Wilton 99192, 99195 Operation And Safety Instructions

Page 1

WARNING:Read and understand all instructions. Failure to follow all instructions may result in electric shock, fire, and/or serious injury.

For your safety

10" Compound

Miter Saw

Models 99192 and 99195

Operation and Safety Instructions

Model 99192 shown

Page 2

IMPORTANT INFORMATION

TABLE OF CONTENTS

INTRODUCTION

Your new Wilton®10-inch Compound Miter Saw is a rugged, dependable tool that will cut wood and other materials at straight and compound angles with extreme accuracy and repeatability. Easy to operate, it’s the ideal saw for the serious Do-It-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

LASER LIGHT

Laser module...........S&S 1984S6; fixed focus, elliptical

dot with line beam lenses

Laser type.......................................................Class III A

Laser power..........................................up to 5mW MAX

Laser wavelength................................................635 nm

MITER SAW

Model numbers...................................99192 and 99195

Power source..............120V AC, 60 Hz, 15 A, 2 3/4 Hp

Speed .............................................................5000 RPM

Blade diameter..........................................10" (40 tooth)

Arbor size...................................................5/8” (16 mm)

Crosscut at 0˚, 0˚ bevel.............................2 3/4 x 5 1/2"

Miter at 45° miter, 0˚ bevel........................2 3/4 x 3 1/2"

Bevel 0° miter, 0° bevel.............................1 7/8 x 4 3/4"

Compound at 45°, 45° bevel.....................1 7/8 x 3 1/2"

Miter detent stops...........0, 15, 22.5, 30, 45° right & left

Positive stops............0, 15, 22.5, 31.6 & 45° left & right

Bevel................................................................0, 45° left

Dust collection...........................................................Yes

Net weight..............................................39 lbs (17.7 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 General Safety Warnings............................3

Special Safety Rules for Miter Saws...................4

Special Safety Rules for the Laser......................6

Electrical Requirements .......................................6

BEFORE YOU START...............................................8

Know Your Miter Saw..........................................8

Unpacking the Miter Saw.....................................9

ASSEMBLY..............................................................10

Woodworking Terms..........................................10

Assembling the Miter Saw.................................10

Installing Extension Wings.................................10

Release the Handle ...........................................11

Blade-to-Fence Adjustment................................11

Base-to-Blade Adjustment.................................12

Bevel Stop Adjustment......................................13

Mounting the Saw..............................................13

OPERATION ............................................................14

Body and Hand Positions..................................14

Supporting the Workpiece .................................14

Using Carbide Tipped Blades ............................14

Changing the Blade...........................................14

Miter Cut............................................................16

Align Laser Pointer with Blade ..........................16

Cutting Bowed Material .....................................17

Bevel Cut...........................................................17

Compound Cut...................................................17

Cutting Base Molding ........................................17

Cutting Crown Molding ......................................18

MAINTENANCE .......................................................19

SERVICE..................................................................20

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SAFETY

Read, understand and follow all operating instructions, safety operations and symbols in this manual and warning labels on the miter saw before operating, maintaining, and cleaning your power tool.

Indicates the presence of a hazardous situation which WILL cause serious injury or death.

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.

Don’t 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

DANGER

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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 MITER SAWS

WARNING:

Do not operate or plug in your miter 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 miter saw.

Before Operating Your Miter Saw

Check for proper assembly and proper alignment of moving parts.

Understand the function and proper use of:

●

Trigger switch/start button

●

Lower blade guard

●

Miter locks

●

Bevel lock knob

●

Handle latch

●

Arbor lock

Know the condition of your miter 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 10-inch blade for the material and type of cut. Do not cut materials which shatter, grab the blade, or cause other danger.

●

The arrow on the blade must correspond with the arrow on the upper blade cover. When you are facing the front of the saw, teeth on the blade should point downward.

●

Only use a sharp blade that is in good condition. Check alignment of the blade after it is installed. Unplug the saw and carefully spin the blade using your hand. The blade should not contact any components of the saw. If it does, correct the problem before operating the saw.

●

Make sure the blade and blade collars are clean and the blade collar is properly installed.

●

Make sure the arbor bolt is properly installed and tightened.

●

Ensure all clamps and locks are tight. Verify there is no excessive play in any parts.

●

Allow the blade to reach full speed before cutting.

Do not cut freehand

●

The workpiece should be tight against the fence. 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, fence, and base of the saw. Agap could allow the workpiece to move when it is being cut.

●

Use clamps, fixtures or other devices to hold an unstable 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 blade.

Be very careful when cutting odd shaped, extremely large, or very small workpieces

●

Plan your work so an odd shaped workpiece cannot slip or pinch the blade. When cutting material like molding, it must lie flat or be held by a fixture. Do not allow the material to rock, twist, or slip.

●

Secure sagging workpieces with saw horses, tables or other additional supports.

●

Do not cut small workpieces that must be held closer than 4 inches (102 mm) from the blade.

●

Properly support round material when cutting. Dowel rods and tubing have a tendency to roll while being cut. This could allow the blade to “bite” into the material causing a hazardous condition. Hold round material in place using clamps or other fixtures.

SAFETY

SAVE THESE SAFETY INSTRUCTIONS

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SAFETY

●

Inspect the workpiece for nails or other foreign objects before it is cut.

●

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 contact with a rotating blade

●

Do not wear gloves, loose clothing, or jewelry.

●

Tie back long hair and roll long sleeves above the elbow.

Avoid injury from accidental starting of saw

●

Unplug the power cord from the electrical source.

●

Disconnect the lower blade guard.

●

Install or remove the blade.

●

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.

When Operating Your Miter 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. Secure the saw to a workbench or table with heavy duty screws, washers, and nuts.

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 Your Miter Saw is Running

WARNING:

• Do not make a careless error just because you operate the

saw frequently. Aneglectful moment can cause a severe injury.

• Do not lubricate the blade while it is spinning.

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 blade causing a hazard.

Avoid awkward operation

●

Make sure your hand is never closer than 4 inches from the blade.

●

Do not cross your arms in front of the blade while operating the saw.

Do not force the blade through the workpiece

●

Lower the blade through the workpiece fast enough to allow the blade to cut without binding or bogging down.

Before removing obstructed material

●

Release the trigger switch/start button, wait for the blade 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 blade to stop moving.

SAVE THESE SAFETY INSTRUCTIONS

Page 6

SPECIAL SAFETY RULES FOR THE LASER

Laser light - do not stare into beam, aperture, or into a reflection from a mirror-like surface.

Avoid exposure - laser radiation is emitted from top rear of the guard housing aperture.

Do not disassemble laser module.

The laser is a CLASS III A laser product that can emit laser power up to 5 mW MAX at 635 nm, which could result in exposure with the module disassembled. The laser unit complies with 21 CFR 1040.10 and 1040.11.

Use of controls or adjustments or

performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

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 miter 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.

SAFETY

SAVE THESE SAFETY INSTRUCTIONS

DANGER

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SAFETY

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 miter 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.

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

Page 8

BEFORE YOU START

KNOW YOUR MITER SAW

Figure 1

1 Power switch handle 2 Lower blade guard 3 Fence 4 Extension wing assembly 5 Miter handle 6 Miter index scale 7 Clamp vise assembly 8 Mounting hole 9 Blade wrench storage

10 Dust bag

11 Laser module 12 Power switch 13 Safety lock-out button (model 99192) 14 Laser switch 15 Dust port 16 Handle stop lock 17 Bevel lock knob 18 Bevel index scale

Model 99192

Model 99195

Page 9

BEFORE YOU START

UNPACKING THE MITER 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 miter 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 miter saw.

1. Carefully unpack the compound miter saw and all its components.

2. Inspect the contents and compare to the list below.

1 Compound miter saw with laser line

assembly 2 Vise clamp knob 3 Dust bag 4 Miter handle

5 Blade wrench 6 Extension wings (2) 7 Bar holder clamp (4) 8 Stop bracket

Figure 2

Model 99192 shown

Page 10

ASSEMBLY

WOODWORKING TERMS

Arbor – shaft which mounts the cutting tool. Bevel cut – angle cut made through the face a

workpiece. Compound cut – bevel cut and miter cut

simultaneously.

Crosscut – cut made across the width of the workpiece. Freehand – a cutting operation without using the

support of the fence or other means to hold the workpiece. Freehand is not recommended.

Kerf – amount of material removed by a blade in a through cut, or the slot produced by the blade in a partial cut.

Miter cut – angle cut made across the width of the workpiece.

Revolutions per minute (RPM) – number of turns completed by a spinning object in one minute.

Saw blade path – part of the workpiece which will be cut, or workpiece directly in line with travel of blade.

Set – distance between two tips of the saw blade teeth, bent outward in opposite directions to each other.

Workpiece – material being cut.

ASSEMBLING THE MITER SAW

Your miter saw requires these minor assembly tasks. Once assembled, complete the adjustment procedures before using the saw.

Installing the miter handle

1. Thread the miter lock handle (1) into the hole located at the front of the miter table.

2. Tighten.

Figure 3

Saw Blade wrench

1. Store the blade wrench (1) in the slot at the rear of the saw to prevent loss.

Figure 4

INSTALLING EXTENSION WINGS AND WORKPIECE STOP

The extension wings support long workpieces during cutting. The adjustable stop bracket attaches to a rail of a wing. The stop bracket can be raised or lowered and moved toward or away from the saw as needed. The extension wings and stop bracket should be installed prior to mounting the saw on a workbench or table.

1. Lock the bevel and miter handles in the down position.

2. Tilt the saw back to gain access to the underside of the base. Secure the saw so that it will not tip or fall off the workbench.

3. Slide the stop bracket (1) onto the rear rail of one of the extension wings (2). Secure the wing screw (3) that holds the stop bracket in place.

Figure 5

Page 11

ASSEMBLY

4. Insert both rails of an extension wing through the first set of holes (4) on the outside of the saw base.

5. Place a bar holder clamp (6) over each rail.

Figure 6

6. Slide the rails through the second set of holes (6) until the rails rest against the base of the saw (7). Make sure the bar holder clamps rest against the outside wall (10) of the saw base.

7. Tighten the screws (8) that secure the bar holder clamps to the rails. Make sure the extension wing does not move and turn the lock nuts (9) clockwise to prevent the screw from loosening.

8. Repeat steps 4 through 7 to install an extension wing on the other side of the saw.

9. Place the saw in the upright position on the workbench.

WARNING:

Make sure the power cord is unplugged from the power source and you have read and understood the safety and operating instructions.

Verify the following adjustments to ensure cutting accuracy.

Note: Avoid touching the saw teeth with the square. The set in the blade’s teeth will hold the square away from the blade.

RELEASE THE HANDLE

(Figure 7)

The handle latch secures the handle position in the down position.

•

Never operate your saw with the handle in the DOWN position.

•

Always store and transport your saw with the handle locked in the DOWN position.

Figure 7

To raise the handle:

1. Push down on the saw handle.

2. Pull out the handle stop latch (1).

3. Allow the handle to rise to the up position.

To lock the handle:

1. Push the saw handle down to the lowest position.

2. Push in the handle latch (1) to lock the cutting head in the down position.

BLADE-TO-FENCE ADJUSTMENT

(Figures 8 & 9)

Make sure the blade is square to the fence.

1. Push the handle latch in to lock the handle in the down position.

2. Hold a combination square (1) against the fence (2) and next to the blade (3). The blade should contact the full length of the square.

Figure 8

3. If the blade does not contact the full length of the square, loosen the four fence screws (4) using a 6 mm wrench.

225

Page 12

ASSEMBLY

Figure 9

4. Hold the square against the blade. Move the fence until it contacts the full length of the square.

5. Slightly tighten screws, then tighten screws (4) alternately.

Note: The combination square and the wrench shown in Figures 8 and 9 are not provided.

BASE-TO-BLADE ADJUSTMENT

(Figures 10, 11, and 12)

Make sure the blade is perpendicular to the base.

1. Push the handle latch in to lock handle in the down position. Tighten the bevel lock handle.

2. While lowering the blade, hold a combination square (1) against the base (2) and next to the blade (3). Avoid touching the saw teeth with the square. The set in the blade's teeth will hold the square away from the blade. The blade should contact the full length of the square.

Figure 10

3. If the blade does not contact the full length of the square, loosen the bevel adjustment screw (4). Hold the square against the base. Rotate the bevel adjustment screw (5), up or down, until the full length of the square is against the blade.

Figure 11

4. Tighten the bevel adjustment screw.

Figure 12

5. Make sure the bevel indicator (6) is aligned with the bevel index 0° mark. Loosen the bevel indicator screw (5) and move it to align with the 0° mark if adjustment is needed.

6. Tighten the bevel indicator screw.

225

Page 13

ASSEMBLY

BEVEL STOP ADJUSTMENT

(Figure 13)

Make sure the bevel indicator aligns with the bevel index 45° mark when the handle assembly is against the bevel stop adjustment screw. If adjustment is necessary:

Figure 13

1. Loosen the bevel stop adjustment screw lock nut (1) using a 10 mm wrench.

2. Rotate the bevel stop adjustment screw (2), up or down, until the bevel indicator aligns with the bevel index 45° mark.

3. Tighten the bevel stop screw lock nut (1).

MOUNTING THE SAW

Before operating your saw, it must be firmly mounted to your workbench or other rigid frame.

WARNING:

Reduce the risk from unexpected saw

movement:

•

Unplug the power cord from the power source.

•

Lock the handle in the down position before moving your saw.

•

Carry your saw close to your body to avoid injury to your back. Bend your knees when lifting the saw.

•

Carry your saw by the handle or the 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.

•

Secure the saw in a position where people cannot stand, sit or walk behind it. Debris thrown from the saw could injure people standing, sitting or walking behind it.

•

Secure the saw to a firm level surface where the saw cannot rock and there is adequate room for handling and properly supporting the workpiece.

Figure 14

To secure the saw to a work surface:

1. Set the saw on the surface and mark the location of the four holes (1).

2. Remove the saw and predrill the holes.

3. Secure the saw to the work surface.

•

Use wood screws if mounting to wood.

•

Use bolts, washers, and nuts if mounting to metal.

PORT ABLE APPLICATIONS

Once properly secured, the saw may be mounted to a portable surface. To mount the saw to a portable surface:

1. Secure your saw to a 3/4 inch piece of plywood. Make sure the plywood is large enough to hold the saw and to allow the use of clamps.

2. Clamp the plywood to sawhorses or a portable workbench.

Note: The plywood mounted to your saw can also help protect it from damage when transporting it.

Page 14

OPERATION

BODY AND HAND POSITIONS

WARNING:

Do not cut short workpieces. You cannot properly hold a short workpiece and have your hand a safe distance from the blade. Never cross your arms or place your hands near the cutting area.

Figure 15

1. Position your body and hands with the saw to make

cutting easier and safer. Keep your face and body to one side of the blade, out of line with a possible debris throwback.

2. Don’t overreach; keep good footing and balance.

Place your hand away from the blade at least 4 inches (102 mm).

3. Hold the workpiece firmly against the fence and

keep hands in position until the trigger has been released and the blade has completely stopped. Before making a cut, make a “dry run” with the power off to determine the path of the blade.

SUPPORTING THE WORKPIECE

Support long workpieces to prevent sagging. Use the extension wings (1) to support long workpieces. The extension wings will allow the workpiece to lie flat on the entire length of the saw's base.

Figure 16

USING CARBIDE TIPPED BLADES

WARNING:

Read, understand and follow all warnings

and instructions provided with your carbide tipped blades. Handle carbide tipped blades carefully. Carbide is very

brittle and can be easily damaged. Use caution when you install, use, and store your blades.

Do not use a carbide tipped blade that is bent or has bent teeth, or if the blade has cracks, broken, missing or loose carbide tips.

Do not operate a carbide tipped blade faster than its maximum recommended speed.

CHANGING THE BLADE

(Figures 17 – 21)

WARNING:

•

Before changing a blade, unplug the power cord from the power source. The power cord must be unplugged whenever you are working on your saw.

•

To avoid injury from a thrown workpiece, do not use a blade larger or smaller than 10" (25.4 cm).

•

Do not use a dull saw blade. Additional force is required to operate, making it unsafe.

Immediately replace the blade if it shows signs of deterioration or damage. Dull or damaged blades can cause personal injury and ineffective operation of your saw.

Page 15

OPERATION

To replace the blade:

1. Loosen the guard plate screw (1).

Figure 17

2. Rotate the lower blade guard up to expose the arbor bolt (2).

Figure 18

3. While pushing in on the arbor lock (3) to hold the blade in position, turn the arbor bolt clockwise using the socket wrench supplied with your saw.

Note: turn the arbor bolt clockwise to loosen and counterclockwise to tighten.

Figure 19

4. Remove the arbor bolt, outer blade collar, and blade.

Figure 20

5. Clean any sawdust from both blade collars before installing the blade. Install a 10" (25.4 cm) blade only. Verify the rotation arrow on the blade matches the cast-in rotation arrow on the upper blade guard. make sure the blade is behind the flange.

6. Install the outer blade collar (4) and arbor bolt (5). While pushing in on the arbor lock, turn the arbor bolt counterclockwise to tighten.

Figure 21

7. Rotate the lower blade guard and guard plate down until the plate is behind the forward plate screw. Tighten both guard plate screws.

8. Slightly raise the lower guard plate until the screw and bushing can be threaded into the brass nut. Tighten the screw and make sure the busing is centered in the lever slot.

Page 16

OPERATION

MITER CUT

To make a miter cut, loosen the miter lock handle. Move the handle to the desired angle. Tighten the miter lock handle. Position your body in line with the miter angle to make the cut. Do not stand in front of the saw.

WARNING:

• Do not cross your arms in front of the blade while operating the saw.

• Be sure both miter locks are tightened before you operate the saw.

1. Unlock the miter handle (1) by turning

counterclockwise.

2. Turn the miter table (2) to the degree of angle

desired.

3. Tighten the miter handle to lock the table in position

before beginning the cut.

4. Position your body in line with the miter angle to

make the cut. Do not stand in front of the saw.

Figure 22

ALIGN LASER POINTER WITH BLADE

The laser pointer must be aligned with the blade to ensure an accurate cut.

Laser light - do not stare into beam, aperture, or into a reflection from a mirror-like surface.

Avoid exposure - laser radiation is emitted from top rear of the guard housing aperture.

Do not disassemble laser module.

Use of controls or adjustments or

performance of procedures other than those specified in this manual may result in hazardous radiation exposure.

1. Make sure the safety lock-out button and the laser switch are in the OFF position.

2. Put a padlock on the power switch to make sure the blade does not start.

3. Plug in the power cord and turn on the laser switch.

4. Remove the laser module cover (1).

Figure 23

5. Loosen, but do not remove the two laser module screws (2).

6. Move the laser module (3) to the left or right until it is aligned properly with the left or right side of the blade. See Figure 24

7. Tighten the laser module screws and replace the cover and remove the padlock.

Note: Turn the laser switch to the OFF position when not in use.

Figure 24

MAINTAIN LASER MODULE

Inspect and remove dust from the laser module as needed. See Figure 23.

1. Turn the saw and laser switches to the OFF position and unplug the saw.

2. Remove the cover from the laser module.

3. Slide out the laser lens cover (4) and clean it with a soft, clean cloth. Do not use solvents of any type as they may damage the lens.

4. Remove dust from the laser module with a soft, clean cloth.

5. Replace the laser module cover.

DANGER

INCORRECT INCORRECTCORRECT CORRECT

Page 17

CUTTING BOWED MATERIAL

Inspect your workpiece before cutting it. If it is bowed, position the workpiece against the fence with the bow facing as illustrated.

WARNING:

Failure to cut a bowed workpiece as described above may result in the blade becoming pinched. This could result in the workpiece moving suddenly, causing personal injury .

Figure 25

BEVEL CUT

To make a bevel cut, loosen the bevel lock handle. Rotate the blade to the desired bevel angle and lock into position. Stand to the left side of the handle to make the cut.

Figure 26

COMPOUND CUT

To make a compound cut, select the correct miter and bevel angles. Lock the blade into position. Move your feet and body in line with the handle to the desired miter angle to make the cut.

Figure 27

CUTTING BASE MOLDING

Base moldings and trims can be cut on a compound miter saw. The method depends on the type of molding, its characteristics and applications.

Figure 28

1. Use vise clamps, hold-down, or C-clamps whenever possible. Place tape on the area being clamped to avoid marking the finish surface of the molding.

2. Tape the area being cut to avoid splintering, and mark the cut line on the tape.

3. Perform practice cuts on scrap pieces before cutting the final molding.

Note: Splintering may be caused due to the thinness of the molding g or use of the wrong type of blade.

OPERATION

CORRECT INCORRECT

F e n c e

Mitre saw table

Mitre at 45o, bevel at 0

F e n c e

Mitre saw table

Mitre at 0o, bevel at 45

Page 18

CUTTING CROWN MOLDING

Crown molding must be compound mitered with extreme accuracy. The two surfaces on the crown molding must fit the wall or ceiling, and each other. The two cut surfaces of the mitered molding must add to a 90° angle. Most crown molding has a top angle of 52° that fits flat on the ceiling, and a bottom rear angle of 38° that fits flat against the wall.

1. The crown molding is thin and cannot stand vertically on edge. Lay the molding flat with its widest back surface flat on the saw table.

Figure 29

2. To avoid splintering and marking, tape the cutting line and any surface that is being clamped.

3. The angle settings for the two pieces of molding that will be adjoining in any one corner will be interdependent with each other. Any change in setting for one side must be equally compensated for on the other side.

Figure 30

4. All settings should be tested on scrap material before cutting the actual molding.

OPERATION

KEY

IL 33.9°

31.6° Right

1. Position top of molding against fence.

2. Miter table set at RIGHT 31.6°.

3. LEFT side is finished piece.

IR 33.9°

31.6° Left

1. Position bottom of molding against fence.

2. Miter table set at LEFT 31.6°.

3. LEFT side is finished piece.

33.9°

31.6° Left

1. Position bottom of molding against fence.

2. Miter table set at LEFT 31.6°.

3. RIGHT side is finished piece.

BEVEL

SETTING

MITER

SETTING

Inside corner - Left side

Inside corner - Right side

utside corner - Left side

Outside corner - Right side

TYPE OF CUT

33.9°

31.6°

Right

1. Position top of molding against fence.

2. Miter table set at RIGHT 31.6°.

3. RIGHT side is finished piece.

F e n c e

Mitre saw table

Workpiece lying flat

Inside corner

Compound cut crown mouldings

Outside corner

Page 19

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.

SAWDUST

WARNING:

Wear eye protection when using air

pressure to clean your saw.

WARNING:

Dust generated from certain materials can be hazardous to your health. Always operate the miter saw in well-ventilated areas and provide proper dust removal. Use dust collection systems whenever possible. Wear a face mask when operating the miter saw.

Empty the sawdust bag regularly. Keep sawdust accumulation around and under your saw to a minimum. Use compressed air or a vacuum to keep the area clean.

INSPECT LOWER BLADE GUARD

Regularly inspect the lower blade guard to ensure it operates properly. Do not operate your saw with a damaged or missing lower blade guard. The lower blade guard is installed for your safety.

Keep the lower blade guard free of sawdust buildup and clean. Use a damp cloth to remove dust from the lower blade guard.

WARNING:

Be sure to unplug the power cord from the

power source before cleaning the lower blade guard.

Note:

To prevent damage to the lower blade guard, clean it only with a damp cloth. Using solvent on it can cause damaged to the plastic.

LUBRICATION

All the ball bearings are permanently lubricated and do not require lubrication.

CLEANING AND STORAGE

Clean any dust or debris which may accumulate. Apply a light coat of automotive wax to the table to keep it clean and make it easier to move the workpiece. Keep the handle in the DOWN position during storage.

REPLACING CARBON BRUSHES

(Figure 31)

WARNING:

Be sure to unplug the power cord from the

power source before inspecting the carbon brushes.

Figure 31

Check the condition of the carbon brushes after 50 hours of use. If the brushes are worn to 1/16 inch (2 mm) in length, replace them.

To inspect the carbon brushes:

1. Remove end cap (1) to expose brushes. Carefully clean any dust or debris present.

2. Carefully remove the spring (2) and brush (3), taking note of their location and position.

3. Inspect the brush and replace if necessary. Be sure to replace both brushes even if only one is damaged.

Note:

If you are not installing new brushes, be sure to reinstall the brushes in the same position they were removed from.

4. Position the brushes into the motor.

5. Reinstall end cap.

MAINTENANCE

Page 20

FOR REPLACEMENT PARTS AND SERVICE

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.

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

SERVICE

Customer Replacement Parts

Part Number Item

99164N001 Bevel lock knob 99164N008 Bolt to secure fence (set of 2) 99164N009 Washer for fence bolt (set of 2) 99164N010 Fence 99164N011 Screws to secure table insert (set of 3) 99164N012 Table insert 99164N022A Extension wings (set of 2) with 4 holders 99164N026A Bar holder clamp with screw (set of 2) 99164N028A Stop bracket with screw 99164N034 Miter index grip 99164N035 Miter lock handle 99164N056A Lower guard with plate 99164N051 Lower guard return spring 99164N050 Return spring cover 99164N055 Guard/spring assembly screw 99164N049 Guard/spring assembly washer 99164N048 Guard/spring assembly lock nut 99164N054A Guard cover screw and washer 99164N116 Lower guard rubber bumper 99164N117A Bumper screw and washer 99164N128 Lower guard arm 99164N071 Motor brushes (set of 2) 99164N072 Brush covers (set of 2) 99164N135 Dust bag 99164N086 Dust chute 99164N102 Blade wrench 99164N124 Blade flanges (set of 2) 99164N127 Blade bolt M99192 Manual