KOBALT ® and the K & Design ® are registered trademarks of LF, LLC. All Rights Reserved.

ITEM #0325953

15-AMP MAGNESIUM

CIRCULAR SAW

MODEL #K15CS-06A

ATTACH YOUR RECEIPT HERE

Serial Number Purchase Date

Questions, problems, missing parts? Before returning to your retailer, call our customer service department at 1-888-3KOBALT (1-888-356-2258), 8 a.m. - 8 p.m., EST, Monday -

Friday.

TABLE OF CONTENTS

Product Specifications ..................................................................................................................................................

2

Safety Information ..........................................................................................................................................................

3

Contents ............................................................................................................................................................................

7

Preparation .......................................................................................................................................................................

8

Operating Instructions ................................................................................................................................................

10

Care and Maintenance ...............................................................................................................................................

16

Troubleshooting ............................................................................................................................................................

16

Warranty .........................................................................................................................................................................

16

PRODUCT SPECIFICATIONS

Component

Rated power input

No-Load speed

Saw blade size

Cutting angle

Depth of cut at 90°

Depth of cut at 45°

Specifications

120V - 60HZ, 15A

6200 RPM

7 1/4 in.

0 - 56°

2 3/8 in.

1 13/16 in.

2

SAFETY INFORMATION

KNOW THE TOOL

To operate this tool, carefully read this manual and all labels affixed to the circular saw before using it. Keep this manual available for future reference.

IMPORTANT

This tool should be serviced only by a qualified service technician.

READ ALL INSTRUCTIONS THOROUGHLY

GENERAL SAFETY RULES FOR ALL POWER TOOLS

WARNING: Read all safety warnings and all instructions. Failure to follow all warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference

The term “power tool” in the warnings refers to your mains operated (corded) power tool or battery operated (cordless) power tool.

1) Work area safety

a) Keep the work area clean and well lit. Cluttered and dark areas invite accidents.

b) Do not operate power tools in explosive atmospheres, such as in the presence of

flammable liquids, gases or dust. Power tools create sparks, which may ignite the dust or fumes.

c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2) Electrical safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not

use any adaptor plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce the risk of electric shock.

b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators,

ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep the cord away from heat, oil, sharp edges or moving parts.

Damaged or entangled cords increase the risk of electric shock.

e) When operating a power tool outdoors, use an extension cord suitable for outdoor

use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

f ) If operating a power tool in a damp location is unavoidable, use a ground-fault

circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.

3

SAFETY INFORMATION

3) Personal safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of

drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection, used for appropriate conditions, will reduce personal injuries.

c) Prevent unintentional starting. Ensure that the switch is in the off-position before connecting to a power source and/or battery pack, picking up or carrying the tool.

Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.

e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.

f ) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and

gloves away from moving parts. Loose clothing, jewelry or long hair can be caught in moving parts.

g) If devices are provided for the connection of dust-extraction and collection facilities,

ensure that these are connected and properly used. Use of these devices can reduce dust-related hazards.

4) Power tool use and care

a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and more safely at the rate for which it was designed.

b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.

c) Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools.

Such preventive safety measures reduce the risk of starting the power tool accidentally.

d) Store idle power tools out of the reach of children and do not allow persons

unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If

damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.

f ) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

4

SAFETY INFORMATION g) Use the power tool, accessories, tool bits, etc. in accordance with these instructions, taking into account the working conditions and the work to be

performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

5) Service a) Have your power tool serviced by a qualified repair person using only identical

replacement parts. This will ensure that the safety of the power tool is maintained.

SPECIFIC SAFETY RULES FOR CIRCULAR SAWS

Safety instructions for all saws

DANGER: Keep hands away from the cutting area and the blade. Keep one hand on the

main handle and the other hand on the auxiliary handle or the motor housing. If both hands are holding the saw, they cannot be cut by the blade.

a) Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.

b) Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.

c) Never hold the piece being cut in your hands or across your leg. Secure the

workpiece to a stable platform. It is important to support the work properly to minimize body exposure, blade binding, and loss of control.

d) Hold power tools by the insulated gripping surfaces when performing an operation

where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will also make exposed metal parts of the power tool “live” and shock the operator.

e) When ripping, always use a rip fence or straight-edge guide. This improves the accuracy of cut and reduces the chance of blade binding.

f ) Always use blades with arbor holes of the correct size and shape (diamond versus

round). Blades that do not match the mounting hardware of the saw will run eccentrically, causing loss of control.

g) Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw for optimum performance and safe of operation.

5

SAFETY INFORMATION

Further safety instructions for all saws

Cause and operator prevention of kickback:

Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator.

When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator.

If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the upper surface of the wood, causing the blade to climb out of the kerf and jump back toward the operator.

Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions, as given below.

a) Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with

the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator if proper precautions are taken.

b) When the blade is binding or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw

backward while the blade is in motion, or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding.

c) When restarting a saw in the workpiece, center the saw blade in the kerf and check

that the saw teeth are not engaged in the material. If the saw blade is binding, it may walk up or kickback from the workpiece as the saw is restarted.

d) Support larger panels to minimize the risk of blade pinching and kickback. Larger 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 dull or damaged blades. Dull or improperly set blades produce narrow kerf, causing excessive friction, blade binding and kickback.

f ) Blade-depth and bevel-adjusting locking levers must be tight and secure before

making a cut. If the blade adjustment shifts while cutting, it may cause binding and kickback.

g) Use extra caution when making a “plunge cut” into existing walls or other blind

areas. The protruding blade may contact hidden objects that can cause kickback.

Safety instructions for lower blade guard a) Check the lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly. Never clamp or tie the

lower guard into the open position. If the saw is accidentally dropped, the lower guard may be bent. Raise the lower guard with the retracting handle and make sure that it moves freely and does not touch the blade or any other part, in all angles and all depths of cut.

b) Check the operation of the lower guard spring. If the guard and the spring are not

operating properly, they must be serviced before use. A lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.

6

SAFETY INFORMATION c) The lower guard should be retracted manually only for special cuts, such as “plunge cuts” and “compound cuts.” Raise the lower guard with the retracting handle and,

as soon as blade enters the material, the lower guard must be released. For all other sawing, the lower guard should be allowed to operate automatically.

d) Always observe that the lower guard is covering the blade before placing the saw

down on the bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

ADDITIONAL SAFETY RULES FOR CIRCULAR SAWS

• Always wear a dust mask

• Only use recommended saw blades

• Always wear hearing protection

• Do not to use any abrasive wheels

WARNING: Some dust created by power sanding, sawing, grinding, drilling and other construction activities contains chemicals known to the state of California to cause cancer, birth 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 risk from these exposures varies, depending upon how often you do this type of work.

To reduce your exposure to these chemicals:

• Work in a well-ventilated area.

• Work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water.

Allowing dust to get into your mouth or eyes or to lie on the skin may promote absorption of harmful chemicals.

CONTENTS

Circular saw, blade, blade wrench, hard case

7

PREPARATION

1

C

L

K

A

D

H

Q

R

V

I

P F

O

A

G

E

B

N

S

J

M

U

W

8

X

T

PREPARATION

KNOW YOUR CIRCULAR SAW (Fig. 1)

(Before attempting to use the circular saw, familiarize yourself with all of its operating features and safety requirements.)

A. Trigger switch

B. Motor housing

C. Main handle

D. Auxiliary handle

E. Bevel-locking knob

F. 0°- 56° bevel scale

G. Edge-guide locking knob

H. Blade-guard lever

I. Lower blade guard

J. Base plate

K. Upper blade guard

L. Dust-extraction port

M. Depth-locking lever

N. Depth scale

O. Spindle-lock button

P. Blade

Q. Blade bolt

R. Blade outer flange

S. Live-tool indicator light

T. 90° Blade-guide notch

U. Edge-guide slots

V. Blade-rotation indicator

W. Blade wrech

X. Bevel blade guide notch

WARNING: Do not allow familiarity with the saw to cause carelessness. Remember that one careless moment is enough to cause severe injury. Before attempting to use any tool, be sure to become familiar with all of the operating features and safety instructions.

APPLICATIONS

This saw can be used for the purpose listed below:

• Cutting all types of wood and wood products

NOTE: The use of abrasive cut-off wheels is not recommended with this saw.

9

OPERATING INSTRUCTIONS

TRIGGER SWITCH (Fig. 2)

Your saw is equipped with a trigger switch (A) to turn the saw on and off.

1. To start the saw, squeeze the trigger switch.

2. To stop the saw, release the trigger switch and allow

it to return to the “OFF” position.

2

A

SAW BLADES

• The best saw blades will not cut efficiently if they are not kept clean, sharp, and properly set. Using a dull blade will place a heavy load on the saw and increase the danger of kickback. Keep extra blades on hand so sharp blades are always available.

• Gum and resin on blades will slow the saw down.

Follow the instructions for REMOVING A SAW BLADE, use gum and resin remover, hot water, or kerosene to remove these accumulations.

WARNING: Do not use gasoline to clean the blade.

3

O

INSTALLING A SAW BLADE (Fig. 3)

1. Disconnect the plug from the power source.

K

2. Depress and hold the spindle-lock button (O).

3. While keeping the spindle-lock button depressed, remove the blade bolt (Q) by turning it clockwise with the blade wrench (W).

H

P

R

Q

4. Remove the outer flange (R).

WARNING: If the inner flange has been removed, replace it before placing the blade on the spindle. Failure to do so will prevent the blade from tightening properly and could result in serious personal injury.

I

V

5. Use the blade guard lever (H) to retract the lower blade guard (I) into the upper blade guard (K).

Make sure that the lower guard works properly and allows the guard to move freely.

6. Verify that the saw teeth, the arrow on the saw blade and the blade-rotation indicator arrow (V) on the lower guard are all pointing in the same direction.

NOTE: The saw teeth should point upward at the front of the saw, as shown in Fig. 3.

7. Fit the saw blade (P) inside the lower blade guard (I) and onto the spindle.

8. Replace the outer blade flange (R).

9. Depress and hold the spindle-lock button, and replace the blade screw.

10. Tighten the blade bolt securely by turning it counterclockwise with the blade wrench (W).

10

OPERATING INSTRUCTIONS

NOTE: Never use a blade that is too thick to allow the outer blade flange to engage with the flat section of the spindle.

WARNING: To prevent personal injury, disconnect the plug from the power source before installing or removing the saw blade!

REMOVING THE SAW BLADE (Fig. 3)

1. Disconnect the plug from the power source.

2. Depress and hold the spindle-lock button (O).

3. While keeping the spindle-lock button depressed, remove the blade bolt (Q) by turning it clockwise with the blade wrench (W).

4. Remove the outer flange (R).

5. Lift the lower blade guard (I).

6. Remove the blade (P).

BLADE GUARD SYSTEM (Fig. 4)

The lower blade guard on the circular saw is there for the operator’s protection and safety. Do not alter it for any reason.

If the blade guard becomes damaged or if the blade begins to run slowly or sluggishly, DO NOT operate the saw until the damaged part has been repaired or replaced.

ALWAYS leave the guard in its correct operating position when using the saw.

DANGER: When sawing through a workpiece, the lower blade guard does not cover the blade on the underside of the workpiece. Since the blade is exposed on the underside of the workpiece, ALWAYS keep hands and fingers away from the cutting area. Serious injury will result if any part of the body comes into contact with the moving blade.

4

WARNING: To avoid possible serious injury, never use the saw when the guard is not operating correctly.

Check the lower blade guard for correct operation before each use. The guard is operating correctly when it moves freely and instantly returns to the closed position. If the saw is dropped, check the lower blade guard and bumper for damage at all depth settings before using it.

If the lower blade guard does not snap closed at any time, disconnect the saw from the power supply. Exercise the lower guard by using the blade-guard lever to move it rapidly back and forth from the full open position to the closed position several times. This will often restore the guard to its normal operating condition. If this does not correct a slow or sluggishly closing lower guard, do not use the saw. Take it to an authorized service technician for repair.

11

OPERATING INSTRUCTIONS

STARTING/STOPPING THE SAW

To start the saw: Depress the trigger switch (A).

Always allow the blade to reach the full selected speed, and then guide the saw into the workpiece.

WARNING: The blade should reach the full selected speed before it comes into contact with the workpiece.

To stop the saw: Release the trigger switch and allow the blade to come to a complete stop.

5

A

N

DEPTH-OF-CUT ADJUSTMENT (Fig. 5)

WARNING: Always maintain the correct blade-depth setting.

The correct blade-depth setting for all cuts should not exceed the thickness of the material being cut by more than 1/4 in. (6.5 mm).

Greater blade depth will increase the chance of kickback, and cause the cut to be rough.

1. Disconnect the plug from the power source.

6

M

J

2. Raise the depth-locking lever (M) to release it.

3. Determine the desired depth of cut.

4. Hold the base plate (J) flat against the workpiece and raise or lower the saw until the indicator mark on the saw aligns with the desired depth on the depth scale (N).

5. Lower the depth-locking lever to lock it into position.

J

ADJUSTING THE CUTTING ANGLE (Fig. 6)

1. Loosen the bevel-locking knob (E), located on the bevel scale (F) on the base plate (J).

F

2. Tilt the body of the saw until the required angle is reached (refer to the 0°- 56° bevel scale).

3. Tighten the bevel-locking knob to secure the saw and angle.

E

12

OPERATING INSTRUCTIONS

CUTTING WITH THE CIRCULAR SAW

Refer to the figures in this section to learn the correct and incorrect ways of handling the saw.

WARNING: To make sawing easier and safer, always maintain proper control of the saw. Loss of control could cause an accident resulting in serious injury.

DANGER: When lifting the saw from the workpiece, the blade is exposed on the underside of the saw until the lower blade guard closes. Make sure that the lower blade guard is closed before setting the saw down.

To make the safest and best possible cut, follow these helpful hints:

1. Hold the saw firmly with both hands.

2. Avoid placing your hand on the workpiece while making

a cut (Fig. 7).

3. Support the workpiece so that the cut is always to the operator’s side and not directly in line with the operator’s body.

4. Support the workpiece near the cut.

5. Clamp the workpiece securely so that the workpiece will not move during the cut (Fig. 8).

6. Always place the saw on the portion of the workpiece that is supported, and not on the “cut off ” piece (Fig. 9).

7. Place the workpiece with the “good” side down.

8. Draw a guideline along the desired cutting line before beginning the cut.

7

8

9

13

OPERATING INSTRUCTIONS

CROSS-CUTTING/RIP CUTTING (Fig. 10-11)

When making a cross-cut or a rip cut, align the guideline with the blade-guide notch (T) on the base, as shown in Fig. 10. The distance from the saw blade to the saw base is approximately 1-1/2 in. (3.8 cm) on the left side of the saw and 4-1/4 in. (10.8 cm) on the right side. Blade thicknesses vary, so you should always make a trial cut in scrap material along a guideline to determine how much the guideline must be offset from the guide to produce an accurate cut.

NOTE: The distance from the cutting line to the guideline is the amount by which the guide should be offset. Use a guide when making long or wide rip cuts.

RIP CUTTING USING A STRAIGHT EDGE:

1. Secure the workpiece.

2. Clamp a straight edge to the workpiece using

C-clamps (not included).

NOTE: Position the C-clamps so that they will not interfere with the saw housing during the cut.

3. Depress the trigger switch to start the saw.

4. Allow the blade to reach full speed, then guide the saw

into the workpiece and make the cut.

5. Saw along the straight edge to achieve a straight rip cut.

6. Release the trigger switch and allow the blade to come

to a complete stop.

7. Lift the saw from the workpiece.

NOTE: Do not bind the blade in the cut.

BEVEL CUTTING (Fig. 12)

To make the best possible cut:

1. Align the cutting line with the bevel blade-guide notch (X) on the base when making 45° bevel cuts.

2. Make a trial cut in scrap material along a guideline to determine the amount to offset the guideline on the cutting material.

3. Adjust the angle of cut to any desired setting between

0° and 56°.

WARNING: Attempting a bevel cut without having the angle-locking knob securely locked in place can result in serious injury.

10

11

12

14

B

T

X

OPERATING INSTRUCTIONS

4. Hold the saw firmly with both hands, as shown.

5. Rest the front edge of the base on the workpiece without touching the blade to the workpiece.

6. Start the saw and allow the blade to reach full speed.

7. Guide the saw into the workpiece, and make the cut.

8. Release the trigger switch and allow the blade to come to a complete stop.

9. Lift the saw from the workpiece.

POCKET CUTTING (Fig. 13)

WARNING: Always adjust the bevel setting to 0° before making a pocket cut. Attempting a pocket cut at any other setting can result in loss of control of the saw and possible serious injury.

1. Adjust the bevel setting to 0° and tighten the bevel locking knob (E).

2. Set the blade to the correct blade-depth setting and tighten the depth-locking lever (M).

3. Swing the lower blade guard up using the bladeguard lever (H).

4. Hold the lower blade guard in place with the blade guard lever.

5. Rest the front of the base plate (J) flat against the workpiece, with the rear of the handle raised so that the blade does not touch the workpiece.

13

H

6. Depress the trigger switch to start the saw.

7. Allow the blade to reach full speed, then guide the

saw into the workpiece and make the cut.

8. Release the trigger switch and allow the blade to come to a complete stop.

9. Lift the saw from the workpiece.

J

E

M

WARNING: Always cut in a forward direction when pocket cutting. Cutting in the reverse direction could cause the saw to climb up on the workpiece and kick back toward the operator.

WARNING: As the blade starts cutting the material, release the blade-guard lever immediately.

When the foot of the guard rests flat on the surface being cut, proceed cutting in a forward direction to the end of the cut.

WARNING: Never tie the lower blade guard in a raised position. Leaving the blade exposed could lead to serious injury.

15

CARE AND MAINTENANCE

All maintenance should only be carried out by an authorized service organization.

Cleaning

Before cleaning or performing any maintenance, disconnect the plug from the power source. For safe and proper operation, always keep the tool and its ventilation slots clean.

Always use only a soft, dry cloth to clean your circular saw; never use detergent or alcohol.

TROUBLESHOOTING

WARNING: Disconnect the plug from the power source before performing troubleshooting procedures.

Problem

Blade binds, jams, or burns the wood

Saw vibrates or shakes

Possible Cause

1. Improper operation

2. Dull blade

3. Improper blade

4. Warped blade

1. Damaged blade

2. Loose blade

Corrective Action

1. See “OPERATING INSTRUCTIONS” section

2. Replace or sharpen blade

3. Replace blade

4. Replace blade

1. Replace blade

2. Tighten blade bolt

5-YEAR HASSLE-FREE WARRANTY

This circular saw is warranted to the original purchaser from the original purchase date for five (5) years subject to the warranty coverage described herein.

This circular saw is warranted for the original user to be free from defects in material and workmanship.

If you believe that the circular saw is defective at any time during the specified warranty period, simply return the circular saw along with proof of purchase to the place of purchase for a free replacement or refund, or call 1-888-3KOBALT (1-888-356-2258) for warranty service.

This warranty is void if: defects in materials or workmanship or damages result from repairs or alterations which have been made or attempted by others or the unauthorized use of nonconforming parts; the damage is due to normal wear, damage is due to abuse (including overloading of the tool beyond capacity), improper maintenance, neglect or accident; or the damage is due to the use of the tool after partial failure or use with improper accessories or unauthorized repair or alteration.

This warranty excludes blades, bits, bulbs and accessories.

This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.

Printed in China

16