Wilton 99174 Operation And Safety Instructions

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WARNING:Read and understand all instructions. Failure to follow all instructions may result in electric shock, fire, and/or serious injury.
For your safety
14" Abrasive
Chop Saw
Model 99174
®
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IMPORTANT INFORMATION
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TABLE OF CONTENTS
INTRODUCTION
Your new Wilton®14-inch Abrasive Chop Saw is a rugged, dependable tool that will cut metal and other materials with extreme accuracy and repeatability. Easy to operate, it’s the ideal saw for the serious Do­It-Yourselfer.
Take time to read these Operation and Safety Instructions. Athorough understanding of your saw will enable you to use it to its full potential.
SPECIFICATIONS
MODEL NUMBER ................................................99174
Motor
Power Source............................120V AC, 60 Hz, 15 A
Horsepower...........................................................2-1/2
Speed...........................................2800 RPM (no load)
Cutting disc..............................................14" (35.6 cm)
Arbor.............................................................1" (2.5 cm)
Swiveling vise clamp assembly .............0 – 45˚ right;
0 – 30˚ left
Maximum cutting diameter ................4 1/2" (11.4 cm)
Net weight........................................46 lbs 3 oz (21 kg)
LIMITED WARRANTY
Wilton Power Tools are warranted against defects in workmanship and material for a period of two (2) years from the date of purchase. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair or alterations, lack of maintenance, or use for purposes other than those for which the tool was designed. This warranty does not cover products used for commercial, industrial or educational purposes. Any return must be preauthorized, so please contact our Consumer Relations Department with warranty claims at 1-800-274-6848 for further instructions. If it is determined that the product is within this warranty, replacement parts or complete product replacement will be made at our discretion.
WMH TOOL GROUPTMLIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS ARE EXCLUDED. SOME STATES DO NOTALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
WMH TOOL GROUPTMSHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOTALLOW THE EXCLUSION OR LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
IMPORTANT INFORMATION ....................................2
Introduction..........................................................2
Specifications.......................................................2
LIMITED WARRANTY...............................................2
SAFETY.....................................................................3
General Safety Warnings.....................................3
Special Safety Rules for Chop Saws...................4
Electrical Requirements .......................................6
BEFORE YOU START...............................................8
Know Your Chop Saw..........................................8
Unpacking the Chop Saw....................................9
ASSEMBLY..............................................................10
OPERATION ............................................................11
On/Off Switch .....................................................11
Swiveling Vise Clamp Assembly........................11
Angle Plate.........................................................11
Remove/Install Cutting Disc ..............................12
Adjust Cutting Depth..........................................12
Cut a Workpiece................................................13
MAINTENANCE .......................................................14
SERVICE..................................................................15
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SAFETY
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Read, understand, and follow all operating instructions, safety operations and symbols in this manual and warning labels on the saw before operating, maintaining, and cleaning your power tool.
WARNING:
Indicates the presence of a hazardous
situation which CAN cause SEVERE personal injury.
CAUTION:
Indicates the presence of a hazardous situation which WILL or CAN cause MINOR or MODERATE PERSONAL injury, or could cause machine damage.
Note:
Indicates installation, operation, or maintenance
information which is important but not hazard-related.
GENERAL SAFETY WARNINGS
WARNING:
Failure to read all instructions and follow the general safety warnings and other safety warnings and cautions may result in serious personal injury.
Know your power tool – read the instruction manual. Understand your power tool’s application, limitations, and potential hazards.
Ground all tools – this tool is equipped with a 3-prong plug. It must be plugged into a properly grounded receptacle.
Keep safety guards in place – and in working order with proper adjustment and alignment.
Keep work area clean – prevent accidents. Take time to clean the tool, the work area, and especially the floor. The floor can become slippery from sawdust, wax and other materials.
Avoid dangerous environments – do not use power tools in damp or wet environments. Select a work area with proper lighting.
Keep children away – from the work area. Children and others should be a safe distance from the work area.
Make the workshop childproof – use padlocks and master switches. Remove starter keys from power tools when not in use.
Do not force the tool – beyond its designed rate. For a better and safer job, allow the tool to work within manufacturer’s recommendation.
Use the right tool – for the job. Do not force a tool or its attachments to perform a task that it is not designed to do.
Wear the proper apparel – and non-slip footwear when operating power tools. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may become caught in moving parts. Keep long hair away from your face and tied back. Roll long sleeves above the elbow.
Use safety goggles at all times – which comply with
ANSI Z87.1. Normal safety glasses only have impact resistant lenses and are not designed for safety. Wear a face or dust mask when working in a dusty environment. Use ear protection, such as plugs or muffs, during extended periods of operation.
Secure your work – using clamps or a vise when practical. It frees both hands and is safer to operate the tool.
Do not overreach – and keep proper balance and footing at all times.
Maintain your tools with care – keeping them clean for best and safest performance.
Disconnect your tool – unplug the power cord from the electrical source when making adjustments, changing parts, cleaning, or working on the tool.
Avoid accidental starting – by ensuring the ON/OFF switch is in the OFF position and the power cord is unplugged from the electrical outlet.
Use recommended accessories – by the tool’s manufacturer. Read, understand and follow the instructions supplied with accessories. Using incorrect accessories may be hazardous.
Never stand on the tool – or store materials above or near it. Standing on the tool to reach materials could result in serious injury if it tips or is accidentally contacted.
Check any damaged parts – discontinue using a damaged tool until the part is carefully checked. Ensure that all parts will operate and perform properly. Check for alignment of moving parts, jamming, breakage, improper mounting, and any other condition that may affect the tool’s operation. Any part that is damaged should be properly repaired or replaced before use.
SAVE THESE SAFETY INSTRUCTIONS
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Never leave the tool unattended while it’s running – turn OFF the power. Do not leave the tool
unattended until it reaches a complete stop. Drugs, alcohol, medication – are not to be used
when operating the tool. Wear a face mask or dust mask – when sawing.
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contain chemicals known to cause cancer, birth defects, or other reproductive harm. Examples of these chemicals include:
– Lead from lead-based paints – Crystalline silica from bricks, cement, and other
masonry products
– Arsenic and chromium from chemically treated
lumber. To reduce your exposure to these chemicals: work in a well-ventilated area, use approved safety equipment, and use dust masks that are specially designed to filter out microscopic particles.
SPECIAL SAFETY RULES FOR CHOP SAWS
WARNING:
Do not use or plug in your saw until it is completely assembled and installed according to the instructions. Read and understand the following operating instructions and safety warnings in the manual and on the saw.
Before Operating Your Chop Saw
Check for proper assembly and proper alignment of moving parts.
Understand the function and proper use of:
Trigger switch/start switch
Lower guard
Spark deflector
Wheel lock lever
Quick-release latch
Know the condition of your saw. If any part is missing, bent, or does not operate properly, replace the component before you continue to use your saw. Determine the type of work you are going to be doing before you operate your saw. Properly protect your body including your eyes, hands, face, and ears.
Avoid injury from jams, slips, or thrown pieces
Use the correct 14-inch cutting disc for the material and type of cut. Do not cut wood with this saw.
Replace cracked cutting disc immediately. Handle disc carefully. and inspect for cracks before each use. Tighten spindle bolt enough to hold the disc firmly. Use only the disc flanges provided with your saw.
Make sure cutting disc is properly installed. Make sure the arbor screw and washer are properly installed and tightened.
Ensure all clamps and locks are tight. Verify there is no excessive play in any parts.
Allow the disc to reach full speed before cutting.
Do not cut freehand
Verify the workpiece will not rock or twist when it is being cut. The area between the workpiece and the saw must be free from debris.
Make sure there is no gap between the workpiece, angle plate, and base of the saw. Agap could allow the workpiece to move when it is being cut.
Use vise clamps to hold the workpiece. Do not secure waste piece.
Do not cut more than one workpiece at a time
Allow room so the cut-off workpiece can move after it is cut. It could create a hazard by becoming wedged against the disc.
Avoid contact with a rotating cutting disc
Do not wear gloves, loose clothing, or jewelry.
Tie back long hair and roll long sleeves above the elbow.
Do not allow anyone to stand behind the saw or close to the workpiece where debris can be thrown.
Operate your saw in a clear, safe environment.
Avoid injury from accidental starting of saw.
Unplug the power cord from the electrical source:
Disconnect the lower guard.
Install or remove the disc.
Perform maintenance or make adjustments.
Avoid injury from electrical shock
Do not touch the metal blades on the power cord plug when inserting or removing the plug from an electric outlet.
Avoid injury from a fire hazard
Do not operate the saw near flammable liquids, vapors, or gases.
SAFETY
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SAVE THESE SAFETY INSTRUCTIONS
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SAFETY
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When Operating Your Saw
Avoid injury from unexpected saw movement
Use the saw on a firm level surface with adequate space for handling and supporting the workpiece.
Be sure the saw cannot move when operated.
Before moving the saw
Unplug the power cord from the electrical source.
Lock the handle in the down position using the handle latch.
Avoid back injury
Obtain help when it is necessary to raise the saw more than 10 inches (254 mm).
Bend your knees when lifting the saw.
Carry your saw by the carrying handle or base. Do not carry your saw by the power cord or the trigger handle. Carrying the saw by the power cord could cause damage to the insulation or the wire connections resulting in electric shock or fire.
Whenever the Saw is Running
WARNING:
Do not make a careless error just because you operate the saw frequently. Aneglectful moment can cause a severe injury.
Prior to cutting a workpiece
Test the operation of your saw. If you feel excessive vibration or hear an unusual noise, immediately stop operating the saw. Correct the problem before using.
Allow movement of the waste portion of the workpiece
Do not hold it, clamp it, touch it or use a length stop against it. The cut-off waste portion must be free to move. It could become wedged against the disc causing a hazard.
Use care when cutting
Flying sparks will occur when cutting. They can cause injury and ignite flammable materials.
Never use a circular saw blade or tooth-type blade in the chop saw.
Use only abrasive cutting discs rated at 3500 RPM or higher.
Avoid awkward operation
Make sure your hand is never closer than 4 inches (102 mm) from the disc.
Do not cross your arms in front of the disc while operating the saw.
Do not force the disc through the workpiece
Lower the disc through the workpiece fast enough to allow it to cut without binding or bogging down.
Before removing obstructed material
Release the trigger switch/start button, wait for the disc to stop moving, and unplug the power cord from the electric outlet.
After completing a cut
Keep the handle in the down position. Release the trigger switch/start button and wait for the disc to stop moving.
Do not touch workpiece after cutting. It is hot and could burn skin.
SAVE THESE SAFETY INSTRUCTIONS
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ELECTRICAL REQUIREMENTS
WARNING:
Use only manufacturer’s recommended replacement parts, or
equivalent, when servicing this tool.
Do not touch the metal blades on the power cord plug when
removing or installing the plug into an electrical outlet.
To avoid electrical hazards, fire hazards, or damage to the
tool, use proper circuit protection.
Your saw is wired at the factory for 120V operation. Connect to a 120V, 15 Amp 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.
Use a separate electrical circuit for your tools. This circuit must not be less than a #12 wire and should be protected with a 15 Amp time delayed fuse. Before connecting the motor 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 nameplate. Running at a lower voltage will damage the motor.
Do not modify the power cord plug. If it does not match the electrical outlet, have the proper outlet installed by a qualified electrician.
This tool is intended for use on a circuit that has a receptacle like the one illustrated: a 3-prong electrical plug (1) and a receptacle (2) that has a grounding conductor. If a properly grounded receptacle is not available, have a certified electrician check the receptacle.
In the event of a malfunction or breakdown,
grounding provides the path of least resistance for electric current and 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 receptacle that is properly installed and grounded in accordance with ALL local codes and ordinances.
Improper connection of the equipment grounding conductor can result in risk of electric shock. The conductor with the green insulation (with or without yellow stripes) is the equipment grounding conductor.
If repair or replacement of the electric cord or plug is necessary, DO NOT connect the equipment grounding conductor to a live terminal.
Check with a qualified electrician or service personnel if you do not completely understand the grounding instructions, or if you are not sure the tool is properly grounded.
WARNING:
This saw is for indoor use only. Do not expose to rain or use in damp locations. This tool must be grounded while in use to protect the operator from electrical shock.
SAFETY
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SAVE THESE SAFETY INSTRUCTIONS
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SAFETY
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Guidelines for Extension Cords
Use proper extension cord. 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 your product will draw. An undersized cord will cause a drop in line voltage, resulting in loss of power and cause overheating. The table below shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.
Use only 3-wire extension cords that have 3-prong plugs and 3-prong outlets that accept the tool’s plug.
Be sure your extension cord is properly wired and in good operating condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it.
Protect your extension cords from sharp objects,
excessive heat and damp or wet areas. Repair or replace damaged or worn cord immediately.
SAVE THESE SAFETY INSTRUCTIONS
Minimum Gauge for Extension Cords (AWG)
(when using 120 volts only)
Ampere Rating Total Length of Cord in Feet (meters)
More Than Not More Than 25 (7.6) 50 (15.2) 100 (30.4) 150 (45.7)
0 6 18 16 16 14
6 10 18161412 10 12 16 16 14 12 12 16 14 12 Not Recommended
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BEFORE YOU START
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KNOW YOUR CHOP SAW
Figure 1
1 Trigger switch 2 D-handle 3 Arbor lock 4 Upper guard 5 Lower guard 6 14" metal cutting disc 7 Angle plate 8 Vise pressure plate 9 Quick-release latch
10 Vise handle
11 Vise wheel 12 Vise screw 13 Rubber feet (4) 14 Base 15 Spark deflector 16 Depth stop bolt 17 Wheel lock lever 18 Carbon brush cap 19 Carrying handle
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BEFORE YOU START
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UNPACKING THE CHOP SAW
WARNING:
To avoid injury:
• Do not plug the power cord into the power source during unpacking or assembly.
• If any part is missing or damaged, do not connect the saw to the power source until the missing or damaged part is replaced and assembly is complete.
• Avoid fire and toxic reaction. Never use gasoline, naphtha, acetone, lacquer, thinner or any volatile solvents to clean the saw.
1. Carefully unpack the abrasive chop saw and all its components.
2. Inspect the contents and compare to the list below.
1 14" abrasive chop saw 2 Vise handle knob 3 Threaded bolt and nut 4 Adjusting wrench
Figure 2
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ASSEMBLY
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ASSEMBLING THE CHOP SAW
Your saw requires these minor assembly tasks. Once assembled, complete the adjustment procedures before using the saw.
INSTALL THE VISE CRANK
1. Insert the bolt (1) through the vise handle (2).
2. Tighten the nut (3) on the bolt.
3. Insert the assembled handle into the opening (4) on the vise wheel and turn it clockwise to secure the handle to the wheel.
Figure 3
RAISE/LOWER THE SAW
1. Pull out the wheel lock lever (1) and use the handle to raise or lower the saw.
2. Push in the wheel lock lever (1) in to lock the saw in the raised or lowered position.
Figure 4
WRENCH STORAGE
Store the wrench provided with your saw in the slots at the rear of the saw.
Figure 5
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OPERATION
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ON/OFF SWITCH
To start the saw, press the trigger switch (1). To stop the saw, release the trigger switch. Allow the disc to come to a complete stop before using the saw again or making adjustments.
Figure 6
SWIVELING VISE CLAMP ASSEMBLY AND QUICK RELEASE LATCH
Always secure the workpiece between the angle plate and the vise pressure plate when cutting.
1. Place the workpiece between the angle plate (1) and the vise pressure plate (2).
Figure 7
2. Push the vise screw (4) toward the angle plate and turn the vise wheel (5) clockwise to secure.
3. To release, turn the wheel counterclockwise two turns, raise the quick-release latch (3) and pull the vise screw toward you.
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OPERATION
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ANGLE PLATE
The angle plate can be moved forward, backward, or rotated for angle cutting.
1. To move the angle plate, loosen the two bolts (1) and place the angle plate (2) in the desired position. Retighten the bolts.
Figure 8
2. To set a cutting angle, loosen the bolts and rotate the angle plate (2) up to 45˚ right or 30˚ left. Align the index with the left edge of the angle plate slot. Retighten the bolts.
Figure 9
3. Always center the workpiece over the table slot­web to maximize cutting depths. Move the angle plate (2) toward the vise pressure plate (3) until the workpiece is centered over the web. Tighten angle plate bolts (1) and vise pressure plate (3).
REMOVE/INSTALL CUTTING DISC
1. Unplug the saw.
2. Push the arbor lock lever (1) toward the cutting disc (2) and slowly turn the disc (either direction) until it locks.
Figure 10
3. Loosen the hex bolt (5) in the center of the disc with the wrench. Remove the bolt, washer (4), flange (3), and disc (2).
Figure 11
4. To install a new cutting disc, reverse the process in step 3. Do not over tighten the bolt.
5. Make sure all guards are in place and the disc rotates freely.
6. Adjust the depth stop bolt (Fig. 12).
7. Return the wrench to the storage slot (Fig. 5).
8. Plug in the saw.
9. Run the saw and check to make sure the disc is in good condition. When testing a new disc, run the saw for 3 minutes. When testing an existing disc, run the saw for 1 minute.
Note: Always stand to one side when turning on the saw.
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OPERATION
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ADJUST THE CUTTING DEPTH
The depth stop bolt must be adjusted as the diameter of the cutting disc decreases with use. This will prevent the disc from cutting the work surface below the saw table.
1. Loosen the lock nut (2).
2. Turn the stop bolt (1) to set the downward travel of the disc.
Figure 12
3. Re-tighten the lock nut when the disc is at the desired depth.
CUT A WORKPIECE
1. Set the angle plate (1) to the desired cutting angle.
2. Make sure the workpiece lies flat on the saw table. 3 Use the vise (2) to secure the workpiece to the
table.
Figure 13
4. Pull the trigger switch.
5. After the motor reaches full speed, lower the disc into the center of the workpiece.
6. Using a smooth, firm, and gentle downward motion, make a clean cut through the workpiece. Do not allow the disc to bump or jump when making contact with the workpiece; this may damage both the workpiece and the disc.
7. Keep consistent pressure when coming to the bottom of the cut to avoid forming a heavy burr and overheating the workpiece.
8. Raise the disc completely from the workpiece before releasing the trigger switch and allow the motor to stop before removing the workpiece.
Note: Along workpiece should be supported on both ends with blocks of a non-flammable materials, so the workpiece is level to the saw table.
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MAINTENANCE
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WARNING:
Before performing any maintenance or cleaning on your saw, unplug the power cord from the power source. The power cord must remain unplugged whenever you are working on your saw.
To prevent electrical shock, fire or injury, use only identical replacements parts with equivalent characteristics, including type, strength and material. Be sure to assemble replacement parts exactly as the original components to reduce the risk of electrical shock.
If the power cord is worn, cut or damaged, have it replaced immediately.
WARNING:
Never use flammable or combustible solvents around tools. When servicing, use only identical Wilton replacement parts. Use of any other parts may create a hazard or cause product failure.
WARNING:
Dust generated from certain materials can be hazardous to your health. Always operate the saw in well­ventilated areas and provide proper dust removal. Use dust collection systems whenever possible. Wear a face mask when operating the saw.
GENERAL MAINTENANCE
Before each use, inspect guards, switches, power cord, and extension cord. Check for loose screws, jamming, broken parts and any other condition that may affect the safe operation of the saw. If an unusual operating noise or vibration occurs, turn the saw off and immediately correct the problem before using the saw again.
CLEANING
Clean dust and debris from vents, table top, and vise screw. Use a dry, clean rag to clean all areas of the saw. Never use solvents or other harsh chemicals for cleaning as they are harmful to plastic and other insulated parts. Petroleum-based products, brake fluid, thinners, and ammonia detergents are also harmful to your saw.
LUBRICATION
All the ball bearings are permanently lubricated and do not require lubrication.
REPLACING CARBON BRUSHES
WARNING:
Be sure to unplug the power cord from the
power source before inspecting the carbon brushes.
Check the condition of the carbon brushes after 50 hours of use of your new saw. If the brushes are worn to 1/4 inch (6 mm) in length, replace them.
To inspect the carbon brushes:
1. Loosen and remove the two brush caps (1) using a slotted screwdriver.
2. Carefully remove the caps from the motor. The caps are spring loaded from the spring on the brush.
3. Pull out one brush at a time. Inspect the brush and replace them if necessary. Be sure to replace both brushes even if only one is damaged.
Figure 14
Note:
If you are not installing new brushes, be sure to re-install the brushes into the same positions they were removed from.
4. Position the brushes into the motor.
5. Tighten the brush caps snugly. Do not over-tighten.
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SERVICE
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REPLACEMENT PARTS
When servicing your Wilton®product, use only Wilton®replacement parts. Use of any other parts may cause product damage. All servicing of the tool should be performed by a qualified service technician. When requesting service or ordering parts, always provide the model number, part number and description.
Customer Replacement Parts
Part Number Item
TS-2286252 Phillips screw at rubber foot, M6x25 TS-1550041 Flat washer at rubber foot, M6 99174N003 Rubber foot TS-1540061 Nut, M8 TS-1490111 Depth stop hex bolt, M8x60 TS-1491013 Angle plate hex bolt, M10x25 99174N013 Disc hex bolt, M10x25 TS-2361101 Angle plate lock washer, M10 TS-1550071 Angle plate flat washer, M10 TS-1550071 Disc bolt small washer, M10 99174N016 Angle plate 99174N018 Vise pressure plate 99174N029 Vise wheel spring pin, 4x20 99174N030 Vise tension wheel TS-1550061 Vise flat washer, M8 99174N032 Vise tension handle TS-2288502 Vise handle screw, M8x50 99174N052 Motor brushes (set of 2) 99174N053 Brush covers (set of 2) 99174N063 Return spring cover (plastic) TS-2285352 Phillips screw, carry handle, M5x35 99174N067 Carry handle 99174N090 Spring support cover 99174N091 Lower guard return spring 99174N093 Lower guard 99174N095 Lower guard roller 99174N098 Disc flange 99174N099 Bushing, 1" cut-off disc 99174N102 Disc bolt large washer 99174N103 Spark deflector 99174N107 Wrench, hex bolt M99174 Manual
Page 16
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SERVICE
99174 A0904 ©WMH Tool Group Printed in China
FOR REPLACEMENT PARTS AND SERVICE
In the U.S.: WMH TOOL GROUP
Consumer Relations 427 Sanford Road Lavergne, TN 37086 Phone: 1-800-274-6846 (technical assistance)
1-800-274-6848 (parts)
www.wmhtoolgroup.com
In Canada: WMH TOOL GROUP LTD
Customer Service 212A Wilkinson Road Brampton, Ontario L6T 4M4 CANADA Phone: 1-800-689-9928 www.wmhtoolgroup.com
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