MasterForce 241-0706 Operator's Manual

6 ½” PLUNGE CUT CIRCULAR SAW

241-0706

OPERATOR’S MANUAL

To Reduce The Risk Of Injury, User Must Read And

Und

erstand Operator’s Manual. Save These Instructions For Future Reference.

CAUTION:

!

For questions/comments, technical assistance or repair parts –
Please call toll free: 1-866-349-8665 (M–F 9am–5pm EST)

2

Front cover ……………….………………………………………………………………...

1

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

2

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

3-4

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

3-4

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

4

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

5-6

Specific Safety Rules……………………………………….…………..……….... …………..

7-9

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

9

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

10

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

11

Know your Plunge cut circular saw……………………………………………………….

12

Assembly and Operating…………………………………………………………………….....

13-17

Maintentance ………………………………………………………….……..……….....

18-19

Replacing carbon motor brushes ………………………………….……..………..... 18-19

Exploded view …………………………………………………………………… … ……….. .….

20

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

21-22

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

23

Back cover ……………………………………………………………………….……………...….

24

TABLE OF CONTENTS

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

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

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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.

!

!

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.

4

EYE, EAR & LUNG PROTECTION – cont’d

ELECTRICAL SAFETY

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 defe cts, or other genetic abnormalitie s. Thes e
chemicals include:

Lead from lead-based paints
Crystalline silica fro m bric ks, cement, and other masonry products
Arsenic and chromium from chemi ca lly treated lum ber

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.

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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 Volts AC operation. It must be
connected to a 120 Volts AC, 15 Amps circuit that is protected by a time­delayed 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

5

WARNING: Read all safety warnings and
all 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
opera t ing a power tool. Distraction s 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) 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 energizing 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.

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

control of the power tool in unexpected
situations.

POWER TOOL SAFETY

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6

PERSONAL SAFETY – cont’d

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.

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 conditi ons
and the work to be performed. Use of the

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

Hold power tools by insulated gripping
surfaces when performing an operation
where cutting tool may contact hidden
wiri ng or its ow n c ord. Contact with a "live"

wire will make exposed metal parts of the tool
"live" and shock the operator

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

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7

WARNING: Know your Plunge cut

circular saw. Do not plug the saw 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” (10mm).

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.

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

reduces the chance of the blade binding.

Hold power tool by insulated gripping
surfaces when performing an operation
where the cutting tool may contact hidden
wiri ng or its ow n c ord. Contact with a “live”

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

Always use blades with the 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.

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.

SPECIFIC SAFETY RULES

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8

CAUSES AND O PERATOR PRE VEN TION OF
KICKBACK – cont’d

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, center
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 RU LES

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.

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 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.

SPECIFIC SAFETY RULES

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9

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ADDITIONAL SPECIFIC SAFETY RULES
– cont’d

When replacing the blade, make sure the
replacement blade is 6-1/2" in diameter and
is rated for 6,000 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.

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 below 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 15A 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

More

than

Not

more

than

25'

(7.5 m)

50'

(15 m)

100'

(30 m)

150'

(45 m)

0 6 18

16

16

14 6 10

18

16

14

12

10

12

16

16

14

12

12

16

14

12

Not Applicable

SPECIFIC SAFETY RULES

EXTENSION CORD

SAFETY

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10

PRODUCT SPECIFICATIONS

Rating:

120 V AC, 60 Hz,

Amperes:

10 AMP

No load speed:

5200 RPM

Arbor: 5/8”

Blade:

6-1/2"

Guide rail size:

4 x (27-1/2" x 7")

Maximum cutting depth without track (90o)

56mm (2-1/8")

Maximum cutting depth without track (45o)

45mm(1-3/4”)

Maximum cutting depth with track (90o)

50mm(1-7/8”)

Maximum cutting depth with track (45o)

40mm(1-1/2”)

Weight:

10.8 lb(4.9 kg)

Need Assistance?
Call us on our toll free customer support line:
1-866-349-8665 Monday – Friday from 9am to 5pm
Eastern Standard Time

• Technical questions

• Replacement parts

• Parts missing from package

PRODUCT SPECIFICATIONS

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11

V

Volts

Three-phase alternating current
with neutral

A

Amperes

Read all safety warnings and
instructions

Hz

Hertz

Direct current

W

Watts

No load speed

kW

Kilowatts

Alternating or direct current

Microfarads

Class II construction

L

Litres

Splash-proof construction

kg

Kilograms

Watertight construction

H

Hours

Protective grounding at

grounding terminal, Class I

tools

N/cm2

Newtons per square
centimetre

Revolutions or reciprocat ion s
per minute

Pa

Pascals

Diameter

OPM

Oscillations per minute

Off position

Min

Minutes

Directional Arrow

S

Seconds

Warning symbol

or a.c.

Alternating current

Wear your safet y glasses

Three-phase alternating
current

Wear hearing p rotection

SYMBOLS

WARNING:

Some of the following symbols may appear on the 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 th is tool is
listed with Canadian requirements by
ETL Testing Laboratories, Inc.
Conforms to UL Std. 60745-1 and
60745-2-5.

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12

1. Dust port

2. Upper Guard

3. Blade 24T

4. Blade securing bolt

5. outer flange

6. Front handle

7. Angle adjustment lock knob

8. Base plate

9. Guard window

10. Direction indicator

11. On/Off trigger

12. Plunge release

13. Main handle

14. Depth scale

15. Depth locking knob

16. Track tension adjusters

17. Track channel

18. Safety button

19. Motor cover screw

20. Motor vents

21. Motor cover

22. Guide plate

23. Joining bar

24. Work piece clamp

25. Hex. Key (3mm,5mm)

26. Blade 40T

27. Spindle locking lever

28. 1-1/4” dust adaptor

KNOW YOUR PLUNGE CUT CIRCULAR SAW

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9

13

INSTALLING THE BLADE

WARNING: Always remove the plug

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

1. Place a clean piece of cardboard on a
workbench to protect the blade and the
workbench.

2. Push the plunge release (12), rotate the
saw head clockwise until the blade
securing bolt and the guard window are in
same position.( Fig. 1)

3. Insert the 5 mm blade hex key into the
blade securing bolt (4).( Fig. 1)

4. Press the spindle locking lever (27) (Fig. 2)
and Rotate the blade hex screw counter
clockwise and remove both the blade
screw and the outer flange (5). ( Fig. 1)

NOTE: If the arbor turns with the blade screw,
then press on the blade locking lever (27) and
slowly rotate the blade screw until the locking
lever engages the spindle (Fig. 2).

The tool is supplied with 2 blades;

Blade 24T (see (3) in Know your Plunge cut
circular saw on page 12
– Coarse wood blade suitable for fast coarse
cutting of wood and light density composite
materials (comes installed on tool) (Fig. 3)

Blade 40T (see (26) in Know your Plunge cut
circular saw on page 12)
– Fine wood blade for smooth clean cuts in
wood and normal use in very light density
woods and composite materials.

NOTE: Do NOT remove the inner flange (a)
from the arbor (b). (see Fig.3)

5. Slide the blade upward through the slot in
the base plate and place the blade hole
onto the arbor.

NOTE: Make sure the blade teeth are pointing
toward the front of the saw.

6. Place the outer flange (5) onto the arbor
and thread the blade screw (4) into the
arbour. ( Fig. 1)

7. Tighten the blade screw.

NOTE: Press on the spindle locking lever (27)
and slowly rotate the blade screw clockwise until
the locking lever engages the spindle. Continue
to turn the blade screw clockwise until the blade
is firmly tightened onto the spindle. (Fig. 2)

When installing a new blade, make sure you
follow these precautions:
a) Make sure the teeth at the bottom of the
blade are pointing toward the front of the saw.

b) Check the inner flange washer to make sure
the thicker boss is pointing toward the motor.

d) Make sure the flanged blade screw is NOT
cross threaded and is fully tightened with the
wrench provided.

ASSEMBLY AND OPERATING

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14

e) Before turning the saw ON, carefully rotate
the blade by hand to make sure it does not
wobble.

DUST ADAPTO R

1. The Plunge cut circular saw is supplied
with a dust adaptor for a vacuum. It is
attached to the dust port located at the
back end of the fixed guard.

2. Insert the dust adaptor to dust port until it
fastens.(Fig. 4)

3. Use a 1-1/4” tube to connect the dust
adaptor and vacuum to keep work area
clean while cutting.

Fig. 4

TRIGGER SWITCH

1. To turn the saw ON, push forward the
plunge release (12), then squeeze the
ON/OFF trigger switch (11) (Fig. 5).

NOTE: Please ensure the safety button (18) is
in the ‘lock on’ position before starting the tool,
otherwise, if the safety button is in the ‘lock off’
position the tool will not start. (Fig. 5)

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

MATERIALS THAT YOU CAN CUT

The circular 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, composite board and panelling

● Drywall.

● Masonite and plastic.

NOTE: There are several different types of
blades available. Generally, blades with carbide­tipped 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.

BEFORE YOU CUT

1. Make any adjustments to the saw before
installing the blade.

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 workbench
or table

DANGER: Any workpiece that is not
adequately clamped in place may come
loose and cause serious injury. Never hold
the workpiece in your hand.

ASSEMBLY AND OPERATING

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Lock off

Lock on

15

!

WARNING: Never carry the saw with your finger
on the trigger s witch. The saw could be
accidentally started and cause severe personal
injury.

GENERAL CUTTING

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

2. With both hands firmly gripping the saw,
and with the blade NOT in contact with the
surface to be cut, start the saw by
squeezing the trigger switch.

3. Once the saw has reached full speed,
place the front edge of the base plate on
the workpiece and gradually bring the
moving blade into contact with the
workpiece at the appropriate location.

WARNING: DO NOT force the Plunge

cut 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.

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 saw on the workpiece (1) so the

base plate is flat on the workpiece (Fig. 6).

3. Align the saw blade with the cutting line (3).

4. Press the plunge release (12) and switch

trigger (11) to start the saw and slowly
lower the blade onto the workpiece to allow
the blade to cut into the workpiece (Fig. 7).
Allow the blade to cut through the wood.

5. 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.
NOTE: Make sure the saw blade is inside the
area to be cut out.

BEVEL CUTTING

Loosen both the angle adjustment lock knob (7)
and tilt the tool to the desired angle for bevel
cuts (0 -45°). Secure the lock knob (7) tightly
after making the adjustment.

ASSEMBLY AND OPERATING

For safety reasons, the operator must
read the sections of this Owner’s Manual
entitled "GENERAL SAF ETY
WARNINGS", "POWER TOOL SAFETY",
"SPECIFIC SAFETY RULES",
"EXTENSION CORD SAFETY" and
"SYMBOLS" before using this circular
saw.

Verify the following every time the
Plunge Cut Circular Saw is used:

1. The blade is tight and sharp.

2. All adjustments are tight.

3. The workpiece is properly secured.

4. Safety glasses and hearing
protection are being worn.

Failure to adhere to these safety rules can
greatly increase the chances of serious
injury.

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16

SETTING DEPTH ADJUSTMENT

Alter the depth of the cut by loosening the Depth
Locking Knob (15),(Fig.8). The Base Plate (8) is
now free to adjust to the required depth when
the Plunge Release (12) is pressed. (Fig.7)

Adjust the Base Plate to the required depth
using the Depth Scale (14) or a ruler and
retighten the Depth Locking Knob at the base so
it cannot exceed that depth. (Fig.8)

ASSEMBLING THE GUIDE TRACK

The aluminum guide track is used in conjunction
with the Plunge cut circular saw to make precise
cuts up to 110-1/4” (2.8 m). The guide track is
shipped in four sections. To assemble the guide
track, you will need a table or work bench at
least 8’ (2 m) long. Assembl e the guide track as
follows:

1. Lay the track section (without joining bars)

on its back toward the left hand side of the

work surface.

2. Using the supplied hexagon key to loosen

the 4 screws in the joining bar, Slide the

cavities over the joining bar that is

protruding from track secti on. (Fig.9. Fig.10)

3. Insert joining bar into the matching cavities

in the left hand track section.(Fig.11)
NOTE: Do not tighten any screws until the guide

track has been fully assembled.

Fig.9

Fig.10

Fig.11

4. Repeat steps 2 and 3 to assemble the 3nd

and 4nd track section. (Fig 12)

Fig.12

5. 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.

SAVE THESE INSTRUCTIONS FOR REFERENCE

ASSEMBLY AND OPERATING

17

CUTTING USING THE GUIDE TRACK

The guide track can be used to make precision
cuts on workpieces up to 110-1/4” (2.8 m).

1. Place workpiece on a table.

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

13).

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

3. Place the guide track (2) on the workpiece.

Line up cutting edge of track with the cut
line (1) (Fig 14).

4.

Place the clamp (4) on the left hand side of
the guide track at each end to hold it firmly
onto the workpiece with the left edge on
the guide track alignment marks (1).(Fig.15)

5.

Set the saw cutting depth (see page 16,

section of SETTING DEPTH

ADJUSTMENT).

6. Place the saw on the guide track, the rear

cover of the saw near the alignment marks

(2), the blade near the cutting line (1). The

track features two low friction strips (3) to

allow smooth movement of the saw along

the track. (Fig.16)

7.

Set the Track Tension Adjusters (16) to the

minimum tensions setting before placing

the saw onto the track.(Fig.17)

Fig. 13

ASSEMBLY AND OPERATING

Fig. 14

SAVE THESE INSTRUCTIONS FOR REFERENCE

18

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8.

Use the Track Tension Adjusters to control
movement resistance of the saw along the
track. Set them to equal tension at the
maximum level that allows smooth
movement along the track. This will reduce
or eliminate sideways movement for more
precise cuts and improved safety.

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

9.

Turn the saw ON and slide the saw to cut.

GENERAL

WARNING: When servicing, 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
fiberglass 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 fiberglass material,
wallboard, spackling compounds or plaster.
During any use on these materials it is
extremely important that the tool is cleaned
frequently by blowing it 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 also 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 high-grade lubricant for
the life of the unit under normal conditions.
Therefore, no further lubrication is required.

REPLACING CARBON MOTOR BRUSHES

The carbon motor brushes will wear down
and require replacing. The time intervals
between replacements will vary depending upon
the hours of use. It is recommended that the
brushes be checked after each 10 hours of use.

WARNING: Unplug the tool from the

power source before replacing brushes.

1.

Use a Philips (+) cross screwdriver (1) and

remove the motor rear cover. (Fig. 18)

2. Remove the brush clamp plate (2).(Fig.19)

3. Remove the carbon brush connection wire

(3) from brush terminal (4).(Fig.20)

4. Remove the carbon brush holder (5) with

the carbon brush from the motor housing

(6). (Fig.21)

5. Remove the carbon brush (6) from the

brush holder (5).(Fig.22-23)

6. Reverse the process above to insert the

carbon motor brushes back into the tool

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MAINTENANCE

SAVE THESE INSTRUCTIONS FOR REFERENCE

19

SAVE THESE INSTRUCTIONS FOR REFERENCE

MAINTENANCE

20

EXPLODED VIEW

21

WARNING:

When servicing, use only original equipm ent replacement parts. The use of any

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

are performed by a qualified technician. For more information, call the Toll-free Helpline, at
1-866-349-8665.

Always order by PART NUMBER, not by key number.

PARTS LIST

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