MasterCraft 55-6896-2 Owner's Manual
OWNER’S MANUAL
SLIDING COMPOUND MITRE SAW
55-6896-2
IMPORTANT:
Read through this Owner’s Manual carefully before using this tool. Pay
close attention to all Safety Instructions, Warnings, and Caution sections. Use
this tool properly, and only for its intended use.
Safety symbols in this Manual are used to call attention to possible dangers.
The safety symbols and their explanations require the operator’s full understanding. The safety warnings do not, by themselves, eliminate any danger, and
they are not a substitute for proper accident-prevention measures.
This Safety Alert Symbol indicates caution, warning, or danger. Failure to
obey a safety warning can result in serious injury to the operator or to others.
To reduce the risk of injury, fire, or electric shock, always follow the safety
precautions.
2
TABLE OF CONTENTS
Rules for Safe Operation…………..……………………………….......Page 3
Glossary of Woodworking Terms……………………………................Page 9
Description…………..…………………………………………..........Page 10
Assembly…………..…………………………………………........... . . Page11
Adjustments…………..…………………………………………........Page 11
Operation…………..………………………………………….............Page 14
Maintenance…………..………………………………………............Page 23
Troubleshooting…………..……………………………………...........Page 24
Repair Parts…………..……………………………………................ Page 25
Exploded View & Part List…………..……………………...................Page 26
Warranty…………..……………………………………………..........Page 32
SPECIFICATIONS
Mitre Saw Specifications:
Model: 55-6896-2
Motor: 120 V 60 Hz 15 A,
Speed: 5500 RPM, no load
Blade: 10˝ (25.4 cm) (40-tooth) carbide-tipped
Laser: CLASS llla
Laser wavelength: 635-655 nm
Laser max outpower: 2.5 mW
sliding length: 8 1/4”
Weight: 38 lb 9 oz (17.5 kg)
Cutting capacity: 3 1/8 x 11 5/8”crosscut at 0º mitre, 0º bevel
3 1/8 x 8˝ mitre at 45º mitre, 0º bevel
1 1/2 x 11 5/8˝ at 0º mitre, 45º bevel
1 1/2 x 8˝ compound at 45º mitre, 45º bevel
3
RULES FOR SAFE OPERATION
KNOW THE TOOL
To operate this tool safely, carefully read this Owner’s Manual and all labels
affixed to the Compound Mitre Saw before using it, and follow all instructions
contained therein. Keep this Manual for future reference.
IMPORTANT
This tool should only be serviced by a qualified service technician.
READ ALL INSTRUCTIONS THOROUGHLY
SAFETY PRECAUTIONS FOR LASERS
This Mitre Saw has a built-in
laser light. The laser is Class
IIIa, and emits a maximum
output power of 2.5 mW at
635-655 nm wavelengths.
These lasers do not normally
present an optical hazard.
However, DO NOT stare at the
beam, because this can cause
flash blindness.
CAUTION: The following label appears on the tool. It indicates the location
from which the saw emits the laser light. BE AWARE of the laser-light location
when using the tool. Always make sure that any bystanders in the vicinity are
made aware of the dangers of looking directly into the laser.
• Do not remove or deface any product labels. Removing product labels
increases the risk of exposure to laser radiation.
• The laser beam can be harmful to the eyes. Always avoid direct eye
exposure.
• Do not look directly into the laser-beam-output aperture during operation.
• Do not project the laser beam directly into the eyes of others.
• Turn the laser on only when making cuts. The laser on the Mitre Saw is not a
toy. Always keep it out of the reach of children. The laser light emitted from
this device should never be directed toward any person for any reason.
• Be sure that the laser beam is aimed at a workpiece that does not have a
reflective surface (e.g.: wood or a rough-coated surface).
635-655 nm Output: ≤ 2.5 mW Class llla Laser Product
Complies with 21 CFR parts 1040.10 and 1040.11
635 à 650 nm. Puissance de sortie : ≤ 2,5 mW. Produit à laser de
classe llla. Conforme aux normes des paragraphe 1040.10 et 1040.11
du code 21 des règlements fédéraux américains (CFR) de la FDA.
LASER RADIATION. DO NOT STARE INTO BEAM.
RAYONNEMENT LASER. Ne regardez pas directement
le faisceau.
CAUTION
r
ATTENTION
AVOID EXPOSURE
t
ÉVITEZ TOUTE EXPOSITION
Laser radiation is emitted through this aperture.
Le rayonnement laser émane de cette ouverture.
10" Sliding Compound Mitre Saw
Scie à onglets mixtes coulissante de 10 po
55-6896-2
MADE IN CHINA/FABRIQUÉ EN CHINE
IMPORTED BY/IMPORTÉ PAR MASTERCRAFT CANADA, TORONTO CANADA M4S 2B8
Motor: / Moteur : 120 V AC 60 Hz 15 A / C.A. 120 V 60 Hz 15 A
No-load speed: / Vitesse à vide : 5500 /min / 5 500 tr/min
Serial No.: / N
o
de série :
WARNING:
4
• Do not use on materials that have shiny, reflective surfaces, such as sheet
steel. The reflective surface could reflect the beam back at the operator.
Be aware that laser light reflected off of a mirror or any other reflective
surface can also be dangerous.
• Always turn the laser beam off when it is not in use. Leaving the tool on
increases the risk of someone inadvertently staring into the laser beam.
CAUTION: Always follow the instructions contained in this Manual when
using this laser. The use of this feature in any manner other than what is described in this Manual may result in hazardous exposure to radiation.
• Always wear laser-protective eyewear when working on or near reflective
surfaces
GENERAL SAFETY PRECAUTIONS
Read and become familiar with the entire Owner’s Manual.
Learn the tool’s application, limitations, and possible hazards.
Keep the guard in place and in working order.
Remove all adjusting keys and wrenches before turning tools on. Form the
habit of checking to see that keys and adjusting wrenches are removed from
the tool before turning the tool ON.
Keep the work area clean. Cluttered areas and benches invite accidents.
Do not use the tool in wet locations. Do not use power tools in damp
locations, and do not expose them to rain or snow.
Keep the work area well lit.
Keep children away. All visitors and bystanders should be kept a safe
distance away from the work area.
Make the workshop childproof by using padlocks and/or master switches,
and/or by removing starter keys.
Do not force the tool. The tool will do the job better and more safely at the
speed that it was designed to work at.
Use the correct tool. Do not force the tool or any attachment to do a job that
it was not designed for.
Use proper extension cords. Make sure extension cords are in good
condition. When using an extension cord, be sure to use a cord that is heavy
enough to carry the drawn current needed by the Compound Mitre Saw. An
undersized cord will result in a drop in line voltage and loss of power, which
will cause the tool to overheat. The table on Page 5 shows the correct size
to use, depending on cord length and nameplate amperage rating. When in
5
doubt, use the next heavier gauge: the smaller the gauge number, the heavier
the cord.
Wear proper apparel. Do not wear loose clothing, gloves, neckties, rings,
bracelets, or other jewellery that may get caught in moving parts. Non-slip
footwear is recommended. Wear a protective hair covering to contain long hair
Wear a facemask or a dust mask. Sawing operations produce dust.
Secure the work. Use clamps or a vise to hold the work. It is safer than using
the hand/body, and it frees both hands to operate the Compound Mitre Saw.
Disconnect tools before servicing the tool and when changing accessories,
such as blades, bits, and cutters.
Reduce the risk of accidental start-ups. Make sure the switch is in the OFF
position before plugging in the tool.
Only use recommended accessories. Consult this Owner’s Manual for
recommended accessories. The use of improper accessories may cause a risk
of injury to the operator or to others.
Never stand on the tool. Serious injury could occur if the tool is tipped or if
the cutting tool is unintentionally contacted.
WARNING: The operation of any tool can result in foreign objects be-
ing propelled into the eyes, which could result in severe eye damage. When
operating a power tool, always wear safety goggles or safety glasses with side
shields, or a full face shield, if necessary.
Check for damaged parts. Any guard or other part that is damaged should
be carefully checked to determine that it will operate properly and perform its
intended function before using the tool. Check for misalignment or binding of
moving parts, broken parts, mounting, and any other condition that may affect
the operation of the tool. A guard or other part that is damaged should be
properly repaired or replaced before using the tool.
Never leave the tool unattended while the power is “on.” Turn the power
“off”. Do not leave the tool until the blade has come to a complete stop and
the Mitre Saw has been unplugged.
Do not overreach. Keep proper footing and balance at all times.
Maintain tools with care. Keep tools sharp and clean for optimum
performance. Follow instructions for lubricating and changing accessories.
CAUTION: Do not attempt to operate this tool until you have thoroughly
read all instructions, safety rules, and warnings. Failure to comply can result
in fire, electric shock, or serious personal injury. Keep the Owner’s Manual for
future reference, and review it frequently.
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WARNING: Dust generated from certain materials can be hazardous to your
health. Always operate the saw in a well-ventilated area, and provide for proper
dust removal.
ELECTRICAL SAFETY
Grounding instruction: In the event of a malfunction or breakdown, grounding
provides a path of least resistance for electric current that reduces the risk
of electric shock. This tool is equipped with an electric cord that has an
equipment-grounding conductor and a grounding plug. The plug must be
plugged into a matching outlet that is properly installed and grounded, in
accordance with all local codes and ordinances.
Do not modify the plug provided. If it will not fit the outlet, have a proper
outlet installed by a qualified electrician.
Use only 3-wired extension cords that have 3-pronged grounding plugs and
3-holed receptacles that accept the tool’s plug.
Permanently connected tools: This tool should be connected to a grounded
metal permanent wiring system or to a system that has an equipmentgrounding conductor.
GUIDELINES FOR EXTENSION CORDS
Use a proper extension cord. Make sure extension cords are in good
condition. When using an extension cord, be sure to use a cord that is heavy
enough to carry the drawn current needed by the Compound Mitre Saw. An
undersized cord will cause a drop in line voltage, resulting in loss of power
and overheating. The table below shows the correct size to use, depending on
the cord length and nameplate amperage rating. When in doubt, use the next
heavier gauge: the smaller the gauge number, the heavier the cord.
Be sure extension cords are properly wired and in good condition. Always
replace a damaged extension cord, or have it repaired by a qualified technician
before using it. Protect extension cords from sharp objects, excessive heat,
and damp or wet areas.
Use a separate electrical circuit for power tools. This circuit must not be less
than #6 wire, and should be protected with a time-delayed fuse or circuit breaker.
Before connecting the tool to the power line, make sure the switch is in the OFF
position and the electric current is rated the same as the current stamped on the
motor’s nameplate; running at a lower voltage will damage the motor.
Recommended size of extension cords
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Amperage rating of the
tool (120 V circuit only)
Total length of the extension cord
25’
(7.6 m)
50’
(15.2 m)
100’
(30.4 m)
150’
(45.7 m)
More than
Not more
than
Minimum Gauge for the extension cord
(AWG)
0 6 18 16 16 14
6 10 18 16 14 12
10 12 16 16 14 12
12 16 14 12
Not recommended
WARNING: Ensure that the power-supply outlet in question is properly
grounded. If you are not sure, have a licensed electrician check the outlet.
WARNING: Use proper circuit protection to avoid electrical hazards, fire
hazards, or damage to the tool.
SPECIFIC SAFETY RULES
Use only crosscutting saw blades. When using the mitre saw to cut
nonferrous metal, make sure the blade has a negative hook angle.
IMPORTANT: Do not use thin-kerf blades. Thin-kerf blades can deflect and
contact the guard, which may cause injury to the operator.
Do not operate the Mitre Saw until it is completely assembled and installed
according to these instructions.
If not thoroughly familiar with the operation of mitre saws, seek guidance
from a supervisor, instructor, or other qualified person.
Always hold the workpiece firmly against the fence and table. Do not perform
any operation freehand. Use a clamp or vise whenever possible
Keep hands out of the path of the saw blade. If holding the workpiece causes
the hands to be within the “No-Hands” zone (3’’ (7.6 cm) away from the
blade), the workpiece should be clamped in place before making the cut.
Be sure the blade is sharp, runs freely, and is free of vibrations.
Allow the motor to come to full speed before starting a cut.
Keep the motor’s air slots clean and free of chips or dust.
Always make sure all adjusting knobs are tightened before cutting, even if the
table is positioned in one of the positive stops.
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Be sure both the blade and the flange are clean, and the blade screw is
tightened securely.
Use only blade flanges specified for this saw.
Never use blades that are larger or smaller in diameter than 10” (25.4 cm).
Never apply lubricants to the blade while it is running.
Always check the blade for cracks or damage before operation. Replace a
cracked or damaged blade before further use.
Never use blades recommended for operation at less than 5500 RPM
Use the blade guards at all times.
Always keep the blade guards in place.
Never reach around the saw blade.
Make sure the blade is not contacting the workpiece before the ON/OFF switch
is turned ON.
IMPORTANT: After completing the cut, release the power switch and wait for
the blade to stop before returning the saw to the raised position.
Make sure the blade has come to a complete stop before removing or
securing the workpiece, changing the angle of the workpiece, or changing the
angle of the blade.
Never cut metals or masonry products with this tool. This Mitre Saw is
designed for use on wood and wood-like products.
Never cut small pieces. Keep hands outside of the no-hands zone: at least 3”
(7.6 cm) away from the blade.
Provide adequate support to the sides of the mitre table for long workpiece.
Never use the Mitre Saw in an area with flammable liquids or gases.
Never use solvents to clean plastic parts. Solvents may dissolve or otherwise
damage the material.
Shut off the power and unplug the tool before servicing or adjusting it.
Disconnect the saw from the power source and clean the tool when finished
using it.
Make sure the work area is clean before leaving the tool.
If any part of this Compound Mitre Saw is missing or damaged or fails in
any way, or if any electrical component fails to perform properly, shut off the
power and remove the plug from the power-supply outlet. Replace missing,
damaged, or failed parts before resuming operation.
GLOSSARY OF WOODWORKING TERMS
• Spindle: The revolving shaft on which a blade or cutting tool is mounted.
9
• Spindle Lock: Allows the user to stop the blade from rotating while
tightening or loosening the blade screw during blade replacement or removal.
• Bevel Cut: A cutting operation made with the blade at any angle other than
90° to the mitre table.
• Chamfer Cut: A cut that removes a wedge from a block of wood so that
the end (or part of the end) is angled at other than 90°.
• Compound Mitre Cut: A cut made using both a mitre angle and a bevel
angle at the same time.
• Crosscut: A cutting operation made across the grain of the workpiece.
• Slide Rails: Guide the head assembly when making a slide cut.
• Head Assembly Locking pin: The compound mitre saw is equipped with a
locking pin that is used to lock the head assembly in the down position.
• Flange: A ring or collar on the end of a spindle or arbor that permits other
objects, such as a blade, to be attached to it.
• Freehand Cut: Performing a cut without using a fence, mitre gauge,
fixture, work clamp, or other proper device to keep the workpiece from
twisting or moving during the cut. Do not perform any operation freehand.
Use a clamp or vise wherever possible.
• Gum: A sticky, sap-based residue of wood products.
• Kerf: The material removed by the blade in a through cut, or the slot
produced by the blade in a non-through or partial cut.
• Kickback: A hazard that can occur when the blade binds or stalls, throwing
the workpiece back toward the operator.
• Mitre Cut: A cutting operation made with the blade at any angle other than
90° to the fence.
• No-Hands Zone: The area between the marked lines on the left and right
side of the mitre-table base. This zone is identified by No-Hands Zone
symbols inside the lines marked on the mitre table base.
• Non-Through Cut: Any cutting operation where the blade does not extend
completely through the thickness of the workpiece.
• Resin: A sticky, sap-based substance that has hardened.
• Revolutions Per Minute (RPM): The number of turns completed by a
spinning object in one minute.
• Saw Blade Path: The area over, under, behind, or in front of the blade, as it
applies to the workpiece. The area that will be or has been cut by the blade.
• Set: The distance that the saw blade tooth is bent (or set) outward from
the face of the blade.
10
• Throat Plate: A plate inserted in the Mitre Saw’s table that allows for blade
clearance.
• Through Sawing: Any cutting operation where the blade extends
completely through the thickness of the workpiece.
• Workpiece or Material: The item on which the cutting operation is being
done. The surfaces of a workpiece are commonly referred to as faces,
ends, and edges.
DESCRIPTION
KNOW THE COMPOUND MITRE SAW (See Fig. 1)
Before attempting to use this Compound Mitre Saw, become familiar with all
of its operating features and safety requirements.
Fig. 1
1. ON/OFF trigger switch
2. Horizontal, rubberized
D-handle
3. Safety lock-off button
4. Upper blade guard
5. Blade-screw guard
6. Dust-extraction port
7. Saw blade
8. Laser guide
9. Mounting holes
10. Mitre table
11. Mitre-angle scale
12. Throat plate
13. Mitre-angle indicator
14. Mitre lock
15. Clamp mounting holes
16. Fence
17. Lower blade guard
12
14
11
13
10
15
25
6
19
1
20
27
9
22
26
4
16
2
3
5
7
17
8
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