Porter Cable 3802 TYPE 2, 3802 T2 Owner’s Manual
Instruction
12" Compound
Manual
Miter Saw
_t our_e at."
3802 Type 2
IMPORTANT
Please make certain that the person who is to
use this equipment carefully reads and
understands these instructions before starting
operations.
The Model and Senal No. plate tslocated on the mam
hous=ng of the tool. Record these numbers Jn the
spaces below and retain for future reference.
Model No.
Type
Serial No.
Part No. 900988 - 11-30-00
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS.
This tool was designed for certain applications.DO NOT modify or use it for any application other than for which
it was designed, if you have any questions relative to its application do not use the tool until you have written
Porter-Cable and we have advised you.
Technical Service Manager
Porter-Cable Corporation
4825 Highway 45 North
Jackson, TN 38305
WARNING: FAILURE TO FOLLOW THESE RULES
MAY RESULT IN SERIOUS PERSONAL INJURY.
1. FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING THE TOOL. Learn the
tool's application and limitations as well as the specific hazards peculiar to it.
2. KEEP GUARDS IN PLACE and in working order.
3. GROUND ALL TOOLS. If toot is equipped with three-prong plug. it should be plugged into a three-hole
electrical receptacle. If an adapter is used to accommodate a two-prong receptacle, the adapter lug must be
attached to a known ground. Never remove the third prong.
4. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting
wrenches ere removed from the tool before turning it on.
5. KEEP WORK AREA CLEAN. Cluttered areas and beeches invite accidents.
6. DON'T USE IN DANGEROUS ENVIRONMENT. Don't use power tools in damp or wet locations, or expose
them to rain. Keep work area well-lighted.
7. KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe distance from work
area.
8, MAKE WORKSHOP CHILDPROOF - with padlocks, master switches, or by removing starter keys.
9. DON'T FORCE TOOL. It will do the job better and be safer at the rate for which it was designed.
10. USE RIGHT TOOL Don't force tool or attachment to do a job for which it was not designed.
11. WEAR PROPER APPAREL. No loose clothing, gloves, neckties, rings, bracelets, or other jewelry to get caught
in moving parts. Neeslip footwear is recommended. Wear protective hair covering to contain long hair.
12. ALWAYS USE SAFETY GLASSES. Wear safety glasses (must comply with ANSI Z87.1). Everyday eyeglasses
only have impact resistant lenses; they are not safety glasses. Also use face or dust mask if cutting operation is dusty.
13. SECURE WORK. Use clamps or a vise to hold work when practical.
14. DON'T OVERREACH. Keep proper footing and balance at all times.
15. MAINTAIN TOOLS IN TOP CONDITION. Keep tools sharp and clean for best and safest performance. Follow
instructions for lubricating and changing accessories.
16. DISCONNECT TOOLS before servicing and when changing accessories such as blades, bits, cutters, etc.
17. USE RECOMMENDED ACCESSORIES. The use of improper accessories may cause hazards or risk of injury to
persons.
18. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in "OFF" position before plugging
in power cord.
19. NEVER STAND ON TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is accidentally
contacted.
20. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be
carefully checked to determine that it will operate properly and perform its intended function. Check for alignment
of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its
operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized service
center unless otherwise indicated elsewhere in this instruction manual. Have defective switches replaced by
authorized service center. Do not use tool if switch does not turn it on and off.
21. DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter
only.
22. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don't leave tool until it comes to a
complete stop.
23, DRUGS, ALCOHOL, MEDICATION. Do not operate tool while under the influence of drugs, alcohol or any
medication.
24. MAKE SURE TOOL IS DISCONNECTED FROM POWER SUPPLY while motor is being mounted, connected
or reconnected.
2
25.WARNING:SOMEDUSTCREATEDBYPOWERSANDING,SAWING,GRINDING,DRILLING,ANDOTHER
CONSTRUCTIONACTIVITIEScontainschemicalsknownto causecancer,birthdefectsorotherreproductive
harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure
to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust
masks that are specially designed to filter out microscopic particles.
1. WARNING: USE ONLY CROSS-CUTTING SAW BLADES. DO NOT USE BLADES WITH DEEP GULLETS AS
THEY CAN DEFLECT AND CONTACT THE GUARD.
2. WARNING: Do not operate the miter saw until itiscompletely assembled and installed according to the instructions.
3. IF YOU ARE NOT thoroughly familiar with the operation of compound miter saws, obtain advice from your
supervisor, instructor or other qualified person.
4. BE SURE blade is sharp, runs freely and is free of vibration.
5. ALLOW the motor to come up to full speed before starting cut.
6. KEEP motor air slots clean and free of chips.
7. ALWAYS MAKE SURE rotating table is tight before cutting, even if the table is positioned in one of the positive
stops.
8. BE SURE blade and flanges are clean and that arbor screw is tightened securely.
9. USE ONLY blade flanges specified for your saw.
t0. NEVER apply lubricants to the blade when it is running.
11. ALWAYS CHECK the blade for cracks or damage before operation. Replace cracked or damaged blade
immediately.
12. ALWAYS KEEP the lower blade guard in place and operating properly.
13. MAKE SURE blade is not contacting workpiece before switch is turned on.
14. NEVER LOCK the switch in the "ON" position.
15. IMPORTANT: After completing cut, release power switch and wait for coasting blade to stop before returning
saw to raised position.
16. DO NOT remove jammed or cut-oft pieces until blade has stopped.
17. NEVER cut ferrous metals or masonry.
18. NEVER recut small pieces.
19. PROVIDE ADEQUATE SUPPORT to the sides of the saw table for long workpieces.
20. NEVER use the miter saw in an area with flammable liquids or gases.
21. NEVER USE SOLVENTS TO CLEAN PLASTIC PARTS. Solvents could possibly dissolve or otherwise damage
the material. Only a soft, damp cloth should be used to clean plastic parts.
22. DISCONNECT SAW from power source and clean the machine before leaving it.
23. MAKE SURE the work area is cleaned before leaving the machine.
24. ADDITIONAL INFORMATION regarding the safe and proper operation of this product is available from the
National Safety Council, 1121 Spring Lake Drive, ]tasca, IL 60143-3201, in the Accident Prevention Manual for
Industrial Operation and also in the Safety Data Sheets provided by the NSC. Please also refer to the American
National Standard Institute ANSI 01.1 Safety Requirements for the Woodworking Machinery and the U.S.
Department of Labor OSHA 1910.213 Regulations,
25. SOME WOOD CONTAINS PRESERVATIVES WHICH CAN BE TOXIC. Take extra care to prevent inhalation
and skin contact when working with these materials. Request, and follow, any safety information available from your
material supplier.
26. DON'T ABUSE CORD, Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat,
oil, and sharp edges. Have damaged or worn power cord and strain reliever replaced immediately. DO NOT
ATTEMPT TO REPAIR POWER CORD.
27. WEAR EAR PROTECTION to safeguard against possible hearing loss.
28. AVOID CUTTING NAILS AND KNOTS. Inspect for and remove all nails from lumber before cutting. Try to do
layout cuts between knots.
29. NEVER USE LIQUID COOLANT. To do so could present electrical shock hazard.
30. KEEP CLEAR OF SAWDUST EJECTION CHUTE. Sawdust and chips are expelled out the ejection chute at
rear of saw. Do not allow anyone in this area while saw is in operatiod.
31. WHEN THE MITER SAW IS NOT IN USE, the switch should be locked in the OFF position to prevent
unauthorized use of the saw.
SAVE THESE INSTRUCTIONS. Refer to them often and use them to instruct others.
ADDITIONAL SAFETY RULES FOR COMPOUND MITER SAWS
3
REPLACEMENT PARTS
When servicing, use only identical replacement parts.
POLARIZED PLUGS: To reduce the risk of electric shock, this equipment has a polarized plug (one blade is wider than
the ether). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug.
If it still does not fit, contact a qualified electrician to install the proper outlet. Do not change the plug in any way.
MOTOR
Many Porter-Cable tools will operate on either D.C., or single phase 25 to 60 cycle A.C. current and voltage
within plus or minus 5 percent of that shown on the specification plate of the tool. Several models, however,
are designed for A.C. current only. Refer to the specification plate on your tool for proper voltage and current
rating.
CAUTION: Do not operate your tool on a current where the voltage is not within correct limits. Do not operate
tools rated A.C. on a D.C. current. To do so may seriously damage the tool.
RECOMMENDED EXTENSIONCORD SIZES FOR
USEWITH STATIONARYELECTRICTOOLS
MINIMUM GAUGE EXTENSION CORD
EXTENSION CORD SELECTION
Use proper extension cords. Make sure your
extension cord is in good condition. When
using an extension cord, be sure to use one
heavy enough to carry the current of the saw.
An undersized cord will cause a drop in line
voltage, resulting in loss of power and
overheating. Fig. 1, shows the correct gauge to
use depending on the cord length. If in doubt,
use the next heavier gauge. The smaller the
gauge number, the heavier the cord.
RECOMMENDED SIZES FOR USE WfTH STATIONARY ELECTRIC TOOLS
Ampere Volts Total Length of Gauge of
Rating Cord in Feet Extension Cord
0-6 120 up to 25 18 AWG
0-6 120 25-50 16 AWG
0-6 120 50-100 16 AWG
0-6 120 100-150 14 AWG
6-10 120 up to 25 18AWG
6-10 120 25-50 16AWG
6-10 120 50-100 14 AWG
6-10 120 100-150 12AWG
10-12 120 upto 25 16AWG
10-12 120 25-50 16 AWG
10-12 120 50-100 14 AWG
10-12 120 100-150 12 AWG
12-16 120 up to 25 14AWG
12-16 120 25-50 12AWG
12-16 120 GREATERTHAN5OFEETNOTRECOMMENDED
Fig. 1
OPERATING INSTRUCTIONS
FOREWORD
Porter-Cable Model 3802 Type 2 is a high capacity 12" compound miter saw designed to cut wood and non-
ferrous metals. It can crosscut 8" x 21,4" and 7" x 3V_", miter at 45 both left and right 51/4" x 21A", bevel at 45 left
61A'' x 2_A'' and 8" x I_A ", and compound 45 x 45, 5_ " x 2 1/2" and 41A" x 2_A''. It has positive miter stops at 0,
15, 22.5, 31.62, and 45 degrees both left and right, and bevel stops at 0 and 45 degrees left.
POWER CONNECTIONS
A separate electrical circuit should be used for your tools. If an extension cord is used, make sure the conductor
size is large enough to prevent excessive voltage drop which will cause loss of power and possible motor
damage. For distances up to 100 feet, use #12 wire. For distances up to 150 feet, use #10 wire. If an extension
cord is to be used outdoors, it must be marked with the suffix W-A following the cord type designation. For
example - SJTW-A indicates that it is acceptable for outdoor use. Replace damaged or worn cords
immediately. Before connecting the motor to the power line, make sure the switch is in the "OFF" position and
be sure that the electric current is of the same characteristics as stamped on motor nameplate.
4
UNPACKING
1. Carefully remove the machine from the car_on.
Retain all packing materials until you have inspected
and satisfactorily operated the machine.
WARNING: Do not connect the machine to the
power source until you have read and understood
this entire instruction manual,
2. Place the machine on a firm, level surface with extra
room for handling and proper support of the workpiece.
3. Familiarize yourself with all features and controls as
explained in this manual.
4. The machine is shipped with the cuttinghead locked
in the down position and the table rotated to 45 degrees
left, Fig. 2. To release the head and move it to the
operating position, see "MOVING CUTFINGHEAD TO
THE UP POSITION" and "MOVING THE TABLE TO
THE 90 DEGREE CUT-OFF POSITION" inthis section.
5. Unassembled items are shown in Fig. 3 for
identification and use in assembling the saw.
1 Extension table
2 Fence slide
3 Fence slide support
4 Dust bag
5 Arbor and fence wrench
6 1/4"wrench
7 Open end wrench
8 Lock handle for slide fence
9 1/4"flat washer
10 1/4"lock washer
11 1/4- 18 x I 1/4" long hex head screw (2)
12 1/4- 18 x 3/4" long hex head screws (2)
Fig.2
4
/
Fig. 3
ASSEMBLY
WARNING: FOR YOUR OWN SAFETY, DO NOT
CONNECT THE MITER SAW TO THE POWER
SOURCE UNTIL THE MACHINE IS COMPLETELY
ASSEMBLED AND YOU HAVE READ AND
UNDERSTOOD THE ENTIRE OWNER'S MANUAL.
MOVING CUTTINGHEAD TO THE UP
POSITION
1. Pull out cuttinghead Iockpin (A) Fig. 4, and move the
cuttinghead (B) to the up position.
2. Fig. 5, illustrates the Iockpin (A) pulled out and the
cuttinghead (B) in the up position.
Fig.4
B
\
Fig. 5
5
MOVING TABLE TO THE 0 DEGREE CUT-OFF POSITION
1. Rotate locking knob (A) Fig. 6, counter-clockwise as far as it will go to unlock. Depress lever (B) and rotate
table (C) to the 0 degree straight cut-off position, release lever (B) and tighten locking knob (A).
2. Fig. 7, illustrates the table (C)in the 0 degree straight cut-off position.
3. For proper operation and adjustment of the table, refer to sections, "ROTATING TABLE FOR MITER
CUTTING", "ADJUSTING CLAMPING ACTION OF TABLE LOCKING MECHANISM" and "ADJUSTING
SLIDING FIT BETWEEN MOVABLE TABLE AND BASE."
ATTACHING EXTENSION TABLE AND FENCE SLIDE
C
C
A
Fig. 6
A
Fig. 7A Fig. 7B
1. Attach flat washers to the two 3/4" screw assemblies (A) Fig. 7A, and thread into the threaded holes on left
side of the saw.
NOTE: Turn the screws only a few threads into the holes at this time.
2. Attach the table extension (B) Figs. 7A and 7B, to left side 6f saw table, making sure groove of table
extension (B) is inside flat washers (C) as shown in Fig. 7B.
Fig, 7
C
D
Fig. 7C
3. Use a straightedge (C) Fig. 7C, to make the extens on table (B) even with saw table (D), and tighten the two
screws (A) Fig.TB.
Fig.7D
4. Attachthe fence slide support{E).,Fi9.7D, to the extension table (B) by using the two 1 1/4" long hex head
screws, _/]6 Iockwashers and 5/lb Tlatwashers (F). Bringscrews up through the two holes ({3) in table
extension and thread them into the two threaded holes (H)onbottom of fence slide support.
NOTE: Do not completely tighten screws at this time.
E
J
K
Rg. 7E Fig. 7F
5. Use a straight edge (C) Fig. 7E, to levelthe fence slide support (E)with saw fence (J), and tighten the two
6. Position the fence slide (K) Fig. 7F,in position on top of saw fence (J) and fence slide support (E).Slide fence
slide (K) back and forth several times to check alignment of fence slide support (E). Make any necessary final
adjustments to fence slide support.
N
O
I
Fig.7G Fig.7H
7,
Remove screw and spring (L) Fig. 7G, and ock handle (M) from locking st_!_ (N).
8.
PLace 1/4" flat washer (O) Fig. 7G, onto locking stud (N) and ir_ert locking stud (N) Fig. 7H, through slot in
fence slide. Thread locking stud into threaded hole in fence slide support (E).
7
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