RIDGID | R3203-1 | User manual | RIDGID R3203-1 User's Manual

OPERATOR’S MANUAL
6-1/2 in. CIRCULAR SAW
DOUBLE INSULATED
R3203-1
Your circular saw has been engineered and manufactured to our high standards for dependability, ease of operation, and
operator safety. When properly cared for, it will give you years of rugged, trouble-free performance.
WARNING:
To reduce the risk of injury, the user must read and understand the operator’s manual before using this product.
Thank you for buying a RIDGID product.
SAVE THIS MANUAL FOR FUTURE REFERENCE
TABLE OF CONTENTS
 Introduction ...................................................................................................................................................................... 2
 General Safety Rules .....................................................................................................................................................3-4
 Specific Safety Rules.....................................................................................................................................................4-5
 Symbols .........................................................................................................................................................................6-7
 Electrical ........................................................................................................................................................................... 8
 Features .......................................................................................................................................................................9-10
 Assembly ...................................................................................................................................................................11-12
 Operation ...................................................................................................................................................................13-20
 Adjustments...............................................................................................................................................................20-21
 Maintenance ..............................................................................................................................................................21-22
 Accessories .................................................................................................................................................................... 22
 Warranty ......................................................................................................................................................................... 23
 Customer Service Information ........................................................................................................................................ 24
INTRODUCTION
This tool has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability have
been given top priority in the design of this product making it easy to maintain and operate.
2
GENERAL SAFETY RULES
 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.
 Do not overreach. Keep proper footing and balance
at all times. This enables better control of the power tool
in unexpected situations.
 Dress properly. Do not wear loose clothing or jewelry.
Keep your hair, clothing and gloves away from moving
parts. Loose clothes, jewelry or long hair can be caught
in moving parts.
 If devices are provided for the connection of dust
extraction and collection facilities, ensure these are
connected and properly used. Use of these devices can
reduce dust-related hazards.
 Do not wear loose clothing or jewelry. Contain long
hair. Loose clothes, jewelry, or long hair can be drawn
into air vents.
 Do not use on a ladder or unstable support. Stable
footing on a solid surface enables better control of the
power tool in unexpected situations.
WARNING!
Read all instructions. Failure to follow all
instructions listed below may result in electric
shock, fire and/or serious injury. The term “power
tool” in all of the warnings listed below refers
to your mains-operated (corded) power tool or
battery-operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
WORK AREA SAFETY
 Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
 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.
 Keep children and bystanders away while operating a
power tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
POWER TOOL USE AND CARE
 Power tool plugs must match the outlet. Never modify
the plug in any way. Do not use any adapter plugs with
earthed (grounded) power tools. Unmodified plugs and
matching outlets will reduce risk of electric shock.
 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.
 Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of
electric shock.
 Do not abuse the cord. Never use the cord for carrying,
pulling or unplugging the power tool. Keep cord away
from heat, oil, sharp edges or moving parts. Damaged
or entangled cords increase the risk of electric shock.
 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.
 Do not force the power tool. Use the correct power
tool for your application. The correct power tool will
do the job better and safer at the rate for which it was
designed.
 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.
 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.
 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.
 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.
 Keep cutting tools sharp and clean. Properly maintained
cutting tools with sharp cutting edges are less likely to
bind and are easier to control.
 Use the power tool, accessories and tool bits etc., in
accordance with these instructions and in the manner
intended for the particular type of power tool, 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.
PERSONAL SAFETY
 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.
 Use safety equipment. Always wear eye protection.
Safety equipment such as dust mask, non-skid safety
shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
 Avoid accidental starting. Ensure the switch is in the
off-position before plugging in. Carrying power tools
with your finger on the switch or plugging in power tools
that have the switch on invites accidents.
3
GENERAL SAFETY RULES
 When servicing a power tool, use only identical
replacement parts. Follow instructions in the
Maintenance section of this manual. Use of unauthorized
parts or failure to follow Maintenance instructions may
create a risk of shock or injury.
SERVICE
 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.
WARNING!
To reduce the risk of injury, user must read
instruction manual.
SPECIFIC SAFETY RULES
 DANGER! Keep hands away from cutting area and the
blade. Keep your second hand on auxiliary handle or
motor housing. If both hands are holding the saw, they
cannot be cut by the blade.
 Do not reach underneath the workpiece. The
guard cannot protect you from the blade below the
workpiece.
 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.
 Never hold 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, or loss of control.
 Hold power tool by 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.
 When ripping, always use a rip fence or straight edge
guide. This improves the accuracy of cut and reduces
the chance of blade binding.
 Always use blades with correct size and shape
(diamond versus round) of arbor holes. Blades that
do not match the mounting hardware of the saw will run
eccentrically, causing loss of control.
 Never use damaged or incorrect blade washers or
bolt. The blade washers and bolt were specially designed
for your saw for optimum performance and safety of
operation.
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:
 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.
 When 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.
 When restarting a saw in the workpiece, center the
saw blade in the kerf and check that saw teeth are
not engaged into the material. If saw blade is binding,
it may walk up or kickback from the workpiece as the
saw is restarted.
 Support large panels to minimize the risk of blade
pinching and kickback. Large panels tend to sag under
their own weight. Supports must be placed under the
panel on both sides, near the line of cut and near the
edge of the panel.
 Do not use dull or damaged blades. Unsharpened
or improperly set blades produce narrow kerf causing
excessive friction, blade binding and kickback.
 Blade depth and bevel adjusting locking levers must be
tight and secure before making cut. If blade adjustment
shifts while cutting, it may cause binding and kickback.
 Use extra caution when making a “Plunge Cut” into
existing walls or other blind areas. The protruding blade
may cut objects that can cause kickback.
 Check lower guard for proper closing before each use.
Do not operate saw if lower guard does not move freely
and close instantly. Never clamp or tie the lower guard
into the open position. If saw is accidentally dropped,
lower guard may be bent. Raise the lower guard with the
retracting handle. Make sure it moves freely and does
not touch the blade or any other part, in all angles and
depths of cut.
CAUSES AND OPERATOR PREVENTION OF
KICKBACK:
Kickback is a sudden reaction to a pinched, bound, or
misaligned saw blade, causing an uncontrolled saw to lift
up and out of the workpiece toward the operator.
When the 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 top
surface of the wood causing the blade to climb out of the
kerf and jump back toward the operator.
4
SPECIFIC SAFETY RULES
 Check damaged parts. Before further use of the
tool, a guard or other part that is damaged should
be carefully checked to determine that it will operate
properly and perform its intended function. Check for
alignment of moving parts, binding of moving parts,
breakage of parts, mounting, and any other conditions
that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced
by an authorized service center. Following this rule will
reduce the risk of shock, fire, or serious injury.
 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. A wire gage size (A.W.G.) of at least 14 is
recommended for an extension cord 50 feet or
less in length. A cord exceeding 100 feet is not
recommended. If in doubt, use the next heavier gage.
The smaller the gage number, the heavier the cord. An
undersized cord will cause a drop in line voltage resulting
in loss of power and overheating.
 Inspect for and remove all nails from lumber before
using this tool. Following this rule will reduce the risk of
serious personal injury.
 Check the operation of the lower guard spring. If the
guard and the spring are not operating properly, they
must be serviced before use. Lower guard may operate
sluggishly due to damaged parts, gummy deposits, or a
buildup of debris.
 Lower guard should be retracted manually only for
special cuts, such as “Plunge Cuts” and “Compound
Cuts.” Raise lower guard by retracting handle. As
soon as blade enters the material, the lower guard
must be released. For all other sawing, the lower guard
should operate automatically.
 Always observe that the lower guard is covering the
blade before placing saw down on 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.
 Know your power tool. Read operator’s manual
carefully. Learn its applications and limitations, as well
as the specific potential hazards related to this tool.
Following this rule will reduce the risk of electric shock,
fire, or serious injury.
 Always wear safety glasses. Everyday eyeglasses
have only impact-resistant lenses; they are NOT safety
glasses. Following this rule will reduce the risk of serious
personal injury.
 Protect your lungs. Wear a face or dust mask if the
operation is dusty. Following this rule will reduce the
risk of serious personal injury.
 Protect your hearing. Wear hearing protection during
extended periods of operation. Following this rule will
reduce the risk of serious personal injury.
 Inspect tool cords periodically and, if damaged, have
repaired at your nearest authorized service center.
Constantly stay aware of cord location. Following this
rule will reduce the risk of electric shock or fire.
 If the power supply cord is damaged, it must be replaced
only by the manufacturer or by an authorized service
center to avoid risk.
 Save these instructions. Refer to them frequently and
use them to instruct others who may use this tool. If you
loan someone this tool, loan them these instructions
also.
WARNING:
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals
known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure
to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust
masks that are specially designed to filter out microscopic particles.
5
SYMBOLS
Some of the following symbols may be used on this tool. Please study them and learn their meaning. Proper interpretation
of these symbols will allow you to operate the tool better and safer.
SYMBOL
NAME
DESIGNATION/EXPLANATION
V
Volts
Voltage
A
Amperes
Current
Hz
Hertz
Frequency (cycles per second)
W
Watt
Power
Minutes
Time
Alternating Current
Type of current
Direct Current
Type or a characteristic of current
No Load Speed
Rotational speed, at no load
Class II Tool
Double-insulated construction
Per Minute
Revolutions, strokes, surface speed, orbits etc., per minute
Wet Conditions Alert
Do not expose to rain or use in damp locations.
Read The Operator’s Manual
To reduce the risk of injury, user must read and understand
operator’s manual before using this product.
Eye Protection
Always wear safety goggles or safety glasses with side shields
and, as necessary, a full face shield when operating this
product.
Safety Alert
Precautions that involve your safety.
No Hands Symbol
Failure to keep your hands away from the blade will result in
serious personal injury.
No Hands Symbol
Failure to keep your hands away from the blade will result in
serious personal injury.
No Hands Symbol
Failure to keep your hands away from the blade will result in
serious personal injury.
No Hands Symbol
Failure to keep your hands away from the blade will result in
serious personal injury.
Hot Surface
To reduce the risk of injury or damage, avoid contact with any
hot surface.
min
no
.../min
6
SYMBOLS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL
SIGNAL
MEANING
DANGER:
Indicates an imminently hazardous situation, which, if not avoided, will
result in death or serious injury.
WARNING:
Indicates a potentially hazardous situation, which, if not avoided, could
result in death or serious injury.
CAUTION:
Indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury.
CAUTION:
(Without Safety Alert Symbol) Indicates a situation that may result in
property damage.
SERVICE
WARNING:
Servicing requires extreme care and knowledge and should
be performed only by a qualified service technician. For
service we suggest you return the product to your nearest
AUTHORIZED SERVICE CENTER for repair. When servicing,
use only identical replacement parts.
To avoid serious personal injury, do not attempt
to use this product until you read thoroughly and
understand completely the operator’s manual.
If you do not understand the warnings and
instructions in the operator’s manual, do not use
this product. Call RIDGID customer service for
assistance.
WARNING:
The operation of any power tool can result in foreign objects being thrown into your eyes, which can result
in severe eye damage. Before beginning power tool operation, always wear safety goggles or safety glasses
with side shields and, when needed, a full face shield. We recommend Wide Vision Safety Mask for use
over eyeglasses or standard safety glasses with side shields. Always use eye protection which is marked
to comply with ANSI Z87.1.
SAVE THESE INSTRUCTIONS
7
ELECTRICAL
DOUBLE INSULATION
EXTENSION CORDS
Double insulation is a concept in safety in electric power
tools, which eliminates the need for the usual three-wire
grounded power cord. All exposed metal parts are isolated
from the internal metal motor components with protecting
insulation. Double insulated tools do not need to be
grounded.
When using a power tool at a considerable distance from
a power source, be sure to use an extension cord that has
the capacity to handle the current the tool will draw. An
undersized cord will cause a drop in line voltage, resulting in
overheating and loss of power. Use the chart to determine
the minimum wire size required in an extension cord. Only
round jacketed cords listed by Underwriter’s Laboratories
(UL) should be used.
WARNING:
When working outdoors with a tool, use an extension
cord that is designed for outside use. This type of cord is
designated with “WA” on the cord’s jacket.
The double insulated system is intended to protect
the user from shock resulting from a break in the
tool’s internal wiring. Observe all normal safety
precautions to avoid electrical shock.
Before using any extension cord, inspect it for loose or
exposed wires and cut or worn insulation.
NOTE: Servicing of a tool with double insulation requires
extreme care and knowledge of the system and should
be performed only by a qualified service technician. For
service, we suggest you return the tool to your nearest
authorized service center for repair. Always use original
factory replacement parts when servicing.
**Ampere rating (on tool data plate)
0-2.0
2.1-3.4
Cord Length
ELECTRICAL CONNECTION
This tool has a precision-built electric motor. It should be
connected to a power supply that is 120 volts, 60 Hz, AC
only (normal household current). Do not operate this tool
on direct current (DC). A substantial voltage drop will cause
a loss of power and the motor will overheat. If your tool does
not operate when plugged into an outlet, double-check the
power supply.
3.5-5.0
5.1-7.0
7.1-12.0 12.1-16.0
Wire Size (A.W.G.)
25'
16
16
16
16
14
14
50'
16
16
16
14
14
12
100'
16
16
14
12
10
—
**Used on 12 gauge - 20 amp circuit.
NOTE: AWG = American Wire Gauge
WARNING:
Keep the extension cord clear of the working area.
Position the cord so that it will not get caught on
lumber, tools or other obstructions while you are
working with a power tool. Failure to do so can
result in serious personal injury.
WARNING:
Check extension cords before each use. If
damaged replace immediately. Never use tool with
a damaged cord since touching the damaged area
could cause electrical shock resulting in serious
injury.
8
FEATURES
PRODUCT SPECIFICATIONS
Blade Diameter ......................................................6-1/2 in.
No Load Speed .................................... 6,100 r/min. (RPM)
Blade Arbor .............................................................. 5/8 in.
Input ................................120 V, 60 Hz, AC only, 12 Amps
Cutting Depth at 90°..............................................2-1/8 in.
Net Weight................................................................. 8 lbs.
Cutting Depth at 45°..............................................1-5/8 in.
Cutting Depth at 50°..............................................1-1/2 in.
HANDLE
DUST CHUTE
DEPTH OF CUT SCALE
FRONT HANDLE
PLYWOOD ID SYSTEM
SWITCH TRIGGER
SPINDLE LOCK
DETACHABLE CORD
POSITIVE 50°
STOP BUTTON
DEPTH ADJUSTMENT
LEVER
LIGHTED PLUG
50
45
30
12
22
15
FULL LENGTH
KERF INDICATOR
EXTERNALLY
ACCESSIBLE
BRUSH (2)
HEX KEY STORAGE
BEVEL ADJUSTMENT
LEVER
Fig. 1
9
FEATURES
KNOW YOUR CIRCULAR SAW
HEX KEY STORAGE
See Figure 1.
The safe use of this product requires an understanding of
the information on the tool and in this operator’s manual as
well as a knowledge of the project you are attempting. Before
use of this product, familiarize yourself with all operating
features and safety rules.
INDEXING LEVERS
Hex key storage is located on the saw base. The storage area
can be accessed by adjusting the saw to a bevel position.
The lock levers on the saw can be repositioned to suit user
preference.
LIGHTED PLUG
DETACHABLE CORD
The lighted plug helps to easily identify live tools.
The detachable cord can be easily stored or replaced quickly
if damaged.
PLYWOOD ID SYSTEM
Quickly identify common plywood thicknesses using the
plywood ID system.
DUST CHUTE
To direct saw dust and chips away from the operator, a dust
chute is located on the rear of the upper blade guard.
SHOCK ABSORBING FRONT HANDLE
The handle is designed for durability and operator
comfort.
ERGONOMIC DESIGN
The design provides for easy handling. It is designed for
comfort when operating in different positions and at different
angles.
SPINDLE LOCK
The spindle lock allows you to secure the blade when turning
the blade screw for blade changes.
EXTERNALLY ACCESSIBLE BRUSHES
Externally accessible brushes extend the life of the
machine.
FRONT AND REAR KERF INDICATORS
The front kerf indicator aides in following the line of cut
when cutting the workpiece. The rear kerf indicator aids in
aligning plunge cuts and following the kerf when exiting the
workpiece.
10
ASSEMBLY
UNPACKING
WARNING:
This product requires assembly.
Do not attempt to modify this tool or create
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 serious personal injury.
 Carefully remove the tool and any accessories from the
box. Make sure that all items listed in the packing list are
included.
 Inspect the tool carefully to make sure no breakage or
damage occurred during shipping.
 Do not discard the packing material until you have
carefully inspected and satisfactorily operated the tool.
WARNING:
Do not connect to power supply until assembly
is complete. Failure to comply could result in
accidental starting and possible serious personal
injury.
 If any parts are damaged or missing, please call
1-866-539-1710 for assistance.
PACKING LIST
6-1/2 in. Circular Saw
18-tooth Carbide Tipped Blade
Cord Wrap
WARNING:
Hex Key
Tool Bag
Operator’s Manual
A 6-1/2 in. blade is the maximum blade capacity
of the saw. Never use a blade that is too thick to
allow outer blade washer to engage with the flat
on the spindle. Larger blades will come in contact
with the blade guards, while thicker blades will
prevent blade screw from securing blade on
spindle. Either of these situations could result in a
serious accident.
WARNING:
If any parts are damaged or missing do not operate
this tool until the parts are replaced. Failure to
heed this warning could result in serious personal
injury.
11
ASSEMBLY
CAUTION:
SPINDLE
LOCK
To prevent damage to the spindle or spindle lock,
always allow motor to come to a complete stop
before engaging spindle lock.
ATTACHING BLADE
See Figures 2 - 3.
 Unplug the saw.
 Depress and hold spindle lock.
 Remove blade screw by turning it counterclockwise with
the provided hex key, while keeping the spindle lock
depressed.
 Remove outer blade washer (“D” washer).
HEX KEY
WARNING:
If inner flange bushing has been removed, replace
it before placing blade on spindle. Failure to do
so will prevent blade from tightening properly and
could result in serious personal injury.
BLADE
SCREW
 Retract the lower blade guard into the upper blade guard
using the lower blade guard handle. Make sure the lower
guard spring works properly, allowing the guard to move
freely.
 Check to see that the saw teeth and arrow on the saw
blade and the arrow on the lower guard are pointing in
the same direction.
NOTE: The saw teeth point upward at the front of the
saw as shown.
 Fit the saw blade inside the lower blade guard and onto
the spindle.
 Replace “D” washer.
 Depress and hold spindle lock and replace blade
screw.
 Tighten blade screw securely by turning it clockwise with
the hex key.
NOTE: Never use a blade that is too thick to allow the
“D” washer to engage with the flat on the spindle.
LOWER BLADE GUARD
Fig. 2
BLADE
BLADE
SCREW
REMOVING BLADE
See Figures 2 - 3.
 Unplug the saw.
 Depress spindle lock.
 Remove blade screw by turning it counterclockwise with
the provided hex key, while keeping the spindle lock
depressed.
 Remove outer blade washer (“D” washer).
 Lift lower blade guard.
 Remove blade.
OUTER BLADE
WASHER
(“D” WASHER)
12
SPINDLE
INNER
FLANGE
BUSHING
Fig. 3
OPERATION
WARNING:
Do not allow familiarity with tools to make you
careless. Remember that a careless fraction of a
second is sufficient to inflict serious injury.
WARNING:
Always wear safety goggles or safety glasses with
side shields when operating power tools. Failure
to do so could result in objects being thrown into
your eyes resulting in possible serious injury.
KICKBACK - BLADE SET TOO DEEP
Fig. 4
APPLICATIONS
You may use this tool for the purpose listed below:
 Cutting all types of wood and wood products
NOTE: The use of abrasive cut-off wheels is not
recommended for this saw.
KICKBACK
See Figures 4 - 7.
Kickback occurs when the blade stalls rapidly and the saw
is driven back towards you. Blade stalling is caused by any
action which pinches the blade in the wood.
DANGER:
Release switch immediately if blade binds or saw
stalls. Kickback could cause you to lose control
of the saw. Loss of control can lead to serious
personal injury.
INCORRECT SUPPORT
Fig. 5
To guard against kickback, avoid dangerous practices such
as the following:
 Setting blade depth incorrectly
 Sawing into knots or nails in workpiece
 Twisting the blade while making a cut
 Making a cut with a dull, gummed up, or improperly set
blade
 Supporting the workpiece incorrectly
No more than 1/4 inch
 Forcing a cut
 Cutting warped or wet lumber
 Operating the tool incorrectly or misusing the tool
CORRECT BLADE DEPTH SETTING = BLADE EXPOSED 1/4 in.
OR LESS ON UNDERSIDE OF WORKPIECE
Fig. 6
13
OPERATION
To lessen the chance of kickback, follow these safety
practices:
 Keep the blade at the correct depth setting. The depth
setting should not exceed 1/4 in. below the material being
cut.
 Inspect the workpiece for knots or nails before cutting.
Never saw into a knot or nail.
 Make straight cuts. Always use a straight edge guide
when rip cutting. This helps prevent twisting the blade.
 Use clean, sharp, and properly set blades. Never make
cuts with dull blades.
 Support the workpiece properly before beginning a cut.
 Use steady, even pressure when making a cut. Never
force a cut.
 Do not cut warped or wet lumber.
 Hold the saw firmly with both hands and keep your body
in a balanced position so as to resist the forces if kickback
should occur.
CORRECT SUPPORT
Fig. 7
LOWER BLADE GUARD IS IN UP
POSITION WHEN MAKING A CUT
WARNING:
When using the saw, always stay alert and
exercise control. Do not remove the saw from
the workpiece while the blade is moving.
SAW BLADES
The best of 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 that sharp blades
are always available.
Gum and wood pitch hardened on blades will slow the
saw down. Remove saw blade from the saw and use gum
and pitch remover, hot water, or kerosene to remove these
accumulations. DO NOT USE GASOLINE.
Fig. 8
CAUTION:
To avoid possible serious injury, never use saw
when guard is not operating correctly. Check the
guard for correct operation before each use. The
guard is operating correctly when it moves freely,
and instantly returns to the closed position. If you
drop the saw, check the lower blade guard and
bumper for damage at all depth settings before
reuse.
BLADE GUARD SYSTEM
See Figure 8.
The lower blade guard attached to the circular saw is there
for your protection and safety. Do not alter it for any reason.
If it becomes damaged, do not operate the saw until you
have the guard repaired or replaced. Always leave guard in
operating position when using the saw.
If at any time the lower blade guard does not snap closed,
unplug the saw from the power supply. Exercise the lower
guard by moving it rapidly back and forth from the full open
position to the closed position several times. Normally this
will restore the guard to its normal operating condition. If
it does not correct a slow or sluggish closing lower guard,
do not use the saw. Take it to an authorized factory service
center for repair.
DANGER:
When sawing through work, lower blade guard
does not cover blade on the underside of work.
Since blade is exposed on underside of work, keep
hands and fingers away from cutting area. Any part
of your body coming in contact with moving blade
will result in serious injury.
14
OPERATION
DETACHABLE CORD
See figures 9 - 10.
The detachable cord can be easily stored or replaced quickly
if damaged.
To detach:
 Push cord lock button forward and hold.
 Twist cord fully counterclockwise and pull away from the
saw.
DETACHABLE
CORD
To reattach:
 Align notch in the saw cord receptacle with the ridge in
the cord head.
 Insert cord head into cord receptacle and twist fully
clockwise.
NOTE: You will hear a click when the cord is securely
attached to the saw.
CORD LOCK
BUTTON
STARTING/STOPPING THE SAW
Fig. 9
See Figure 11.
To start the saw: Depress the switch trigger.
Always let the blade reach full speed, then guide the saw
into the workpiece.
TO REATTACH
WARNING:
The blade coming in contact with the workpiece
before it reaches full speed could cause the saw to
“kickback” toward you, resulting in serious injury.
To stop the saw: Release the switch trigger.
After you release the switch trigger, allow the blade to
come to a complete stop. Do not remove the saw from the
workpiece while the blade is moving.
TO DETACH
Fig. 10
SWITCH
TRIGGER
Fig. 11
15
OPERATION
ADJUSTING BLADE DEPTH
See Figures 12 - 13.
Always keep correct blade depth setting. The correct blade
depth setting for all cuts should not exceed 1/4 in. below
the material being cut. More blade depth will increase the
chance of kickback and cause the cut to be rough.
 Unplug the saw.
 Pull depth adjustment lever upward to release.
DEPTH INDICATOR
DEPTH OF CUT SCALE
 Determine the desired depth of cut.
 Hold base flat against the workpiece and raise or lower
saw until the indicator mark on the saw aligns with the
desired depth on the scale.
 Push down on depth adjustment lever to lock into
position.
PLYWOOD ID SYSTEM
DEPTH ADJUSTMENT
LEVER
INDEXING LEVERS
See Figure 13.
Fig. 12
The levers on the saw can be repositioned for the best
tightening position.
 Pull the lever out from the saw and move to desired
position.
 Push lever back in and down to lock into place.
PUSH IN AND
DOWN TO LOCK
 Check to be sure the base is clamped securely.
PLYWOOD ID SYSTEM
See Figure 12.
Indicators along the elevation bracket help to quickly identify
the following common plywood thicknesses: 1/4, 3/8, 1/2,
5/8, 3/4, and 1 in. A “click” can be heard as the saw is moved
from one thickness setting to the next.
 Unplug the saw.
 Pull depth adjustment lever upward to release.
PULL OUT AND UP
TO RATCHET
 Determine the thickness of the workpiece.
 Hold base flat against the workpiece and raise or lower saw
until the saw clicks into the correct thickness setting.
 Push down on depth adjustment lever to lock into
position.
NOTE: Saw teeth will extend slightly further than the selected
thickness setting to allow the blade to pass completely
through the workpiece.
16
Fig. 13
OPERATION
OPERATING THE SAW
See Figures 14 - 16.
Refer to the figures in this section to learn the correct and
incorrect ways for 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 possible 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 the lower
blade guard is closed before setting the saw
down.
Fig. 14
To make the best possible cut, follow these helpful hints.
 Hold the saw firmly with both hands.
 Avoid placing your hand on the workpiece while making
a cut.
 Support the workpiece so that the cut (kerf) is always to
your side.
 Support the workpiece near the cut.
 Clamp the workpiece securely so that the workpiece will
not move during the cut.
 Always place the saw on the workpiece that is supported,
not the “cut off” piece.
 Place the workpiece with the “good” side down.
 Draw a guideline along the desired line of cut before
beginning the cut.
 Keep the cord away from the cutting area. Always place
the cord to prevent it from hanging up on the workpiece
while making a cut.
Fig. 15
DANGER:
If the cord hangs up on the workpiece during a
cut, release the switch trigger immediately. Unplug
the saw and reposition the cord to prevent it from
hanging up again.
DANGER:
Using a saw with a damaged cord could result
in serious injury or death. If the cord has been
damaged, have it replaced before using the saw
again.
Fig. 16
17
OPERATION
CROSS CUTTING/RIP CUTTING
See Figures 17 - 19.
When making a cross cut or rip cut, align the guideline with
the full length kerf indicator on the base as shown in the
figure. The distance from the saw blade to the saw base is
approximately 5 in. on the left side of the saw and 1 in. on
the right side.
Since blade thicknesses vary, 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.
FULL LENGTH
KERF INDICATOR
GUIDELINE
NOTE: The distance from the line of cut to the guideline is
the amount you should offset the guide.
TO RIP CUT
See Figures 18 - 19.
Use a guide when making long or wide rip cuts with the
saw.
To rip cut using optional edge guide:
 Slide edge guide into the slot.
 Align the guideline with the full length kerf indicator on
the base.
 Adjust the guide so that the “0” on the guide is aligned
with the edge of the workpiece.
 Secure the guide with the lock knob provided with the
saw.
 Secure the workpiece.
 Position the face of the edge guide firmly against the edge
of workpiece.
Fig. 17
LOCK KNOB
EDGE GUIDE
FULL LENGTH
KERF INDICATOR
NOTE: The guiding edge of the workpiece must be
straight for your cut to be straight. Use caution to prevent
the blade from binding in the cut.
SLOT
 Saw along workpiece keeping guide firmly against edge
to achieve a straight rip cut.
To rip cut using a straight edge:
 Secure the workpiece.
 Clamp a straight edge to the workpiece using
C-clamps.
NOTE: Position C-clamps so they will not interfere with
the saw housing during the cut.
Fig. 18
C-CLAMPS
STRAIGHT
EDGE
 Saw along the straight edge to achieve a straight rip
cut.
NOTE: Do not bind the blade in the cut.
GUIDELINE
C-CLAMPS
WORKPIECE
18
Fig. 19
OPERATION
BEVEL CUTTING
BEVEL SCALE
See Figures 20 - 22.
To make the best possible cut, follow these helpful hints.
 Align the line of cut with the inner blade guide notch on
the base when making 45° bevel cuts.
BEVEL
ADJUSTMENT
LEVER
 Make a trial cut in scrap material along a guideline to
determine how much you should offset the guideline on
the cutting material.
 Adjust the angle of cut to any desired setting between zero
and 50°. Positive stops are located at 0°, 45°, and 50°.
Refer to To Adjust Bevel Setting later in this manual.
NOTE: Push the positive 50° stop button in while raising
the motor housing to set the bevel setting above 45° and
up to 50°.
INNER BLADE
GUIDE NOTCH
POSITIVE 50°
STOP BUTTON
TO ADJUST BEVEL SETTING
See Figures 20 - 21.
 Unplug the saw.
Fig. 20
 Pull the bevel adjustment lever upward until the motor
housing moves freely.
 Raise motor housing end of saw until you reach the
desired angle setting on bevel scale.
PUSH IN AND
DOWN TO LOCK
NOTE: Positive stops are located at 0°, 45°, and 50°.
Push the positive 50° stop button in while raising the
motor housing to set the bevel setting above 45° and up
to 50°.
 Push downward on the bevel adjustment lever until the
motor housing is securely locked in place.
INDEXING LEVERS
See Figure 21.
The levers on the saw can be repositioned for the best
tightening position.
PULL OUT AND UP
TO RATCHET
 Pull the lever out from the saw and move to desired
position.
 Push lever back in and down to lock into place.
Fig. 21
 Check to be sure the base is clamped securely.
WARNING:
Attempting a bevel cut without having the bevel
adjustment lever securely locked in place can
result in serious injury.
TO BEVEL CUT
See Figure 22.
 Hold the saw firmly with both hands as shown.
 Rest the front edge of the base on the workpiece.
 Start the saw and let the blade reach full speed.
 Guide the saw into the workpiece and make the cut.
 Release the trigger and allow the blade to come to a
complete stop.
Fig. 22
 Lift the saw from the workpiece.
19
OPERATION
POCKET CUTTING
See Figure 23.
WARNING:
Always adjust bevel setting to zero before making
a pocket cut. Attempting a pocket cut at any other
setting can result in loss of control of the saw
possibly causing serious injury.
 Adjust the bevel setting to zero.
 Set the blade to the correct blade depth setting.
 Swing the lower blade guard up using the lower blade
guard handle.
NOTE: Always raise the lower blade guard with the handle
to avoid serious injury.
Fig. 23
 Hold the lower blade guard by the handle.
 Rest the front of the base flat against the workpiece with
the rear of the handle raised so the blade does not touch
the workpiece.
 Release the trigger and allow the blade to come to a
complete stop.
 Start the saw and let the blade reach full speed.
 Clear corners out with a hand saw or sabre saw.
 Lift the saw from the workpiece.
 Guide the saw into the workpiece and make the cut.
WARNING:
WARNING:
Never tie the lower blade guard in a raised position.
Leaving the blade exposed could lead to serious
injury.
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
back toward you.
ADJUSTMENTS
To check positive 0° bevel stop:
WARNING:
 Unplug the saw.
 Place saw in an upside down position on a workbench.
Before performing any adjustment, make sure
the tool is unplugged from the power supply and
the switch is in the OFF ( O ) position. Failure to
heed this warning could result in serious personal
injury.
 Move the lower blade guard out of the way so that the
saw blade is exposed.
 Check the squareness of the saw blade to the base of
the saw using a combination square.
POSITIVE 0° BEVEL STOP
See Figure 24.
The saw has a positive 0° bevel stop that has been factory
adjusted to assure 0° angle of the saw blade when making 90°
cuts. However, misalignment can occur during shipping.
20
ADJUSTMENTS
To adjust positive 0° bevel stop:
 Unplug the saw.
 Pull bevel adjustment lever upward to release.
BEVEL ADJUSTMENT
LEVER
 Turn T8 setscrew with hex key (not provided) and adjust
base until it is square with the saw blade.
 Securely lock the bevel adjustment lever.
WARNING:
Attempting a bevel cut without having the bevel
adjustment lever securely locked in place can
result in serious injury.
SETSCREW
COMBINATION
SQUARE
Fig. 24
MAINTENANCE
Electric tools used on fiberglass material, wallboard,
spackling compounds, or plaster are subject to accelerated
wear and possible premature failure because the fiberglass
chips and grindings are highly abrasive to bearings, brushes,
commutators, etc. Consequently, we do not recommend
using this tool for extended work on these types of materials.
However, if you do work with any of these materials, it is
extremely important to clean the tool using compressed
air.
WARNING:
When servicing use only identical RIDGID
replacement parts. Use of any other parts may
create a hazard or cause product damage.
WARNING:
Always wear safety goggles or safety glasses with
side shields during power tool operation or when
blowing dust. If operation is dusty, also wear a
dust mask.
LUBRICATION
All of the bearings in this tool are lubricated with a sufficient
amount of high grade lubricant for the life of the unit under
normal operating conditions. Therefore, no further lubrication
is required.
GENERAL MAINTENANCE
Avoid using solvents when cleaning plastic parts. Most
plastics are susceptible to damage from various types of
commercial solvents and may be damaged by their use. Use
clean cloths to remove dirt, dust, oil, grease, etc.
WARNING:
Do not at any time let brake fluids, gasoline,
petroleum-based products, penetrating oils, etc.,
come in contact with plastic parts. Chemicals can
damage, weaken or destroy plastic which may
result in serious personal injury.
21
MAINTENANCE
CHECKING/REPLACING EXTERNAL
BRUSHES
See Figure 25.
NOTE: The saw is equipped with externally accessible
brushes.
BRUSH
CAP
 Unplug the saw.
WARNING:
50
Failure to unplug the tool could result in accidental
starting causing possible serious injury.






BRUSH
ASSEMBLY
45
30
12
22
15
BRUSH
ASSEMBLY
NOTE: Brush caps (2) are located on each side of the
motor housing.
Remove brush caps (2) using a screwdriver.
Remove brush assemblies (2).
Check for wear. Replace both brush assemblies when
either has less than 1/4 in. length of carbon remaining.
NOTE: Do not replace one side without replacing the
other.
Reassemble using new brush assemblies. Make sure
curvature of brush matches curvature of motor and that
brush moves freely in brush tube.
Reassemble by reversing the steps listed above.
Tighten all brush caps securely. Do not over tighten.
BRUSH CAP
Fig. 25
ACCESSORIES
Look for these accessories where you purchased this product:
� Edge Guide ...................................................................................................................................................... 631697001
WARNING:
Current attachments and accessories available for use with this tool are listed above. Do not use any attachments
or accessories not recommended by the manufacturer of this tool. The use of attachments or accessories not
recommended can result in serious personal injury.
22
WARRANTY
RIDGID® HAND HELD AND STATIONARY POWER TOOL
3 YEAR LIMITED SERVICE WARRANTY
WHAT IS NOT COVERED
Proof of purchase must be presented when requesting
warranty service.
This warranty applies only to the original purchaser at retail
and may not be transferred. This warranty only covers
defects arising under normal usage and does not cover
any malfunction, failure or defect resulting from misuse,
abuse, neglect, alteration, modification or repair by other
than an authorized service center for RIDGID® branded hand
held and stationary power tools. Consumable accessories
provided with the tool such as, but not limited to, blades,
bits and sand paper are not covered.
Limited to RIDGID® hand held and stationary power tools
purchased 2/1/04 and after. This product is manufactured
by One World Technologies, Inc. The trademark is licensed
from RIDGID, Inc. All warranty communications should be
directed to One World Technologies, Inc., attn: RIDGID Hand
Held and Stationary Power Tool Technical Service at (toll
free) 1-866-539-1710.
90-DAY SATISFACTION GUARANTEE POLICY
RIDGID, INC. AND ONE WORLD TECHNOLOGIES, INC.
MAKE NO WARRANTIES, REPRESENTATIONS OR
PROMISES AS TO THE QUALITY OR PERFORMANCE OF
ITS POWER TOOLS OTHER THAN THOSE SPECIFICALLY
STATED IN THIS WARRANTY.
During the first 90 days after the date of purchase, if you are
dissatisfied with the performance of this RIDGID® Hand Held
and Stationary Power Tool for any reason you may return
the tool to the dealer from which it was purchased for a full
refund or exchange. To receive a replacement tool you must
present proof of purchase and return all original equipment
packaged with the original product. The replacement tool
will be covered by the limited warranty for the balance of
the 3 YEAR service warranty period.
ADDITIONAL LIMITATIONS
To the extent permitted by applicable law, all implied
warranties, including warranties of MERCHANTABILITY or
FITNESS FOR A PARTICULAR PURPOSE, are disclaimed. Any
implied warranties, including warranties of merchantability or
fitness for a particular purpose, that cannot be disclaimed
under state law are limited to three years from the date
of purchase. One World Technologies, Inc. and RIDGID,
Inc. are not responsible for direct, indirect, incidental or
consequential damages. Some states do not allow limitations
on how long an implied warranty lasts and/or do not allow
the exclusion or limitation of incidental or consequential
damages, so the above limitations may not apply to you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
WHAT IS COVERED UNDER THE 3 YEAR
LIMITED SERVICE WARRANTY
This warranty on RIDGID® Hand Held and Stationary Power
Tools covers all defects in workmanship or materials and
normal wear items such as brushes, chucks, motors,
switches, cords, gears and even cordless batteries in this
RIDGID® tool for three years following the purchase date of
the tool. Warranties for other RIDGID® products may vary.
HOW TO OBTAIN SERVICE
To obtain service for this RIDGID® tool you must return it;
freight prepaid, or take it in to an authorized service center
for RIDGID® branded hand held and stationary power
tools. You may obtain the location of the authorized service
center nearest you by calling (toll free) 1-866-539-1710 or
by logging on to the RIDGID® website at www.ridgid.com.
When requesting warranty service, you must present the
original dated sales receipt. The authorized service center will
repair any faulty workmanship, and either repair or replace
any part covered under the warranty, at our option, at no
charge to you.
One World Technologies, Inc.
P.O. Box 35, Hwy. 8
Pickens, SC 29671
23
OPERATOR’S MANUAL
6-1/2 in. CIRCULAR SAW
DOUBLE INSULATED
R3203-1
Customer Service Information:
For parts or service, contact your nearest RIDGID authorized service center. Be
sure to provide all relevant information when you call or visit. For the location of
the authorized service center nearest you, please call 1-866-539-1710 or visit us
online at www.ridgid.com.
The model number of this tool is found on a plate attached to the motor housing.
Please record the serial number in the space provided below. When ordering repair
parts, always give the following information:
Model No.
Serial No.
987000-059
9-28-06 (REV:00)
R3203-1

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