OPERATING MANUAL

12” COMPOUND MITRE SAW

WITH LASER

55-6898-8

Parts missing or damaged? Questions? Toll-Free Help Line – 1-800-689-9928

IMPORTANT:

Read through this operating manual carefully before using this tool. Pay close attention to all Safety Instructions, Warnings, and Caution sections .

Use this tool properly and only for its intended use.

Safety symbols in this manual are used to call attention to possible dangers.

The safety symbols and their explanations require the operator’s full understanding.

The safety warnings do not, by themselves, eliminate any danger, nor are they a substitute for proper accident-prevention measures.

This Safety Alert Symbol indicates caution, warning, or danger. Failure to obey a safety warning can result in serious injury to the operator or to others. To reduce the risk of injury, fire, or electric shock, always follow the safety precautions.

1

TABLE OF CONTENTS

Specifications…………………………………………..Page 2

Rules for Safe Operation……………………… ….. Page 3-7

Glossary of Woodworking Terms……………………Page 8

Description…………………………………….............Page 9

Assembly……………………........……..................... Page 10-11

Adjustments............................................................. Page 12

Operation...................………………….....................Page 13-20

Maintenance............................................................ Page 20

Troubleshooting....................................................... Page 21

Repair Parts.............................................................Page 22

Exploded View & Part List....................................... Page 23-24

Warranty………………………………………………..Page 25

SPECIFICATIONS

Motor: 120 V 60Hz 15 A,

Speed: 4500 RPM (no load)

Blade size: 12 ″ (30.5 cm) 40-tooth, carbide -tipped

Arbour size: 5/8” (15.9mm)

Weight: 44.1 lbs (20kg)

Cutting capacity: 2" X 7"

2" X 7"

2" X 5"

2" X 4-7/8" at 90 at 90 at 45 at 45

°

°

°

° mitre, 0 mitre, 0

° mitre, 45

° mitre, 45 bevel

° bevel bevel

° bevel

2

RULES FOR SAFE OPERATION

KNOW THE TOOL

To operate this tool safely, carefully read this operating manual and all the labels affixed to the Compound Mitre Saw before using it, and follow all instructions contained therein. Retain this manual for future reference.

MPORTANT

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

READ ALL INSTRUCTIONS THOROUGHLY

SAFETY PRECAUTIONS FOR LASERS

This Mitre Saw has a built-in laser light. The laser is ClassIIlA and emits output power of a maximum 2.5mW and 635-650nm wavelengths. These lasers do not normally present an optical hazard. However, DO NOT stare at the beam, as this can cause flash blindness.

CAUTION: The following label is on the tool. It indicates the location from which the saw emits the laser light. Be aware of the laser-light location when using. Always make sure that any bystanders in the vicinity of use are made aware of the dangers of looking directly into the laser.

•

Do not

remove or deface any product labels. Removing product labels increases the risk of exposure to laser radiation.

•

The laser beam can be harmful to the eyes. Always avoid direct eye exposure.

•

Do not look directly into the laser-beam-output aperture during operation.

•

Do not project the laser beam directly into the eyes of others.

•

Turn the laser on only when making cuts. The laser on the Mitre Saw is not a toy.

Always keep it out of the reach of children. The laser light emitted from this device should never be directed toward any person for any reason.

•

Be sure that the laser beam is aimed at a work piece (such as wood or a roughcoated surface) that does not have a reflective surface.

•

Do not use on materials, such as sheet steel, that have shiny, reflective surfaces.

The reflective surface could reflect the beam back at the operator. Be aware that laser light reflected off of a mirror or any other reflective surfaces can also be dangerous.

•

Always

turn the laser beam off when it is not in use. Leaving the tool on increases the risk of someone inadvertently staring into the laser's beam.

CAUTION: Always follow the instructions contained in this manual when using this laser. Use of this feature in any manner other than which is directed in this manual may result in a hazardous radiation exposure.

•

Always wear laser-protective eyewear when working on or near reflective surfaces

3

GENERAL SAFETY PRECAUTIONS

Read and become familiar with the entire Operating Manual.

Learn the tool’s application, limitations, and possible hazards.

Keep the guard in place and in working order.

Remove all adjusting tools before turning tools on. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning the tool ON.

Keep the work area clean. Cluttered areas and benches invite accidents.

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

Keep the work area well lit.

Keep children away. All visitors & bystanders should be kept a safe distance from the work area.

Make the workshop childproof with padlocks, master switches, or by removing starter keys.

Do not force the tool. The tool will do the job better and more safely at its designed rate.

Only use the correct tool. Do not force the tool or an attachment to do a job that it was not designed to perform.

Use proper extension cords. Make sure that extension cords are in good condition.

When using an extension cord, be sure to use a cord heavy enough to carry the drawn current needed by the Compound Mitre Saw. An undersized cord will result in a drop in line voltage and in loss of power, which will cause the tool to overheat. The table on Page 5 shows the correct size to use, depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge: the smaller the gauge number, the heavier the cord.

Wear proper apparel. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewellery that may get caught in moving parts. Non-slip footwear is recommended. Wear a protective hair covering to contain long hair

Wear a facemask or a dust mask. Sawing operations produce dust.

Secure the work. Use clamps or a vise to hold the work; it is safer than using the hand/body and it allows both hands to operate the Compound Mitre Saw.

Disconnect tools before servicing the tool and when changing accessories, such as blades, bits, and cutters.

Reduce the risk of the tool unintentionally starting.

Make sure that the switch is in the OFF position before plugging in the tool.

Only use recommended accessories. Consult this Operating Manual for recommended accessories. The use of improper accessories may cause risk of injury to the operator or to others.

Never stand on the tool.

Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted.

4

WARNING: The operation of any tool can result in foreign objects being propelled into the eyes, which could result in severe eye damage. When operating a power tool, always wear safety goggles or safety glasses with side shields, or a fullface shield, if necessary.

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 the operation of the tool. A guard or other part that is damaged should be properly repaired or replaced.

Never leave the tool unattended while the power is “on.” Turn the power “off.” Do not leave the tool until the blade has come to a complete stop and the Mitre Saw has been unplugged.

Do not over-reach. Keep proper footing and balance at all times.

Maintain tools with care. Keep tools sharp and clean for optimum performance.

Follow instructions for lubricating and changing accessories.

CAUTION: Do not attempt to operate this tool until having thoroughly read all instructions, safety rules, and warnings. Failure to comply can result in fire, electric shock, or serious personal injury. Retain the Operating Manual for future reference and review it frequently.

WARNING: Dust generated from certain materials can be hazardous to one’s health. Always operate the saw in a well-ventilated area, and provide for proper dust removal.

ELECTRICAL SAFETY

Ground instruction: In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Do not modify the plug provided. If it will not fit the outlet, have a proper outlet installed by a qualified electrician.

Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug.

Permanently connected tools: This tool should be connected to a grounded metal permanent wiring system or to a system having an equipment-grounding conductor.

5

GUIDELINES FOR EXTENSION CORDS

Use a proper extension cord . Make sure that extension cords are in good condition. When using an extension cord, be sure to use a cord heavy enough to carry the drawn current needed by the Compound Mitre Saw. An undersized cord will cause a drop in line voltage, resulting in loss of power and overheating. The table below shows the correct size to use, depending on the 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 extension cords are properly wired and in good condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it.

Protect extension cords from sharp objects, excessive heat, and damp or wet areas.

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

#6 wire and should be protected with a time-delay fuse. Before connecting the tool to the power line, make sure the switch is in the OFF position and the electric current is rated the same as the current stamped on the motor nameplate; running at a lower voltage will damage the motor.

Recommended size of extension cords

Amperage rating of the tool

(120 V circuit only)

More than

Total length of the extension cord

25’ (7.6 m) 50’ (15.2 m) 100’ (30.4 m)

150’ (45.7 m)

Not more than Minimum Gauge for the extension cord (AWG)

Not recommended

WARNING: Ensure the power supply outlet in question is properly grounded. If not sure, have a licensed electrician check the outlet.

WARNING: To avoid electrical hazards, fire hazards, or damage to the tool, use proper circuit protection.

SPECIFIC SAFETY RULES

Use only crosscutting saw blades. When using the mitre saw to cut non-ferrous metal, make sure that the blade has a negative hook angle.

IMPORTANT: Do not use thin-kerf blades.

Thin-kerf blades can deflect and contact the guard, which can cause possible injury to the operator.

Do not operate the Mitre Saw until it is completely assembled and installed according to these instructions.

If not thoroughly familiar with the operation of Mitre Saws, seek guidance from a supervisor, instructor, or other qualified person.

Always hold the work firmly against the fence and table. Do not perform any operation free hand; use a clamp or vise whenever possible

Keep hands out of the path of the saw blade. If the work piece causes the hands to be within the “no hands” zone (3’’ (7.6 cm) from the blade), the work piece should be clamped in place before making the cut.

Be sure that the blade is sharp, runs freely, and is free of vibration.

6

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

Keep the motor’s air slots clean and free of chips or dust.

Always make sure that all adjusting knobs are tightened before cutting, even if the table is positioned in one of the positive stops.

Be sure that both the blade and the flange are clean and the arbour bolt is tightened securely.

Use only flanges specified for this saw.

Never use blades larger or smaller in diameter than 12 inches (30.5 cm).

Never apply lubricants to the blade while it is running.

Always check the blade for cracks or damage before operation. Replace a cracked or damaged blade before further use.

Never use blades recommended for operation at less than 4500 RPM.

Use the blade guards at all times.

Always keep the blade guards in place.

Never reach around the saw blade.

Make sure that the blade is not contacting the work piece before the ON/OFF switch is turned ON.

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

Make sure that the blade has come to a complete stop before removing or securing the work piece, changing the work-piece angle, or changing the angle of the blade.

Never cut ferrous metals or masonry products with this tool.

Never cut small pieces. Keep hands outside the no-hands zone: at least 3” (7.6 cm) from the blade.

Provide adequate support to the sides of the mitre 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 and unplug the tool before servicing or adjusting the tool.

Disconnect the saw from the power source and clean the tool when finished using it.

Make sure that the work area is clean before leaving the tool.

Should any part of this Compound Mitre Saw be missing, damaged, or fail in any way, or should any electrical component fail to perform properly, shut off the power switch and remove the plug from the power-supply outlet. Replace missing, damaged, or failed parts before resuming operation.

7

GLOSSARY OF TERMS FOR WOODWORKING

•

Arbour: The revolving shaft on which a blade or cutting tool is mounted.

•

Arbour Lock: Allows the user to stop the blade from rotating while tightening or loosening the arbour screw during blade replacement or removal.

•

Bevel Cut: A cutting operation made with the blade at any angle other than 90° to the mitre table.

•

Chamfer Cut: A cut removing a wedge from a block of wood so the end (or part of the end) is angled at other than 90°.

•

Compound Mitre Cut: A cut made using both a mitre angle and a bevel angle at the same time.

•

Cross cut: A cutting operation made across the grain of the work piece.

•

Flange: A ring or collar on the end of a spindle that permits other objects, such as a blade, to be attached to it.

•

Freehand Cut: Performing a cut without using a fence, mitre gauge, fixture, work clamp, or other proper device to keep the work piece from twisting or moving during the cut. Do not perform any operation free hand. Use a clamp or vise wherever possible.

•

Gum: A sticky, sap-based residue from wood products.

•

Kerf: The material removed by the blade in a through cut or the slot produced by the blade in a non-through or partial cut.

•

Kickback: A hazard that can occur when the blade binds or stalls, throwing the work piece back toward operator.

•

Mitre Cut: A cutting operation made with the blade at any angle other than 90° to the fence.

•

No Hands Zone: The area between the marked lines on the left and right side of the mitre-table base. This zone is identified by No Hands Zone symbols inside the marked lines on the mitre table base.

•

Non-Through Cuts:

Any cutting operation where the blade does not extend completely through the thickness of the work piece.

•

Resin: A sticky, sap-based substance that has hardened.

•

Revolutions Per Minute (RPM): The number of turns completed by a spinning object in one minute.

•

Saw Blade Path: The area over, under, behind, or in front of the blade, as it applies to the work piece: that area which will be or has been cut by the blade.

•

Set: The distance that the saw blade tooth is bent (or set) outward from the face of the blade.

•

Throat Plate: A plate inserted in the Mitre Saw's table that allows for blade clearance.

•

Through Sawing: Any cutting operation where the blade extends completely through the thickness of the work piece.

•

Work Piece or Material: The item on which the cutting operation is being done.

The surfaces of a work piece are commonly referred to as faces, ends, and edges.

8

DESCRIPTION

KNOW THE COMPOUND MITRE SAW

(See Fig. 1) Before attempting to use this Compound Mitre Saw, become familiar with all its operating features and safety requirements.

Fig.1

1 ON/OFF trigger switch 3

2

2 Horizontal, rubberized

D-handle

3 Safety lock-off button

4

18

4 Upper blade guard

6

17

8

5

16

15

7

24

14 Mitre lock

15 Clamp mounting holes

16 Fence

17 Lower blade guard

18 Spindle-lock button

19 Laser ON/OFF switch

25

9

10 11 12

23

13 14

21

1

19

Blade Wrench

20

22

Dust Bag Shop Vacuum Adapter

Saw Blade

Dust Bag Adapter

9

10

ASSEMBLY

Installation of dust bag (see Fig. 2)

Squeeze the metal collar wings on the dust bag, and place the bag’s neck opening around the dustextraction port. Release the metal collar wings.

Fig. 2

Dust bag

Dust extraction port

Installation of adapter for shop vacuum

Remove the dust extraction port for the dust bag by removing the two screws that hold it in place. Attach the shop-vacuum adapter with the same two screws.

Release and lock the saw head

1. Press and lightly hold down the saw head.

Pull out the stop latch to release the saw head. The saw head should freely move up and down (see Fig. 3).

2. Place the saw head at the lowest position.

Insert the stop latch to lock the saw head for transporting and storage.

Removing the blade (see Fig. 4)

Fig. 3

Stop latch

WARNING: To reduce the risk of injury, always unplug the tool before removing and installing a blade.

1. Raise the saw head.

Fig. 4 2. Remove the upper screw on the bladescrew guard (Fig. 1, point 5) by turning it counter-clockwise with a screwdriver.

Outer flange

Inner flange

3. Lift and hold up the lower blade guard and rotate the blade-screw guard to expose the threaded blade screw.

4. Press and hold the spindle-lock button

(Fig. 1, point 18) and rotate the blade at the same time, until it is locked in position.

5. Use the wrench to turn the threaded blade screw clockwise and remove the threaded blade screw.

Threaded screw Blade

6. Remove the outer flange and the blade. Wipe the flanges and spindle to remove any dust and debris.

11

Installing the blade

IMPORTANT: Do not use thin-kerf blades.

Thin-kerf blades can deflect and contact the guard, which can cause injury to the operator.

1. Unplug the saw

2. Ensure that the inner flange is properly installed

3. Match the arrow on the blade with the arrow on the upper blade guard. Make sure that the blade teeth are pointing downward. Install the selected blade by sliding the blade into the upper blade guard and then placing the blade into position.

4. Install the outer flange.

IMPORTANT: Make sure the flat side of the flange is placed against the blade.

5. Press and hold the spindle-lock button, and use the wrench supplied to turn the blade screw counter-clockwise until the lock engages. Securely tighten the blade screw.

6. Rotate the blade-screw guard into position, and use the wrench to securely tighten the screw by turning it clockwise. Remove and store the wrench in a safe place.

7. Make sure that the spindle-lock button is released sot that the blade will rotate freely.

8. Lower the saw head, and check the clearance between the blade and the mitre table. The blade should rotate freely.

Installing extension wings

The extension wings support long work pieces during cutting. (Fig. 5)

1. Insert both rails of an extension wing through the holes on the outside of the Mitre Saw base.

2. Tighten the wing screw that locks the extension wing in place. Make sure that the extension wings do not move.

Fig. 5

12

ADJUSTMENT

WARNING: To avoid possible injury, disconnect the tool’s plug from the power source before performing any assembly, adjustment, or repair.

IMPORTANT: Do not use thin-kerf blades.

Thin-kerf blades can deflect and contact the guard, which can cause injury to the operator.

Mitre adjustment

1. Lock the saw head in the down position, and loosen the mitre-lock knob.

2. Hold the cutting handle firmly to rotate the mitre table to any desired angle. The most common angle settings have positive stops: 0°, 15°, 22.5°, 31.6°and 45°.

3. Tighten the mitre-lock knob and release the saw head.

Mitre-angle indicator adjustment

(if necessary)

1. Place the mitre table at the zero position, making sure the mitre lock is secured in position.

2. Loosen the mitre-angle indicator screw and adjust the indicator to the “0” mark on the mitre scale. (See Fig. 6.)

3. Tighten the mitre-angle indicator screw.

Fig. 6

Mitre scale Indicator screw

Bevel adjustment

1. When a bevel cut is required, loosen the bevel lock (Fig.1 point 22) by turning it counter-clockwise.

2. Tilt the saw head to the desired angle, as shown on the bevel scale. The blade can be positioned at any angle, from a 90° straight cut (0° on the scale) to a 45° left bevel. (See

Fig. 7).

3. Tighten the bevel lock to secure the saw head.

Fig. 7

Bevel angle indicator

13

OPERATION

WARNING: To reduce the risk of injury, wear safety goggles or glasses with side shields.

WARNING: Before each use, check that the blade is free from cracks, loose teeth, missing teeth, or any other damage. Do not use if damage is noticed or suspected.

WARNING : Always wait for the blade to stop completely, and unplug the tool before changing accessories or making adjustment.

Moving the Mitre Saw

Lift the Mitre Saw only when the saw is OFF, the plug is removed from the powersupply outlet, and the saw head is locked in the “down” position.

To avoid damage, never carry the Mitre Saw by the cutting handle. Always carry the saw by the base.

Mounting the Mitre Saw

To prevent the tool from sliding, falling, or tipping during operation, the Mitre Saw can be mounted to a supporting surface, such as a level, sturdy worktable or bench.

Position the Mitre Saw and workbench to allow adequate room for crosscutting long work pieces. To mount the Mitre Saw, insert fasteners through the four holes in the base of the Mitre Saw and use the fasteners to secure the saw to the table or bench.

Selection of Desired Angle

Follow the steps in “MITRE ADJUSTMENT” and “BEVEL ADJUSTMENT”

WARNING: The throat plate (see Fig.1, point 12) is factory-cut only for a 0º bevel cut; the first cut made with the tool in the 45° bevel position will create a slot on throat plate.

WARNING: Always make sure that the spindle-lock button is released, so that the blade will rotate freely.

WARNING:

Make sure that the stop latch is loose and that the saw head moves freely up and down. Ensure that all clamps and locks are tight, in place, and that there is no excessive movement of Mitre-Saw parts.

Selection of work piece

Be cautious with pitchy, knotty, wet, or warped work pieces. These materials are likely to create pinching conditions. Work pieces that bow and pinch may result in the saw blade kicking back.

Before cutting, inspect for and remove any nails from the work piece.

This tool is not recommended for cutting ferrous metals, such as iron and steel. Cut non-ferrous metals only if under the supervision of an experienced person.

14

Support the work piece

WARNING: Never use the help of another person as a substitute for a table extension, as support for a work piece that is longer or wider than the basic mitre table. Never have another person help feed, support, or pull the work piece instead of using table extensions.

•

Use the fence.

Align the work piece flush against the fence. This

Fig. 8 will help to eliminate the tendency of the blade teeth to bind. The fence can be used to support mitre, bevel, and compound cuts.

Work-piece clamp

(included)

•

Use the work-piece clamp (included).

The work-piece clamp fits into the clamp mounting holes in the front of the mitre table.

Securely clamp the work piece to the mitre table.

(See Fig. 8.)

Aligning the blade

WARNING: Do not look into the laser line.

•

Do not aim the laser line at people or animals.

•

Do not use the laser line on highly reflective materials. Danger from reflected light.

•

Only have the laser repaired by qualified service technicians.

•

Do not insert hard objects into the laser lens.

•

Clean the laser lens with a soft, dry brush.

Before starting a cut, draw the desired cut line on the work piece.

1. Press the laser ON/OFF switch (Fig. 1, point 19) forward to start.

2. Align the left side of laser line with the right side of cut line. The blade will cut the line marked out on wood piece.

NOTE: The laser adjustment has already been made at the factory. Align the left side of the laser line with the right side of the blade. Align the user-marked line with the left side of the laser line. (See Fig. 9) Fig. 9

15

Pay attention to body and hand positions.

Proper positioning of the body and hands when operating the Mitre Saw will make cutting easier and safer. Never place hands near the cutting area.

Hold the work piece firmly against the fence. Keep hands in position until the

ON/OFF trigger switch has been released and the blade has completely stopped.

Start the Compound Mitre Saw

WARNING: Always hold the cutting handle firmly, because the starting and stopping action of the motor may cause the handle to move up or down slightly.

1. Plug the Compound Mitre Saw into a power-supply outlet.

2. Push the safety lock-off button while squeezing the ON/OFF trigger switch

Fig. 10 to turn the tool ON. (See Fig. 10.)

Wait until the blade reaches full speed. Safety lock-off button

WARNING: Always keep hands and fingers away from the cutting area.

Any part of the body coming into contact with a moving blade will result in serious injury.

Cutting handle

Trigger

Stop the Mitre Saw and remove the work piece

1. After completing a cut, release the ON/OFF trigger switch and push the laser

ON/OFF switch backward to turn it off.

2. Allow the saw blade to come to a complete stop. Do not remove the work piece from the sawing plate until the blade has stopped rotating.

3. Gently raise the saw head and remove the work piece. Ensure that the lower blade guard can easily close.

4. Unplug the tool.

5. Remove loose or scrap pieces.

Fig. 11

CROSSCUTTING (Fig. 11 and Fig. 12)

A crosscut is a cut made across the grain of the work piece. A straight crosscut is a cut made with the mitre table set in the 0° position (Fig. 12).

Mitre crosscuts are made with the mitre table set at an angle, left or right, other than 0°.

To Crosscut With the Mitre Saw

1. Unplug the saw. injury.

WARNING: Failure to unplug the saw could result in accidental starting, causing serious

2. Push in the locking pin to lock the saw arm in the down position.

3. Loosen the mitre lock.

4. Firmly hold the base of the saw arm and use it to rotate the mitre table while holding the saw base steady.

Fig. 12

16

5. Quickly locate 0°, 15°, 22.5°, 31.6° and 45°, left or right, by the stops or clicks at these angle settings.

6. Once the mitre angle is set, tighten the mitre-lock lever by tightening the mitrelock knob.

7. Pull out the locking pin to release the saw arm.

8. Place the work piece flat on the mitre table with one edge securely against the fence. If the board is warped, place the convex side against the fence. If the concave edge of the board is against the fence, the board could collapse on the blade at the end of the cut and jam the blade (Figs. 15 and 16).

9. Align the “red laser line” to touch the right edge of the pencil line on the work piece.

10. Use the hold-down clamp to secure the work piece against the saw table and fence.

11. When cutting long work pieces, support the opposite end of the work piece with a roller stand or with another work surface that is level with the saw table.

WARNING: To avoid serious personal injury, always securely tighten the mitre-lock lever before making a cut. Failure to do so could result in movement of the control arm or mitre table while making a cut.

CAUTION: Never use another person as an additional support for a work piece that is longer or wider than the basic saw table, or to help feed, support, or pull the work piece.

WARNING: To avoid serious personal injury, always keep hands outside the

“no hands zone”, as marked on the saw table, which is at least 3 inches (7.6 cm) from the blade. Also, never perform any cutting operation “freehand” (i.e. without holding the work piece against the fence); the blade could grab the work piece, causing it to slip and twist.

12. Before turning on the saw, perform a test of the cutting operation by lowering the saw arm to make sure that no problems will occur when the cut is made.

13. Hold the saw handle, and use the index finger to push the laser switch forward to turn on the laser light.

14. To turn on the saw, push the safety lock button in with the thumb while squeezing the On/Off trigger switch located under the handle (Fig. 1-1 and 1-3). Allow several seconds for the blade to reach maximum speed.

15. Slowly lower the blade into and through the work piece.

16. Release the safety lock and the trigger switch, and turn off the laser switch. Allow the saw blade to stop rotating before raising the blade out of the work piece.

17

BEVEL CUTTING (Fig. 13)

A bevel cut is a cut made across the grain of the work piece with the blade at an angle to the work piece.

A straight bevel cut is made with the mitre table set in the 0° position and the saw arm set at a bevel angle between 0° and

45

°

.

To Bevel Cut With the Mitre Saw

1. Unplug the saw.

Fig. 13

WARNING: Failure to unplug the saw could result in accidental starting, causing serious injury.

2. Make sure that the mitre table is at 0

° and locked, and check that the mitre-table lock is locked and secured in position.

WARNING: To avoid serious personal injury, always securely tighten the mitre-lock lever before making a cut. Failure to do so could result in movement of the control arm or mitre table while making a cut.

3. Pull out the locking pin to release the saw arm.

4. To make a bevel cut, loosen the bevel-lock knob (Fig.1-22) by turning the knob counter clockwise.

5. Tilt the saw arm to the desired bevel angle, as indicated on the bevel scale. The blade can be positioned at any angle, from a 90° straight cut (0 on the scale) to a

45 ° left bevel (Fig. 13).

WARNING: Tighten the bevel-lock knob to secure the saw arm in its position.

6. Place the work piece flat on the mitre table with one edge securely against the fence. If the board is warped, place the convex side against the fence. If the concave edge of the board is against the fence, the board could collapse on the blade at the end of the cut and jam the blade (Fig. 15 and 16).

7. Align the red laser line to touch the right edge of the pencil line on the work piece.

8. Use the hold-down clamp to secure the work piece against the Mitre Saw table and fence.

9. When cutting long work pieces, support the opposite end of the work piece with a roller stand or with another work surface that is level with the saw table.

CAUTION: Never use another person as an additional support for a work piece that is longer or wider than the basic saw table or to help feed, support, or pull the work piece.

WARNING: To avoid serious personal injury, always keep hands outside the

“no hands zone”, as marked on the saw table, which is at least 3 inches (7.6 cm) from the blade. Also, never perform any cutting operation “freehand” (i.e. without holding the work piece against the fence); the blade could grab the work piece, causing it to slip and twist.

10. Before turning on the saw, perform a trial of the cutting operation by lowering the

18

saw arm to make sure that no problems will occur when the cut is made.

11. Hold the saw handle and use the index finger to turn on the laser switch by pushing it forward.

12. To turn on the saw, push the safety-lock button in with the thumb while squeezing the On/Off trigger switch located under the handle (Fig.1-1 and Fig.1-3). Allow several seconds for the blade to reach maximum speed.

13. Slowly lower the blade into and through the work piece.

14. Release the safety lock and the trigger switch, and turn off the laser switch. Allow the saw blade to stop rotating before raising the blade out of the work piece

CAUTION: Always perform a “dry run” cut to determine if the operation being attempted is possible before power is applied to Mitre Saw.

COMPOUND MITRE CUTTING

(Fig. 14)

A compound mitre cut is a cut made using a mitre angle and a bevel angle at the same time. This type of cut is used for decorative mouldings, picture frames, and other fine joinery.

To make this type of cut, the mitre table must be rotated to the correct mitre angle and the saw arm must be tilted to the correct bevel angle.

Fig. 14

Always take special care when making compound mitre cuts, due to the interaction of the two angle settings.

Adjustments of mitre and bevel settings are dependent on one another. Each time the mitre setting is adjusted, the effect of the bevel setting also changes. Each time the bevel setting is adjusted, the effect of the mitre setting is changed.

It may take several settings to obtain the desired cut. The first angle setting should be checked after setting the second angle, since adjusting the second angle affects the first.

Once the two correct settings for a particular cut have been obtained, always make a test cut in scrap material before making a finish cut in good material.

To Make a Compound Mitre Cut with the Mitre Saw

1. Unplug the saw.

WARNING: Failure to unplug the saw could result in accidental starting, causing serious injury.

2. Pull out the locking pin to release the saw arm.

3. Loosen the mitre-lock knob to loosen the mitre table.

4. Hold the base of the saw arm firmly and use it to rotate the mitre table while holding the saw base steady.

5. The 0

°

, 15

°

, 22.5

°

, 31.6°, and 45

°,

left and right settings are quickly identifiable with the stops at the angle settings.

6. When the desired mitre-table setting is achieved, tighten the mitre-lock.

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WARNING: To avoid serious personal injury, always securely tighten the mitre-lock lever before making a cut. Failure to do so could result in movement of the control arm or mitre table while making a cut.

7. To set the bevel angle, loosen the bevel-lock knob (Fig. 1-22) by turning the knob counter clockwise.

8. Tilt the saw arm to the desired bevel angle, as shown on the bevel scale. Bevel angles can be set from 0

° to 45

° left bevel.

9. Once the saw arm has been set at the desired angle, securely tighten the bevellock knob.

10. Place the work piece flat on the mitre table with one edge securely against the fence. If the board is warped, place the convex side against the fence. If the concave edge of the board is against the fence, the board could collapse on the blade at the end of the cut and jam the blade (Figs. 15 and 16).

11. Align the red laser line to touch the right edge of the pencil line on the work piece.

12. Use the hold-down clamp to secure the work piece against the saw table and fence.

13. When cutting long work pieces, support the opposite end of the work piece with a roller stand or with another work surface that is level with the saw table.

CAUTION: NEVER use another person as an additional support for a work piece that is longer or wider than the basic saw table, or to help feed, support, or pull the work piece.

WARNING: To avoid serious personal injury, always keep hands outside the

“no hands zone”, as marked on the saw table, which is at least 3 inches (7.6 cm) from the blade. Also, never perform any cutting operation “freehand” (i.e. without holding the work piece against the fence); the blade could grab the work piece, causing it to slip and twist.

14. Make sure that there will be no obstructions to interfere with making the cut.

15. Hold the saw handle and use the index finger to turn on the laser switch by pushing it forward.

16. To turn on the saw, push the safety-lock button in with the thumb while squeezing the On/Off trigger switch located under the handle (Fig.1-1 and 1-3). Allow several seconds for the blade to reach maximum speed.

17. Slowly lower the blade into and through the work piece.

18. Release the safety lock and trigger switch, and turn off the laser switch. Allow the saw blade to stop rotating before raising the blade out of the work piece

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CUTTING WARPED MATERIAL (Fig. 15 and 16)

WARNING: To avoid kickback and to avoid serious personal injury never position the concave side of bowed or warped material against the fence.

When cutting warped material, be certain that the material to be cut is positioned on the mitre table with the convex side against the fence, as shown (Fig. 15).

If the warped material is positioned the wrong way, (Fig. 16), it will pinch the blade near the end of the cut.

Fig. 15 Fig. 16

MAINTENANCE

Before cleaning or performing any maintenance, make sure that the Mitre Saw has been disconnected from the power supply. Keep all ventilation openings clean. Avoid using solvents when cleaning plastic parts. Most plastics are susceptible to damage from various types of commercial solvents and may be damaged by their use. Use a clean cloth to remove dirt, oil and grease.

WARNING: Do not allow improper materials, such as brake fluids, gasoline, petroleum-based products, penetrating oil, etc., to come in contact with plastic parts as improper materials contain chemicals that can damage, weaken or destroy plastic.

WARNING:

To ensure safety and reliability, all repairs should be performed by a qualified service technician.

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TROUBLESHOOTING

PROBLEM

Br ake does not stop blade within

6 seconds

PROBABLE CAUSE SUGGESTED CORRECTIVE

ACTION

Electric hand brake has failed Take saw for servicing

Motor does not start

Angle of cut inaccurate

Cutting arm cannot fully raise, or blade guard cannot fully close

Motor brake overheated from use of defective or wrong size blade or rapid ON/OFF cycling

Arbour bolt is loose

Saw not plugged in

Use a recommended blade

Retighten

Check that all cords are plugged in

Fuse Check time delay fuse or circuit breaker

Mitre table unlocked Use mitre table locking lever

See ADJUSTMENT section”

Too much sawdust under table Vacuum or blow out dust.

Wear Eye Protection!

Parts failure Contact CTC Service Centre

Pivot spring not replaced properly after service

Sawdust build up

Contact CTC Service Centre

Clean and lubricate moving parts

Blade binds, jams, or burns wood

Saw vibrates or shakes

Saw-head locking pin not set properly

Improper operation

Dull blade

Improper blade

Warped blade

Saw blade damaged

Saw blade loosened

Check, adjust, and properly set saw-head locking pin

“See OPERATION section”

Replace or sharpen blade

Replace blade

Replace blade

Replace blade

Tighten arbour bolt

Saw not properly fastened down

Fasten saw to stand, bench, or table

Laser line projection is hard to see

Work piece not properly supported

Properly support or clamp work piece

Light in work area is too bright Move the Mitre Saw to the work area with proper light

Saw dust on the laser lens Clean laser lens with a soft, dry brush

Contact CTC Service Centre Toll free at 1-800-689-9928 when problems remain unsolved after the above checks.

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Repair Parts

INCLUDES:

• 1 pc of 40T carbide tip blades

• 1 pc of hold clamp

• 1 pc of dust collection bag

• 1 pair of extension rails

• 1 pc wrench

• 1 pc vacuum adapter

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Exploded View

24

Parts List

No Name

1

2

3

36

37

38

39

32

33

34

35

40

41

42

43

44

28

29

30

31

24

25

26

27

16

17

18

19

12

13

14

15

20

21

22

23

8

9

10

11

4

5

6

7

57

58

59

60

53

54

55

56

61

62

49

50

51

52

45

46

47

48

Brush hold

Rubber boot

Armature

Fan baffle

Gear lock pin cap

Gear case

Lower handle

Qty. No

2

1

1 76

1

1 86

1 87

1

68

73

81

93

Laser switch cap 1 98

Cable plug

Upper handle

Carry handle

1 102

1 103

1 107

Name

Blade

Qty.

1

Blade 1

Rivet

Moving guard

4

1

Screw

Spring washer

Big washer

1

1

1

1

1

1

Plate

Screw

Hex crub

1

Bushing 1

Socket 1

Lock pin cap 1

1

1

1

Bevel lock handle 1

Washer 1

1

1

1

1

1

1

Washer

Spring washer 2

2

1

2

Screw

Laser

Laser cover

Screw

Screw

Washer

2

2

2

1

2

1

2

1

1

Switch lock 1 112 Bevel pointer

Cutting insert

2

Torsion 1

1

6

2

2

1

1

1

1

Gear case cover 1 122

Washer

Socket head

Fence 1

2

4

4

1

2

2

2

150

151

152

153

154

155

156

157

142

143

144

145

146

147

148

149

158

159

160

132

133

134

135

136

137

138

139

140

141

No

125

126

127

128

129

130

131

Name

Screw

Angle orientation

Spring washer

Screw

Turntable

Mitre pointer

Clamp nut

Clamp plate

Spring washer

Socket head

Screw

Curved spring

Lock bolt

Lock handle

Screw

Lock handle cap

Support bar

Clamp set

Rivet

Mitre Scale

Table pressing

Bracket stator

Wing screw

Base

1

2

2

Screw

Steel ball

1

3

1

Spring 1

Hex crub screw 1

1 Condole plate

Ferrule

Wave wsher

Washer

Socket head

Knob

Orientation case

Blade spanner

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

2

Qty.

4

1

2

1

1

2

1

1

2

1

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MASTERCRAFT LIMITED WARRANTY

This Mastercraft® product is guaranteed three (3) years from the date of original retail purchase] against defects in materials and workmanship,

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 our option. 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) 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) or which is being used for industrial, professional, commercial or rental purposes; c) this warranty will not apply to normal wear and tear or to expendable parts or accessories that may be supplied with the product which are expected to become inoperative or unusable after a reasonable period of use; d) 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, tune-ups or adjustments; e) this warranty will not apply where damage is caused by repairs made or attempted by others (i.e. persons not authorized by the manufacturer); f) 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); g) 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; h) 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 i) this warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under the product manufacturer’s warranty, if any.

Additional Limitations

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

Neither the retailer 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.

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.

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