HERCULES 56790 Owner's Manual & Safety Instructions

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Page 1

Owner’s Manual & Safety Instructions

21k

Model

HE79

14" Abrasive Cut-Off Saw

WARNING: To prevent serious injury, User must read and

understand Owner’s Manual. SAVE THIS MANUAL.

When unpacking, make sure that the product is intact and

undamaged. If any parts are missing or broken, please call

1-888-866-5797 as soon as possible. Reference 56790.

Page 2

IMPORTANT SAFETY INFORMATION

GENERAL POWER TOOL SAFETY WARNINGS

Read all safety warnings, instructions, illustrations and specifications provided with this power tool.

Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

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

1. Work area safety

a. Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

b. Do not operate power tools in explosive

atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools

create sparks which may ignite the dust or fumes.

c. Keep children and bystanders away

while operating a power tool. Distractions

can cause you to lose control.

2. Electrical safety

a. Power tool plugs must match the outlet.

Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching

outlets will reduce risk of electric shock.

b. Avoid body contact with earthed or grounded

surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of

electric shock if your body is earthed or grounded.

c. Do not expose power tools to rain or wet

conditions. Water entering a power tool

will increase the risk of electric shock.

d. Do not abuse the cord. Never use the cord

for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled

cords increase the risk of electric shock.

e. When operating a power tool outdoors,

use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor

use reduces the risk of electric shock.

f. If operating a power tool in a damp location

is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of

a GFCI reduces the risk of electric shock.

3. Personal safety

a. Stay alert, watch what you are doing and

use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment

of inattention while operating power tools may result in serious personal injury.

b. Use personal protective equipment. Always

wear eye protection. Protective equipment

such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

c. Prevent unintentional starting. Ensure the

switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools

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

d. Remove any adjusting key or wrench

before turning the power tool on. A wrench

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

e. Do not overreach. Keep proper footing and

balance at all times. This enables better control

of the power tool in unexpected situations.

f. Dress properly. Do not wear loose clothing or

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

or long hair can be caught in moving parts.

g. If devices are provided for the connection of

dust extraction and collection facilities, ensure these are connected and properly used. Use of

dust collection can reduce dust-related hazards.

h. Do not let familiarity gained from frequent

use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause

severe injury within a fraction of a second.

i. Only use safety equipment that has been

approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the work area.

j. Avoid unintentional starting.

Prepare to begin work before turning on the tool.

k. Do not depress the spindle lock when

starting or during operation.

l. Do not leave the tool unattended when

it is plugged into an electrical outlet. Turn off the tool, and unplug it from its electrical outlet before leaving.

Page 2 For technical questions, please call 1-888-866-5797. Item 56790

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m. This product is not a toy.

Keep it out of reach of children.

n. People with pacemakers should consult their

physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure. In addition, people with pacemakers should:

• Avoid operating alone.

• Do not use with Trigger locked on.

• Properly maintain and inspect to avoid electrical shock.

• Properly ground power cord. Ground Fault Circuit Interrupter (GFCI) should also be implemented – it prevents sustained electrical shock.

o. The warnings, precautions, and instructions

discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

4. Power tool use and care

a. Do not force the power tool. Use the correct

power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.

b. Do not use the power tool if the switch

does not turn it on and off. Any power

tool that cannot be controlled with the switch is dangerous and must be repaired.

c. Disconnect the plug from the power

source and/or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools.

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

d. Store idle power tools out of the reach of

children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are

dangerous in the hands of untrained users.

e. Maintain power tools and accessories.

Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are

caused by poorly maintained power tools.

f. Keep cutting tools sharp and clean. Properly

maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

g. Use the power tool, accessories and tool bits

etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the

power tool for operations different from those intended could result in a hazardous situation.

h. Keep handles and grasping surfaces

dry, clean and free from oil and grease.

Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

5. Service

a. Have your power tool serviced by a

qualified repair person using only identical replacement parts. This will ensure that

the safety of the power tool is maintained.

b. Maintain labels and nameplates on the tool.

These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

6. Cut-off machine safety warnings

a. Position yourself and bystanders away from

the plane of the rotating wheel. The guard helps to protect the operator from broken wheel fragments and accidental contact with wheel.

b. Use only bonded reinforced wheels

for your power tool. Just because an

accessory can be attached to your power tool, it does not assure safe operation.

c. The rated speed of the accessory must be at

least equal to the maximum speed marked on the power tool. Accessories running faster

than their rated speed can break and fly apart.

d. Wheels must be used only for recommended

applications. For example: do not grind with the side of a cut-off wheel. Abrasive

cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.

e. Always use undamaged wheel flanges that

are of correct diameter for your selected wheel. Proper wheel flanges supporl the wheel

thus reducing the possibility of wheel breakage.

f. The outside diameter and the thickness of your

accessory must be within the capacity rating of your power tool. Incorrectly sized accessories

cannot be adequately guarded or controlled.

g. The arbour size of wheels and flanges

must properly flt the spindle of the power tool. Wheels and flanges with arbour holes

that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

h. Do not use damaged wheels. Before each

use, Inspect the wheels for chips and cracks. If the power tool or wheel Is dropped, inspect for damage or install an undamaged wheel. After inspecting and installing the wheel, position yourself and bystanders away from the plane of the rotating wheel and run the power tool at maximum no load speed for one minute. Damaged wheels will

normally break apart during this test time.

Page 3For technical questions, please call 1-888-866-5797.Item 56790

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i. Wear personal protective equipment.

Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and shop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable

of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.

j. Keep bystanders a safe distance away

from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a

broken wheel may fly away and cause injury beyond immediate area of operation.

k. Position the cord clear of the spinning

accessory. If you lose control, the cord may

be cut or snagged and your hand or arm may be pulled into the spinning wheel.

l. Regularly clean the power tool’s air vents.

The motor’s fan can draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

m. Do not operate the power tool near flammable

materials. Do not operate the power tool while placed on a combustible surface such as wood. Sparks could ignite these materials.

n. Do not use accessories that require liquid

coolants. Using water or other liquid coolants

may result in electrocution or shock.

7. Kickback and related warnings

- Kickback is a sudden reaction to a pinched or snagged rotating wheel. Pinching or snagging causes rapid stalling of the rotating wheel which in turn causes the uncontrolled cutting unit to be forced upwards toward the operator.

- For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. Abrasive wheels may also break under these conditions.

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

a. Maintain a firm grip on the power tool

and position your body and arm to allow you to resist kickback forces. The

operator can control upward kickback forces, if proper precautions are taken.

b. Do not position your body in line with the

rotating wheel. If kickback occurs, it will propel

the cutting unit upwards toward the operator.

c. Do not attach a saw chain, woodcarving

blade, segmented diamond wheel with a peripheral gap greater than 10 mm or toothed saw blade. Such blades create

frequent kickback and loss of control.

d. Do not “jam” the wheel or apply excessive

pressure. Do not attempt to make an

excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.

e. When the wheel is binding or when

interrupting a cut for any reason, switch off the power tool and hold the cutting unit motionless in the material until the wheel comes to a complete stop. Never attempt to remove the wheel from the cut while the wheel is in motion or kickback may occur. Investigate and take corrective actions

to eliminate the cause of wheel binding.

f. Do not restart the cutting operation in the

workpiece. Let the wheel reach full speed and carefully re-enter the cut. The wheel

may bind, walk up or kickback if the power tool is restarted in the workpiece.

g. Support any oversized workpiece to minimise

the risk of wheel pinching and kickback.

Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

Vibration Safety

This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury:

a. Anyone using vibrating tools regularly or for

an extended period should first be examined by a doctor and then have regular medical check-ups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud’s Disease should not use this tool. If you feel any symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible.

b. Do not smoke during use. Nicotine reduces

the blood supply to the hands and fingers, increasing the risk of vibration-related injury.

c. Wear suitable gloves to reduce the

vibration effects on the user.

d. Use tools with the lowest vibration when there

is a choice between different processes.

e. Include vibration-free periods each day of work.

Page 4 For technical questions, please call 1-888-866-5797. Item 56790

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f. Grip tool as lightly as possible (while still keeping

safe control of it). Let the tool do the work.

g. To reduce vibration, maintain the tool as

explained in this manual. If any abnormal vibration occurs, stop use immediately.

Grounding Instructions

TO PREVENT ELECTRIC SHOCK

AND DEATH FROM INCORRECT GROUNDING WIRE CONNECTION: 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.

Double Insulated Tools: Tools with

Two Prong Plugs

1. To reduce the risk of electric shock, double insulated equipment 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.

2. Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration.

(See Outlets for 2-Prong Plug.)

Outlets for 2-Prong Plug

Extension Cords

1. Grounded tools require a three wire extension cord. Double Insulated tools can use either

a two or three wire extension cord.

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

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 Table A.)

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 Table A.)

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 Table A.)

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

TABLE A: RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS* (120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

* Based on limiting the line voltage drop to five volts at

150% of the rated amperes.

EXTENSION CORD

LENGTH

25´ 50´ 75´ 100´ 150´

Page 5For technical questions, please call 1-888-866-5797.Item 56790

Page 6

Warning Symbols and Definitions

Specifications

This is the safety alert symbol. It is used to

alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate injury.

Addresses practices not related to personal injury.

Symbology

Volts

Alternating Current

Amperes

Electrical Rating 120 VAC / 60 Hz / 15 A

Spindle No Load Speed 4100 /min

Max. Accessory Diameter

Arbor 1" Round

Cutting Capacity 5"

Cut-Off Wheel Diameter – 14"

SETUP - BEFORE USE

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning

of this manual including all text under subheadings therein before set up or use of this product.

Note: For additional information regarding

the parts listed in the following pages, refer to Parts List and Diagram on page 12.

Mounting

1. Use the four bolt holes provided in the Base

to mount the Cut-Off Saw to a stable support before use. Mounting hardware not included.

2. Ensure that the Cut-Off Saw is always stable

and secure (e.g. fixed to a bench).

Work Area

n0 xxxx/min.

No Load Revolutions per Minute (RPM)

WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields.

Read the manual before set-up and/or use.

WARNING marking concerning Risk of Electric Shock. Properly connect power cord to appropriate outlet.

Keep hands clear of fence area.

DANGER marking concerning Risk of Amputation. Keep hands well clear of cutting area.

1. Designate a work area that is clean and well lit.

The work area must not allow access by children or pets to prevent distraction and injury.

2. There must not be objects, such as utility lines,

nearby that will present a hazard while working.

3. Route the power cord along a safe route to reach

the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working.

Cut-Off Wheel Selection

1. Any cut-off wheel that will be used must be

marked as suitable for the material to be cut.

2. Use only a cut-off wheel diameter in accordance

with the markings on the saw. See specification table for the bore diameter of the cut-off wheel.

3. Use only cut-off wheels that are marked with a speed

equal or higher than the speed marked on the tool.

Guard Setup

Check that the Lower Blade Guard is in place, moves freely, and closes instantly.

Page 6 For technical questions, please call 1-888-866-5797. Item 56790

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Functions

Head

Lock-Down

Depth Stop

Angle Scale

Handle

Spindle

Lock

Vise Clamp

Quick

Release

Vise Handle

Hex Wrench

Trigger

Lower Blade

Guard

Cut-Off

Wheel

Upper Blade

Guard

Page 7For technical questions, please call 1-888-866-5797.Item 56790

Page 8

OPERATION

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning

of this manual including all text under subheadings therein before set up or use of this product.

Tool Changing

5. Closely inspect the new cut-off wheel before mounting. Perform a ring-test on the wheel as follows:

a. Suspend wheel using a dowel or

finger through the arbor hole.

b. Tap the flat side of the wheel with a light

non-metallic object, such as a screwdriver handle, at a point 45° from the vertical center line on each side of the wheel and 1 - 2 inches from the edge of the wheel. Refer to Figure C.

CAUTION! TO PREVENT INJURY: Wear heavyduty work gloves when handling abrasive wheels.

The cut-off wheel MUST be:

• rated to at least 4100 RPM

• no larger than 14″ (356 mm) in diameter

• fitted with a 1″ round arbor hole

• suitable for edge grinding, not surface grinding

• dry and clean

• proven undamaged by inspection and by the ring-test explained below

1. Unplug the tool from its power source.

2. Pull out the Head Lock-Down Pin, raise the Saw Head to the upper position, then raise the Lower Blade Guard out of the way and hold it up.

3. Press in the Spindle Lock on the back of the Saw Head and hold it in.

Lower

Blade

Guard

Spindle

Lock

Figure A: Spindle Lock

4. Remove the Arbor Bolt, Flange Washer, Outer Flange and Cut-Off Wheel. Refer to Figure B.

Note: Make sure the Inner Flange stays in place on the Spindle.

Cut-Off

Wheel

Outer

Flange

Washer

Hang

Wheel

from

Dowel

V V E E R R T T

I I C C A A LL

Tap

45°45° 45°45°

Wheel

Here

C C E E N N T T E E RR

45°45° 45°45°

Figure C:

Cut-Off Wheel Ring-Test

c. Rotate the wheel 90° and repeat the test

until the entire wheel has been checked.

d. An undamaged wheel will give a clear tone.

If cracked, there will be a dead sound and not a clear ring.

6. For wheels with paper gaskets (blotters) or metal gaskets: Slip the

cut-off

wheel onto the Spindle with the gasket first. The gasket should be centered on the wheel and the wheel and gasket should rest flat against the Inner Flange.

WARNING: To prevent serious injury, gaskets

must be used for all

cut-off

wheels they are provided with. Gaskets help prevent cut-off wheel damage and wheel slippage, causes of wheel failure.

7. Install the new cut-off wheel, and reassemble the parts shown in Figure B. The concave side of the Outer Flange must face the Wheel.

8. Hold in the Spindle Lock and wrench tighten the Arbor Bolt by turning it clockwise. Release the Spindle Lock.

WARNING: To prevent serious injury, do not overtighten flange. Overtightening can damage the wheel, causing wheel failure.

Arbor

Bolt

Figure B: Removing Cut-Off Wheel

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Page 9

Setting and Testing

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Make sure that the Trigger is in the off position and unplug the tool from its electrical outlet before performing any procedure in this section.

Using the Depth Stop

1. Loosen the Nut on the Depth Adjustment Bolt shown in Figure D.

Using the Vise

1. After setting the cutting angle, secure loose work pieces using the Vise to prevent movement while working:

a. Lift up the Quick Release to the released

position and push the Vise Handle until the Vise Clamp is up against the workpiece.

b. Put the Quick Release in the engaged

position shown and tighten the Vise Handle to secure the workpiece.

Note: To cut the workpiece at an angle, see Setting Up an Angle Cut.

Vise Clamp

Quick

Release

Nut

BracketBracket

Figure D: Depth Adjustment

2. Turn the Depth Adjustment Bolt to change the depth so that the Cut-Off Wheel will not contact the base at any time during cutting.

3. After adjustment, tighten the Nut down against the bracket to lock the adjustment in place.

Depth Depth

Adjustment Adjustment

BoltBolt

Setting Up an Angle Cut

1. To cut at various angles (up to 45º), adjust the Angle Scale by loosening the two Bolts as shown in Figure E.

2. Adjust the Angle Scale to the desired setting and then tighten both Bolts.

Upper Two

Screw Holes

Angle

Scale

Figure E: Angle Scale

3. To reposition the Angle Scale for a wider workpiece, remove both of the Bolts and reattach the Angle Scale at the upper two screw holes.

Bolts

Place Workpiece Place Workpiece

HereHere

Vise Handle

Figure F: Vise Components

2. To release the workpiece, loosen the Vise Handle a few turns, lift up the Quick Release and pull the Vise Handle out to release the Vise Clamp.

Workpiece and Work Area Set Up

1. Designate a work area that is clean and well lit. The work area must not allow access by children or pets to prevent distraction and injury.

2. Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working.

3. Allow room on both left and right of saw for extended workpieces.

4. There must not be objects, such as utility lines, nearby that will present a hazard while working.

5. Secure workpieces to the saw table using the Vise to prevent movement during the cutting operation. Securing the workpiece will provide safety by removing the need to hold workpieces near the Cut-Off Wheel by hand and also improve cutting accuracy by preventing the workpiece from moving when cutting.

Page 9For technical questions, please call 1-888-866-5797.Item 56790

Page 10

General Operation

TO PREVENT SERIOUS INJURY: DO NOT OPERATE WITH ANY GUARD DISABLED, DAMAGED, OR REMOVED. Moving guards must move freely and close instantly.

1. Raise the Saw Head Assembly by pushing down on the Handle and pulling out the Head Lock-Down Pin.

2. Using the Vise, secure the workpiece and, if necessary, adjust the angle of the cut.

3. Plug the Power Cord into the nearest 120 VAC, grounded electrical outlet.

4. Grip the Saw Handle and squeeze the Trigger to start the Saw. Allow the Cut-Off Wheel to attain full speed.

5. With one hand on the Handle and the other hand clear, slowly bring the Cut-Off Wheel down onto the workpiece, letting the Saw do the work. Do not apply excessive force.

6. If the Cut-Off Wheel does not cut all the way through the workpiece:

a. Raise the Saw Head and release the Trigger.

b. Unplug the unit.

c. Wait until the Cut-Off Wheel comes to a full stop.

d. Remove the workpiece.

e. Set the depth adjustment to a deeper setting.

See Using the Depth Stop on page 9.

f. After adjusting the depth, bring the Saw

Head all the way down to make sure the Cut-Off Wheel doesn’t contact the Base.

g. If it does contact any part of the Base,

re-adjust the depth so it doesn’t.

h. Repeat the cutting process

starting with step 1 above.

7. When the cut is completed, raise the Saw Head and release the Trigger.

CAUTION! Do not attempt to remove the workpiece until the Cut-Off Wheel has stopped moving.

8. After the Wheel has stopped turning, release the Vise and remove the workpiece from the Saw.

9. To prevent accidents after use, turn off the tool, disconnect its power supply, and lock it down by pushing the Saw Head down as far as it will go and pushing in the Head Lock-Down Pin. Clean, then store the tool indoors out of children’s reach.

MAINTENANCE AND SERVICING

Procedures not specifically explained

in this manual must be performed only by a qualified technician.

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Make sure that the Trigger is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section. TO PREVENT SERIOUS INJURY FROM TOOL FAILURE: Do not use damaged equipment. If abnormal noise or vibration occurs, have the problem corrected before further use.

Cleaning, Maintenance,

and Lubrication

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

• loose hardware

• misalignment or binding of moving parts

• cracked or broken parts

• damaged cord/electrical wiring

• cracked or broken parts

• any other condition that may

affect its safe operation.

2. AFTER USE, wipe external surfaces of the tool with clean cloth.

3. Periodically, wear ANSI-approved safety goggles and NIOSH-approved breathing protection and blow dust and grit out of the motor vents using dry compressed air.

4. For wheel changing instructions see Tool Changing on page 8.

5. WARNING! TO PREVENT SERIOUS

INJURY: If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician.

Cut-Off Wheel Storage and Handling

1. Handle Cut-Off Wheels carefully to prevent dropping or bumping. Do not use wheels that have been dropped or bumped.

2. Store Cut-Off Wheels in shelves, racks, boxes, or drawers. Keep storage area dry and above freezing. Any grinding or Cut-Off Wheels exposed to humidity or freezing temperatures must not be used.

Page 10 For technical questions, please call 1-888-866-5797. Item 56790

Page 11

Troubleshooting

Problem Possible Causes Likely Solutions

Tool will not start. 1. Cord not connected.

2. No power at outlet.

3. Tool’s thermal reset breaker tripped (if equipped).

4. Internal damage or wear. (Carbon brushes or switch, for example.)

Tool operates slowly. Extension cord too long or

wire size too small.

Performance decreases over time.

Excessive noise or rattling.

Overheating. 1. Forcing machine to work too fast.

1. Cut-off wheel worn or dull.

2. Carbon brushes worn or damaged.

Internal damage or wear. (Carbon brushes or bearings, for example.)

2. Cut-off wheel worn or dull.

3. Blocked motor housing vents.

4. Motor being strained by long or small diameter extension cord.

1. Check that cord is plugged in.

2. Check power at outlet. If outlet is unpowered, turn off tool and check circuit breaker. If breaker is tripped, make sure circuit is right capacity for tool and circuit has no other loads.

3. Turn off tool and allow to cool. Press reset button on tool.

4. Have technician service tool.

Eliminate use of extension cord. If an extension cord is needed, use shorter/heavier gauge cord. See Table A on page 5.

1. Replace cut-off wheel.

2. Have qualified technician replace brushes.

Have technician service tool.

1. Allow machine to work at its own rate.

2. Replace cut-off wheel.

3. Wear ANSI-approved safety goggles and NIOSHapproved dust mask/respirator while blowing dust out of motor using compressed air.

4. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See Table A on page 5.

Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service.

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Page 12

PARTS LIST AND DIAGRAM

Parts List

Part Description Qty

1 Flange Bolt 3 2 Flange Washer 1 3 Lower Wheel Flange 2 4 Cutting Wheel 355 mm 1 5 O-Ring 1 6 Shaft Sleeve 2 7 Lower Blade Guard Screw 1 8 Lower Blade Guard 1 9 Lock Nut 2

Cross Recessed Countersunk Head Screw 11 Upper Blade Guard 1 12 Bearing 6203-DU 1 13 Aluminum Flange 1 14 O-Ring 1 15 Gear 1 16 Spindle 1 17 Bearing 6000-2Z 1 18 Woodruff Key 1 19 Brush Holder Cover 2 20 Carbon Brush 2 21 Hex Socket Bolt M5 x 8 2 22 Brush Holder 2 23 Motor End Cap 1 24 Self-Tapping Screw With Pad 4 25 Motor Housing 1 26

Cross Recessed Countersunk Head Screw 27 Stator 1 28

Cross Recessed Countersunk Head Screw 29 Air Deflector 1 30 Bearing Bushing 1 31 Bearing 629-RZ 1 32 Armature 1 33 Washer 1 34 Lock Pin 1 35 Bearing 6202-2RS 1 36 Lock Pin Spring 1 37 Rubber Pin 1 38 Power Cord Sleeve 1 39

Cross Recessed Countersunk Head Screw 40 Power Cord 1 41 Terminal Block 1 42

Cross Recessed Countersunk Head Screw 43 Handle Frame 1

Part Description Qty

44 Upper Handle 1 45 Bottom Cover 1 46 Carry Handle 1

Cross Recessed Countersunk Head

Screw with Spring Washer 48 Self-Tapping Screw 5 49 Slot Pan Head Self-Tapping Screw 1 50 Switch 1 51 Lower Handle 1 52 Vise Lock Handle Assembly 1 53 T-Pin 1 54 Spring Washer Φ8 2 55 Cotter Pin 1 56 Vise Clamp 1 57 Angle Scale 1 58 Spring Pressure Frame 1 59 Lock Nut 2 60 Torsion Spring 1 61 Hex Key Grommet 1 62 Washer Ф8 2 63 Hex Wrench 1 64 Work Clamp Lock Lever 1 65 Elastic Cylindrical Pin 1 66 Vise Lock Lever 1 67 Hex Head Bolt 2 68 Base 1 69 Rubber Foot 4 70

Cross Recessed Countersunk Head Screw 71 Hinge Rod 1 72 Flat Washer Ф10 2 73 Lock Nut 2 74 Spark Guard 1 75

Cross Recessed Countersunk Head Screw 76 Hex Socket Bolt 1 77 Lock-Down Pin 1 78 O-Ring 1 79 Lock-Down Pin Handle 1 80 Hex Head Nut 1 81 Hex Socket Bolt 1 82 Upper Arm 1 83 Lower Guard Pad 1 84 Rubber Pad 2 85 Hex Socket Bolt 1

Page 12 For technical questions, please call 1-888-866-5797. Item 56790

Page 13

Assembly Diagram

2 2

4 8

4 5

2 8

2 9

4 2

3 7

3 8

8 2

5 0

5 2

Page 13For technical questions, please call 1-888-866-5797.Item 56790

Page 14

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR 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.

Record Product’s Serial Number Here:

Note: If product has no serial number, record month and year of purchase instead.

Note: Some parts are listed and shown for illustration purposes only, and are not available

individually as replacement parts. Specify UPC 792363567909 when ordering parts.

Page 14 For technical questions, please call 1-888-866-5797. Item 56790

Page 15

LIMITED 90 DAYS WARRANTY

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product.

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

Page 15For technical questions, please call 1-888-866-5797.Item 56790

Page 16

Visit our website at: http://www.harborfreight.com

Email our technical support at: productsupport@harborfreight.com

For technical questions, please call 1-888-866-5797

any artwork contained herein may be reproduced in any shape or form without the express

written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn

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

product described herein. Tools required for assembly and service may not be included.

26677 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797