Chicago Electric 91938 User manual

®
Model 91938
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright©2004 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 and replacement parts, please call 1-800-444-3353.
14” HEAVY DUTY CUT-OFF SAW
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 2
PRODUCT SPECIFICATIONS
E105017
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Power tools create sparks
which may ignite the dust or fumes.
3. 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.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, op-
erating, inspection, maintenance and cleaning procedures, parts list and assem-
bly 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 reference.
REV 09/04
Electrical Requirements 120V/60Hz/15 AMP’s Rated
Speed 3500 RPM
Maximum Cut-Off Wheel Diameter 14”
Recommended Cut-Off Wheel
Types
14” Cut-Off Wheel for Metal (SKU 44814,
included)
14” Cut-Off Wheel for Masonry (SKU 44815)
Cutting Capacity 4-1/4”
Quick Release Vice Capacities 7” (1st Setting), 9-1/2” (2nd Setting)
Arbor Size 1”
Overall Dimensions 25-1/2”L x 18-1/2”W x 10-3/4”W
Weight 34-1/2 lbs.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 3
ELECTRICAL SAFETY
4. 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 qualified 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.
5. Double insulated tools are equipped with a polarized plug (one blade is
wider than the other). 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 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.
6. Avoid body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if your
body is grounded.
7. Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
8. 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 immedi-
ately. Damaged Power Cords increase the risk of electric shock.
9. 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
10. 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 influ-
ence of drugs, alcohol, or medication. A moment of inattention while operat-
ing power tools may result in serious personal injury.
11. 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.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 4
12. Avoid accidental starting. Be sure the Power Switch is off before plugging
in. Carrying power tools with your finger on the Power Switch, or plugging in
power tools with the Power Switch on, invites accidents.
13. 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.
14. Do not overreach. Keep proper footing and balance at all times. Proper
footing and balance enables better control of the power tool in unexpected
situations.
15. Use safety equipment. Always wear ANSI approve eye protection. Dust
mask, non-skid safety shoes, hard hat, or hearing protection must be used for
appropriate conditions.
TOOL USE AND CARE
16. Use the included clamp or other practical ways to secure and support the
workpiece to the Base (13). Holding the work by hand or against your body is
unstable and may lead to loss of control.
17. 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.
18. 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.
19. 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.
20. Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
21. 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.
22. 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.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 5
23. Use only accessories that are recommended by the manufacturer of your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
24. Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result in a risk of injury.
25. When servicing a tool, use only identical replacement parts. Follow
instructions 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
1. Maintain labels and nameplates on the Cut-Off Saw. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replace
ment
2. 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 ob-
structions, grease, oil, trash, and other debris. Do not use a power tool in areas
near flammable chemicals, dusts, and vapors. Do not use this product in a damp
or wet location.
3. Avoid unintentional starting. Make sure you are prepared to begin work
before turning on the Cut-Off Saw.
4. Do not force the Cut-Off Saw. This tool will do the work better and safer at
the speed and capacity for which it was designed.
5. Always keep the extension cord away from moving parts on the tool.
6. Keep hands and fingers away from the cutting area and the Cut-Off Wheel.
Keep one hand on the handle and the other on the motor housing. If both hands
are holding the saw, you hands and fingers cannot be cut by the Cut-Off Wheel.
7. Do not reach under the base of the Cut-Off Saw. The Swing Guard (53)
cannot protect you from the Cut-Off Wheel below the base.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 6
8. Check Swing Guard (53) for proper closing before each use. Do not operate
the Saw if the Swing Guard does not move freely and close instantly. Never
clamp or tie the Swing Guard (53) into the open position. If the saw is acci-
dently dropped, the Swing Guard (53) may be bent. Raise the Swing Guard (53)
and make sure it moves freely and does not touch the Cut-Off Wheel or another
part, in all depths of cut.
9. The Swing Guard (53) should be retracted manually only for special cuts
such as “Pocket Cuts) and “Compound Cuts.” Raise the Swing Guard (53)
only enough to begin the cut. As soon as the Cut-Off Wheel enters the
material, the Swing Guard (53) must be released. For all other sawing, the
Swing Guard (53) should be allowed to operate automatically.
10. The Saw is not to be used for any cutting in the locked down position. The
Saw should be locked down position only for carrying and storage.
11. Always use Cut-Off Wheels with a 14” diameter, 1” arbor hole, and rated at
a minimum of 3750 RPM. Cut-Off Wheels that do not match the mounting hard-
ware of the Saw or that are rated at less than the Saw’s maximum RPM may fly
off the Saw or may run eccentrically, causing loss of control.
12. Never use damaged or incorrect Cut-Off Wheel washers or bolts. The Cut-
Off Wheel’s washers and bolts were specially designed for your Saw, for opti-
mum performance and safety of operation.
13. Do not use the included Cut-Off Wheel to cut aluminum, copper, brass, or
other non-ferrous metals. The included Cut-Off Wheel is designed to cut only
ferrous (iron containing) metals such as steel alloys and cast iron. If using other
Cut-Off Wheels, only use them on materials that the manufacturer recommends.
14. To avoid accidental injury, always wear heavy duty work gloves and work
bib when changing a Cut-Off Wheel.
15. Before using the Cut-Off Saw, make sure the Cut-Off Wheel is properly
mounted on the saw spindle. Make sure the Cut-Off Wheel is balanced and is
not broken or bent.
16. Always unplug the Cut-Off Saw from its electrical outlet before perform-
ing any inspection, maintenance, or cleaning procedures.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 7
23. WARNING! Some dust created by power sanding, sawing, grinding, drilling,
and other construction activities, contain chemicals known (to the State of Califor-
nia) 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 filter out microscopic particles.
(California Health & Safety Code 25249.5, et seq.)
24. WARNING! People with pacemakers should consult their physician(s) be-
fore using this product. Electromagnetic fields in close proximity to a heart pace-
maker could cause interference to or failure of the pacemaker.
17. The Cut-Off Wheel will become hot while cutting. Allow the Cut-Off Wheel to
completely cool before touching.
18. Allow the Cut-Off Wheel to spin to full speed before feeding it into the
workpiece. When turning off the Saw, allow the Cut-Off Wheel to spin down and
stop on its own. Do not press against the Cut-Off Wheel to stop it.
19. Do not force the Cut-Off Wheel into the workpiece when cutting. Apply
moderate pressure, allowing the Cut-Off Wheel to cut without being forced.
20. Industrial applications must follow OSHA requirements.
21. Always locate the Cut-Off Saw on a level, flat work surface capable of sup-
porting the solid weight of the saw, workpiece and related tools.
22. Always 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 attach-
ment. There are certain applications for which this product was designed. It will
do the 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
intended.

SKU 91938 For technical questions, please call 1-800-444-3353. Page 8
GROUNDING
WARNING!
Improperly connecting the grounding wire can result in the risk of electric shock.
Check with a qualified 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 fit the outlet, have a proper outlet installed by a qualified electrician.
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS
1. 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 elec-
tric shock. (See Figure A.)
2. 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 Figure A.)
3. Your 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 Figure A.)
FIGURE A

SKU 91938 For technical questions, please call 1-800-444-3353. Page 9
FIGURE B
DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS
4. Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satisfies OSHA requirements and complies with
the applicable standards of Underwriters Laboratories, Inc., the Canadian
Standard Association, and the National Electrical Code. (See Figure B.)
5. Double insulated tools may be used in either of the 120 volt outlets shown in the
following illustration. (See Figure B.)
EXTENSION CORDS
1. Grounded tools require a three wire extension cord. Double Insulated tools
can use either a two or three wire extension cord.
2. 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 Figure C, next page.)
3. 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 Figure C.)
4. 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 Figure C.)
5. 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 Figure C.)

SKU 91938 For technical questions, please call 1-800-444-3353. Page 10
6. If you are using an extension cord outdoors, make sure it is marked with the suf-
fix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
7. Make sure your extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified elec-
trician before using it.
8. Protect your extension cords from sharp objects, excessive heat, and damp or
wet areas.
SYMBOLOGY
Double Insulated
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions
per Minute (RPM)
noxxxx/min.
A
V ~
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 VOLT)
NAMEPLATE
AMPERES
(At Full Load)
EXTENSION CORD LENGTH
25 FEET 50 FEET 75 FEET 100 FEET 150 FEET
0 - 2.0 18 18 16 16 16
2.1 - 3.4 18 18 16 14 14
3.5 - 5.0 18 18 16 14 12
5.1 - 7.0 18 16 14 12 12
7.1 - 12.0 16 14 12 10 -
12.1 - 16.0 14 12 10 - -
16.1 - 20.0 12 10 - - -
FIGURE C *Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.