Chicago Electric 90891 Installation manual

10” COMPOUND SLIDE MITER SAW
Model 90891
SET UP AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2003 by Harbor Freight Tools®. All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor Freight Tools.
For technical questions or replacement parts, please call 1-800-444-3353.
Cover revised 07h

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SPECIFICATIONS
Electrical
Requirements
120 V / 60 Hz / 4600 RPM
10.8 A Input Working Amperage (with load)
1-3/4 HP Motor / Single Phase
2-Prong Power Plug
Double Insulated Motor w/ External Access Brushes
Arbor Diameter 5/8” (0.625”)
Positive Stops 0°, 15°, 22.5°, 30°, 45° Miter
0°, 45° Compound
Blade Diameter 10”, 60 Tooth, C2 Carbide Tipped Blade
Cutting Capacity At 90 Degrees: 3-1/2” Deep x 12” Front to Back
At 45 Degrees: 1-3/4” Deep x 10” Front to Back
Features Trigger Safety Button
Transparent, Retractable, Blade Guard
Accessories Workpiece Holders (Qty. 2)
Hex Socket Wrench (Qty. 1)
Bafe Plate (Qty. 1)
Bafe Plate Screw (Qty. 1)
Carbon Brushes (Qty. 2)
Dust Collect Bag (Qty. 1)
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and assembly
diagram. Keep your invoice with this manual. Write the invoice number on the inside
of the front cover. Keep this manual and invoice in a safe and dry place for future refer-
ence.
GENERAL SAFETY RULES
WARNING! Read all instructions
Failure to follow all instructions listed below may result in electric shock,
re, and/or serious injury. The term “power tool” in all of the warnings listed
below refers to your mains-operated (corded) power tool or battery-operated
(cordless) power tool.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
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Do not operate power tools in explosive atmospheres, such as in the pres-
ence of ammable liquids, gases, or dust. Power tools create sparks which
may ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly installed and
grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in any way. Do not use any adapter
plugs. Check with a qualied electrician if you are in doubt as to whether
the outlet is properly grounded. If the tools should electrically malfunction or
break down, grounding provides a low resistance path to carry electricity away
from the user.
Double insulated tools are equipped with a polarized plug (one blade is
wider than the other). This plug will t in a polarized outlet only one way.
If the plug does not t fully in the outlet, reverse the plug. If it still does
not t, contact a qualied electrician to install a polarized outlet. Do not
change the plug in any way. Double insulation eliminates the need for the
three wire grounded power cord and grounded power supply system.
Avoid body contact with grounded surfaces such as pipes, radiators, rang-
es, and refrigerators. There is an increased risk of electric shock if your body is
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 Power Cord. Never use the Power Cord to carry the tools
or pull the Plug from an outlet. Keep the Power Cord away from heat, oil,
sharp edges, or moving parts. Replace damaged Power Cords immediate-
ly. Damaged Power Cords increase the risk of electric shock.
When operating a power tool outside, use an outdoor extension cord
marked “W-A” or “W”. These extension cords are rated for outdoor use, and
reduce the risk of electric shock.
PERSONAL SAFETY
Stay alert. Watch what you are doing, and use common sense when oper-
ating a power tool. Do not use a power tool while tired or under the inu-
ence of drugs, alcohol, or medication. A moment of inattention while operating
power tools may result in serious personal injury.
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Dress properly. Do not wear loose clothing or jewelry. Contain long
hair. Keep your hair, clothing, and gloves away from moving parts. Loose
clothes, jewelry, or long hair can be caught in moving parts.
Avoid accidental starting. Be sure the Power Switch is off before plugging
in. Carrying power tools with your nger on the Power Switch, or plugging in
power tools with the Power Switch on, invites accidents.
Remove adjusting keys or wrenches before turning the power tool on. A
wrench or a key that is 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. Proper
footing and balance enables better control of the power tool in unexpected situa-
tions.
Use safety equipment. Always wear eye protection. Dust mask, non-skid
safety shoes, hard hat, or hearing protection must be used for appropriate condi-
tions.
TOOL USE AND CARE
Use clamps (not included) or other practical ways to secure and support
the workpiece to a stable platform. Holding the work by hand or against your
body is unstable and may lead to loss of control.
Do not force the tool. Use the correct tool for your application. The correct
tool will do the job better and safer at the rate for which it is designed.
Do not use the power tool if the Power Switch does not turn it on or off.
Any tool that cannot be controlled with the Power Switch is dangerous and must
be replaced.
Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive
safety measures reduce the risk of starting the tool accidentally.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintained tools with a sharp cutting edge are less likely to bind and are easier
to control. Do not use a damaged tool. Tag damaged tools “Do not use” until
repaired.
Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the tool’s operation. If damaged, have
the tool serviced before using. Many accidents are caused by poorly main-
tained tools.
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Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
Tool service must be performed only by qualied repair personnel. Service
or maintenance performed by unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow in-
structions in the “Inspection, Maintenance, And Cleaning” section of this
manual. Use of unauthorized parts or failure to follow maintenance instructions
may create a risk of electric shock or injury.
SPECIFIC SAFETY RULES
Maintain a safe working environment. Keep the work area well lit. Make sure
there is adequate surrounding workspace. Always keep the work area free of
obstructions, grease, oil, trash, and other debris. Do not use the Miter Saw in
areas near ammable chemicals, dusts, and vapors. Do not use this product in a
damp or wet location.
Maintain labels and nameplates on the Miter Saw. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replace-
ment.
Do not force the equipment. This Miter Saw will do the work better and safer at
the speed and capacity for which it was designed.
Keep all guards in place and in working order.
Remove all adjusting wrenches from the Miter Saw before turning it on.
Do not abuse the Power Cord. Do not use the Power Cord to pull its Plug from
an electrical outlet. Keep the Power Cord away from heat, oil, sharp edges, and
moving parts. Route the Power Cord safely. Protect the Power Cord from be-
ing damaged by other equipment in the work area. Do not route the Power Cord
where it can be walked on or tripped over. Replace a damaged Power Cord im-
mediately.
Make sure the Power Switch is in the “OFF” position before plugging in the
Power Cord.
Do not use this Miter Saw for cutting metals or brittle materials. Do not cut
dangerous materials, such as asbestos which can cause harmful dust or vapors.
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When replacing the Saw Blade, make sure the new Saw Blade has a diam-
eter of 10”, has an RPM rating of at least 4600, and has an arbor hole of 5/8”
diameter.
To avoid accidental injury, always wear heavy duty work gloves when
changing a Saw Blade.
Before using the Miter Saw, make sure the Saw Blade is properly mounted
on the Saw Spindle. Make sure the Saw Blade is balanced, and is not cracked
or bent.
The Saw Blade will become hot while cutting. Allow the Saw Blade to com-
pletely cool before touching.
Allow the Saw Blade to spin up to full speed before feeding it into wood.
When turning off the Miter Saw, allow the Saw Blade to spin down and stop on its
own. Do not press against the Saw Blade to stop it.
Do not force the material into the Saw Blade when cutting. Apply moderate
pressure, allowing the Saw Blade to cut without being forced.
Never attempt to remove material stuck in the moving parts of the Miter
Saw while the machine is plugged in and running.
Whenever possible, use clamps or other safe, practical ways to hold and
support the workpiece. Do not attempt to cut material that does not have a at
surface, unless a suitable support is used.
Turn off the Miter Saw and allow the Saw Blade to stop on its own if the
Saw Blade is to be backed out of an uncompleted cut.
Always keep hands and ngers away from the spinning Saw Blade.
Use eye, hearing, and breathing protection. Always wear ANSI approved
safety impact eye goggles, hearing protectors, and dust masks or respirator
when working with the Miter Saw.
Do not use this product if under the inuence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgement or reexes are impaired
while taking drugs. If there is any doubt, do not attempt to use this product.
Industrial applications must follow OSHA requirements.
Maintain this product with care. Keep the Miter Saw clean and dry for better and
safer performance. For your safety, service and maintenance should be per-
formed regularly by a qualied technician.
Use the right tool or attachment for the right job. Do not attempt to force a
small tool or attachment to do the work of a larger industrial tool or attachment.
There are certain applications for which this product was designed. It will do the
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job better and more safely at the rate for which it was intended. Do not modify
this product, and do not use this product for a purpose for which it was not in-
tended.
Always turn off the Miter Saw and unplug the Power Cord from its electrical
outlet before changing accessories or performing any inspection, mainte-
nance, or cleaning procedures.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities, contains chemicals known [to the State of California]
to cause cancer, birth defects or other reproductive harm. Some examples of
these chemicals are:
Lead from lead-based paints
Crystalline silica from bricks and cement or other masonry products
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 lter out microscopic particles. (California Health &
Safety Code § 25249.5, et seq.)
People with pacemakers should consult their physician(s) before use. Electro-
magnetic elds in close proximity to heart pacemaker could cause pacemaker
interference or pacemaker failure.
The warnings, precautions, and instructions discussed in this manual cannot
cover all possible conditions and situations that may occur. The operator must
understand that common sense and caution are factors which cannot be built into
this product, but must be supplied by the operator.
Only lock the Motor Housing in the lock down position for carrying or storing the
Miter Saw. Never attempt to cut with the Miter Saw when the Motor Housing is in
the lock down position.
GROUNDING
Improperly connecting the grounding wire can result in
electric shock.
Check with a qualied electrician if you are in doubt as to
whether the outlet is properly grounded. Do not modify
the power cord plug provided with the tool. Never remove
the grounding prong from the plug. Do not use the tool if
the power cord or plug is damaged. If damaged, have it
repaired by a service facility before use. If the plug will not
t the outlet, have a proper outlet installed by a qualied
electrician.
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Page 8SKU 90891 For technical questions, please call 1-800-444-3353.
Grounded Tools: Tools with Three Prong Plugs
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If
the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user, reducing the risk of electric
shock. (See 3-Prong Plug and Outlet.)
The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached
to an electrically “live” terminal. (See 3-Prong Plug and Outlet.)
The tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
should look like those in the following illustration.
(See 3-Prong Plug and Outlet.)
3-Prong Plug and Outlet Outlets for 2-Prong Plug
Double Insulated Tools: Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satises OSHA requirements and complies with
the applicable standards of Underwriters Laboratories, Inc., the Canadian Stan-
dard Association, and the National Electrical Code.
(See Outlets for 2-Prong Plug.)
Double insulated tools may be used in either of the 120 volt outlets shown in the
preceding illustration. (See Outlets for 2-Prong Plug.)
Extension Cords
Grounded tools require a three wire extension cord. Double Insulated tools can
use either a two or three wire extension cord.
As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool damage.
(See Table A.)
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The smaller the gauge number of the wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
(See Table A.)
When using more than one extension cord to make up the total length, make
sure each cord contains at least the minimum wire size required. (See Table A.)
If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size.
(See Table A.)
If you are using an extension cord outdoors, make sure it is marked with the suf-
x “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
Make sure the extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualied elec-
trician before using it.
Protect the extension cords from sharp objects, excessive heat, and damp or wet
areas.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD LENGTH
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A * Based on limiting the line voltage drop to ve volts at 150% of the rated amperes.
Symbology
Double Insulated V~ Volts Alternating Current
Canadian Standards Association AAmperes
Underwriters Laboratories, Inc. n0xxxx/min. No Load Revolutions per Minute
(RPM)
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UNPACKING
When unpacking, check to make sure all the parts shown on the Parts Lists on
pages 22 and 23 are included. If any parts are missing or broken, please call Harbor
Freight Tools at the number shown on the cover of this manual as soon as possible.
ASSEMBLY AND FUNCTIONS
Note: For additional references to the parts listed in the following pages, refer to the As-
sembly Diagrams on pages 24 and 25.
To Assemble The Accessories:
WARNING! Prior to performing any assembly procedures, make sure the Power
Cord of the Miter Saw is unplugged from its electrical outlet.
The Miter Saw comes with several accessories that may be attached to the unit.
DUST COLLECTION BAG
(154)
ELBOW
(47)
FIGURE D
BAFFLE PLATE
(151) HOLDER (149)
The Dust Collection Bag (154) can be attached by inserting the bag opening onto
the top of the Elbow (47). The Dust Collection Bag helps keep the work area
clean by catching sawdust and wood chips which are thrown off by the Saw
Blade (51). When the Dust Collection Bag is half full, remove it from the Miter
Saw, empty, and reattach it to the Miter Saw. (See Figure D.)
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