Maximum 055-6767-0 Instruction manual

Model no. 055-6767-0

IMPORTANT:

Please read this manual carefully before using this mitre saw and save it for reference.

INSTRUCTION

MANUAL

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model no. 055-6767-0 | contact us 1-888-670-6682

TABLE OF CONTENTS

QUICK START GUIDE

SYMBOLS

SPECIFICATIONS

SAFETY GUIDELINES

ACCESSORIES AND ATTACHMENTS

TOOLS NEEDED FOR ASSEMBLY

CARTON CONTENTS

KNOW YOUR SLIDING MITRE SAW

ASSEMBLY

ADJUSTMENTS

OPERATION

MAINTENANCE

TROUBLESHOOTING GUIDE

REPLACEMENT PARTS

WARRANTY

NOTE:

If any parts are missing or damaged, or if you have any questions, please call our toll-free helpline at 1-888-670-6682.

SAVE THESE INSTRUCTIONS

This manual contains important safety and operating instructions.

Read all instructions and follow them with use of this products.

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Read and understand the instruction manual to get the best use of the dual-bevel sliding compound mitre saw.

1

Make sure the all accessories and the blade are installed correctly and are tight before operating the saw.

NOTE: The blade has been installed in the mitre saw at the factory.

Recheck and adjust the alignment of the blade before cutting if necessary.

7 1/2”

(19 cm)

7 1/2”

(19 cm)

3

Use the hold-down clamp to hold the workpiece firmly against the fence to prevent movement towards the blade. It is safer than using your hand and it frees both hands to operate the mitre saw.

2

Place hands at least 7 1/2" (19 cm) away from the path of the blade— out of the “no-hands zone.”

4

Turn the laser guide on for pre-alignment of your cut. Use the laser adjustment knobs to adjust the laser beam if necessary.

6

Hold the cutting arm in the down position. Release the trigger switch and wait for all moving parts to stop before moving your hands and raising the cutting arm.

5

With the power switch OFF, bring the saw blade down to the workpiece to see the cutting path of the blade.

Then, squeeze trigger switch to start the saw and lower the blade into the workpiece with a firm downward motion.

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WARNING ICONS

Your power tool and its Operator’s Manual may contain “WARNING ICONS” (a picture symbol intended to alert you to, and/or instruct you how to avoid, a potentially hazardous condition). Understanding and heeding these symbols will help you operate your tool better and safer. Shown below are some of the symbols you may see.

SAFETY ALERT: Precautions that involve your safety.

PROHIBITION

WEAR EYE PROTECTION: Always wear safety goggles or safety glasses with side shields.

WEAR RESPIRATORY AND HEARING PROTECTION: Always wear respiratory and hearing protection.

READ AND UNDERSTAND INSTRUCTION MANUAL: To reduce the risk of injury, user and all bystanders must read and understand instruction manual before using this product.

KEEP HANDS AWAY FROM BLADE: Failure to keep your hands away from the blade will result in serious personal injury.

SUPPORT AND CLAMP WORK

DANGER

WARNING

CAUTION

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.

SPECIFICATIONS

MOTOR

POWER SOURCE

SPEED

BRAKE

DOUBLE INSULATED

ARBOUR SHAFT SIZE

BLADE

DIAMETER

ARBOUR SIZE

ROTATING TABLE

MITRE ANGLE RANGE

POSITIVE MITRE STOPS

BEVEL ANGLE RANGE

BEVEL POSITIVE STOPS

CUTTING CAPACITY

CROSSCUT (MAXIMUM HEIGHT)

CROSSCUT (MAXIMUM WIDTH)

MITRE 45° RIGHT & LEFT

BEVEL 45° RIGHT

BEVEL 45° LEFT

45° MITRE AND 45° BEVEL

CROWN MOULDING NESTED

BASE MOULDING AGAINST FENCE

NET WEIGHT

LASER

CLASS IIIA

LASER WAVELENGTH

MAX. LASER OUTPUT

120V AC, 60 Hz, 15A

3200 RPM (No load)

ELECTRIC

Yes

5/8" (15.9 mm)

10" (25.4 cm), 60-tooth carbide-tipped

5/8" (15.9 mm)

0°–50° Right & Left

0°, 15°, 22.5°, 31.6°, 45° Right & Left

0°–45° Right / 0°–47° Left

0°, 33.9°, 45° Right & Left

3 1/2" x 11 1/2" (8.9 x 29.2 cm)

3 1/2" x 12 1/2" (8.9 x 31.8 cm)

3 1/2" x 8 3/4" (8.9 x 22.2 cm)

1" x 12 1/2" (2.5 x 31.8 cm)

1 5/8" x 12 1/2" (4.1 x 31.8 cm)

1 5/8" x 8 3/4" (4.1 x 22.2 cm)

5 3/4" (14.6 cm)

3 1/2" (8.9 cm)

20.06 kg (44 lb 4 oz)

630–660 nm

< 5 mW

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GENERAL SAFETY INSTRUCTIONS BEFORE USING THIS POWER TOOL

Safety is a combination of common sense, staying alert and knowing how to use your power tool.

• READ and become familiar with the entire Operator’s Manual. LEARN the tool’s application, limitations and possible hazards.

• KEEP GUARDS IN PLACE and in working order.

• 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.

• KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

• DO NOT USE IN DANGEROUS ENVIRONMENTS. Do not use power tools in damp locations, or expose them to rain or snow. Keep work area well lit.

• KEEP CHILDREN AWAY. All visitors and bystanders should be kept a safe distance from work area.

• MAKE WORKSHOP CHILD PROOF with padlocks, master switches or by removing starter keys.

• DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed.

• USE THE RIGHT TOOL. Do not force the tool or an attachment to do a job for which it was not designed.

• 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 that the product will draw. An undersized cord will result in a drop in line voltage and in loss of power, which will cause the tool overheat. The table on page 14 shows the proper wire gauge size usage for each extension cord length and ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

• WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewellery which may get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair.

WARNING!

• To avoid mistakes that could cause serious injury, do not plug the tool in until you have read and understood the safety guidelines.

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• 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–resistant lenses. They ARE NOT safety glasses.

NOTE:

Glasses or goggles not in compliance with ANSI Z87.1 could seriously injure you when they break.

WEAR A FACE MASK OR DUST MASK. Sawing produces dust.

SECURE WORK. Use clamps or a vice to hold work when practical. It is safer than using your hand and it frees both hands to operate the tool.

• DISCONNECT TOOLS FROM POWER SOURCE before servicing, and when changing accessories such as blades, bits and cutters.

• REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in the OFF position before plugging the tool in.

• USE RECOMMENDED ACCESSORIES. Consult this Operator’s Manual for recommended accessories. The use of improper accessories may cause a risk of injury to yourself or others.

• NEVER STAND ON THE TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.

• 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 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.

• NEVER LEAVE THE TOOL RUNNING UNATTENDED. TURN THE POWER “OFF”. Do not walk away from a running tool until the blade comes to a complete stop and the tool is unplugged from the power source.

• DO NOT OVERREACH. Keep proper footing and balance at all times. NEVER reach across the path of the cutting blade while tool is in operation.

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

• DO NOT use power tool in the presence of flammable liquids or gases.

• DO NOT operate the tool if you are under the influence of any drugs, alcohol or medication that could affect your ability to use the tool properly.

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• People with electronic devices, such as pacemakers, should consult their physician(s) before using this product. Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker.

• WEAR HEARING PROTECTION to reduce the risk of induced hearing loss.

SPECIFIC SAFETY INSTRUCTIONS FOR THIS SLIDING MITRE SAW

• DO NOT operate the mitre saw until it is completely assembled and installed according to these instructions.

• IF YOU ARE NOT thoroughly familiar with the operation of mitre saws, seek guidance from your supervisor, instructor or other qualified person.

• ALWAYS hold the work firmly against the fence and table. DO NOT perform any operation free hand (use clamp wherever possible).

• KEEP HANDS out of the path of the saw blade. If the workpiece you are cutting would cause your hands to be within 7 1/2" (19 cm) of the saw blade, the workpiece should be clamped in place before making the cut.

• BE SURE the blade is sharp, runs freely and is free of vibration.

• ALLOW the motor to come up to full speed before starting a cut.

• KEEP THE MOTOR AIR SLOTS CLEAN and free of chips or dust.

• ALWAYS MAKE SURE all handles are tight before cutting, even if the table is positioned in one of the positive stops.

• BE SURE both the blade and the collar are clean and the arbour bolt is tightened securely.

• USE only blade collars specified for your saw.

• NEVER use blades larger in diameter than 10 inches.

• NEVER apply lubricants to the blade when it is running.

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.

• ALWAYS check the blade for cracks or damage before operation. Replace a cracked or damaged blade immediately.

• NEVER use blades recommended for operation at less than 3200 RPM.

• ALWAYS keep the blade guards in place and use at all times.

• NEVER reach around the saw blade.

• MAKE SURE the blade is not contacting the workpiece before the switch is

turned ON.

• IMPORTANT: After completing the cut, release the trigger and wait for the blade to stop before returning the saw to the raised position.

• 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.

• NEVER cut metals or masonry products with this tool. This mitre saw is designed for use on wood and wood-like products.

• NEVER cut small pieces. If the workpiece being cut would cause your hand or fingers to be within 7 1/2" (19 cm) of the saw blade, the workpiece is too small.

• PROVIDE adequate support to the sides of the saw table for long work pieces.

• NEVER use the mitre saw in an area with flammable liquids or gases.

• NEVER use solvents to clean plastic parts. Solvents could possibly dissolve or otherwise damage the material.

• SHUT OFF the power before servicing or adjusting the tool.

• DISCONNECT the saw from the power source and clean the machine when

finished using.

• MAKE SURE the work area is clean before leaving the machine.

• SHOULD any part of your mitre saw be missing, damaged, or fail in any way, or any electrical component fail to perform properly, lock the switch and remove the plug from the power supply outlet. Replace missing, damaged, or failed parts before resuming operation.

• Because of the downward cutting motion, your safety requires that you stay very alert to keeping hands and fingers away from the path that the blade travels.

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• Be sure all guards are in place and working. If a guard seems slow to return to its normal position or “hangs-up,” adjust or repair it immediately. Be alert at all times—especially during repetitive, monotonous operations. Don’t be lulled into carelessness due to a false sense of security. Blades are extremely unforgiving.

Clean the lower guard frequently to help visibility and movement. Unplug before adjustment or cleaning.

• Abrasive cut-off wheels should not be used on mitre saws. Mitre saw guards are not appropriate for abrasive cut-off wheels.

• To avoid loss of control or placing hands in the path of the blade, hold or clamp all material securely against the fence when cutting. Do not perform operations freehand.

• Support long material at the same height as the saw table.

• After completing a cut, release the trigger switch and allow the blade to come to a complete stop, then raise the saw blade from the workpiece.

• Lock the mitre saw head in the down position during transport or when not in use.

• DRY RUN - It is important to know where the blade will intersect with the workpiece during cutting operations. Always perform a simulated cutting sequence with the power tool switched OFF to gain an understanding of the projected path of the saw blade. At some extreme angles, the right or left side fence might have to be removed to ensure proper clearance prior to making a cut.

POWER SUPPLY AND MOTOR SPECIFICATIONS

• The AC motor used in this saw is a universal, nonreversible type. See “MOTOR” in the

“TECHNICAL SPECIFICATIONS” section on page 7.

ELECTRICAL REQUIREMENTS – DOUBLE INSULATED

• The power tool is double insulated to provide a double thickness of insulation between you and tool’s electrical system. All exposed metal parts are isolated from the internal metal motor components with protecting insulation.

WARNING!

• To avoid electrical hazards, fire hazards, or damage to the tool, use proper circuit protection. Your saw is wired at the factory for 120 V operation. Connect to a 120 V, 15 A circuit and use a 15 A 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.

• Replacement parts – When servicing, use only identical replacement parts.

• Polarized plugs – This saw has a plug that looks like the one shown below:

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• To reduce 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.

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.

• CONNECT this saw to a 120 V, 15 A circuit with a 15 A time-delay fuse or circuit breaker. Using the wrong size fuse can damage the motor.

• 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 saw again. If the motor still does not start, refer to the TROUBLESHOOTING GUIDE.

• 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.

• FUSES may “blow” or circuit breakers may trip frequently if:

- MOTOR is overloaded – overloading can occur if you feed too rapidly or make too many start/stops in a short time.

WARNING!

• Double insulation does not take the place of normal safety precautions when operating this tool.

• To avoid electrocution:

- Use only identical replacement parts when servicing a tool with double insulation. Servicing should be performed by a qualified technician.

- Do not use power tools in wet or damp locations or expose them to rain or snow.

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- 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.

- IMPROPER or dull saw blades are used.

• 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.

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. 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.

• Use a separate electrical circuit for your tools. This circuit must not be less than a

#12 wire with a 20 A time-lag fuse or a #14 wire with a 15 A time-lag fuse.

NOTE: When using an extension cord on a circuit with a #14 wire, the extension cord must not exceed 25 feet in length. 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.

MINIMUM GAUGE FOR EXTENSION CORDS (AWG)

(when using 120 V only)

Amperage rating

More than Not more than

25’ (7.6 m)

0

6

6

10

18

18

Total length of cord in feet

50’ (15 m)

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100’ (30 m)

16

14

150’ (45 m)

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12

10

12

12

16

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14

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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.

RECOMMENDED ACCESSORIES

• Use only accessories recommended for this mitre saw. Follow instructions that accompany accessories. Use of improper accessories may cause hazards.

• The use of any cutting tool except 10" saw blades which meet the requirements under recommended accessories is prohibited. Do not use accessories such as shaper cutters or dado sets. Ferrous metal cutting and the use of abrasive wheels is prohibited.

ACCESSORIES

• To avoid the risk of personal injury, do not modify this power tool or use accessories not recommended.

• Read warnings and conditions on your CARBIDE TIPPED 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 blade, cracks, breakage, missing or loose tips, or other damage. Do not use if damage is suspected. Failure to heed safety instructions and warnings can result in serious bodily injury.

BLADE INFORMATION

• Always use a crosscut blade that is designed for cutting across the wood grain.

NEVER use Rip, Combination, Plywood, Dado or Abrasive type saw blades at

any time.

• Always use a 10" diameter blade with a 5/8" arbour hole. Speed rating must be at least 3200 RPM.

• Read and understand all instructions provided with each blade before using on this mitre saw.

• There are two main materials used for saw blades; high-speed steel (HSS) and carbide tipped (TCT). While the HSS blades are generally less expensive than carbide tipped,

TCT blades will stay sharper longer than HSS. As a general rule the more teeth per inch (TPI) the smoother the cut. Please read the information provided on the blade for more details for their use.

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- General Purpose Wood Cutting: 24–40 TPI

- Fine Woodworking Cutting: 60–80 TPI

- Non-Ferrous Metal Cutting: Use only special blades designed for cutting this type of material.

- Plastic Cutting: Use only special blades designed for cutting plastic.

• When cutting non-ferrous or plastic, be sure to clean up completely after each use.

Take special care with metal shavings after each cut, as these can cause damage to the table top. ALWAYS WEAR EYE PROTECTION.

Supplied

Blade wrench

Not supplied

Adjustable wrench

Star-head screwdriver

5 mm hex wrench

Combination square Slotted screwdriver

COMBINATION SQUARE MUST BE TRUE

Should not gap or overlap when square is flipped over (see dotted figure).

Draw light line on board along this edge.

Straight edge or a 3/4" board—this edge must be perfectly straight.

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Should not gap or overlap when square is flipped over (see dotted figure).

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1

No. Description

Mitre saw

4

Instruction manual

Hold-down clamp

Mitre handle hardware bag

Dust bag

7

Blade wrench

Bevel locking handle hardware bag

WARNING!

• Remove the product and any accessories from the package. 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 carton or any packaging material until all parts have been examined.

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1

No. Description

ON/OFF trigger switch handle

Laser vertical adjustment knob

Laser horizontal adjustment knob

Lower blade guard

Base

Mitre handle

Positive stop locking lever

Bevel locking handle

No. Description

9 Mitre detent override

10 Table

11 Stop plate

12 Left extension wing

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Sliding fence

14

Hold-down clamp

15

Power cord storage

16

Built-in carry handle

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32

17

30

31

28

29

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20

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19

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No. Description

17 Slide carriage lock knob

18 Stop knob

19 Hold-down latch

20 Stop plate

21

Bevel detent pin

22

Sliding fence cam locking lever

23

Right extension wing

24

Mounting hole

25

Extension wing locking lever

26

25

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23

No. Description

26 Mitre scale

27 Quick-cam mitre locking lever

28 Table insert

29 Blade

30 Safety lock-off switch

31

ON/OFF trigger switch

32

Laser ON/OFF rocker switch

33

Motor

RELEASING CUTTING HEAD (Fig. 1)

Raising

• Push down slightly on the trigger switch handle (1).

• Pull out the hold-down latch (2).

• Raise the cutting head to the uppermost position.

NOTE: This cutting head is spring loaded.

Locking

When transporting or storing the mitre saw, the cutting head should always be locked in the down position.

• Push the cutting head down.

• Press the hold-down latch (2) in to lock.

IMPORTANT: To avoid damage, never carry the mitre saw by the trigger switch handle or the cutting arm.

INSTALLING THE DUST BAG (Fig. 2)

• Install the dust bag assembly (1) onto the exhaust port (2) on the mitre saw. Fit the connecting tube of dust bag assembly and the exhaust port together.

NOTE:

• The dust bag assembly should be angled towards the right side of the saw for best results. This will also avoid any interference during the saw operation.

• To empty dust bag, pull out dust bag assembly from exhaust port. Open zipper on underside of bag and empty into waste container.

IMPORTANT: Check frequently and empty bag before it gets full.

Fig. 1

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Fig. 2

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2

WARNING!

• To avoid injury, do not connect this mitre saw to the power source until it is completely assembled and adjusted and you have read and understood this Instruction Manual.

• To avoid injury and damage to the saw, transport and store the mitre 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.

• Do not use this saw to cut and/or sand metals. The hot chips or sparks may ignite sawdust from the bag material.

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INSTALLING THE BEVEL LOCKING

HANDLE (Fig. 3)

• Insert the bevel locking handle (1) onto the shaft (2) at an approximately angle 30° below the level as shown in Fig. 3.

• Thread the hex screw (3) through the washer (4) into the bevel locking handle (1).

• Tighten the screw (3) with the 5 mm

Fig. 3

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1

hex wrench.

INSTALLING THE MITRE HANDLE (Fig. 3)

• Insert the mitre handle (5) into the hole in front of the mitre saw and align the hole (6) on the mitre handle (5) with the hole (7) in the front of the table.

• Thread the screw (8) through the hole (7) in the table into the hole (6) on the mitre handle (5).

• Tighten the screw (8) with a screwdriver.

INSTALLING THE HOLD-DOWN CLAMP

ASSEMBLY (Fig. 4, 5)

• Place the hold-down clamp assembly (1) facing toward the back of the mitre saw as shown in Fig. 4.

• The groove on the clamp rod should be fully inserted into the mounting hole (2) of the base without being visible.

• Rotate the hold-down clamp assembly (1) toward the front of the mitre saw.

• Loosen the knob (3) to adjust the clamp up or down to firmly clamp the workpiece.

• The hold-down clamp assembly (1) can be inserted in one of the mounting holes (2) located behind the fence.

Fig. 4

3

Fig. 5

4

3

1

2

2

8

7

6

5

WARNING!

• To avoid interference, the bevel locking handle shall be installed before the mitre handle.

UNLOCKING THE SLIDE CARRIAGE

(Fig. 6)

• After removing the saw from the carton, loosen the slide carriage lock knob (1),

located on the left side of the slide carriage. When transporting or storing the mitre saw, the slide carriage should always be locked in position.

Fig. 6

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REMOVING AND INSTALLING THE BLADE

Removing the Blade (Fig. 7, 8, 9)

• Unplug the saw from the outlet.

• Raise the cutting head to the upright position.

• Raise the lower blade guard (1) to the uppermost position. (Fig. 7)

• Remove the cover plate screw (2) with a star-head screwdriver.

• Rotate the cover plate (3) back to expose the arbour bolt (4).

• Place the provided blade wrench over the arbour bolt (4).

• Locate the arbour lock button (5) below the trigger switch handle. (Fig. 8)

• Press the arbour lock button (5), holding it in firmly while turning the blade wrench clockwise. This will engage the arbour lock allowing the arbour bolt to be loosened with the blade wrench. Continue to hold the arbour lock button (5) while turning the wrench clockwise to loosen the arbour bolt.

Fig. 7

Fig. 8

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WARNING!

• Do not use a blade larger than 10" in diameter. To avoid injury from an accidental start, make sure the switch is in the OFF position and the plug is not connected to the power source outlet.

NOTE: The mitre saw comes with the saw blade already installed.

• Make sure the blade is installed correctly and is tight before operating saw.

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• Remove the arbour bolt (4), the outer blade collar (6), and the blade (7). Do not remove the inner blade collar. (Fig. 9)

• Raise the lower blade guard (1) to the upright position to remove the blade. (Fig. 7)

NOTE: Pay attention to the pieces removed, noting their position and the direction they face. Wipe the blade collars clean of any sawdust before installing a new blade.

Fig. 9

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6

7

Installing the Blade (Fig. 7, 8, 9)

• Install a 10" blade with a 5/8" arbour hole making sure the rotation arrow on the blade matches the clockwise rotation arrow on the upper guard, and the blade teeth are pointing downward at the front of the saw.

• Place the outer blade collar (6) against

the blade and on the arbour. Thread the arbour bolt (4) onto the arbour in a

counter-clockwise direction. (Fig. 7)

IMPORTANT: The flat side of the blade collar must be placed against the blade. Do not install the collar with the curved side against the blade.

• Place the blade wrench on the arbour bolt (4).

• Press the arbour lock button (5), holding it in firmly while turning the blade wrench counter-clockwise Continue to press it in while tightening the arbour bolt securely.

(Fig. 8)

• Rotate the cover plate (3) and lower blade guard (1) back to its original position. (Fig. 7)

• Replace the cover plate screw (2) and tighten with a star-head screwdriver and then lower the blade guard.

• Pull the main handle down and up several times to confirm the lower blade guard operates without binding.

• Be sure the arbour lock button (5) is released so the blade turns freely. (Fig. 8)

WARNING!

• To avoid injury, never use the saw without the cover plate securely in place. It keeps the arbour 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 table and check for any contact with the metal base or the saw table.

REMOVING AND INSTALLING THE TABLE

INSERTS (Fig. 10)

• To remove, loosen and remove the six screws (1) on the table inserts (2) with a star-head screwdriver and remove the inserts.

• To install, reposition the table inserts, install the six screws and tighten.

• Check for blade clearance by moving the slide carriage through the full motion of the blade in the table slot.

Fig. 10

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WARNING!

• To avoid injury:

- Always unplug the saw to avoid accidental starting. Remove all small pieces of material from the table cavity before performing any cuts.

The table insert may be removed for this purpose, but always reattach the table insert prior to performing a cutting operation.

- Do not start the sliding compound mitre saw without checking for interference between the blade and table insert. Damage could result to the blade, table insert or turntable if blade strike occurs during the cutting operation.

26


REMOVING OR INSTALLING THE SLIDING

FENCE (Fig. 11)

Fig. 11

Removing

• Unlock the fence cam locking lever (1)

by pushing it out towards the rear of

the machine.

• Align the slot (2) with the bolt (3) in the rear of the fence, and then lift up the sliding fence to remove it from the saw.

Installing

• Align the slot (2) with the bolt (3) in the rear of the fence to place the sliding fence onto the mitre saw fence.

• Slide the nut (4) to align the nut (4) with the slot (5).

• To lock the sliding fence, push the cam locking lever (1) in towards the front of

the machine.

5

3

1

4

2

WARNING!

• DRY RUN - It is important to know where the blade will intersect with the workpiece during cutting operations. Always perform a simulated cutting sequence with the power tool switched OFF to gain an understanding of the projected path of the saw blade. At some extreme angles, the left side or the right side sliding fence might have to be removed to ensure proper clearance prior to making the cut.

CAUTION!

• The left sliding fence must be removed when making any left bevel angle cuts greater than 33.9° in combination with any right or left mitre angle.

This left sliding fence must also be removed whenever a 45° bevel angle is desired with a mitre angle greater than 31.6°.

• The right sliding fence must be removed when making any right bevel angle cuts.

MOUNTING THE MITRE SAW (Fig. 12, 13)

• For stationary use, place the saw in the desired location, directly on a workbench where there is room for handling and proper support of the workpiece. The base of the saw has eight mounting holes, four

1/4" holes and four 3/8" holes. Select the proper mounting holes based on the size of bolts used. Bolt the base of the mitre saw (1) to the workbench (5), using the fastening method as shown in Fig 12.

NOTE: Mounting hardware is not included with this tool. Bolts, nuts, washers, and screws must be purchased separately.

• For portable use, place the saw on a 3/4"

thick piece of plywood. Bolt the base of the mitre saw securely to the plywood using the mounting holes on the base. Use C-clamps to clamp this mounting board to a stable work surface at the worksite. (Fig. 13)

NOTE: If a mitre saw stand is used, please follow all instructions shown in that product’s instructions for proper mounting.

Fig. 12

1

4

3

2

5

6

7 8

9

1 Mitre saw base

2 Hex head bolt

3 Rubber washer

4 Flat washer

5 Workbench

6 Flat washer

7 Lockwasher

8 Hex nut

9 Jam nut

Fig. 13

3/4" plywood

27

WARNING!

• To avoid injury from unexpected saw movement:

- Before moving the saw, disconnect the power cord from the outlet, and lock the cutting arm in the lower position using the head

hold-down latch.

NOTE: The head hold-down latch is for carrying or storing the tool. It is not to be used for holding the saw while cutting. Lower blade and press in head hold-down latch to secure saw for transport or storage.

- Never carry the mitre saw by the power cord or by the trigger switch handle. Carrying the tool by the power cord could cause damage to the insulation or wire connections resulting in electric shock or fire.

- To avoid injury from flying debris, do not allow visitors to stand behind the saw.

- Place the saw on a firm, level workbench where there is room for handling and properly supporting the workpiece.

- Support the saw on a level work surface.

- Bolt or clamp the saw to its support.

28


SAW BLADE WRENCH STORAGE (Fig. 14)

• For convenient storage and prevention of loss, there is a bracket (1) set on the rear side of the right sliding fence (2) for storing the blade wrench (3) when not in use.

Fig. 14

2

3

THE POWER CORD STORAGE (Fig. 15, 16)

• For convenience and to prevent damage to the power cord when the mitre saw is not in use or is in transportation, the rear side of the slide carriage has two brackets (1, 2) for winding the cord. (Fig. 15)

NOTE: To rapidly release the power cord, turn the upper bracket (1) 180°. This will release the cord. (Fig. 16)

Fig. 15

1

2

Fig. 16

1

1

BEVEL STOP ADJUSTMENT

NOTE: To ensure accurate cuts, alignment should be checked and adjustments made prior to use.

90° (0°) Bevel adjustment (Fig. 17, 18)

• Loosen bevel locking handle (1) by lifting up and tilting the cutting arm while pushing in the bevel detent pin (6 - Fig. 18) against the 0° bevel stop. Tighten the bevel locking handle (1). (Fig. 17)

• Place a combination square (2) on the mitre table with the rule against the table and heel of the square against the saw blade.

• If the blade is not 0° to the mitre table, loosen the three adjustment bolts (3) at the rear of the unit with a 4 mm hex wrench.

Unlock the bevel locking handle (1) and adjust the cutting arm zero degrees to the table. After alignment is achieved, tighten the three adjustment bolts (3) and press down on the bevel locking handle (1) to secure the cutting head.

90° Bevel pointer adjustment (Fig. 18)

• When the blade is exactly 90° (0°)

to the table, loosen the bevel indicator screw (4) using a star-head screwdriver.

• Adjust bevel indicator (5) to the “0” mark on the bevel scale and retighten the screw.

Fig. 17

3

Fig. 18

5

4

2 1

6

View from left front of machine

29

WARNING!

• To avoid injury from an accidental start, make sure the switch is in the

OFF position and the plug is not connected to the power source outlet.

30


45° Left bevel positive stop adjustment

(Fig. 17, 19)

• Fully extend the sliding fence completely

to the left, and then pull the bevel detent pin (6) towards the front of the machine.

NOTE: When retracting the bevel detent pin, it may be necessary to shift the mitre saw upper arm assembly to the left/right to release the holding pressure.

• Loosen the bevel locking handle (1) and

tilt the cutting arm completely to the left.

(Fig. 17)

• Using a combination square, check to see if the blade is 45° to the table.

• To adjust, tilt the cutting arm to 0°, loosen the locknut (7), and turn the bolt (8) in or out to increase or decrease the angle.

• Tilt the cutting arm back to the left, and recheck alignment.

• Repeat steps until the blade is 45° to

the table. Once alignment is achieved, tighten the locknut (7) to secure the positive stop bolt.

Fig. 19

9

10

45° Right bevel positive stop adjustment

(Fig. 17, 19)

• Set the mitre angle to 0°. Fully extend the sliding fence completely to the right, and then pull the bevel detent pin (6) towards the front of the machine.

NOTE: When retracting the bevel detent pin, it may be necessary to shift the mitre saw upper arm assembly to the left/right to release the holding pressure.

• Loosen the bevel locking handle (1) and tilt the cutting arm completely to the right.

(Fig. 17)

• Using a combination square, check to see if the blade is 45° to the table.

• To adjust, tilt the cutting arm to 0°, loosen the locknut (9), and turn the bolt (10) in or out accordingly.

• Tilt the cutting arm back to the right, and recheck alignment.

• Repeat steps until the blade is 45° to

the table. Once alignment is achieved, tighten the locknut (9) to secure the positive stop bolt.

7

8

6

33.9° Left and right bevel adjustment (Fig. 20)

• Set the mitre angle to 0°. Fully extend both sliding fences.

• Loosen the bevel locking handle, and tilt cutting arm to the 33.9° right bevel positive stop by pushing in on the bevel detent

pin (6) towards the rear of the machine.

• Using a combination square, check to see if the blade is 33.9° to the table.

• To adjust, turn the hex screw (11) in or out with a 3 mm wrench until the blade is 33.9° to the table.

• Repeat the above steps and turn the hex screw (12) for the 33.9° left bevel adjustment.

MITRE SCALE (Fig. 21)

The sliding compound mitre saw scale can be easily read, showing mitre angles from 0° to 50° to the left, and 0° to 50° to the right.

The mitre saw table has positive stops at the most common angle settings: 0°, 15°, 22.5°,

31.6°, and 45°. These positive stops position the blade at the desired angle quickly and accurately. Follow the process below for the quickest and most accurate adjustments.

Adjusting mitre angles:

• Lift the quick-cam mitre locking lever (1) to unlock the table.

• Move the turntable while lifting the positive mitre stop locking lever (2) to align the indicator (3) to the desired degree measurement.

• Lock the table into position by pressing down on the quick-cam mitre locking

lever (1).

Mitre angle pointer adjustment:

• Move the table to the 0° positive stop.

• Loosen the screw (4) that holds the indicator with a star-head screwdriver.

• Adjust the indicator (3) to the 0° mark and retighten the screw.

Fig. 20

12

Fig. 21

11

4

3

2

6

1

31

32


ADJUSTING FENCE SQUARENESS (Fig. 22)

Remove the left side and right side sliding fences.

• Loosen the four fence locking bolts (1).

• Lower the cutting arm and lock in position.

• Using a square (2), lay the heel of the square against the blade and the ruler against the fence (3) as shown.

• Adjust the fence 90° to the blade and tighten the four fence locking bolts (1).

NOTE: If the saw has not been used recently, recheck blade squareness to the fence and readjust if needed.

• After fence has been aligned, replace the left side and right side sliding fences.

• Using a scrap piece of wood, make a cut at

90° then check squareness on the piece.

Readjust if necessary.

Fig. 22

3

1

2

QUICK-CAM MITRE TABLE LOCK

ADJUSTMENT (Fig. 23)

• Press down and lock the quick-cam mitre table lock (1).

• If the table moves with the quick-cam mitre table lock in the down position, turn the stop nut (2) to the left as shown using a

1/2" (13 mm) wrench to extend the locking arm against the base of the mitre saw.

• Test the quick cam mitre lock to verify it locks the table into position securely.

• Turn the lock nut (3) to the right as shown to lock the mitre locking mechanism

into place.

Fig. 23

1

3

1

2

ADJUSTING CUTTING DEPTH (Fig. 24, 25)

The maximum depth travel of the cutting head was set at the factory.

Setting the maximum width travel of the cutting head (Fig. 24):

• Turn the stop knob (1) counter-clockwise until the stop knob is not protruding out of the stop block (4) bottom while moving the cutting head upward.

• Rotate the stop plate (2) clockwise to touch the stop rod (3).

• Recheck the blade depth by moving the cutting head front to back through the

full motion of a typical cut along the

control arm.

Setting the maximum height travel of the cutting head (Fig. 25):

• Turn the stop knob (1) counter-clockwise until the stop knob is not protruding out of the stop block (4) bottom while moving the cutting head upward.

• Rotate the stop plate (2) counter-clockwise to touch the stop seat (5).

• Make sure the stop block (4) touches the stop plate (2) completely.

Setting the cutting depth (Fig. 25):

The depth of cut can be preset for even and repetitive shallow cuts.

• Adjust the cutting head down until the teeth of the blade are at the desired depth.

• While holding the upper arm in that position, turn the stop knob (1) until it touches the stop plate (2).

• Recheck the blade depth by moving the cutting head front to back through the

full motion of a typical cut along the

control arm.

Fig. 24

4

Fig. 25

1

4

5

2

1

2

3

33

34


TURNING LASER GUIDE ON (Fig. 26)

• To turn laser on, press rocker switch (1) to

“I” position.

• To turn laser off, press rocker switch (1) to

“O” position.

NOTE: The laser switch is covered with a transparent protecting cover (2).

Fig. 26

2

ALIGNING THE LASER GUIDE

• The laser beam must always be correctly aligned with the blade to ensure straight, even cutting. Your tool is equipped with the Laser Guide cutting guide using a

Class IIIa laser beam. The laser beam will enable you to preview the saw blade path on the stock to be cut before starting the mitre saw. This laser guide is powered by the transformed alternating current supply directly through the power lead. The saw must be connected to the power source and the laser on/off switch must be turned on for the laser line to show.

NOTE: All the adjustments for the operation of this machine have been completed at the factory.

1

WARNING!

• Do not remove the lock from the ON/OFF switch during any laser adjustments.

AVOID DIRECT EYE CONTACT

• All the adjustments for the operation of this laser guide have been completed at

the factory.

• Laser beam is calibrated and set up to project to the left of the blade.

• If you have any problem or question on the laser guide, please call the toll-free helpline at 1-888-670-6682.

• Laser Warning Label: Max. Output < 5 mW

Wavelength: 630–660 nm. Complies with

21 CFR 1040.10 and 1040.11. Class IIIa

Laser Product.

• Laser Aperture Label: AVOID EXPOSURE:

Laser radiation is emitted from this aperture.

Laser Warning Label

Laser Aperture Label

Fig. 27

Laser aperture label

Laser warning label

35

WARNING!

• Do not remove the lock from the ON/OFF switch during any laser adjustments.

• Laser radiated when laser guide is turned on. Avoid direct eye contact.

• All the adjustments for the operation of this machine have been completed at the factory. Due to normal wear and use, some occasional readjustments may be necessary.

• Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

• The use of optical instruments with this product will increase eye hazard.

• Do not attempt to repair or disassemble the laser. If unqualified persons attempt to repair this laser product, serious injury may result. Any repair required on this laser product should be performed by authorized service centre personnel.

36


LASER GUIDE ADJUSTMENT

(Fig. 28, 29, 30, 31)

NOTE: All the adjustments for the operation of this machine have been completed at the factory. Due to normal wear and use, some occasional readjustments may be necessary.

Fig. 28

A. Checking Laser Beam Alignment (Fig. 28)

• Set the saw to a 0° mitre and 0° bevel setting.

• Take a board and, using a straight edge (not included), mark a 90° line on the top and front of the board. This line will serve as a

“pattern line” for all laser beam alignments.

Place the board on the saw table.

• Carefully lower the saw head down to align the saw blade with the pattern line. Position the saw blade to the left, centre or right side of the “pattern line” depending on your preference for the laser beam location.

• With the saw plugged in, turn on the laser guide. Your saw has been preset with the laser beam to the left side of the blade.

• Looking at the front of the board, if the laser beam is not parallel to the “pattern line” please follow the instructions listed below under Procedure A.

• Looking at the top of the board, if the laser beam is not parallel to the “pattern line” please follow the instructions listed below under Procedure B.

B. Adjusting the Position of the Laser Beam

(Fig. 29, 30, 31)

Procedure A (Fig. 29, 30)

• Slightly turn the laser vertical adjustment knob (1) to adjust the vertical angle of the laser beam on the front of the board. When the laser beam angles from left to right, turn the laser vertical adjustment knob (1) clockwise; if the laser beam angles right to left, turn laser vertical adjustment knob (1)

counter-clockwise until the laser beam is parallel with the vertical “pattern line.”

TOP VIEW

Laser beam

Cutting line

Blade

Laser beam

Workpiece

Cutting line

Fig. 29

Fig. 30

Laser beam

1

2

Pattern line

Counter-clockwise Clockwise

Procedure B (Fig. 29, 31)

• Slightly turn the laser horizontal adjustment knob (2) to adjust the horizontal angle of the laser beam on the top of the board. If the laser beam is out of parallel from left to right, turn the laser horizontal adjustment knob (2) clockwise;

If the laser beam is out of parallel from

right to left, turn the laser horizontal adjustment knob (2) counter-clockwise until the laser beam is parallel with the horizontal “pattern line.”

• Recheck the laser beam alignment.

EXTENSION WING USE AND

ADJUSTMENT (Fig. 32)

The left and right side extension wings can offer extra support for long workpieces.

• Lift the locking lever (1) and pull out the left extension wing to the desired support length. Push down on the locking lever (1) to tighten the extension wing. Repeat for the right side extension wing if needed.

• If the locking lever (1) will not tighten, adjust the nut (2), located under the base,

1/4 turn clockwise using a 3/8" (10 mm) wrench until tight.

REPETITIVE CUTTING USING THE STOP

PLATE (Fig. 32)

The stop plate is designed for making repetitive cuts of the same length.

NOTE: Use only one stop plate at a time,

NEVER use both stop plates.

• Rotate the stop plate (3) to vertical position.

• If stop plate will not rotate, loosen the locking screw (4) 1/4 turn using a screwdriver and 8 mm wrench.

Fig. 31

Laser beam Pattern line

Counter-clockwise Clockwise

Fig. 32

3

4

1

2

37

38


SAFETY INSTRUCTIONS FOR BASIC SAW OPERATION

BEFORE USING THE MITRE SAW

• Completely assemble and adjust the saw, following the instructions. (ASSEMBLY

& ADJUSTMENTS)

• Learn the use and function of the ON/OFF trigger switch, on/off switch for laser, upper and lower blade guards, head hold-down latch, bevel lock handle, and cover plate screw.

• Review and understand all safety instructions and operating procedures in this

Instruction Manual. (SAFETY & OPERATION)

• Review the MAINTENANCE and TROUBLESHOOTING GUIDE for your mitre saw.

• To avoid injury or possible death from electrical shock:

Make sure your fingers do not touch the plug’s metal prongs when plugging or unplugging your mitre saw. (ELECTRICAL EQUIREMENTS AND SAFETY)

BEFORE EACH USE INSPECT YOUR SAW

• Disconnect the mitre saw. To avoid injury from accidental starting, unplug the saw before any adjustments, including set-up and blade changes.

• Compare the direction of rotation arrow on the guard to the direction arrow on the blade. The blade teeth should always point downward at the front of the saw.

• Tighten the arbour bolt.

• Tighten the cover plate screw.

• Check for damaged parts. Check for:

- Alignment of moving parts

- Damaged electrical cords

- Binding of moving parts

- Mounting holes

- Function of arm return spring and lower guard: Push the cutting arm all the way down, then let it rise until it stops. The lower guard should fully close. Follow instructions in the TROUBLESHOOTING GUIDE to adjust if necessary.

- Other conditions that may affect the way the mitre saw works.

• Keep all guards in place, in working order and properly adjusted. If any part of this mitre 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 bent, damaged, missing or defective parts before using the saw again.

• Maintain tools with care. Keep the mitre saw clean for best and safest performance.

Follow instructions for lubricating. Do not put lubricants on the blade while it is spinning.

• Remove adjusting wrench from the tool before turning it on.

• To avoid injury from jams, slips, or thrown pieces, use only recommended accessories.

• Check the dust bag before you work. Empty the bag if it is more than half-full.

WARNING!

• To avoid mistakes that could cause serious, permanent injury, do not plug the tool in until the above steps are completed.

RECOMMENDED ACCESSORIES

• Consult the ACCESSORIES and ATTACHMENTS section of this Instruction Manual for recommended accessories. Follow the instructions that come with the accessory. The use of improper accessories may cause risk of injury to persons.

• Choose the correct 10" diameter blade for the material and the type of cutting you plan to do.

• Make sure the blade is sharp, undamaged and properly aligned. With the saw unplugged, push the cutting arm all the way down. Manually spin the blade and check for clearance. Tilt the power-head to a 45° bevel and repeat the test.

• Make sure the blade and arbour 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.

• Plan ahead to protect your eyes, hands, face and ears.

• Know your mitre saw. Read and understand this Operator’s Manual and labels affixed to this tool. Learn its application and limitations as well as the specific potential hazards peculiar to this tool. To avoid injury from accidental contact with moving parts, do not do layout, assembly, or setup work on the mitre saw while any parts

are moving.

• Avoid accidental starting, make sure the trigger switch is disengaged before plugging the mitre saw into a power outlet.

PLAN YOUR WORK

• 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.

39

WARNING!

• To avoid burns or other fire damage, never use the mitre saw near flammable liquids, vapours, or gases.

CAUTION!

• This machine is not designed for cutting masonry, masonry products, ferrous metals (steel, iron, and iron-based metals). Use this mitre saw to cut only wood, wood-like products, or non-ferrous metals. 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.

Remove dust bag when cutting non-ferrous metals.

40


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 jewellery (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 mitre 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 are too small to clamp and hold securely.

• Plan the way you will grasp the workpiece from start to finish. Avoid awkward operations and hand positions. A sudden slip could cause your fingers or hand to move into the blade.

DO NOT OVERREACH

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.

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.

• Make sure there are no gaps between the workpiece, fence and table that will let the workpiece shift after it is 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 violently.

• Only the workpiece should be on the saw table.

• Secure work. Use clamps or a vice to help hold the work when it’s practical.

USE EXTRA CAUTION WITH LARGE OR ODD SHAPED WORKPIECES

• 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 support for a workpiece that is longer or wider than the basic mitre saw table, or to help feed, support, or pull the workpiece.

• Do not use this saw to cut small pieces. If the workpiece being cut would cause your hand or fingers to be within 7 1/2" (19 cm) of the saw blade the workpiece is too small. Keep hands and fingers out of the “no hands zone” area marked on the

saw table.

• When cutting odd shaped workpieces, plan your work so it will not bind in the blade and cause possible injury. Moulding, for example, must lie flat 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.”

WHEN SAW IS RUNNING

Before cutting, if the saw makes an unfamiliar noise or vibrates, stop immediately. Turn the saw OFF. Unplug the saw. Do not restart until you find and correct the problem.

41

WARNING!

• To avoid injury, follow all applicable safety instructions, when cutting non-ferrous metals:

- Use only saw blades specifically recommended 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 and the dust bag has been removed from the saw.

• Do not allow familiarity from frequent use of your mitre saw to result in a careless mistake. A careless fraction of a second is enough to cause a severe injury.

42


MAKING A BASIC CUT (Fig. 33)

BODY AND HAND POSITION

Starting a cut:

• Place hands at least 7 1/2" (19 cm) away

from the path of the blade – out of the

“no-hands zone” (1).

• Hold workpiece firmly against the fence to prevent movement towards the blade.

• Turn the laser guide on for pre-alignment of your cut.

• With the power switch OFF, bring the saw blade down to the workpiece to see the cutting path of the blade.

• Squeeze trigger switch to start saw.

• Lower blade into workpiece with a firm downward motion.

Fig. 33

Finishing a cut:

• Hold the cutting arm in the down position.

• Release trigger switch and wait for all moving parts to stop before moving your hands and raising the cutting arm.

• If the blade doesn’t stop within 10 seconds, unplug the saw and follow the instructions in the TROUBLESHOOTING GUIDE section.

7 1/2" (19 cm)

Before freeing jammed material:

• Release trigger switch.

• Wait for all moving parts to stop.

• Unplug the mitre saw.

1

7 1/2" (19 cm)

WARNING!

• Never place hands near the cutting area. Proper positioning of your body and hands when operating the mitre saw will make cutting easier and safer. Keep children away. Keep all visitors at a safe distance from the mitre saw. Make sure bystanders are clear of the saw and workpiece. Don’t force the saw. It will do the job better and safer at its designed rate.

BASIC SAW OPERATIONS

• For your convenience, your saw has a blade brake. The brake is not a safety device.

Never rely on it to replace the proper use

of the guard on your saw. If the blade doesn’t stop within approximately

10 seconds, wait for the blade to stop, unplug the saw and contact the service centre or another qualified service dealer.

TURNING THE SAW ON (Fig. 34)

• This mitre saw is equipped with an ON/OFF trigger switch (1). With the safety lock (2) pressed, squeeze the trigger switch to turn the mitre saw ON.

NOTE:

• To make the ON/OFF switch childproof, insert a padlock (not provided), or chain with padlock, through the hole (3) in the trigger switch, locking the tool’s switch, preventing children and other unqualified users from turning the machine on.

• The mitre saw is equipped with an electric blade brake. When the trigger switch is released, the blade brake will stop the blade within approximately 10 seconds.

SLIDING FENCE (Fig. 35)

• Unlock the fence cam locking lever (1) by pushing it towards the rear of the machine.

• Extend the fence (2) by sliding it out. Lock the fence cam locking lever (1) by pulling it in towards the fence.

NOTE: When transporting the saw, always secure the sliding fence in the collapsed position and lock it.

Fig. 34

1

2

3

Fig. 35

2

1

43

WARNING!

• The sliding fence must be extended when making any bevel cut. Failure to extend the sliding fence will not allow enough space for the blade to pass through which could result in serious injury. At extreme mitre or bevel angles the saw blade may also contact the fence.

44


SLIDING CARRIAGE SYSTEM (Fig. 36)

• For chop cutting operations on small workpieces, slide the cutting head assembly completely towards the rear of the unit and tighten the sliding carriage lock knob (1).

• To cut wide boards up to 12 1/2", the sliding carriage lock knob (1) must be loosened to allow the cutting head to slide freely.

Fig. 36

1

QUICK-CAM MITRE TABLE LOCK

OPERATION (Fig. 37)

If required mitre angles are NOT one of the nine positive stops, the mitre table can be locked at any angle between these positive stops by using the quick-cam mitre table lock.

• Unlock the mitre table by lifting the quickcam mitre table lock (1).

• While holding the positive stop locking lever (2) up, grasp the mitre handle (3) and move the mitre table left or right to the desired angle.

• Release the positive stop locking lever (2).

• Press down on the quick-cam mitre table lock (1) until it locks the mitre table in place.

NOTE: The quick-cam mitre table lock should lock the table and prevent it from moving. If adjustment is needed, see the section “QUICK-

CAM MITRE TABLE LOCK ADJUSTMENT.”

Fig. 37

3

2

1

WARNING!

• To reduce the risk of injury, return carriage to the full rear position after each crosscut operation.

MITRE DETENT OVERRIDE (Fig. 38)

The mitre detent override allows for the table to be micro adjusted, disengaging the positive detent stops feature. When a required mitre angle is close to a positive detent stop, this override prevents the wedge on the mitre arm from slipping into that detent slot on the base.

• Unlock the mitre table by lifting the quickcam mitre locking lever (1).

NOTE: The mitre handle (2) does not lock or unlock the table.

• While holding the mitre handle (2), pull the positive mitre stop locking lever (3) up and press the override lock (4) in, then release the positive stop locking lever (3) while holding the override lock (4) in. The detent override is now engaged.

• Turn the table to the desired angle, secure the table at the desired angle by pressing the quick-cam mitre locking lever (1).

• To disengage the detent override, pull the quick-cam mitre locking lever (1), pull the positive stop locking lever (3) up. This will release the override lock and the table will now stop at the positive detent angles.

BEFORE LEAVING THE SAW

• Never leave tool running unattended.

Turn power OFF. Wait for all moving parts to stop.

• Make workshop childproof. Lock the

shop. Disconnect master switches.

Store tool away from children and other unqualified users.

Fig. 38

4

3

1

2

45

WARNING!

• To avoid injury from materials being thrown, always unplug the saw to avoid accidental starting, and remove small pieces of material from the table cavity. The table insert may be removed for this purpose, but always reattach the table insert prior to performing a cutting operation.

46


MITRE CUT (Fig. 39)

The sliding compound mitre saw is equipped with nine positive mitre stops (1) on the saw base. The locations are at 0, 15, 22.5, 31.6 and

45 degrees left and right. These locations represent the most common angles for cutting operations. To make a mitre cut:

Fig. 39

• Unlock the mitre table by lifting the quickcam mitre locking lever (2).

• While raising the positive stop locking

lever (3), grasp the mitre handle (4) and rotate the mitre table left or right to the desired angle.

• Release the positive stop locking lever and set the mitre at the desired angle making sure the lever snaps into place.

NOTE: The lever will only lock into place at one of the nine positive stops.

• Once the desired mitre angle is achieved, press down on the quick-cam mitre table lock (2) to secure the table into position.

• If the desired mitre angle is NOT one of the nine positive stops noted above, simply lock the table at the desired angle by pressing down on the quick-cam mitre locking lever (2).

• Turn the laser guide on and position the workpiece on the table for pre-alignment of your cut.

IMPORTANT: Always lock the mitre lock lever before performing a cut.

4

3

2

1

BEVEL CUT (Fig. 40, 41)

• When a bevel cut is required, loosen

the bevel locking handle (1) by turning

it clockwise.

• 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 bevel locking handle (1) to lock the cutting head in position. Positive stops are provided at 0°,

33.9° and 45°.

NOTE: The saw comes with a 33.9° bevel detent pin for setting up crown moulding cuts when the angle of the walls equals 90°.


NOTE: If 47° left bevel is necessary, slide the bevel stop plate (3) clockwise away from the stop block (4) to achieve 47° left bevel.

Fig. 40

1

Fig. 41

4

3

2

47

WARNING!

• The sliding fence must be extended to the left when making left bevel cuts. The sliding fences note three bevel angles where the user must adjust the fences to match the degree of the bevel cut. Failure to extend the sliding fence will not allow enough space for the blade to pass through which could result in serious injury. At extreme mitre or bevel angles the saw blade may also contact the fence.

• The left sliding fence must be removed when making left bevel angle cuts greater than 33.9° in combination with any right or left mitre angle.

This fence must also be removed whenever a 45° bevel angle is desired with a mitre angle greater than 31.6°.

• The right sliding fence must be removed when making any right bevel angle cuts.

48


33.9° BEVEL DETENT PIN FOR CROWN

MOULDINGS (Fig. 42)

• Push the bevel detent stop pin (1) in towards the rear of the machine.

• Loosen the bevel lock handle (2) by

pulling up.

• Rotate the cutting head until the bevel detent pin stops the bevel angle at 33.9° on the bevel scale.

• Tighten the bevel lock handle (2) by pressing down before making your cut.

Fig. 42

1

COMPOUND CUT (Fig. 43)

A compound cut is the combination of a mitre and a bevel cut simultaneously.

• Extend the fence by sliding it out to the required location or remove the left/right sliding fence if necessary. See “SLIDING

FENCE” or “REMOVING OR INSTALLING

THE SLIDING FENCE.”

• Set the desired bevel angle using the bevel locking handle (1).

• Set the desired mitre angle and lock into position. See “MITRE CUT.”

SLIDE CUTTING WIDE BOARDS UP TO

12 1/2" WIDE (Fig. 44)

To slide cut wide boards:

• Unlock the sliding carriage lock knob (1) and allow the cutting head assembly to move freely.

• Set both the desired bevel angle and/or the mitre angle and lock into position.

• Use a hold-down clamp to secure the workpiece.


Fig. 43

1

Fig. 44

2

4

2

1

3

• Grasp the trigger switch handle (2) and

pull the carriage (3) forward until the centre of the saw blade is over the front

of the workpiece (4).

• Engage the trigger to turn the saw on.

• When the saw reaches full speed, slowly push the saw handle down, cutting through the leading edge of the workpiece.

• Slowly move the trigger switch handle back towards the fence, completing the cut.

• Release the trigger and allow the blade to stop spinning before raising the cutting head and removing the workpiece.

CUTTING BOWED MATERIAL (Fig. 45)

• The table insert may be removed for this purpose, but always reattach table insert prior to performing a cutting operation. A bowed workpiece (1) must be positioned against the fence and secured with a holddown clamp (2) as shown 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. 45

2

1

WARNING!

• To avoid injury:

- Never pull the cutting head assembly and spinning blade towards you during the cut. The blade may try to climb up on the top of the workpiece, causing the cutting assembly and spinning blade to kick back, forcefully. The cutting head assembly should be drawn back completely then pushed forward when sawing.

- Let the blade reach full speed before cutting. This will help reduce the risk of a thrown workpiece.

• To avoid injury from materials being thrown, always unplug the saw to avoid accidental starting and remove small pieces of material from the table cavity underlying the table insert.

49

50


CUTTING GROOVES (Fig. 46)

• Mark lines identifying the width and depth of the desired cut on the workpiece and position on the table so the outside tip of the blade is positioned on the inside edge of the line. Use a clamp to secure the workpiece beside the blade.

• Lower the cutting head to the depth marked on the workpiece, holding the upper arm, and adjust the stop knob (1) until it touches the stop plate (2). (SEE

“Adjusting cutting depth” on page 33).

• Cut two parallel grooves as shown.

Fig. 46

2

1

AUXILIARY WOOD FENCE (Fig. 47)

• When making multiple or repetitive cuts that result in cut-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, an auxiliary wood fence can be mounted to your saw.

• Holes are provided in the saw fence to attach an auxiliary wood fence. This fence is to be constructed of straight wood approximately 3/4" thick by 2 1/2" high by

22" 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.

NOTE: This auxiliary fence is used only with the saw blade in the 0° bevel position (90° to the table). The auxiliary wood fence must be removed when bevel cutting.

Fig. 47

Blade slot

Cut these grooves with saw

Use a chisel to cut out the middle

WARNING!

• DO NOT USE A DADO BLADE, use only the standard 10" diameter saw blade for cutting groove operation.

CUTTING BASE MOULDING (Fig. 48)

Base mouldings and many other mouldings can be cut on a compound mitre saw. The setup of the saw depends on moulding characteristics and application, as shown.

Perform practice cuts on scrap material to achieve best results:

• Always make sure mouldings rest firmly against fence and table. Use hold-down, crown moulding vice or C-clamps, whenever possible, and place tape on the area being clamped to avoid marks.

• Reduce splintering by taping the cut area prior to making the cut. Mark the cut line directly on the tape.

• Splintering typically happens due to an incorrect blade application and thinness of the material.

NOTE: Always perform a dry run cut so you can determine if the operation being attempted is possible before power is applied to the saw.

CUTTING CROWN MOULDING (Fig. 49, 50)

• Your compound mitre saw is suited for the difficult task of cutting crown moulding.

To fit properly, crown moulding must be compound-mitred with extreme accuracy.

The two surfaces on a piece of crown moulding that fit flat against the ceiling and wall are at angles that, when added together, equal exactly 90°.

• Most crown moulding has a top rear angle

(the section that fits flat against the ceiling) of 52° and a bottom rear angle (the section that fits flat against the wall) of 38°.

Fig. 48 n c

F e e

Workpiece

Mitre saw table

Mitre at 45°, bevel at 0° n c

F e e

Workpiece

Mitre saw table

Mitre at 0°, bevel at 45°

Fig. 49 n c

F e e

Workpiece

Mitre saw table

51

52


• In order to accurately cut crown moulding for a

90° inside or outside corner, lay the moulding with its broad back surface flat on the saw table.

• When setting the bevel and mitre angles for compound mitres, remember that the settings are interdependent; changing one changes the other, as well.

Fig. 50

Bevel/Mitre Settings

Settings for standard crown moulding lying flat on compound mitre saw table

Inside corner

OL

OR

IL

IR

Outside corner

Compound cut crown mouldings

NOTE: The chart below references a compound cut for crown moulding ONLY

WHEN THE ANGLE BETWEEN THE WALLS EQUALS EXACTLY 90°.

KEY

BEVEL

SETTING

Inside corner - Left side

MITRE

SETTING

IL 33.9°

TYPE OF CUT

31.6° Right

1. Position top of moulding against fence.

2. Mitre table set at RIGHT 31.6°.

3. LEFT side is finished piece.

Inside corner - Right side

IR 33.9° 31.6° Left

1. Position bottom of moulding against fence.

2. Mitre table set at LEFT 31.6°.

3. LEFT side is finished piece.

Outside corner - Left side

OL 33.9° 31.6° Left

1. Position bottom of moulding against fence.

2. Mitre table set at LEFT 31.6°.

3. RIGHT side is finished piece.

Outside corner - Right side

OR 33.9° 31.6° Right

1. Position top of moulding against fence.

2. Mitre table set at RIGHT 31.6°.

3. RIGHT side is finished piece.

106

107

108

109

110

111

112

113

98

99

100

101

102

103

104

105

114

115

116

117

118

119

120

Angle Between Walls

67

68

69

70

71

72

73

78

79

80

81

74

75

76

77

94

95

96

97

90

91

92

93

86

87

88

89

82

83

84

85

CROWN MOULDING CHART

Compound Mitre saw

Mitre and Bevel Angle Settings

Wall to Crown Moulding Angle

52/38° Crown Moulding

28.16

27.74

27.32

26.91

26.50

26.09

25.69

25.29

24.89

24.49

24.10

23.71

23.32

22.93

22.55

22.17

21.79

21.42

21.04

20.67

20.30

19.93

19.57

31.62

31.17

30.73

30.30

29.86

29.43

29.00

28.58

35.31

34.83

34.36

33.90

33.43

32.97

32.52

32.07

Mitre Setting

42.93

42.39

41.85

41.32

40.79

40.28

39.76

39.25

38.74

38.24

37.74

37.24

36.75

36.27

35.79

28.31

27.96

27.59

27.23

26.87

26.51

26.15

25.78

31.13

30.78

30.43

30.08

29.73

29.38

29.02

28.67

25.42

25.05

24.68

24.31

23.94

23.57

23.20

33.86

33.53

33.19

32.86

32.51

32.17

31.82

31.48

36.49

36.17

35.85

35.52

35.19

34.86

34.53

34.20

Bevel Setting

41.08

40.79

40.50

40.20

39.90

39.61

39.30

39.00

38.69

38.39

38.08

37.76

37.45

37.13

36.81


28.05

27.62

27.19

26.77

26.34

25.92

25.50

25.08

31.58

31.13

30.68

30.24

29.80

29.36

28.92

28.48

24.66

24.25

23.84

23.43

23.02

22.61

22.21

39.13

38.63

38.14

37.66

37.17

36.69

36.21

35.74

35.26

34.79

34.33

33.86

33.40

32.94

32.48

32.02

Mitre Setting

46.89

46.35

45.81

45.28

44.75

44.22

43.70

43.18

42.66

42.15

41.64

41.13

40.62

40.12

39.62

25.19

24.87

24.56

24.24

23.93

23.61

23.29

22.97

27.64

27.34

27.03

26.73

26.42

26.12

25.81

25.50

22.66

22.33

22.01

21.68

21.36

21.03

20.70

32.25

31.98

31.70

31.42

31.34

30.86

30.57

30.29

30.00

29.71

29.42

29.13

28.83

28.54

28.24

27.94

Bevel Setting

36.13

35.89

35.64

35.40

35.15

34.89

34.64

34.38

34.12

33.86

33.60

33.33

33.07

32.80

32.53

53

168

169

170

171

172

173

174

175

176

177

178

179

160

161

162

163

164

165

166

167

152

153

154

155

156

157

158

159

Angle Between Walls

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

144

145

146

147

148

149

150

151

136

137

138

139

140

141

142

143

54


4.63

4.32

4.01

3.70

3.39

3.08

2.77

2.47

7.14

6.82

6.51

6.20

5.88

5.57

5.26

4.95

2.15

1.85

1.54

1.23

0.92

0.62

0.31

9.69

9.37

9.05

8.73

8.41

8.09

7.77

7.46

12.30

11.97

11.64

11.31

10.99

10.66

10.34

10.01


Mitre Setting

19.20

18.84

18.48

18.13

14.99

14.66

14.30

13.97

13.63

13.30

12.96

12.63

17.77

17.42

17.06

16.71

16.37

16.02

15.67

15.33

Bevel Setting

22.83

22.46

22.09

21.71

21.34

20.96

20.59

20.21

19.83

10.21

9.82

9.43

9.04

8.65

8.26

7.86

7.47

13.32

12.93

12.54

12.16

11.77

11.38

10.99

10.60

16.40

16.02

15.64

15.25

14.87

14.48

14.09

13.71

19.45

19.07

18.69

18.31

17.93

17.55

17.17

16.79

3.94

3.54

3.15

2.75

2.36

1.97

1.58

1.18

0.79

0.39

7.08

6.69

6.30

5.90

5.51

5.12

4.72

4.33

5.32

4.96

4.61

4.25

3.90

3.54

3.19

2.83

8.19

7.83

7.47

7.11

6.75

6.39

6.03

5.68

2.48

2.12

1.77

1.41

1.06

0.71

0.35

11.09

10.73

10.36

10.00

9.63

9.27

8.91

8.55

14.06

13.68

13.31

12.94

12.57

12.20

11.83

11.46


Mitre Setting

21.80

21.40

21.00

20.61

17.09

16.71

16.32

15.94

15.56

15.19

14.81

14.43

20.21

19.81

19.42

19.03

18.64

18.25

17.86

17.48

Bevel Setting

20.38

20.05

19.72

19.39

19.06

18.72

18.39

18.06

17.72

9.15

8.80

8.45

8.10

7.75

7.40

7.05

6.70

11.93

11.59

11.24

10.89

10.55

10.20

9.85

9.50

14.62

14.34

14.00

13.65

13.31

12.97

12.62

12.29

17.39

17.05

16.71

16.38

16.04

15.70

15.36

15.02

3.53

3.18

2.83

2.47

2.12

1.77

1.41

1.06

0.71

0.35

6.35

6.00

5.65

5.30

4.94

4.59

4.24

3.89

MAINTENANCE

• To avoid injury, never put lubricants on the blade while it is spinning.

• To avoid fire or toxic reaction, never use gasoline, naphtha acetone, lacquer thinner or similar highly volatile solvents to clean the mitre saw.

• To avoid injury from unexpected starting or electrical shock, unplug the power cord before working on the saw.

• To avoid electrical shock, fire or injury, use only parts identical to those identified in the parts list. Reassemble exactly as the original assembly to avoid electric shock.

REPLACING CARBON BRUSHES (Fig. 51)

The carbon brushes furnished will last approximately 50 hours of running time, 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.

Follow the below steps to replace the carbon brush:

• Unplug the saw.

• Remove two securing screws (1) and the motor rear cover (2) from the motor.

• Remove the black plastic cap (3) on the side of the motor.

NOTE: Remove the cap cautiously, because it is springloaded.

• Pull out the carbon brush (4) and replace.

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.

• Repeat for the carbon brush located on the other side of the motor.

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 that reduces motor performance and increases wear.

Fig. 51

1

2

4

3

55

56


LOWER BLADE GUARD

• 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. Regularly check

to make sure the lower guard is working properly. Also check before each use

that all bolt/screws are tight. Clean the lower guard of any dust or build-up with a

damp cloth.

SAWDUST

• Periodically, sawdust will accumulate under the work table and base. This could cause difficulty in the movement of the worktable when setting up a mitre cut.

Frequently blow out or vacuum the sawdust.

• If you need to remove small pieces of material from the table cavity, see the section on Removing and Installing the Table Inserts on page 25.

• To empty the dust bag, remove the sawdust bag from the dust port. Open the zipper on the sawdust bag and empty out the sawdust inside. Close the zipper and reinstall the dust bag on the dust port as described on page 21.

WARNING!

• When cleaning the lower guard, unplug the saw from the power source receptacle to avoid unexpected start-up.

• Do not use solvents on the guard. They could make the plastic “cloudy” and brittle.

• Wear proper eye protection to keep debris from entering eyes when removing sawdust from unit.

LUBRICATION (Fig. 52)

All the motor 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.

Lubricate the following as necessary:

• Chop pivot: Apply light machine oil to points indicated in illustration.

•

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.

Fig. 52

Central pivot of plastic guard

(oil here)

Chop pivot (oil here and on opposite side)

57

58


TROUBLESHOOTING GUIDE – MOTOR

PROBLEM

Brake does not stop blade within

10 seconds.

PROBLEM CAUSE SUGGESTED CORRECTIVE ACTION

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. Arbour bolt loose.

4. Brushes cracked, damaged, etc.

5. Other.

1. Inspect/clean/replace brushes.

See MAINTENANCE section.

2. Use a recommended blade. Let cool down. See REMOVING AND

INSTALLING THE BLADE section.

3. Retighten. See REMOVING AND

INSTALLING THE BLADE section.

4. Replace brushes.

5. Call the toll-free helpline, at

1-888-670-6682.

Motor does not start.

1. Limit switch failure.

2. Brush worn.

3. Fuse blown or circuit breaker tripped on home panel.

1. Replace limit switch.

2. Replace brushes. See

MAINTENANCE section.

3. Verify there is electrical power at the outlet.

Brush sparks when switch released.

1. Brush worn.

2. Other.

1. Replace brushes. See

MAINTENANCE section.


1-888-670-6682.

WARNING!

• In order to avoid injury from an accidental start-up, always turn the switch to the OFF position and unplug the mitre saw before moving the mitre saw or the blade, replacing the blade, or making adjustments to the mitre saw or the blade.

TROUBLESHOOTING GUIDE – SAW OPERATION

PROBLEM

Blade hits table.

Angle of cut not accurate. Cannot adjust mitre.

PROBLEM CAUSE

1. Misalignment.

1. Mitre table unlocked.

2. Sawdust under table.

Cutting arm wobbles.

1. Loose pivot points.

Cutting arm will not fully raise, or blade guard won’t fully close.

1. Pivot spring not replaced properly after service.

2. Sawdust build-up.

Blade binds, jams, burns wood.

1. Improper operation.

2. Dull or warped blade.

3. Improper blade size.

4 Wood is moving during cut.

Saw vibrates or shakes.

1. Saw blade not round / damaged / loose.

2. Arbour bolt loose.

SUGGESTED CORRECTIVE ACTION

1. See ADJUSTMENTS - ADJUSTING

CUTTING DEPTH section.

1. See OPERATION - MITRE CUT section.

2. Vacuum or blow out dust. WEAR

EYE PROTECTION.


1-888-670-6682.


1-888-670-6682.

2. Clean and lubricate moving parts.

1. See BASIC SAW OPERATION section.

2. Replace or sharpen blade.

3. Replace with 10" diameter blade.

4. Use hold-down clamp to secure workpiece to table.

1. Replace blade.

2. Tighten arbour bolt.

59

60


MAXIMUM™ 10" DUAL-BEVEL SLIDING MITRE SAW

When servicing the Mazimum™ 10" Dual-Bevel Sliding Mitre Saw, use only Maximum™ replacement parts. The use of any other parts may cause damage to the product. All servicing should be performed by a qualified service technician. To find the nearest technician, call the toll-free helpline, at 1-888-670-6628.

PARTS LIST (A) FOR MITRE SAW

I.D.No. Description

082J CUSHION

082L BOLT

082P SCREW STOP

082Q LOCK NUT

083Z CORD CLAMP

0CES COMPRESSION SPRING

0CPD CENTRE BOLT

0DT4 ROLLING WHEEL

0DT7 BEARING

0DTZ ARBOUR COLLAR

0DVJ BLADE WRENCH

0J3Q HEX WRENCH

0J6P FLAT WASHER

0JAZ WAVE WASHER

0JB0 WAVE WASHER

0JBG DISC SPRING WASHER

0JC8 SPRING PIN

0JCT SPRING PIN

0JE7 C-RING

0JMN O-RING

0JMP O-RING

0JNR O-RING ROD

0K05 HEX. SOC. TRUSS HD. SCREW

0K9Y DRIVE SCREW

0KR2 LOCK NUT

0KR3 LOCK NUT

0KTP CABLE CLAMP

0KUW TERMINAL

0S1S COLLAR

20PL CLAMP HANDLE

224U ROLL PIN

22A4 LOCKING CABLE TIE

23NX CORD GUARD

25B1 CR. RE. TRUSS HD. SCREW

27PQ ROLL PIN

2BQA PLATE

2C0F CONTROLLER ASS'Y

2D7E COMPRESSION SPRING

2E35 TRIGGER

2F39 CLEVIS PIN

Size

5 MM

φ6*16-2

WW-6

WW-8

φ12

M8*1.25-20

φ2.3-5

M5*0.8 T=5

M6*1.0 T=6

M2505

M5*0.8-25

Q'ty I.D. No. Description

2 2JTR INSULATING SLEEVE

2 2M0S LIMIT SWITCH

1 2MC3 ROLL PIN

1 2MRE BLADE

1 2N7W BRACING PLATE

1 2NAH CR. RE. TRUSS HD. SCREW

1 2RXR CR. RE. PAN HD. SCREW

2 2S5C CAUTION LABEL

2 2S5D WARNING LABEL

2 2VEP SHAFT

1 2VH6 LINEAR MOTION BEARING

1 2VN7 BLANKET WASHER

1 2VS0 LEAD WIRE ASS'Y

1 2VZ1 RUBBER INSERT

4 2WK0 COMPRESSION SPRING

1 306G BUSHING

1 31XE SLIDE PLATE

2 32R9 CHUCK NUT

1 32RA CHUCK NUT

1 32RB CHUCK NUT

1 32RC CHUCK NUT

2 34BN COMPRESSION SPRING

4 34NJ UPPER TUBE

5 34NK UPPER TUBE

2 351P BUMPER

1 35QJ LEVER

1 37TB FLAT WASHER

4 37TC FLAT WASHER

1 38AW SPRING GUARD

2 3ADS HEX. NUT

2 3ADZ CHUCK NUT

1 3AE3 FLAT WASHER

1 3BKA EXTENSION WING (RIGHT)

1 3BKB EXTENSION WING (LEFT)

1 3BKD SLIDE-BAR SEAT (FRONT)

2 3BPY CLAMP HANDLE

1 3BSB TABLE BRACKET

1 3DJ8 LOCATING BAR

1 3DJ9 FRAME ENDCAP

1 3DJA WASHER BEARING

Size

M4*0.7-8

M4*0.7-8

φ25*φ38

M5*0.8 T=5

M6*1.0 T=6

M8*1.25 T=8 1

M12*1.75 T=12 1

3

1

4

4

1

8

1

1

2

1

1

1

2

1

1

2

1

Q'ty

1

1

φ6*13-1

φ8*16-2.5

M6*1.0 T=5

M10*1.5 T=10

φ10*20-3

2

1

1

1

2

1

1

1

2

2

1

1

1

1

1

1

1

1

1

WARNING!

• Any attempt to repair or replace electrical parts on this mitre saw

may create a hazard unless the repairs are carried out by a qualified service technician.


PARTS LIST (B) FOR MITRE SAW

I.D. No. Description

3DJG SPACER

3DJL SET PLATE

3DJP MITRE BAR ASS’Y

3DJR MITRE BAR

3DK9 BOLT

3DKA BOLT

3DKC SEGMENT HANDLE

3DKF PIVOT SHAFT

3DKJ TORSION SPRING

3DLH FOLLOWER PLATE (RIGHT)

3DLJ FOLLOWER PLATE (LEFT)

3DMM BEARING COVER

3DTM SHAFT SLEEVE

3DTZ RUBBER PAD

3DWQ PLATE

3DWT INSERT

3DWV PIN

3DWW LASER SET

3DWY PIVOT SUPPORT

3DWZ LASER PLUNGER HOUSING

3DXM LINEAR MOTION BEARING

3F4X SHAFT

3F8Q PLUNGER HOUSING

3FJG CUTTER SHAFT GUARD

3FJH SET PLATE

3FJN FENCE

3FJP ASSIST-FENCE (RIGHT)

3FJQ WRENCH SET

3FJS MOTOR HANDLE (UP)

3FJT MOTOR HANDLE (DOWN)

3FJU CABLE SHIELD

Size

3FJV ASSIST FENCE (LEFT)

3FM3 SPECIAL BOLT

3FS5 BASE

3FVK LASER COVER

3FVL COVERLASER COVER

3G0D HEX. SOC. HD.CAP SCREW

3G0U CLAMP BOLT

3G0W CLAMP BOLT

3G10 KNOB-HANDLE

3G14 PLUNGER HANDLE

3G3T PLUNGER HANDLE

3G3V CLAMP HANDLE

3GGC COMPRESSION SPRING

3GGE TABLE INSERT

3GGF TILTING SCALE

3GGG LOCKING HANDLE

3GGH SPECIAL BOLT

3GGL LOCKING ROD

3GGP ARM-MITRE

3GGQ ARM MITRE COVER

3GGS POWER CORD CLAMP

3GGT CLAMP-CORD

3GH0 PC-GUARD

3GPZ ROCKER SWITCH

3H25 LEVER BRACKET

3H26 LEVER

3H38 BUTTON SWITCH

3H3E TORSION SPRING

3H3G TABLE

3H46 MOTOR ASS'Y

3H9P POWER CABLE

3H9T LEAD WIRE ASS'Y

M6*1.0-16

3H9U LEAD WIRE ASS’Y

3HA0 BUTTON

3HAA KNOB

3HHN CR. RE. COUNT HD. SCREW

3HHQ CR. RE. COUNT HD. SCREW

M5*0.8-12

M3*0.5-6

3HHR CR. RE. TRUSS HD. ROUND NECK SCREW M5*0.8-12


2 3HHX CR. RE. PAN HD. TAPPING SCREW

1 3HJ0 CR. RE. PAN HD. TAPPING SCREW

1 3HJ5 CR. RE. PAN HD. SCREW

1 3HJA CR. RE. PAN HD. SCREW

1 3HJE HEX. SOC. SET SCREW

1 3HJF HEX. SOC. SET SCREW

1 3HJG HEX. SOC. SET SCREW

1 3HJH HEX. SOC. HD.CAP SCREW

1 3HJK HEX. SOC. HD.CAP SCREW

1 3HJL HEX. SOC. HD.CAP SCREW

1 3HJP HEX. SOC. TRUSS HEAD & WASHER ASS’Y

3 3HJU HEX WASHER HD BOLT

1 3HJV HEX. HD. BOLT

1 3HJW HEX. NUT

1 3HJX SELF-LOCKING RING

1 3HJY LOCK NUT

2 3HJZ FLAT WASHER

1 3HK1 FLAT WASHER

1 3HK2 FLAT WASHER

1 3HK3 FLAT WASHER

1 3HK4 FLAT WASHER

1 3HK6 FLAT WASHER

1 3HK8 FLAT WASHER

1 3HK9 FLAT WASHER

1 3HKB HEX. SOC. SET SCREW

1 3J5W NEEDLE POINTER

1 3JCP INSTRUCTION MANUAL

1 3JDM NEEDLE POINTER

1 3JE7 HEX. SOC. HD. CAP SCREW

1 3JQE PLATE (RIGHT)

1 3JQF PLATE (LEFT)

1 3JST LABEL

2 3JSU CAUTION LABEL

1 3JSV TILTING SCALE

1 3JSW CAUTION LABEL

1 3JSX CAUTION LABEL

1 3JSY CAUTION LABEL

1 3JSZ CAUTION LABEL

1 3JT0 WARNING LABEL

1 3JT1 WARNING LABEL

1 3JT2 DUST BAG ASS’Y

1 3K0U ANCHOR PLATE

2 3KJ1 INSULATING SLEEVE

1 3KRJ SOC. TRUSS HEAD ROUND NECK SCREW

2 3KRL SOC. TRUSS HEAD ROUND NECK SCREW

1 3KRN SOC. TRUSS HEAD ROUND NECK SCREW

1 3KTN SOC. ROUND WASHER HEAD SCREW

M6*1.0-10

M6*1.0-14

M6*1.0-16

M5*0.8-16

1 3KTP SOC. PAN HEAD SCREW

1 3KTQ SOC. TRUSS HEAD SCREW

M5*08-20

M6*1.0-8

1 3KTR SOC. COUNTERSUNK HEAD TAPPING SCREW M4*18-16

1 3KTT SOC. COUNTERSUNK HEAD TAPPING SCREW M4*18-25

1 3KTU SOC. COUNTERSUNK HEAD TAPPING SCREW M4*16-20

1 3KTV SOC. BUTTON HEAD CAP SCREW

1 3KTW SOC. TRUSS HEAD SCREW

1 3KTX SOC. BUTTON HEAD CAP SCREW

1 3KTZ SOC. FLAT HEAD SCREW

1 3KUA SOC. PAN HEAD SCREW

M5*0.8-16

M4*0.7-10

1 3KU1 SOC. FLAT HEAD SCREW

1 3KU2 SOC. PAN HEAD SCREW








4 3KUB SOC. PAN HEAD ROUND NECK SCREW

2 3N4Y HOLD-DOWN CLAMP ASS’Y

1

M5*0.8-6

M4*0.7-8

M5*0.8-55

M6*1.0-22

M6*1.0-16

M5*0.8-8

M4*0.7-8

M4*0.7-8

M4*0.7-12

M5*0.8-35

M5*0.8-12

M5*0.8-16

M6*1.0-12

3/8*29/32-1/8 1

M6*1.0-12 1

1

M5*0.8-20 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Size

M4*18-16

M3*24-8

M5*0.8-6

M5*0.8-25

M6*1.0-16

M6*1.0-16

M6*1.0-10

M5*0.8-40

M6*1.0-12

M5*0.8-10

M6*1.0-16

M8*1.25-20

M6*1.0-25

M5*0.8 T=4

M6*1.0 T=9

φ4*8-1

φ12*21-1

φ5*14-1

φ6*12-1

φ4*10-1

φ6*10-1 3

1/4*1/2-3/32 1

2

1

1

2

2

2

1

2

1

2

3

2

3

2

2

2

1

1

Q'ty

2

1

3

1

1

4

3

2

1

3

4

1

6

1

4

1

1

2

1

3

3

1

1

1

1

61

62



SCHEMAITC

3JCP


PARTS LIST FOR MOTR

I.D. No. Description

0HUR BALL BEARING

0HUZ BALL BEARING

0HVK BALL BEARING

0HX9 NEEDLE BEARING

0J6H FLAT WASHER

0JEA C-RING

0JEC C-RING

Size

φ15.02*19.2-1

0JG7 PARALLEL KEY

0K6X CR. RE. TRUSS HD. SCREW M4*0.7-6

0KCP CR. RE. PAN HEAD TAPPING & WASHER SCREW M5*12-60

0QM2 BRUSH HOLDER ASS’Y

0QQT BRUSH ASS’Y

0QR0 BRUSH COVER

20ZA C-RING

2RUY BALL BEARING

33NE MAGNET

35V0 BEARING BUSHING

3FJ5 ARM

3FJ6 CUTTER SHAFT

3FJ7 COLLAR

3FJ8 HELIX GEAR

3FJA GEAR SHAFT

3FJB STRAIGHT BEVEL GEAR

3FJD FRONT HOUSING


1 3FJE CLEVIS PIN

1 3FJF LOCK KNOB

1 3FJM MOTOR COVER

1 3FJR GEAR BOX

1 3GGU OIL CAP

1 3GGW FLOW GUIDE

1 3GGX MOTOR REAR COVER

1 3GH6 HALL SENSOR ASS’Y

2 3H48 ARMATURE ASS’Y

2 3H49 CONTROLLER ASS’Y

2 3H5A NEEDLE ROLLER

2 3H5C OIL PAPER

2 3H7F FIELD ASS’Y

1 3H9V LEAD WIRE ASS’Y

Size

1 3HJN HEX. SOC. HD. CAP SCREW

1 3HJR HEX. SOC. TRUSS HD. SCREW

1 3HJS HEX. SOC. TRUSS HD. SCREW

1 3HK5 FLAT WASHER

1 3HLH HEX. SOC. SET SCREW

1 3JDW PARALLEL KEY

1 3JDY CR. RE. PAN HD. TAPPING SCREW

1 3GGC COMPRESSION SPRING

M5*0.8-25

M5*0.8-10

M4*0.7-6

φ5*16-2

M5*0.8-6

M4*16-8

1 3KTS SOC. COUNTERSUNK HEAD TAPPING SCREW M5*16-25

1 3KUC SOC. PAN HEAD & WASHER SCREW M5*0.8-60

1

1

1

1

2

1

1

1

1

1

1

Q'ty

1

1

1

1

1

2

1

2

4

4

1

4

1

63

64


5-Year Limited Warranty

This MAXIMUM product is guaranteed for a period of 5 years from the date of original retail purchase against defects in workmanship and materials only and is subject to the following components:

90

DE SATISFACTION

GARANTIE

SATISFACTION

GUARANTEE

DAYS

JOURS

1

YEAR

AN

REPAIR

WARRANTY

DE GARANTIE

SUR RÉPARATIONS

5

LIMITED

WARRANTY

YEAR

ANS

DE GARANTIE

LIMITÉE

See back for details

a) Component A: The carrying case is guaranteed for a period of 1-year from the date of original retail purchase against defects in workmanship and materials.

b) Component B: Accessories, including drill bits and saw blades, do not carry a warranty.

Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period and if covered under this warranty, will be repaired or replaced (with the same model, or one of equal value or specification), at the sole discretion of the

Maximum Canada authorised repair centre (“Service Provider”). We will bear the cost of any repair or replacement and any costs of labour relating thereto.

These warranties are subject to the following conditions and limitations:* a) a bill of sale verifying the purchase and purchase date must be provided; b) defects in workmanship and material to be assessed and determined by the

Service Provider; c) this warranty will not apply to any product or part thereof which is worn or broken or which has become inoperative due to abuse, misuse, accidental damage, neglect or lack of proper installation, operation or maintenance (as outlined in the applicable owner’s manual or operating instructions); d) this warranty does not apply to normal wear and tear or to expendable parts or accessories (including drill bits and saw blades) that may be supplied with the product that by their nature have a limited life span and are expected to become inoperative or unusable after a reasonable period of use; e) this warranty will not apply to routine maintenance and consumable items such as, but not limited to, fuel, lubricants, vacuum bags, blades, belts, sandpaper, bits, fluids, rubber o-rings, tune-ups or adjustments;

f) this warranty excludes the following components that may accompany your product:

(1) The carrying case, which is only for a period of 1-year from the date of original retail purchase against defects in workmanship and materials.

(2) Accessories, including drill bits and saw blades, which do not carry a warranty of any kind.

g) this warranty will not apply where damage is caused by repairs made or attempted by others (i.e. persons not authorized by the manufacturer), and any such unauthorized repairs or attempted repairs shall void this warranty in its entirety; h) this warranty will not apply to any parts other than original parts, except to the extent that the retailer or manufacturer or persons authorized by either of them have repaired or replaced them; i) this warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product (unless otherwise specified in writing); j) this warranty will not apply to any product or part thereof if any part from another manufacturer is installed therein or any repairs or alterations have been made or attempted by unauthorized persons; k) this warranty will not apply to normal deterioration of the exterior finish, such as, but not limited to, scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and l) this warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under that product manufacturer’s warranty, if any; m) any products replaced by the retailer in attempt to fulfill warranty obligations is subject to the original product warranty conditions and related time period as initiated by the original date of purchase; if product is purchased in Quebec, the warranty term will be extended for a period equal to the time during which the Quebec retailer possesses the product in attempt to fulfill warranty obligations; replaced product will not default to new product warranty conditions; and

65

66

model no. 055-6767-0 | contact us 1-888-670-6682 n) The retailer and manufacturer’s sole obligation and the purchaser’s sole remedy under this warranty shall be as set out herein. The warranties contained herein are not transferable and are given only to the purchaser.

FURTHER, THE WARRANTIES SET OUT HEREIN ARE IN LIEU OF ALL

OTHER WARRANTIES OR CONDITIONS, WHETHER EXPRESS, IMPLIED OR

STATUTORY (INCLUDING SUCH AS ARISE UNDER THE SALE OF GOODS

ACT OR THE INTERNATIONAL SALE OF GOODS ACT), ARISING OUT OF A

COURSE OF DEALING OR USAGE OF TRADE OR OTHERWISE, INCLUDING,

SUBJECT TO APPLICABLE LAW, ANY IMPLIED WARRANTIES OR

CONDITIONS OF MERCHANTABILITY, MERCHANTABLE QUALITY, FITNESS

OR ADEQUACY FOR A PARTICULAR PURPOSE OR USE, AND ALL OTHER

SUCH WARRANTIES ARE EXPRESSLY DISCLAIMED BY THE RETAILER AND

MANUFACTURER.

Additional Limitations

This warranty applies only to the original purchaser and may not be transferred.

This warranty applies for a period of 5 years from the date of original retail purchase, as indicated on the bill of sale.

Neither the retailer, Maximum Canada, nor the manufacturer shall be liable for any other expense, loss or damage, including, without limitation, any indirect, incidental, consequential or exemplary damages arising in connection with the sale, use or inability to use this product.

Under no circumstances shall the retailer, Maximum Canada, or manufacturer be liable to the purchaser for any claim for (a) indirect, special, punitive, incidental, exemplary, or consequential damages, (b) compensation for loss of profits, anticipated revenue, savings or goodwill, or other economic loss of the purchaser, (c) exemplary, aggravated or punitive damages howsoever incurred,

(d) contribution or set-off in respect of any claims against the purchaser, (e) any damages whatsoever relating to third party products or services or the purchaser’s materials, or (f) any damages whatsoever relating to interruption, delays, errors or omissions; in each case under any theory of law or equity, arising out of or in any way related to this warranty, even if advised of the possibility thereof. Notwithstanding any provision herein or entitlement of the purchaser at law, in equity or otherwise, in no event shall the liability of the retailer or manufacturer under this warranty, whether in contract, tort, product liability or otherwise, exceed, in the aggregate, the amount paid by the purchaser to the retailer for the product to which this warranty applies.

*Notice to Consumer

This warranty gives you specific legal rights, and you may have other rights, which may vary from province to province. The provisions contained in this warranty are not intended to limit, modify, take away from, disclaim or exclude any statutory warranties set forth in any applicable provincial or federal legislation.

In addition to the 5-Year Limited Warranty, this MAXIMUM product is covered by our:

1-Year Repair Warranty

Maximum Canada will maintain this product and replace critical parts which have worn beyond reasonable use through normal use of such product, any time during the first year after purchase.

The following are excluded from this 1-Year Repair Warranty:

a) Missing or damaged parts or components that are a result of abuse or misuse;

b) Any wear and tear to non-critical parts or accessories that do not affect the core function of the product.

90-Day Satisfaction Guarantee

If you are not completely satisfied with the performance of your MAXIMUM product for any reason, you can return it within 90 days from the date of purchase with proof of purchase for exchange or a full refund.

Made in China

Imported by MAXIMUM Canada Toronto, Canada M4S 2B8

67

68


Maximum 055-6767-0 Instruction manual

IMPORTANT:

Please read this manual carefully before using this mitre saw and save it for reference.

INSTRUCTION

MANUAL

TABLE OF CONTENTS

QUICK START GUIDE

SYMBOLS

SPECIFICATIONS

SAFETY GUIDELINES

ACCESSORIES AND ATTACHMENTS

TOOLS NEEDED FOR ASSEMBLY

CARTON CONTENTS

KNOW YOUR SLIDING MITRE SAW

ASSEMBLY

ADJUSTMENTS

OPERATION

MAINTENANCE

TROUBLESHOOTING GUIDE

REPLACEMENT PARTS

WARRANTY

15

17

18

19

21

7

8

4

6

58

60

64

29

38

55

WARNING ICONS

DANGER

WARNING

CAUTION

SPECIFICATIONS

CROWN MOULDING CHART

TROUBLESHOOTING GUIDE – MOTOR

TROUBLESHOOTING GUIDE – SAW OPERATION

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