Harbor Freight Tools 93827 User Manual

18V CIRCULAR SAW

®

93827

ASSEMBLY AND OPERATING INSTRUCTIONS

Due to continuing improvements, actual product may differ slightly from the product described herein.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Copyright© 2005 by Harbor Freight Tools® . All rights reserved. No portion of this manual or
any artwork contained herein may be reproduced in any shape or form without the express
written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353.

Contents

UNPACKING.............................................................................. 2

PRODUCT SPECIFICATIONS................................................... 3

GENERAL SAFETY RULES ..................................................... 3

CHARGING THE BATTERY ..................................................... 10

OPERATION ............................................................................. 11

Circular Saw .................................................................................... 11

INSPECTION, MAINTENANCE, AND CLEANING ................... 14

PARTS LISTS AND DIAGRAMS.............................................. 15

Parts List/Diagram C - Circular Saw ............................................. 15

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts Lists at the

end of the manual are included. If any parts are missing or broken, please call Harbor

Freight Tools at the number shown on the cover of this manual as soon as possible.

Note: Before first use, the Battery (64) will require charging. The first charge requires 8

hours charge time. See charging instructions on page 10.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 2

PRODUCT SPECIFICATIONS

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Save This Manual

You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and assembly
diagram. Keep your invoice with this manual. Write the invoice number on the inside
of the front cover. Keep this manual and invoice in a safe and dry place for future
reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

Work Area

1. Keep your work area clean and well lit. Cluttered benches and dark areas invite

accidents.

2. Do not operate power tools in explosive atmospheres, such as in the presence

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

the dust or fumes.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 3

3. Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Protect others in the work area from

debris such as chips and sparks. Provide barriers or shields as needed. Do not

allow children to handle or play with these products.

Electrical Safety

4. Grounded tools must be plugged into an outlet properly installed and grounded

in accordance with all codes and ordinances. Never remove the grounding

prong or modify the plug in any way. Do not use any adapter plugs. Check

with a qualified electrician if you are in doubt as to whether the outlet is properly

grounded. If the tools should electrically malfunction or break down, grounding

provides a low resistance path to carry electricity away from the user.

5. Double insulated tools are equipped with 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 a polarized outlet. Do not change the plug in any

way. Double insulation eliminates the need for the three wire grounded power

cord and grounded power supply system.

6. Avoid body contact with grounded surfaces such as pipes, radiators, ranges,

and refrigerators. There is an increased risk of electric shock if your body is

grounded.

7. Do not expose power tools to rain or wet conditions. Water entering a power

tool will increase the risk of electric shock.

8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or

pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp

edges, or moving parts. Replace damaged Power Cords immediately. Damaged

Power Cords increase the risk of electric shock.

9. When operating a power tool outside, use an outdoor extension cord marked

“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the risk

of electric shock.

Personal Safety

10. Stay alert. Watch what you are doing, and use common sense when operating

a power tool. Do not use a power tool while tired or under the influence of

drugs, alcohol, or medication. A moment of inattention while operating power

tools may result in serious personal injury.

11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep

your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry,

or long hair can be caught in moving parts.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 4

12. Avoid accidental starting. Be sure the Power Switch is off before plugging in.

Carrying power tools with your finger on the Power Switch, or plugging in power

tools with the Power Switch on, invites accidents.

13. Remove adjusting keys or wrenches before turning the power tool on. A wrench

or a key that is left attached to a rotating part of the power tool may result in personal

injury.

14. Do not overreach. Keep proper footing and balance at all times. Proper footing

and balance enables better control of the power tool in unexpected situations.

15. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety

shoes, hard hat, or hearing protection must be used for appropriate conditions.

Always wear ANSI approved safety goggles and a dust mask/respirator when using

or performing maintenance on this tool.

Tool Use and Care

16. Use clamps (not included) or other practical ways to secure and support the

workpiece to a stable platform. Holding the work by hand or against your body is

unstable and may lead to loss of control.

17. Do not force the tool. Use the correct tool for your application. The correct tool

will do the job better and safer at the rate for which it is designed. Do not force the

tool and do not use the tool for a purpose for which it is not intended. Do not modify

this product.

18. Do not use the power tool if the Power Switch does not turn it on or off. Any

tool that cannot be controlled with the Power Switch is dangerous and must be

replaced.

19. Disconnect the Power Cord Plug from the power source before making any

adjustments, changing accessories, or storing the tool. Such preventive safety

measures reduce the risk of starting the tool accidentally. Always unplug the tool

from its electrical outlet before performing any inspection, maintenance, or

cleaning procedures.

20. Store idle tools out of reach of children and other untrained persons. Tools are

dangerous in the hands of untrained users.

21. Maintain tools with care. Keep cutting tools sharp and clean. Properly

maintained tools with a sharp cutting edge are less likely to bind and are easier to

control. Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.

22. Check for misalignment or binding of moving parts, breakage of parts, and

any other condition that may affect the tool’s operation. If damaged, have the

tool serviced before using. Many accidents are caused by poorly maintained

tools.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 5

23. Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one tool may become hazardous when

used on another tool.

Service

24. Tool service must be performed only by qualified repair personnel. Service or

maintenance performed by unqualified personnel could result in a risk of injury.

25. When servicing a tool, use only identical replacement parts. Follow instructions

in the

unauthorized parts or failure to follow maintenance instructions may create a risk of

electric shock or injury.

“Inspection, Maintenance, And Cleaning”

section of this manual. Use of

Grounding

WARNING!

Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualified electrician if you are in doubt as to whether the
outlet is properly grounded. Do not modify the power cord plug provided with
the tool. Never remove the grounding prong from the plug. Do not use the
tool if the power cord or plug is damaged. If damaged, have it repaired by a
service facility before use. If the plug will not fit the outlet, have a proper outlet
installed by a qualified electrician.

Grounded Tools: Tools With Three Prong Plugs

1. Tools marked with “Grounding Required” have a three wire cord and three prong

grounding plug. The plug must be connected to a properly grounded outlet. If the

tool should electrically malfunction or break down, grounding provides a low

resistance path to carry electricity away from the user, reducing the risk of electric

shock. (See Figure A.)

2. The grounding prong in the plug is connected through the green wire inside the

cord to the grounding system in the tool. The green wire in the cord must be the only

wire connected to the tool’s grounding system and must never be attached to an

electrically “live” terminal. (See Figure A.)

SKU 93827 For technical questions, please call 1-800-444-3353. Page 6

3. Your tool must be plugged into an appropriate outlet, properly installed and grounded

in accordance with all codes and ordinances. The plug and outlet should look like

those in the following illustration. (See Figure A.)

FIGURE A

Double Insulated Tools: Tools With Two Prong Plugs

4. Tools marked “Double Insulated” do not require grounding. They have a special

double insulation system which satisfies OSHA requirements and complies with

the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard

Association, and the National Electrical Code. (See Figure B.)

5. Double insulated tools may be used in either of the 120 volt outlets shown in the

following illustration. (See Figure B.)

FIGURE B

Extension Cords

1.

2. As the distance from the supply outlet increases, you must use a heavier gauge

Grounded

use either a two or three wire extension cord.

extension cord. Using extension cords with inadequately sized wire causes a serious

drop in voltage, resulting in loss of power and possible tool damage.

(See Figure C, next page.)

tools require a three wire extension cord.

Double Insulated

tools can

3. The smaller the gauge number of the wire, the greater the capacity of the cord. For

example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

(See Figure C.)

SKU 93827 For technical questions, please call 1-800-444-3353. Page 7

4. When using more than one extension cord to make up the total length, make sure

each cord contains at least the minimum wire size required. (See Figure C.)

5. If you are using one extension cord for more than one tool, add the nameplate

amperes and use the sum to determine the required minimum cord size.

(See Figure C.)

6. If you are using an extension cord outdoors, make sure it is marked with the suffix

“W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.

7. Make sure your extension cord is properly wired and in good electrical condition.

Always replace a damaged extension cord or have it repaired by a qualified

electrician before using it.

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

areas.

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SKU 93827 For technical questions, please call 1-800-444-3353. Page 8

Specific Safety Rules

1. Maintain a safe working environment. Make sure there is adequate surrounding

workspace. Always keep the work area free of obstructions, grease, oil, trash, and

other debris.

2. Maintain labels and nameplates on this item. These carry important information.

If unreadable or missing, contact Harbor Freight Tools for a replacement.

3. When using a handheld power tool, always maintain a firm grip on the tool

with both hands.

4. To avoid electrical shock, do not pull or carry the AC Charger Adapter (63) by

its Power Cord or pull the Power Cord around sharp corners or edges. Do not

unplug the AC Charger Adapter by pulling on the Power Cord. Keep the Power

Cord away from heated surfaces.

5. Never leave the AC Charger Adapter (63) unattended when it is plugged in.

Make sure to unplug the AC Charger Adapter from its outlet before leaving.

6. Proper Battery Care: Battery (64) leakage may occur under extreme usage or

temperature conditions. If Battery fluid comes in contact with skin, wash with soap

and water and rinse with lemon juice and vinegar. If the fluid comes in contact with

eyes, flush with water for several minutes and contact a doctor immediately. Never

burn the Battery, as it can explode in a fire. Do not attempt to charge a leaking

Battery. Contact local solid waste authorities for instructions on correct disposal or

recycling of the Battery.

7. Store idle equipment. When not in use, tools and equipment should be stored in a

dry location to inhibit rust. Always lock up tools and equipment, and keep out of

reach of children.

8. Industrial applications must follow OSHA requirements.

9. WARNING! Some dust created by power sanding, sawing, grinding, drilling,

and other construction activities, contain chemicals known (to the State of California)

to cause cancer, birth defects or other reproductive harm. Some examples of these

chemicals are: lead from lead-based paints, crystalline silica from bricks and cement

or other masonry products, arsenic and chromium from chemically treated lumber.

Your risk from these exposures varies, depending on how often you do this type of

work. To reduce your exposure to these chemicals: work in a well ventilated area,

and work with approved safety equipment, such as those dust masks that are specially

designed to filter out microscopic particles. (California Health & Safety Code §

25249.5,

10. WARNING! People with pacemakers should consult their physician(s) before

using this product. Electromagnetic fields in close proximity to a heart pacemaker

could cause interference to or failure of the pacemaker.

11. WARNING! The warnings, precautions, and instructions discussed in this manual

cannot cover all possible conditions and situations that may occur. The operator

must understand that common sense and caution are factors which cannot be built

into this product, but must be supplied by the operator.

et seq.

)

SKU 93827 For technical questions, please call 1-800-444-3353. Page 9

CHARGING THE BATTERY

Note: Always switch to a fresh battery when tool performance begins to diminish.

Severe heat is most destructive to a battery; the more heat generated, the faster the

battery loses power. A battery that gets too hot can be permanently damaged. Never

over-discharge a battery by using the tool even after tool performance is decreasing.

Never attempt to discharge a tool’s battery by continuing to pull the tool trigger. When

tool performance begins to diminish, stop the tool, recharge the battery and

use the fresh battery for optimal performance.

1. When a Battery (64) requires recharging, a 3 to 5 hour* charge allows the tool to

operate at full power. Do not recharge the Battery longer than 5 hours*, as damage

to the Battery and/or tool will occur.

2. To charge the Battery (64), plug the AC Charger Adapter’s (63) plug into the Charger

(62). Insert the Charger (62) onto the top of the Battery (64) until it locks into place.

Charging room temperature: 50° F - 104° F. Then, plug the AC Charger Adapter

into the nearest 120 Volt, grounded, electrical outlet. (See illustration below.)

(62)

(64)

3. Two

Charging Indicator LEDs

on the Charger (62) will illuminate to show that charging

(63)

is taking place. NOTE: The AC Charger Adapter (63) will not automatically turn off

when the Battery is fully charged, and the Charging Indicator LEDs will remain on

until the AC Charger Adapter is disconnected from the electrical outlet. Recharging

the Battery more than 5 hours* can cause damage to the battery cells.

4. While charging, the Battery (64), AC Charger Adapter (63), and/or Charger (62)

may become warm to the touch. This is normal, and does not indicate a problem.

5. Once the Battery (64) is fully charged, disconnect the AC Charger Adapter (63) from

the electrical outlet. Then, disconnect the Charger from the Battery.

* The Battery (64) require an initial charge time of 8 hours. Do not recharge the Battery more than 5

hours after this initial charging.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 10

OPERATION

Note: For additional information regarding the parts listed in the following pages, refer to

the Assembly Diagrams at the end of the manual.

Circular Saw

WARNING: Always make sure the Battery (64) of the Circular Saw is removed

making any adjustments to the tool, except for adjusting the depth of cut (required to

install the battery).

(4)

(14)

(8)

(21)

(35)

(7)

(42)

(34)

(39)

(64)

(42)

1. Blade Installation:

A.

Make certain that the Battery (64) is removed before proceeding.

B. Remove the Hex Wrench (55) from its holder near the Depth Knob (34).

C. Press in and hold the Shaft Lock (7) while you loosen the Bolt (14). Remove the

Bolt (14) and the Outer Flange (13).

D. Hold the Guard (8) open and slide the Blade (10) over and onto the shaft from

the bottom. Make certain that the arrow marked on the Blade (10) is facing

the same direction as the arrow molded into the Fixed Guard (12).

E. Replace the Outer Flange (13) lining up the flats in the Flange with the flats on

the shaft.

F. Press in and hold the Shaft Lock (7) while you reinstall the Bolt (14) and securely

tighten it. Return the Hex Wrench (55) to its holder.

prior

(34)

to

2. The Fence (39) helps you cut multiple times at roughly the same distance.

To Adjust the Fence (39):

A. Loosen the Fence Knob (42).

B. Move the Fence as desired.

C. Retighten the Fence Knob securely.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 11

3. To Adjust the Angle of Cut:

A. Loosen the Angle Knob (34).

B. Pivot the Saw body in relation to the Foot (35) to adjust the angle. Read the

angle from the arrow and scale near the Angle Knob.

C. Retighten the Angle Knob (34) securely.

4. To Adjust the Depth of Cut:

A. Be sure to keep your fingers well away from the Trigger (4), Safety (21), and

Blade (10) while performing any adjustment, but especially when adjusting
the Depth, because the battery may be installed.

B. Loosen the Depth Knob (34).

C. Raise/lower the Saw body in relation to the Foot (35) to adjust the depth.

Note: Add 1/8” to the depth so the Saw Blade (10) can cut through the material cleanly.

D. Retighten the Depth Knob (34) securely.

5. Make certain that both halves of the workpiece are properly supported and secured

in place. Also, make sure that the path you will be cutting along is free from all

obstructions under/on the board and that there are no obstructions in the board itself

(such as knots or hardware).

Keep your fingers AWAY from the Trigger (4) and Safety (21) until you

are lined up with the board and ready to cut.

6. Adjust the depth of cut to the shallowest setting. Insert the fully charged Battery (64)

in the Circular Saw’s handle, and make sure it snaps into place on the handle. The

depth of cut can now be adjusted to the desired setting for use.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 12

7. Causes and operator prevention of “kickback”: Kickback is a sudden reaction

to a pinched, bound, or misaligned Saw Blade (10), causing an uncontrolled Saw to

lift up and out of the workpiece toward the operator. When the Saw Blade is pinched

or bound tightly by the kerf (i.e. the slot that was cut) closing down, the Saw Blade

stalls and the Motor reaction drives the tool rapidly toward the operator. If the Saw

Blade becomes twisted or misaligned in the cut, the teeth at the back edge of the

Saw Blade can dig into the top surface of the workpiece, causing the Saw Blade to

climb out of the kerf and jump back toward the operator. Kickback is a result of

tool misuse and/or incorrect operating procedures or conditions and can be

minimized by taking proper precautions as given below:

A. Maintain a firm grip with both hands on the Saw, and position your body

and arm to allow you to resist kickback forces.

B. When the Saw Blade (10) is binding, or when interrupting a cut for any

reason, release the Trigger (4) and hold the Saw motionless in the workpiece
until the Saw Blade comes to a complete stop. Never attempt to remove the

Saw from the workpiece or pull the Saw backward while the Saw Blade is in
motion or kickback can occur.

C. When restarting the Saw in the workpiece, center the Saw Blade (10) in the

kerf and check that the saw teeth are not engaged into the workpiece. If the
Saw Blade is binding, it may walk up or kickback from the workpiece as the Saw
is restarted.

D. Support large panels to minimize the risk of Saw Blade pinching and

kickback. Large panels tend to sag under their own weight. Supports must be
placed under the panel on both sides, near the line of cut and near the edge of
the panel.

E. Do not use a dull or damaged Saw Blade (10). Unsharpened or improperly

set Saw Blades produce a narrow kerf causing excessive friction, Saw Blade
binding and kickback.

F. Make sure all Saw adjustments are tight and secure before making a cut. If

Saw adjustments shift while cutting, it may cause binding and kickback.

G. Use caution when making a pocket cut into existing walls. The Saw Blade

(10) may cut objects that can cause kickback. Always check to make sure there
are no electrical wires or cables in the cutting path.

8. Get in Position for and Perform the Cut:

A. Rest the front section of the Foot (35) on the edge of the workpiece. Line up the

Saw Blade (10) with the line you will cut along.

B. Press the Safety (21) in and squeeze the Trigger (4). Allow the Saw Blade to

rotate up to full speed before evenly moving the Saw along the cut.
Do not force the saw, allow it to cut at its own pace.

9. Release the Trigger (4) and Safety (21) once the cut is completed. As a

safety measure, remove the Battery (64) when work is completed.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 13

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY
REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO
MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY
PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED
AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND
LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT
PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS
THERETO.

INSPECTION, MAINTENANCE, AND CLEANING

1. WARNING! Always remove the Battery Pack (64) from a tool and unplug

the AC Charger Adapter (63) from its electrical outlet before performing any

inspection, maintenance, or cleaning on the tool.

2. BEFORE EACH USE, inspect the general condition of the tool. Check for

misalignment or binding of moving parts, cracked or broken parts, damaged wiring,

and any other condition that may affect its safe operation. If abnormal noise or

vibration occurs with a tool, have the problem corrected before further use. Do not

use damaged equipment.

3. TO CLEAN, use a clean, slightly damp cloth to clean the outer surfaces of the tool.

A mild detergent may be used. Do not use solvents. Do not immerse the tool,

Battery, or AC Charger Adapter in water.

4. WHEN STORING, always keep the tool a clean, dry location out of reach of children.

Keep charger unplugged from the wall outlet when not in use.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 14

Parts List and Diagram - Circular Saw

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Part 62 - Charger - not shown.
Part 63 - AC Charger Adapter - not shown.
Part 64 - Battery - not shown.

NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as

original or replacement parts.

SKU 93827 For technical questions, please call 1-800-444-3353. Page 15