-20 1 0JMM OD7W O-RING ROD 1 0820 FENCE 1 BK2S HEX. SOC. HD. CAP SCREW M8X1.25-45 2 0JQM HEX. HO. BOLT M6X1 .B*30 2 0JQT HEX. HD. BOLT M10X1,B*75 1 0822 BRACKET-TILT DRWE SCREW 0825 HEX, HD. BOLT 0KDR CR. RE. PAN HD. SCREW M6xl,0-12 2 1 2,3-5 2 1 M5X0.B*10 2 0827 NEEDLE POINTER 2 0828 ROTATION SLIDE PLATE 1 082C ANGLE REGULATOR 1 _"11" .......... 1 1 BRACKET STOP 0KBY 2 4 081L 0DTX 1 M5X0.B*16 26 _ ]1 II1'1 bo / / / .// _/.. i i i<i\ _ o_ .,.-.... ......oj,,.--i _. o= o_sA • \_,.... ..... ..../) o• _--os,A I I o_ow_ .0s2v or "_ .......... ,__,.,Jj--os2_" o 10" COMPOUND PARTS MITER LIST FOR MODEL NO. 137.242760 SAW SCHEMATIC B I.D. No. Description 0DVJ WRENCH Size HEX 0JZN HEX WASHER HD. BOLT 0DTZ ARBOR 0BAG BLADE M8X1.25-20 COLLAR Qty I.D. No. Description Size 1 083Z CLAMP-CORD 1 0QQ1 GUARD'CORD 2 OKB7 CR. RE. PAN HD. SCREW 1 OKUX TERMINAL Qty 1 1 M4X18-25 2 1 0831 SHAFT SLEEVE 1 0L8A POWER CABLE 0087 TORSION 1 0K42 CR. RE. PAN HD. SCREW M6XI.O-25 3 1 0KBC CRRE. PAN HD. TAPPING SCREW MSX10025 4 1 0CKS SPRING WIRE 1 0841 HANDLE I HANDLE SEAT 1 SPRING 1 0QYX MOTOR OK7Z CR. RE, TRUSS HD. ROUND NECK SCREW 0D8A LEVER 0J4E FLAT WASHER 6X13-1 1 084C 0K5C CR. RE. COUNT HD. SCREW M6X1.0016 1 084D HANDLE SEAT 1 0DED COLLAR 1 084F CLAMP HANDLE 1 8SU0 PC'GUARD 1 OJBZ PIN 1 0DER CAUTION LABEL 1 084H BOLT 1 0KMS HEX. NUT I 084J CUSHION 1 0DHT SPRING GUARD 1 0JB3 WAVE WASHER 0K56 CR. RE. COUNT HD. SCREW 1 084K SET PLATE 1 0S4X HOUSING ASS'Y 1 0KQY NUT CHUCK 1 3 084M SPRING PLATE 2 OKA6 CR. RE. TRUSS HD. TAPPING SCREW 1 OKTT CABLE CLAMP MBX1.0014 ASS'Y M6X1.0 T=8 OKE7 CR. RE. PAN HD. TAPPING SCREW M4X10016 0KD6 CR. RE. PAN HD. SCREW M4X0.7-8 0DBS CHIP PLATE ODT RUBBER PAD 0KTZ CR. RE. TRUSS HD. ROUND NECK SCREW 23E1 TRADE-MARK OKQX NUT CHUCK 0JZF HEX, SOC. SET SCREW 0CV5 1 8,2X18-2.0 1 1 MSX12-10 1 1 I 084Q COMPRESSION 1 0JET E -RING 1 1 084S TILTING SCALE 1 M6X1.0 T=6 1 OKWT LEAD WIRE ASS'Y 1 M6Xl.0-10 2 0STZ TRADE-MARK LABEL DUST-BAG ASS'Y 1 0J53 M6X1.0°14 LABEL SPRING FLAT WASHER 1 1 8.2X18-2.0 1 0D99 SHIM 1 084V ELBOW 1 ODA ANCHOR BLOCK 1 OCM3 VISE ASS'Y 1 0JUK HEX. SOC. HD. CAP BOLT 1 0J6G FLAT WASHER 1 23A2 LABEL 1 OS2X LOCK HANDLE ASS'Y 1 083S TRIGGER I 0CES SPRING 1 0LU2 LIMIT SWITCH 1 OKBM CR. RE, PAN HD, TAPPING SCREW 083V HANDLE I 083X BUTTON swn'cH I 0B3Y SPRING 1 M6X1.0016 M4X10028 5 28 i8 0 083V 0JUK 0J53 _o OSTZ _. OQYX > o 10" COMPOUND MODEL NO. 137.242760 MITER SAW PARTS LIST FOR SCHEMATIC C MOTOR Part No. 0QM4 0JG7 0K7G PARALLELKEY CR. RE. ROUND HD. WASHER SCREW 0QM7 0HV5 0JEG BEARING COVER BALL BEARING C-RING 0QM8 0JEB 0HX9 HELIX GEAR C-RING NEEDLE BEARING COMPRESSION SPRING 0QGR 0QM9 0JCC 0QME 0QMR 0KVVM 0QR2 0Q9K 149F 110A 0QMY 0QMK 0QMZ 149H 0JX2 0KLA 0QQS 0QQT 0QR0 ..... Size Descri_ion ARBOR SHAFT QV 1 1 M5x0.8-10 5 6204ZZ A-20 A-14 HK-1010 3 1 1 1 1 1 1 1 1 UPPER ARM 1 1 1 SPRING PIN BRACKET STOP ARMATURE LEAD WIRE ASS'Y 1 1 1 BEARING BUSHING FLOW GUIDE FIELD ASS'Y CR. RE.PAN HD.TAPPING SCREW & WASHER PROTECTOR WIRE PLASTIC CAP MOTOR HOUSING CR. RE,PAN HD.TAPPING SCREW & WASHER HE)(, SOC SET SCREW PLASTIC SCREW BRUSH HOLDER ASS'Y RUBBER BUSHING BRUSH COVER M5x12-55 1 2 1 1 1 M5x16-30 M5xO.8-6 4 2 M5xO.8-6 2 2 2 2 30 IIOA L_ OQME 149H OQM80JEB OJ_ _ o• OQM7 OKTC OJG? OQRO ..4 m 0 10" COMPOUND MODEL NO. 137.242760 MITER SAW PARTS LIST FOR SCHEMATIC D STAND I.D. NO. Description Size Qty 4 093B SPACER 0KRR SERRATED TOOTHED HEXAGON FLANGE NUT M8x1.25 "I"--7.5 19 0KJ7 CAP HD. SQ.NECK BOLT M8x1.25-16 16 0KE2 HEX, HD. BOLT M8xl.5-30 3 0J4F FLAT WASHER _ 8x16-2,5 3 22XY LEG 4 22XS UPPER SUPPORT BRACKET (LONG) 2 22XV UPPER SUPPORT BRACKET (SHORT) 22XVV BOTTOM SUPPORT BRACKET (LONG) 22XX BO]-]'OM SUPPORT BRACKET (SHORT) A-14 32 HK-1010 2 2 2 10" COMPOUND MITER SAW MODEL NO. 137.242760 SCHEMATIC D STAND 23A9 0J4F "4 22XS 22XV 0ZIG 22XX 22XY 33 I_[o]ld:l 34 II 35 III Your Home For repair-in your home-of all major brand appliances, lawn and garden equipment, or heating and cooling systems, no matter who made it, no matter who sold it! For the replacement parts, accessories and Operator's Manuals that you need to do-it-yourself. For Sears professional installation of home appliances and items like garage door openers and water heaters. 1-800-4-MY-HOME ® (1400-469-4663) Call anytime, day or night (U.S.A. and Canada) www.sears.com www.sears.ca Our Home For repair of carry-in items like vacuums, lawn equipment, and electronics, call or go on-line for the location of your nearest Sears Parts & Repair Center. 1-800-488-1222 Call anytime, day or night (U.S.A. only) www.sears.com To purchasea protectionagreement (U.S.A) or maintenance agreement (Canada) on a productservicedby Sears: 1-800-827-6655 (U.S.A.) 1-800-361-6665 (Canada) Para pedir servicio de reparacibn a domicilio, y para ordenar piezas: 1-888-SU-HOGAR s" Au Canada pour service en francr,,ais: I"800"LE'FOYER (1-888-784-6427) "c (1-800-533-6937) www.sears.ca 8E/AR8 ® Registered Trademark I TM Trade ma rk / SMService Ms rk of Seal-s. Roebuck and Co. ® Mama Regisb-ada I TMMarca de Fibrioe I m Marca de Servlcio de Sears. Roebuck snd Co. Mc Marque de Commence I _o Marque dlpos6e de Sears. Roebuck and CO_ O Sears, Roebuck and CO.