Chicago Electric 97200 Installation manual

MINI CIRCULAR SAW
Model 97200
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©2007 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.

Page 2SKU 97200 For technical questions, please call 1-800-444-3353.
SAVE THIS MANUAL
Keep this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures. Write the product’s serial number in
the back of the manual near the assembly diagram (or month and year of purchase if
product has no number). Keep this manual and the receipt in a safe and dry place for
future reference.
IMPORTANT SAFETY INFORMATION
In this manual, on the labeling, and all other information
provided with this product:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
CAUTION, used with the safety alert
symbol, indicates a hazardous situation
which, if not avoided, could result in minor
or moderate injury.
NOTICE is used to address practices not
related to personal injury.
CAUTION, without the safety alert symbol,
is used to address practices not related to
personal injury.
DANGERDANGER
WARNINGWARNING
CAUTIONCAUTION
NOTICENOTICE
CAUTIONCAUTION

Page 3SKU 97200 For technical questions, please call 1-800-444-3353.
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 line-operated (corded) Circular Saw.
SAVE THESE INSTRUCTIONS
Work area safety
Keep work area clean and well lit. Cluttered or dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the
presence of ammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
Electrical safety
Power tool plugs must match the outlet. Never modify the plug in any way.
Do not use any adapter plugs with grounded power tools. Unmodied plugs
and matching outlets will reduce risk of electric shock.
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.
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 cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords increase the risk of
electric shock.
When operating a power tool outdoors, use an extension cord suitable for
outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
Personal safety
Stay alert, watch what you are doing and use common sense when operating
a power tool. Do not use a power tool while you are tired or under the
inuence of drugs, alcohol or medication. A moment of inattention while
operating power tools may result in serious personal injury.
Use safety equipment. Always wear eye protection. Wear work gloves
when handling the Blade. Safety equipment such as dust mask,
non-skid safety shoes, work gloves, or hearing protection used for
appropriate conditions will reduce personal injuries.
1.
a.
b.
c.
2.
a.
b.
c.
d.
e.
3.
a.
b.

Page 4SKU 97200 For technical questions, please call 1-800-444-3353.
Avoid accidental starting. Ensure the switch is in the off-position before
plugging in. Carrying power tools with your nger on the switch or plugging in
power tools that have the switch on invites accidents.
Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key 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. This
enables better control of the power tool in unexpected situations.
Dress properly. Do not wear loose clothing or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of these
devices can reduce dust-related hazards.
Power tool use and care
Do not force the power tool. Use the correct power tool for your application.
The correct power tool will do the job better and safer at the rate for which it
was designed.
Do not use the power tool if the power switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and must be
repaired.
Disconnect the plug from the power source before making any
adjustments, changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting the power tool
accidentally.
Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate
the power tool. Power tools are dangerous in the hands of untrained
users.
Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
Use the power tool, accessories and tool bits etc., in accordance with these
instructions and in the manner intended for the particular type of power tool,
taking into account the working conditions and the work to be performed. Use
of the power tool for operations different from those intended could result in a
hazardous situation.
c.
d.
e.
f.
g.
4.
a.
b.
c.
d.
e.
f.
g.

Page 5SKU 97200 For technical questions, please call 1-800-444-3353.
Service
Have your power tool serviced by a qualied repair person using only
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
VIBRATION HAZARD
This tool vibrates during use. Repeated or long-term exposure to vibration may
cause temporary or permanent physical injury, particularly to the hands, arms
and shoulders. To reduce the risk of vibration-related injury:
Anyone using vibrating tools regularly or for an extended period should rst
be examined by a doctor and then have regular medical check-ups to ensure
medical problems are not being caused or worsened from use. Pregnant women
or people who have impaired blood circulation to the hand, past hand injuries,
nervous system disorders, diabetes, or Raynaud’s Disease should not use this
tool. If you feel any medical or physical symptoms related to vibration (such as
tingling, numbness, and white or blue ngers), seek medical advice as soon as
possible.
Do not smoke during use. Nicotine reduces the blood supply to the hands and
ngers, increasing the risk of vibration-related injury.
Wear suitable gloves to reduce the vibration effects on the user.
Use tools with the lowest vibration when there is a choice between different
processes.
Include vibration-free periods each day of work.
Grip tool as lightly as possible (while still keeping safe control of it). Let the tool
do the work.
To reduce vibration, maintain the tool as explained in this manual. If any
abnormal vibration occurs, stop use immediately.
SPECIFIC SAFETY RULES
Maintain labels and nameplates on the tool. These carry important safety
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
Avoid unintentional starting. Prepare to begin work before turning on the tool.
Do not lay the tool down until it has come to a complete stop. Moving parts can
grab the surface and pull the tool out of your control.
5.
a.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.

Page 6SKU 97200 For technical questions, please call 1-800-444-3353.
When using a handheld power tool, maintain a rm grip on the tool with both
hands to resist starting torque and keep both hands out of the way of the Blade.
Do not leave the tool unattended when it is plugged into an electrical outlet. Turn
off the tool, and unplug it from its electrical outlet before leaving.
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.
This product is not a toy. Keep it out of reach of children.
Always use blades with a 2” diameter and round arbor holes. Blades that do not
match the mounting hardware of the Saw will run eccentrically, causing loss of
control.
Change Blade only after it has had a chance to cool down. The Blade will be
very hot after any cutting procedure.
Check Blade Guard and Guard Spring before use to ensure proper condition and
alignment. Blade Guard should move back into place easily and have no contact
with the Blade.
When Blade is binding, or interrupted in a cut for any reason, release the trigger
and hold the Saw motionless in the material until the Blade comes to a complete
stop. Never pull the Saw backward while the Blade is in motion. Investigate and
take corrective actions to eliminate the cause of blade binding.
When starting a Saw in the workpiece, center the Blade in the cut and check that
teeth are not engaged into the material. If Blade is binding, it may walk up the
workpiece when the Saw is restarted.
Do not use dull or damaged Blade. Dull or improperly set Blades produce a
narrow cut causing excessive friction and Blade binding.
People with pacemakers should consult their physician(s) before use.
Electromagnetic elds in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked on.
• Properly maintain and inspect to avoid electrical shock.
• Any power cord must be properly grounded. Ground Fault Circuit Interrupter
(GFCI) should also be implemented – it prevents sustained electrical shock.
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:
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Page 7SKU 97200 For technical questions, please call 1-800-444-3353.
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.)
The warnings, precautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be
understood by the operator that common sense and caution are factors which
cannot be built into this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS.
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.
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
16.
1.
2.
3.
WARNINGWARNING

Page 8SKU 97200 For technical questions, please call 1-800-444-3353.
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
Standard 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.)
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.
1.
2.
1.
2.
3.
4.
5.
6.

Page 9SKU 97200 For technical questions, please call 1-800-444-3353.
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
electrician 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)
7.
8.

Page 10SKU 97200 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Electrical Requirements 120 V~ / 60 Hz
Motor No Load Speed 8000 RPM
Blade Diameter 2”
Arbor Size 7/16”
Cutting Capacity 1/2”
UNPACKING
When unpacking, check to make sure that the item is intact and undamaged. 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.
List of contents
Description Qty
Mini Circular Saw 1
Saw Blade 2
Hex Wrench 2
SET UP INSTRUCTIONS
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the
beginning of this manual including all text under subheadings therein
before set up or use of this product.
Risk of accidental starting; resulting in serious personal
injury. Leave the Power Switch of the tool “OFF” and unplug
the tool from its electrical outlet before assembling or
making any adjustments to the tool.
Note: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram near the end of this manual.
Installing the Saw Blade
If the Saw has been in use, allow the Blade to cool down before changing the
Blade. Blades can become very hot when cutting.
Remove the Hole Cover (39) and use the 5mm Hex Wrench to remove the Nut
(38).
Slide the Bolt (42) out and remove the Blade Guard (37) from the unit.
1.
2.
3.
WARNINGWARNING