MasterCraft 054-8326-0 Owner's Manual

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Page 1

EASY SAW

054-8326-0

Owner’s Manual

PRODUCT SPECIFICATIONS

Rating:

120 V, 60 Hz AC

Amperes:

13 A

Blade speed:

4800 RPM (no load)

Blade:

7 ¼” (18.4 cm), 5/8” (15.9 mm) arbour,

40 Tungsten carbide teeth

Wood maximum cutting depth:

2 ½” (64 mm) @ 90° 1 13/16” (46 mm) @ 45°

Steel maximum thickness:

1/8" (3.2 mm)

Bevel angle:

0–50°

Weight:

13 lb 14 oz (6.3 kg)

Need Assistance?

Call us on our toll free customer support line: 1-800-689-9928

 Technical questions  Replacement parts  Parts missing from package

Imported by Mastercraft Canada Toronto, Canada M4S 2B8

Page 2

Product specifications ………….…………………………………………………….

Table of contents ……………………………………………………………………...

General safety warnings ……………………………………………………………..

3–4

Eye, ear & lung protection ……………………………………………………………

3–4

Electrical safety ……………………………………………………………………….

Power tool safety ……………………………………………………………………...

5–6

General safety rules …………………………………………………………………..

Work area ………………………………………………………………….…………..

Electrical safety ……………………………………………………………………….

Personal safety ………………………………………………………………………..

5–6

Use and care of power tools .………………………………………………………..

Service …………………………………………………………………………………

Specific safety rules …………………………………………………………………..

7–9

Extension cord safety ………………………………………………………………...

Symbols ………………………………………………………………………………..

Know your easy saw ………………………………………………………………

Accessories ……………………………………………………………………………

Contents ……………………………………………………………………………….

13–15

Assembly and operating ……………………………………………………………..

16–33

Installing the track rider ………………………………………………………………

Installing the metal cutting shield ……………………………………………………

16–17

Changing the blade …………………………………………………………………...

17–18

Setting the cutting depth ……………………………………………………………..

Bevel cutting angle ……………………………………………………………………

19–20

Installing the rip guide ………………………………………………………………..

Vacuum port …………………………………………………………………………..

20–21

Lock-off button ………………………………………………………………………..

Trigger switch …………………………………………………………………………

Laser switch …………………………………………………………………………...

Laser adjustment ……………………………………………………………………...

Resettable overload switch ………………………………………………………….

Materials you can cut …………………………………………………………………

General cutting ………………………………………………………………………..

24–25

Plunge cutting …………………………………………………………………………

Metal cutting …………………………………………………………………………...

Cutting using the rip guide …………………………………………………………...

Assembling the guide track ………………………………………………………….

28–29

Cutting using the guide track ………………………………………………………...

30–31

Installing zero clearance inserts …………………………………………………….

31–32

Maintenance …………………………………………………………………………..

33–34

Replacing carbon motor brushes ……………………………………………………

General maintenance ………………………………………………………………...

Exploded view …………………………………………………………………………

35–36

Parts list ………………………………………………………………………………..

37–40

Warranty ……………………………………………………………………….………

41–42

TABLE OF CONTENTS

Page 3

EYE, EAR & LUNG PROTECTION

This instruction manual includes the following:

 General Safety Rules  Specific Safety Rules and Symbols  Functional Description  Assembly  Operation  Maintenance  Accessories

ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA REQUIREMENTS or ANSI SAFETY STANDARD Z87.1

FLYING DEBRIS can cause permanent eye damage. Prescription eyeglasses ARE NOT a replacement for proper eye protection.

WARNING: Non-compliant eyewear can cause serious injury if

broken during the operation of a power tool.

SAVE THESE INSTRUCTIONS FOR REFERENCE

WARNING: Use hearing protection, particularly during extended periods of operation of the tool, or if the operation is noisy.

GENERAL SAFETY WARNINGS

WARNING: Before using this tool or any of its accessories, read this

manual and follow all Safety Rules and Operating Instructions. The important precautions, safeguards and instructions appearing in this manual are not meant to cover all possible situations. It must be understood that common sense and caution are factors which cannot be built into the product.

Page 4

ELECTRICAL SAFETY

WARNING: To avoid electrical hazards, fire hazards or damage to the

tool, use proper circuit protection.

This tool is wired at the factory for 120 V AC operation. It must be connected to a 120 V AC, 15 A circuit that is protected by a time-delayed fuse or circuit breaker. To avoid shock or fire, replace power cord immediately if it is worn, cut or damaged in any way.

GENERAL SAFETY WARNINGS

WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.

WARNING: Dust that is created by power sanding, sawing, grinding,

drilling, and other construction activities may contain chemicals that are known to cause cancer, birth defects, or other genetic abnormalities. These chemicals include:

Lead from lead-based paints Crystalline silica from bricks, cement, and other masonry products Arsenic and chromium from chemically treated lumber

The level of risk from exposure to these chemicals varies, according to how often this type of work is performed. In order to reduce exposure to these chemicals, work in a well-ventilated area, and use approved safety equipment, such as a dust mask that is specifically designed to filter out microscopic particles.

SAVE THESE INSTRUCTIONS FOR REFERENCE

Page 5

WARNING Read all safety warnings and instructions. Failure to follow the

warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

Work area safety Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust.

Power tools create sparks which may ignite the dust or fumes.

Keep children and bystanders away while operating a power tool.

Distractions can cause you to lose control.

Electrical safety Power tool plugs must match the outlet.

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

plugs and matching outlets will reduce risk of electric shock.

Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators.

There is an increased risk of electric shock if your body is earthed or grounded.

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

tool will increase the risk of electric shock.

Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts.

Damaged or entangled cords increase the risk of electric shock.

When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for

outdoor use reduces the risk of electric shock.

If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply.

Use of a ground fault circuit interrupter (GFCI) reduces the risk of electric shock.

Personal safety Stay alert, watch what you are doing

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

operating power tools may result in serious personal injury.

Use 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.

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 energising power tools that have the switch on invites accidents.

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.

POWER TOOL SAFETY

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PERSONAL SAFETY – cont’d

Do not overreach. Keep proper footing and balance at all times. This enables

better control of the power tool in unexpected situations.

Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair

can be caught in moving parts.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of

dust collection can reduce dust-related hazards.

Power tool use and care Do not force the power tool. Use the

correct power tool for your application.

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

Do not use the power tool if the switch does not turn it on and off. Any power

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

Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive

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

Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool.

Power tools are dangerous in the hands of untrained users.

Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power

tool’s operation. If damaged, have the

power tool repaired before use. Many accidents are caused by poorly maintained power tools.

Keep cutting tools sharp and clean.

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

Use the power tool, accessories and tool bits etc. in accordance with these instructions, 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.

Service Have your power tool serviced by a

qualified repair person using only identical replacement parts. This will

ensure that the safety of the power tool is maintained.

POWER TOOL SAFETY

Page 7

WARNING: Know your circular saw. Do not plug the tool into the power source until you have read and understand this Instruction Manual.

Learn the tool’s applications and

limitations, as well as the specific potential hazards related to this tool.

Following this rule will reduce the risk of electric shock, fire, or serious injury.

Always wear eye protection. Any power tool can throw foreign objects into your eyes

and cause permanent eye damage. ALWAYS wear safety goggles (not glasses) that comply with ANSI safety standard Z87.1. Everyday glasses have only impact resistant lenses. They ARE NOT safety glasses.

WARNING: Glasses or goggles not in compliance with ANSI Z87.1 could cause serious injury when they break.

Always keep hands out of the path of the saw blade. Avoid awkward hand positions where a sudden slip could cause your hand to move into the path of the saw blade.

DANGER: Keep hands away from cutting area and the blade. Keep your second hand on the tool. If both hands

are holding the saw, they cannot be cut by the blade.

Do not reach underneath the workpiece.

The guard cannot protect you from the blade below the workpiece.

Adjust the cutting depth according to the thickness of the workpiece. Less

than a full tooth of the blade teeth should be visible below the workpiece or approximately 3/8" (10 mm).

Never hold piece being cut in your hands or across your leg. Secure the workpiece to a stable platform. It is

important to support the work properly to minimize body exposure, blade binding, or loss of control.

Hold power tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact

with a “live” wire will also make exposed metal parts of the power tool “live” and shock the operator.

When ripping always use a straight rip guide. This improves the accuracy of cut

and reduces the chance of the blade binding.

Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades that do not match

the mounting hardware of the saw will run eccentrically, causing loss of control.

Never use damaged or incorrect blade washers or bolt. The blade washers and

bolt were specially designed for your saw, for optimum performance and safety of operation.

SAVE THESE INSTRUCTIONS FOR REFERENCE

SPECIFIC SAFETY RULES

Page 8

CAUSES AND OPERATOR PREVENTION OF KICKBACK

Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator.

When the blade is pinched or bound tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator.

If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator. Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to the left or right side of the blade, but not in line with the blade.

Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.

When the blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw backward while the blade is in motion or kickback may occur. Investigate and take corrective

actions to eliminate the cause of blade binding.

When restarting a saw in the workpiece, centre the saw blade in the kerf and check that saw teeth are not engaged into the material. If the saw blades are

binding, it may walk up or kickback from the workpiece as the saw is restarted.

Support large panels to minimize the risk of blade pinching and kickback.

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

Do not use dull or damaged blades.

Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.

ADDITIONAL SPECIFIC SAFETY RULES Use extra caution when making a

“plunge cut” into existing walls or other blind areas. The protruding blade may cut

objects that can cause kickback.

Check the lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If the saw is accidentally

dropped, the lower guard may be damaged. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part in all depths of cuts.

Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. The lower guard

may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.

SPECIFIC SAFETY RULES

SAVE THESE INSTRUCTIONS FOR REFERENCE

Page 9

ADDITIONAL SPECIFIC SAFETY RULES – cont’d

The lower guard should be retracted manually only for special cuts such as “plunge cuts” and “compound cuts”. Raise lower guard by retracting handle and as soon as the blade enters the material, the lower guard must be released. For all other sawing, the lower

guard should operate automatically.

Always observe that the lower guard is covering the blade before placing saw down on the bench or on the floor. An

unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after the switch is released.

Never operate the saw while it is being carried to another location. The blade guard may be open and potentially cause serious injury.

If the switch fails to turn the saw ON or OFF properly, stop using it immediately and have the saw switch repaired.

Always allow the saw to reach full speed before beginning the cut.

Never use the side of the blade for cutting. When making horizontal cuts, make sure the weight of the tool is not forcing the side of the blade to do the cutting. This will reduce the risk of kickback.

Make sure there are no nails or foreign objects in the area of the workpiece to be cut.

Never lay workpiece on hard surfaces like concrete, stone, etc. The protruding

blade may cause the tool to jump.

DANGER: To avoid injury from

accidental starting, always remove the plug from the power source before making any adjustments and before installing or removing a saw blade.

When replacing the blade, make sure the replacement blade is 7¼ " (18.4 cm) in diameter and is rated for at least 7,000 RPM. Installing an incorrect

blade will result in possible injury and poor cutting action.

After changing a blade or making adjustments, make sure the blade clamp screw is securely tightened.

Loose blades and adjustment devices will be violently thrown.

Never touch the blade during or immediately after use. After use the

blade is too hot to be safely touched with bare hands.

DANGER: Never use the laser in the

presence of small children. Small children may stare directly into the laser light beam and cause serious eye injury.

DANGER: The laser light beam that is projected from the front of the laser level can be dangerous to eyesight. Never allow anyone to stare directly into the light. Staring directly into the light beam may result in serious eye damage.

DANGER: Always remove the plug from the power source when changing the blade.

SPECIFIC SAFETY RULES

! ! !

SAVE THESE INSTRUCTIONS FOR REFERENCE

Page 10

WARNING: Keep the extension cord clear of the working area. Position

the cord so it will not get caught on the workpiece, tools or any other obstructions while you are working with the power tool.

Make sure any extension cord used with this tool is in good condition. When using an extension cord, be sure to use one of heavy enough gauge to carry the current the tool will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.

The table at right shows the correct size to use according to cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number the heavier the cord.

Be sure your extension cord is properly wired and in good condition. Always replace a damaged extension cord or have it repaired by a qualified electrician before using it. Protect your extension cord from sharp objects, excessive heat and damp or wet areas.

Use a separate electrical circuit for your power tools. This circuit must not be less than 14 gauge wire and should be protected with either a 15 A time delayed fuse or circuit breaker. Before connecting the power tool to the power source, make sure the switch is in the OFF position and the power source is the same as indicated on the nameplate. Running at lower voltage will damage the motor.

MINIMUM GAUGE (AWG)

EXTENSION CORDS (120 V use only)

Amperage

rating Total length

than

Not

than

25'

(7.5 m)

50'

(15 m)

100'

(30 m)

150'

(45 m)

0 6 18

14 6 10

Not Applicable

EXTENSION CORD SAFETY

SAVE THESE INSTRUCTIONS FOR REFERENCE

Page 11

Volts

Amperes

Hertz

Watts

Kilowatts

Microfarads

Litres

Kilograms

Hours

N/cm2

Newtons per square centimetre

Pascals

Min

Minutes

Seconds

Alternating current

Three-phase alternating current

Three-phase alternating current with neutral

Direct current

No load speed

Alternating or direct current

Class II construction

Splash-proof construction

Watertight construction

Protective grounding at grounding terminal, Class I tools

Revolutions or reciprocations per minute

Diameter

Off position

Arrow

Warning symbol

Warning, bright light

SYMBOLS

WARNING: Some of the following symbols may appear on the easy

saw. Study these symbols and learn their meaning. Proper interpretation of these symbols will allow for more efficient and safer operation of this tool.

This symbol designates that this tool is listed with both Canadian and U.S. requirements by Underwriters Laboratories. Conforms to UL Std. 60745-1& 60745-2-5. Certified to CAN/CSA Std. C22.2 No. 60745-1 & 60745-2-5.

HOMOLOGUE

61TN

E213739

Page 12

Rip guide

Guide track

(not exactly as illustrated)

KNOW YOUR EASY SAW

ON/OFF

Trigger switch

Laser ON/OFF

button

Lock-off button

Vacuum port

baffle

Laser adjustment

screw

Brush cap

Sole plate

45° & 0°

cutting marks

Bevel cutting

adjustment lever

Rip guide

adjustment knob

Depth adjustment

stop button

Main handle

Front handle

Blade guard

lever

Page 13

AVAILABLE ACCESSORIES

WARNING: Use only accessories

that are recommended for this easy saw. Follow the instructions that accompany the accessories. The use of improper accessories may result in injury to the operator or damage to the tool.

Before using any accessory, carefully read

the instructions or the owner’s manual for

the accessory.  Saw blades

WARNING: If any part is missing or damaged, do not plug the tool into the power source or install any accessory until the missing or damaged part is replaced.

CONTENTS Carefully unpack the easy saw. Compare

the contents against the “EASY SAW

COMPONENTS” and “GUIDE TRACK

COMPONENTS” charts below.

NOTE: See illustrations of the easy saw components on Pages 14 & 15.

WARNING: To avoid fire or toxic reaction, never use gasoline, naphtha, acetone, lacquer thinner or similar highly volatile solvents to clean the tool.

CONTENTS

EASY SAW COMPONENTS

KEY

DESCRIPTION

QTY

Easy saw

5 mm Hex key

40 T blade

Rip guide

Track rider

Zero clearance insert

Metal cutting shield

Owner’s Manual

ACCESSORIES

GUIDE TRACK COMPONENTS

KEY

DESCRIPTION

QTY

Track section “A”

Track section “B”

Track section “C”

Track section “D”

Joining bars

Screws

End caps (preassembled)

Page 14

CONTENTS

Page 15

CONTENTS

Page 16

INSTALLING THE TRACK RIDER

The track rider is required for use with the guide track. It is recommended that the track rider be installed on the easy saw and left in place during general cutting. If necessary, the track rider may be removed for general cutting.

1. Lift the front and rear track rider

locking levers (1) upward to release the locking mechanism (Fig. 1). Insert both track rider tabs (2) into the matching mounting slots (3) in the sole plate (4).

NOTE: Make sure the locking pin heads are below the track rider tabs.

2. When the track rider locking tabs are

fully inserted into the mounting slots, press both locking levers downward to lock the track rider into place on the sole plate.

INSTALLING THE METAL CUTTING SHIELD

WARNING: The metal cutting shield

must be installed on the tool when cutting any type of metal. The cutting shield will prevent hot cuttings and sparks from hitting the operator.

NOTE: When cutting metal, always set the base plate angle to 0°.

To install the metal cutting shield:

1. Remove the plug from the power

source.

2. Rotate the guard lever (1) counter

clockwise (Fig. 2).

3. Slide the lower locking tabs (2) upward into the matching slots (3) in the upper blade guard (Fig. 3).

ASSEMBLY AND OPERATING

Fig. 1

Fig. 2

Fig. 3

Page 17

INSTALLING THE METAL CUTTING SHIELD – cont’d

4. Rotate the locking cam arm (4) counter clockwise and push the locking cam into the matching hole (5) in the upper blade guard.

5. Rotate the locking cam arm clockwise to lock the shield into place.

NOTE: To remove the metal cutting shield, simply reverse the above procedure.

CHANGING THE BLADE

WARNING: Always remove the plug

from the power source before removing the blade or adjusting the saw in any way.

WARNING: Use caution when

handling the blade. It is sharp and can easily cut your hand.

1. Press inward on the shaft locking button (1) (Fig. 4).

2. Insert a 5 mm hex key into the blade screw (2) (Fig. 5). While pressing inward on the shaft locking button, rotate the hex key counter clockwise until the shaft locking button engages with the blade shaft. Continue turning the hex key counter clockwise and remove the blade screw, lock washer (3), flat washer (4) and the large outer flange washer (5).

3. Rotate the blade guard lever (6) clockwise (Fig. 6).

4. Open the blade guard by lifting upward on the blade guard lever. Rotate the blade guard in a clockwise direction to expose the blade (7).

ASSEMBLY AND OPERATING

Fig. 3

Fig. 5

ASSEMBLY AND OPERATING

Fig. 4

Fig. 6

Page 18

CHANGING THE BLADE – cont’d

5. While holding the blade guard lever in the open position, lift the blade off the shaft (8) and slide it out through the slot in the sole plate (9).

NOTE: Do NOT remove the inner large flange washer.

6. To place a new blade onto the motor shaft, rotate the blade guard forward (Fig. 6) and slide the blade through the slot in the sole plate until it fits over the motor shaft.

NOTES: a) Make sure the blade teeth are pointing forward at the bottom of the blade. b) Make sure the hole in the blade is placed over the matching boss on the inner large flange washer.

7. Place the large outer flange washer onto the motor shaft.

NOTE: Make sure the flat sections of the large outer flange washer fit over the matching flat sections on the motor shaft.

8. Insert the blade screw through the lock washer, flat washer and the large outer flange washer and thread it clockwise into the end of the motor shaft.

9. Lock the motor shaft using the shaft locking button and firmly tighten the blade screw using the hex key.

NOTE: Make sure the screw is NOT crossthreaded and that the blade does not wobble when turned by hand.

ASSEMBLY AND OPERATING

Fig. 6

ASSEMBLY AND OPERATING

Page 19

SETTING THE CUTTING DEPTH

The cutting depth of the blade should be set to suit the thickness of the material being cut. The cutting depth should be approximately 1/8" (3 mm) greater than the thickness of the material being cut.

WARNING: The cutting depth

adjusting system is spring loaded. When the cutting depth locking lever is released, the sole plate will immediately open to its minimum depth position. Make sure the base is resting on a table or other flat surface when releasing the locking lever.

1. Lift the cutting depth locking lever (1) upward to release the spring loaded sole plate (2) (Fig. 7).

2. Depress the cutting depth stop button (3) and slide the depth stop (4) to the appropriate depth setting (5).

3. Release the cutting depth stop button.

NOTE: When the cutting depth stop button is released, move the depth stop up and down until it clicks into the appropriate preset position. Preset positions are in ¼” (2.3 mm) increments. Always use the deeper setting.

4. Once the correct depth is set, move the sole plate upward until it stops at the preset depth stop. Push the cutting depth locking lever downward to lock the sole plate into position.

BEVEL CUTTING ANGLE

The sole plate can be tilted to provide bevel cuts from 0°–50°.

ASSEMBLY AND OPERATING

Fig. 7

Page 20

BEVEL CUTTING ANGLE– cont’d

Adjusting the sole plate angle

1. Loosen the bevel adjustment by lifting upward on the bevel gauge adjustment lever (1) (Fig. 8).

2. Rotate the sole plate (2) to the desired angle as shown on the bevel gauge (3).

3. Press downward on the bevel gauge adjustment lever to lock the sole plate into position.

INSTALLING THE RIP GUIDE

1. Loosen the rip guide adjusting knob (1) (Fig. 9).

2. Slide the rip guide rod (2) into the rip guide slot (3). Continue to slide the guide rod across the sole plate and into the adjusting knob slot (4) on the opposite side of the sole plate.

3. Adjust the rip guide shoe (5) to the correct distance from the blade and tighten the rip guide adjusting knob.

NOTE: The rip guide may be installed from the opposite side, but the rip guide rod MUST engage both of the rip guide slots in the sole plate.

VACUUM PORT

A workshop vacuum can be attached to the vacuum port to extract much of the dust that is created while cutting wood.

When using a workshop vacuum, pull the vacuum port baffle tab (1) upward until the hole in the baffle engages with the matching pin (2) in the upper blade guard (Fig. 10).

ASSEMBLY AND OPERATING

Fig. 10

Fig. 8

Fig. 9

Page 21

VACUUM PORT – cont’d

NOTE: When cutting wood without using the workshop vacuum, the vacuum port baffle should be closed to limit the amount of sawdust being exhausted toward the operator.

WARNING: The vacuum port baffle

MUST be in the closed position when cutting metal to prevent hot cuttings from hitting the operator.

WARNING: Never attach a

workshop vacuum to the vacuum port when cutting metal. The cuttings will be hot and may cause a fire in the workshop vacuum.

ASSEMBLY AND OPERATING

For safety reasons, the operator must

read the sections of this Owner’s Manual entitled “GENERAL SAFETY WARNINGS”, “POWER TOOL

SAFETY”, “SPECIFIC SAFETY

RULES”, “EXTENSION CORD SAFETY” and “SYMBOLS” before using this

easy saw. Verify the following every time the

easy saw is used:

1. Safety glasses, safety goggles, or face shield are being worn.

2. Hearing protection is being worn.

3. The blade is in good condition.

4. The metal cutting shield is installed before cutting metal.

5. All adjustment devices are tight and any accessory is properly tightened into the accessory holder of the tool.

Failure to observe these safety rules will significantly increase the risk of injury.

WARNING

Page 22

LOCK-OFF BUTTON

The lock-off button (1) is a safety device designed to reduce the possibility of accidentally starting the saw (Fig. 11). This button must be depressed before the trigger switch (2) can be depressed.

NOTE: The lock-off button can be depressed either left or right.

TRIGGER SWITCH

1. To turn the saw ON, depress the lockoff button with your thumb.

2. While holding the lock-off button in the depressed position, squeeze the trigger switch to start the saw.

3. Once the saw starts, release the lockoff button. The saw will remain running until the trigger switch is released.

4. To turn the saw OFF, release the trigger switch.

NOTE: The lock-off button will have to be depressed again to restart the saw.

LASER SWITCH This saw is equipped with a laser guidance

system for more precise cutting.

DANGER: Never allow the laser

beam to shine into a person’s eyes.

Serious eye damage could result. To turn the laser ON, press the laser

switch (1) once (Fig. 12). To turn the laser OFF, press the laser switch again.

ASSEMBLY AND OPERATING

Fig. 11

Fig. 12

Page 23

LASER ADJUSTMENT

The laser guide line should be centered in the 0° cutting groove (1) (Fig. 13). If the laser guide line is not correctly centered it can be centered using a 5/64” (2 mm) slot screwdriver.

Moving the laser line to the right

1. Turn the right laser adjustment screw (2) counter clockwise ¼ turn.

2. Turn the left laser adjustment screw clockwise ¼ turn.

3. Repeat steps #1 and #2 until the laser guide line is moved to the correct location.

Moving the laser line to the left

4. Turn the left laser adjustment screw counter clockwise ¼ turn.

5. Turn the right laser adjustment screw clockwise ¼ turn.

6. Repeat steps #4 and #5 until the laser guide line is moved to the correct location.

RESETTABLE OVERLOAD SWITCH

To avoid damaging the tool due to overloading, the overload switch will automatically turn the tool OFF when it senses an overloaded condition.

When the switch turns the tool OFF, the overload button (1) will pop out (Fig. 14). When this condition happens, simply wait approximately one minute and press the overload switch button inward. Once reset, the tool will operate normally.

Fig. 13

ASSEMBLY AND OPERATING

Fig. 14

Page 24

MATERIALS YOU CAN CUT

The easy saw is a versatile saw that allows you to cut many different types of materials. Some of the materials include:

● Wood products such as lumber, hardwood, plywood, composition board and panelling

● Drywall

● Masonite and plastic

This circular saw will also cut steel plate up to 1/8” (3.2 mm) thick, aluminum and nonferrous metals.

NOTE: There are several different types of blades available. Generally, blades with carbide-tipped teeth cut better and stay sharp longer. Tooth count and configuration are also important. High tooth counts cut slower and are best suited for making smooth cuts on thinner materials such as panelling. Use the correct blade for your application.

GENERAL CUTTING NOTE: Always make a test cut on a scrap

workpiece to verify that all settings are correct.

1. Make any adjustments to the saw before plugging it into the power source. Adjustments include cutting depth, bevel cutting angle and rip guide (if installed).

2. Clearly mark the workpiece to locate the position of the cut.

3. Hold a smaller workpiece with a vise. Clamp a larger workpiece to a work bench or table.

ASSEMBLY AND OPERATING

Page 25

GENERAL CUTTING – cont’d

DANGER: Any workpiece that is not adequately clamped in place or properly supported for cutting may come loose or jamb the blade, causing serious injury. Never hold the workpiece in your hand.

4. Make sure there are no nails, screws, clamps or foreign materials in the path of the saw blade.

5. Turn the laser ON.

6. Place the front edge of the sole plate on the workpiece.

7. With both hands firmly gripping the saw, and with the blade NOT in contact with the surface to be cut, start the saw by depressing the lockoff button and then the trigger switch.

8. Once the saw has reached full speed, gradually bring the moving blade into contact with the workpiece at the appropriate location.

NOTE: To align the saw blade with the cutting mark, use the guide marks on the front of the sole plate (Fig. 15). Use the 0° cutting mark (1) and the laser line (2) for right angle cuts. Use only the 45° mark (3) for 45° bevel cuts. The 45° mark will allow for the extra material needed for the angle cut. Always make a test cut on a scrap workpiece before cutting the new material.

WARNING: Do not force the circular saw. Use only enough force to keep the blade cutting at full speed. Excessive pressure on the blade will cause it to slow down and overheat, resulting in poor cut quality and damage to the motor.

ASSEMBLY AND OPERATING

Fig. 15

Page 26

PLUNGE CUTTING WARNING: To avoid loss of

control, damage to the blade or damage to the workpiece, always use extreme caution when making plunge cuts. It is not recommended to plunge cut any material other than wood.

1. To plunge cut inside the edges of a workpiece, clearly mark the cutting line on the workpiece.

2. Set the depth stop (Fig. 7) and set the bevel angle at 0° (Fig. 8). Do NOT lock the depth stop locking lever.

3. Set the saw on the workpiece so the sole plate is flat on the workpiece (Fig. 16).

4. Open the blade guard by rotating the blade guard lever (1) forward.

5. Align the saw blade with the cutting line (2) using the 0° cutting mark on the sole plate and the laser line.

NOTE: Make sure the saw blade is inside the area to be cut out.

6. Start the saw and slowly lower the blade onto the workpiece while holding the blade guard lever forward to allow the blade to cut into the workpiece (Fig. 17). Allow the blade to cut through the wood.

7. Continue lowering the blade into the workpiece until the full cutting depth has been achieved. Continue sawing toward the cutting line and complete the cut as required.

ASSEMBLY AND OPERATING

Fig. 16

Fig. 17

Page 27

METAL CUTTING

Several types of metal can be cut with your easy saw.

NOTES:

a. Use only the 40 tooth blade supplied

with the tool to cut metal

b. Only cut aluminum, copper and steel c. Do NOT attempt to cut metals thicker

than 1/8” (3.2 mm). Thicker metals may overheat the blade.

WARNING: Metal cutting shield

must be installed. Never allow bystanders or pets to be in front of the easy saw when cutting metal. Hot sparks can injure bystanders.

When cutting any kind of material, be careful not cut a curve. Do not force the blade. If the blade chatters or vibrates excessively, reduce the travel speed of the blade into the workpiece. Clamp all work firmly and saw as close as possible to the clamping point to eliminate any vibration of the work being cut.

When cutting conduit, pipe or angle iron, clamp the workpiece in a vice if possible and saw close to the vice. To cut thin

sheet materials, “sandwich” the material

between hardboard or plywood and clamp the layers to eliminate material vibration and tearing. By doing this, the material will be cut smoothly. Lay out your pattern or cutting lines on top of the “sandwich”.

CUTTING USING THE RIP GUIDE

Whenever possible, install the rip guide on the right hand side of the sole plate (Fig. 18). This will place the majority of the tool weight on the larger portion of the workpiece, making it easier to control the tool. If necessary, the rip guide may be installed from the opposite side, but the rip guide rod MUST engage both of the rip guide slots in the sole plate.

ASSEMBLY AND OPERATING

Fig. 18

Page 28

ASSEMBLING THE GUIDE TRACK

The aluminum guide track is used in conjunction with the easy saw to make

precise cuts across a workpiece up to 39”

(1 m) wide. The guide track is shipped in four sections. To assemble the guide track, you will need a table or work bench at least 4’ (1.2 m) long. Assemble the guide track as follows:

1. Lay the left track section marked “A” (1) on its back toward the left hand side of the work surface (Fig. 19).

2. Insert two joining bars (2) into the matching cavities (3) in the left hand track section “A” and fasten in place using two screws (4) (Fig. 20).

NOTE: Do not tighten any screws until the guide track has been fully assembled (step #8).

3. Lay the second track section marked “B” (5) on its back (Fig. 21). Slide the cavities over the two joining bars that are protruding from track section (A) and fasten in place using two screws (4).

4. Insert two joining bars into the matching cavities in the right hand end of track section “B” and fasten in place using two screws (Fig. 22).

ASSEMBLY AND OPERATING

Fig. 19

Fig. 20

Fig. 21

Fig. 22

Page 29

ASSEMBLING THE GUIDE TRACK – cont’d

5. Lay the third track section marked “C” (6) on its back (Fig. 23). Slide the cavities over the two joining bars that are protruding from the right hand end of track section “B” and fasten in place using two screws (4).

6. Insert two joining bars into the matching cavities in the right hand end of track section “C” and fasten in place using two screws (Fig. 24).

7. Lay the fourth track section marked “D” (7) on its back (Fig. 25). Slide the cavities over the two joining bars that are protruding from the right hand end of track section “C” and fasten in place using two screws (4).

8. Once all track sections are assembled, tighten all 12 screws.

NOTE: It is important to ensure that the fully assembled guide track forms a straight line for cutting. Turning the guide track assembly on its edge on a flat table or workbench will help in aligning all four sections as they are tightened. Once all screws are fully tightened, recheck the assembly with a straight edge. Loosen and retighten the screws as required to properly align all sections of the guide track assembly.

ASSEMBLY AND OPERATING

Fig. 23

Fig. 24

Fig. 25

Page 30

CUTTING USING THE GUIDE TRACK

The guide track can be used to make precision cuts on workpieces up to 39” (1 m) wide.

1. Install the track rider on the sole plate (Fig. 1).

2. Mark the cut line (1) on the workpiece (Fig. 26).

3. Mark guide track alignment marks (2) on the workpiece at each edge 5½” to the left of the cut line.

NOTE: The guide track alignment mark placement will vary depending upon the type of blade being used and the bevel angle. Always make a test cut on a scrap workpiece to verify the set-back distance.

4. Place the guide track (3) on the workpiece to the left of the guide track alignment marks (2) (Fig 27).

5. Place the right edge of the guide track on the guide track alignment marks.

ASSEMBLY AND OPERATING

Fig. 26

Fig. 27

Page 31

CUTTING USING THE GUIDE TRACK – cont’d

6. Place one small clamp on the left hand side of the guide track at each end to hold it firmly onto the workpiece with the right edge on the guide track alignment marks.

7. Set the saw cutting depth (Fig. 7).

NOTE: Make sure you support both the “good” and “cut-off” sections of the workpiece to prevent binding and kickback as the saw cut is completed.

8. Place the runner of the track rider (7) into the matching groove in the guide track (8) (Fig. 28).

9. Slide the saw back until only 1" (25.4 mm) of the front of the sole plate is resting on the workpiece.

NOTE: Make sure the blade does NOT contact the workpiece.

10. Turn the saw ON and slide the saw and the track rider into the workpiece and complete the cut (Fig. 29).

INSTALLING ZERO CLEARANCE INSERTS

This easy saw includes three zero clearance inserts. These inserts will help to prevent raised wood grain on the top side of the cut. Each insert requires a slot to be cut. The most common slots are 90°, 30° and 45°.

ASSEMBLY AND OPERATING

Fig. 28

Fig. 29

Page 32

INSTALLING ZERO CLEARANCE INSERTS – cont’d

To install a zero clearance insert:

1. Release the depth adjustment lever to allow the sole plate to completely clear the saw blade.

2. Place the insert tabs (1) into the four slots (2) in the under side of the sole plate (3) (Fig. 30).

3. While pressing the insert into the mounting slots, slide it toward the front of the sole plate.

NOTE: The insert will snap into place when it is slid toward the front of the sole plate.

4. Set the depth stop to the desired depth of cut (Fig. 7) and the bevel angle to the desired angle (Fig. 8).

5. Using a scrap workpiece that is THICKER than the depth setting, turn the saw ON and make a plunge cut to the preset depth (Fig. 16 & 17).

NOTE: The plunge cut will allow the blade to make a precise cut in the insert, leaving very little clearance between the blade and the slot in the insert.

6. Turn the saw OFF and remove the insert. It is important to mark the cut angle and depth on the upper side of the insert with a felt marker for future reference.

NOTE: To remove the insert, push a medium sized flat blade screwdriver into the slot at the tab (4) (Fig. 31). Twist the screwdriver to slide the insert back until the four tabs can be removed from the mounting slots in the sole plate.

ASSEMBLY AND OPERATING

Fig. 30

Fig. 31

Page 33

REPLACING THE CARBON MOTOR BRUSHES

The carbon motor brushes will wear down and require replacing. The time intervals between replacements will vary depending upon the torques being achieved and the hours of use. It is recommended that the brushes be checked after each 10 hours of use. When the length of the carbon brush reaches 1/4" (6.35 mm), the brushes should be replaced.

WARNING: Unplug the tool from the

power source.

1. Use a 1/4" (7 mm) slot screwdriver and remove one brush cap (1) (Fig. 32). Turn the brush cap counter clockwise to remove it from the motor housing.

2. Pull the spring & brush assembly (2) from the brush holder (3) in the motor housing (4).

3. Insert the new spring & brush assembly into the motor housing.

4. Compress the spring into the brush holder and thread the brush cap back into the motor housing.

NOTE: Make sure the brush cap threads are not cross-threaded. Do NOT over tighten.

5. Repeat steps 1 to 4 and replace the second carbon brush located on the opposite side of the motor housing.

MAINTENANCE

Fig. 32

Page 34

GENERAL

WARNING: When servicing this

tool, use only identical replacement parts. The use of any other part may create a hazard or cause product damage.

DO NOT use solvents when cleaning plastic parts. 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, dust, oil, grease etc.

WARNING: Do not allow brake

fluids, gasoline, petroleum-based products, penetrating oils, etc. to come into contact with plastic parts. They contain chemicals that can damage, weaken or destroy plastic.

DO NOT abuse power tools. Abusive practices can damage the tool and the workpiece.

WARNING: DO NOT attempt to

modify tools or create accessories. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious injury. It will also void the warranty.

It has been found that electric tools are subjected to accelerated wear and possible premature failure when they are used on fibreglass boats and sports cars, wallboard, spackling compounds or plaster. The chips and grindings from these materials are highly abrasive to electric tool parts such as bearings, brushes, commutators, etc. Consequently, it is not recommended that this tool be used for extended work on any fibreglass material, wallboard, spackling compounds or plaster. During any use on these materials it is extremely important that the tool is cleaned frequently by blowing the accumulated debris out with an air jet.

WARNING: Always wear safety goggles or safety glasses with side shields during all cutting operations. It is critical that you wear safety goggles or safety glasses with side shields and a dust mask while blowing dust out of the circular saw with an air jet. Failure to take these safety precautions could result in permanent eye or lung damage.

LUBRICATION

All of the bearings in this tool are lubricated with a sufficient amount of highgrade lubricant for the life of the unit under normal conditions. Therefore, no further lubrication is required.

MAINTENANCE

! ! ! ! !

Page 35

EXPLODED VIEW

Page 36

EXPLODED VIEW – GUIDE TRACK

Page 37

WARNING: When servicing, use only Mastercraft

replacement parts. The use of

any other parts may create a safety hazard or cause damage to the easy saw. Any attempt to repair or replace electrical parts on this easy saw may create a safety

hazard unless repairs are performed by a qualified technician. For more information, call the Toll-free Helpline, at 1-800-689-9928.

Always order by PART NUMBER, not by key number.

Key #

Part #

Part Name

Quantity

4030010096

Tapping screw 3.9X12

3160010044

Back cover

4020010034

Screw M5x52

4020010035

Screw M5x60

4040030003

Spring washer 5 mm

4040010012

Flat washers 5 mm

4030010106

Tapping screw 4X19

3120070075

Handle

1210190002

Overload protector

1062020030

Switch

1130090006

PCB

1210140003

120V transformer

3120010051

Laser button

3011120005

Housing

4100050011

Circlip 8 mm

2030100040

Plunge pivot bracket

2020060015

Bevel scale

2030020017

Washers 6 mm

3120100036

Locking lever

4100050012

Clamp spring 10 mm

2040150020

Serrated nut M6

4090040012

Rivet Φ6x16

4040010033

Flat washer 8 mm x .8 mm

2040290045

Plunge pivot shaft

4050040005

Cup head square neck bolt M6x25

2050050029

Plunge torsional spring

4030010126

Tapping screw 4x65

3150050048

Air deflector

1020120007

Stator 1 30

3160090061

Pivot spring cover

2040160123

Pin 5 mm

PARTS LIST

Page 38

Key #

Part #

Part Name

Quantity

3140040012

629 bearing cover

3150060030

Plastic brush support

2030070010

Copper brush sleeve

1230010076

Carbon brush

3150140019

Carbon brush cover

4030010099

Tapping screw 4X14

2030050002

Cable clamp

3140010006

Cable guard

1190030031

Cable

4010010084

629 2RS bearing

1010120007

Rotor 1 43

3140070016

Spindle lock cover

2030030175

Spindle lock

2050060011

Spindle lock spring

4010010055

6001 2RS bearing

4020010006

Screw M4x12 (galvanized)

4040030001

Spring washer 4 mm

4020120005

Clamping screw M3x10

2020020020

Gear box

3160060008

Laser holder

1220030006

Laser

3140090001

Rubber bushing

4020080007

Hex head screw M6x16

4010020003

HK0810

2030020203

Flat thrust washer 8 mm

4120010002

Flat key 5x10

2040040053

Transmission shaft

2040080015

Transmission gear

2020150054

Gear box cover

2020080030

Fixed guard

4020120009

Screw M4x12

2050050030

Moveable guard torsional spring

2020080031

Moveable guard

4100020009

Circlip for shaft 36 mm

2040210003

Inner flange

6070050003

Blade 1 68

2040210004

Outer flange

4040030013

Lock washer 6 mm

4020080006

Hex head screw M6x20

3120100037

Metal cutting guard locking lever

2030130030

Metal cutting guard

3150130100

Metal cutting guard lock

PARTS LIST

Page 39

Key #

Part #

Part Name

Quantity

4020010003

Screw M4x12 (black)

2030020163

Flat washer 4x11 (black)

2050060141

Moveable guard tortional spring

3120100038

Tortional spring stop

4020010103

Screw M3x8 (black)

3180040097

Vacuum dust port

3140070017

Vacuum dust port baffle cover

3180040098

Vacuum dust port baffle

4020010019

Screw M5x14 (galvanized)

4020020005

Countersunk screw M5x12

4010010081

6201 2RS bearing

2040080016

Big gear

2040040054

Output shaft

4100020011

Circlip for shaft 15 mm

4010020014

HK101410

4020010001

Screw M4x8 (galvanized)

2030160100

Lead clamp

3160090067

Air baffle

4050040006

Cup head square neck bolt M6x40

3150160131

Depth gauge housing (right)

2030030176

Depth gauge

3120020098

Depth adjusting button

2050040039

Depth button spring

3120120098

Depth slider

2040160124

Depth button pin

3150160132

Depth gauge housing (left)

100

3150130101

Track rider

101

2040160025

Cross pin

102

2040160125

Track rider locking pin

103

2050060142

Track rider locking lever spring

104

3120100039

Track rider locking lever

105

2050060143

Edge guide locking knob spring

106

2050060010

Edge guide locking knob

107

2020120033

Sole plate

108

3150130102

Zero clearance insert

109

6220040011

Rip guide

110

2030100041

Depth adjusting support

111

6140020001

Hex key 5 mm

PARTS LIST

Page 40

Key #

Part #

Part Name

Quantity

2020210006

Track section "A"

2020210007

Track section "B"

2020210008

Track section "C"

2020210009

Track section "D"

2040160132

Joining Rod

4020020001

Screw

3160090066

Track end cap

PARTS LIST – GUIDE TRACK

Page 41

3-Year Limited Warranty

This Mastercraft product is guaranteed for a period of 3 years from the date of original retail purchase against defects in workmanship and materials, except for the following components:

a) Component A: Batteries, chargers and carrying cases, which are

guaranteed for a period of 2 years from the date of original retail purchase against defects in workmanship and materials;

b) Component B: Accessories which are guaranteed for a period of 1 year

from the date of original retail purchase against defects in workmanship and materials.

Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period and is 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 the purchase date must be

provided;

b) This warranty will not apply to any product or part thereof that is worn,

broken or that 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

that 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 that are expected to become inoperative or usable after a reasonable period of use;

d) This warranty will not apply to routine maintenance and consumable items

such as, including 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 specified otherwise in writing);

Page 1 of 2

Page 42

3-Year Limited Warranty – cont’d

These warranties are subject to the following conditions and limitations:

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, including but not limited to, scratches, dents, paint chips, or to any corrosion or discoloring by heat, abrasive and chemical cleaners; and

i) This warranty will not apply to component parts sold by and identified

as the product or company, which shall be covered under the product manufacturer’s warranty, if any.

Additional Limitations

This warranty applies only to the original purchaser, and cannot be transferred. Neither the retailer not the manufacturer shall be liable for any other expense, loss or damage, including, without limitation, but not limited to 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.

Mastercraft is a superior line of products selected for their workmanship and materials. These products are designed to meet rigorous quality and performance standards, and are approved by our Quality Assurance laboratory.

TOLL-FREE HELPLINE: 1-800-689-9928

Page 2 of 2

Rev 1.8 10/11/2010