Craftsman evolv 320.31024 User manual

Operator's Manual
ICRRFTSMRNI
evolv
m
18.0-Volt Ni-Cd Cordless
5-1/2 inch Circular Saw
Model No. 320. 31024
c_ius
LISTED
WARNING: To reduce the risk
of injury, the user must read and
understand the Operator's Manual
before using this product.
Charge battery before first use.
• WARRANTY
•SAFETY
•ASSEMBLY
•OPERATION
•MAINTENANCE
•ESPAI_IOL
Sears Brands Management Corporation, Hoffman Estates, IL60179 U.S.A.
www.oraftsman.oom

I_ _I[I]ii[II_I__I
Warranty page 2
Safety Symbols pages 3-4
Safety Instructions pages 5-11
Description pages 12-13
Assembly page 14
Operation pages 15-26
Maintenance pages 27-29
Troubleshooting page 30
Exploded View and Part List pages 31-33
CRAFTSMAN EVOLV ONE YEAR LIMITED WARRANTY
FOR ONE YEAR from the date of purchase, this product is warranted
against any defects in material or workmanship. With proof of purchase, a
defective product will be replaced free of charge.
For warranty coverage details to obtain free replacement, visit the web
site: www.craftsman.com
This warranty does not cover the blade, which is an expendable part that
can wear out from normal use within the warranty period.
This warranty is void if this product is ever used while providing
commercial services or if rented to another person.
This warranty gives you specific legal rights, and you may also have other
rights which vary from state to state.
Sears Brands Management Corporation, Hoffman Estates, IL 60179
This circular saw has many features for making its use more pleasant and
enjoyable. Safety, performance, and dependability have been given top priority
in the design of this product making it easy to maintain and operate.
SAVE THESE INSTRUCTIONS!
READ ALL INSTRUCTIONS!
_, WARNING: Some dust created by using power tools contain chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
31024Manual Revised 11-0629 Page2

The purpose of safety symbols is to attract your attention to possible dangers.
The safety symbols and the explanations with them deserve your careful
attention and understanding. The symbol warnings do not, by themselves,
eliminate any danger. The instructions and warnings they give are no substitutes
for proper accident prevention measures.
_1_ WARNING: Be sure to read and understand all safety instructions in this
manual, including all safety alert symbols such as "DANGER," "WARNING," and
"CAUTION" before using this circular saw. Failure to follow all instructions listed
in this manual may result in electric shock, fire and/or serious personal injury.
SYMBOL SIGNAL MEANING
_, SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION;
may be used in conjunction with other symbols or pictographs.
_, 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: Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
Damage Prevention and Information Messages
These inform the user of important information and/or instructions that could
lead to equipment or other property damage if they are not followed. Each
message is preceded by the word "NOTICE", as in the example below:
NOTICE: Equipment and/or property damage may result if these instructions are
not followed.
_L. WARNING: To ensure safety and reliability, all repairs should be performed
by a qualified service technician.
_, WARNING: The operation of any power tools can result in
foreign objects being thrown into your eyes, which can result
in severe eye damage. Before beginning power tool operation,
always wear safety goggles or safety glasses with side shield
and a full face shield when needed. We recommend a Wide
Vision Safety Mask for use over eyeglasses or standard safety
glasses with side shields. Always use eye protection which is
marked to comply with ANSI Z87.1.
31024Manual Revised 11-0629 Page3

SAVE THESE INSTRUCTIONS
Some of these following symbols may be used on this tool. Please study them
and learn their meaning. Proper interpretation of these symbols will allow you to
operate the tool better and more safely.
SYMBOL NAME DESIGNATION/EXPLANATION
V Volts Voltage
A Amperes Current
Hz Hertz Frequency (cycles per second)
W Watt Power
rain Minutes Time
Alternating Current Type of current
--_ Direct Current Type or a characteristic of current
n o No Load Speed Rotational speed, at no load
] Class II Construction Double-insulated construction
.../rain Per Minute Revolutions, strokes, surface speed,
orbits, etc., per minute
Wet Conditions Alert Do not expose to rain or use in damp
locations.
To reduce the risk of injury, user must
Read The Operator's Manual read and understand operator's manual
before using this product.
OAlways wear safety goggles or safety
Eye Protection glasses with side shields and a full face
shield when operating this product.
_h, Alert Precautions that involve
Safety your safety.
Failure to keep your hands away from the
No Hands Symbol blade will result in serious personal injury.
Failure to keep your hands away from the
No Hands Symbol blade will result in serious personal injury.
Failure to keep your hands away from the
No Hands Symbol blade will result in serious personal injury.
No Hands Symbol Failure to keep your hands away from the
blade will result in serious personal injury.
To reduce the risk of injury or damage,
Hot Surface avoid contact with any hot surface.
31024Manual Revised 11-0629 Page4

GENERAL POWER TOOL SAFETY WARNINGS
_, WARNING: Read all safety warnings and instructions. Failure to follow the
warnings and instructions listed below may result in electric shock, fire, and/or
serious personal injury.
Save all warnings and instructions for future reference.
The term "power tool" in all warnings listed below refers to corded power tools
or battery-operated (cordless) power tools.
WORK AREA SAFETY
• Keep your work area clean and well lit. Cluttered or dark areas invite accidents.
•Do not operate power tools in explosive environments, such as in the
presence of flammable 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 may 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.
Unmodified plugs and matching outlets will reduce the 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 the cord away from heat, oil, sharp
edge, 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.
•If operating a power tool in a damp location is unavoidable, use a
ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI
reduces the risk of electric shock.
•Use this circular saw only with the battery and power unit listed below:
BATTERY PACK POWER UNIT
320.30864 HYCH0092400250U
31024Manual Revised 11-0629 Page5

PERSONAL SAFETY
• Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use the tool while tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective
equipment such as a dust mask, non-skid safety shoes, hard hat, or hearing
protection, used for appropriate conditions, will reduce personal injuries.
•Prevent unintentional starting. Ensure that the switch is in the OFF-
position before connecting to a power source and/or battery, picking up
or carrying the tool. Carrying power tools with your finger on the switch or
energizing power tools that have the switch turned 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 that 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 more safely at
the rate for which it was designed.
•Do not use the power tool if the 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 and/or the battery from the
power tool 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 operation. If damaged, have the power tool repaired before
use. Many accidents are caused by poorly maintained power tools.
31024Manual Revised 11-0629 Page6

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, tool bits, etc., in accordance with
these instructions, 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.
BATTERY TOOL USE AND CARE
• Recharge only with the charger specified by the manufacturer. A charger
that is suitable for one type of battery pack may create a risk of fire when
used with another battery pack.
• Use power tools only with specifically designated battery packs. Use of
any other battery packs may create a risk of injury and fire.
• When the battery pack is not in use, keep it away from other metal
objects, such as paper clips, coins, keys, nails, screws, or other small
metal objects that can make a connection from one terminal to another
(shorting). Shorting the battery terminals together may cause burns or a fire.
• Under abusive conditions, liquid may be ejected from the battery;
avoid contact. If contact accidentally occurs, flush with water. If liquid
contacts eyes, flush eyes with water and immediately seek medical
help. Liquid ejected from the battery may cause irritation or burns.
SERVICE
•Have your power tool serviced by a qualified repair person using only
identical replacement parts. Thiswillensurethat the safety of the power
tool ismaintained.
•Follow instructions in the Maintenance section of this manual. Use of
unauthorized parts or failure to follow Maintenance instructions may create a
risk of shock or injury.
FURTHER SAFETY INSTRUCTIONS FOR SAWS
_h, WARNING: To reduce the risk of injury, check the guarding system. It must
cover the blade instantly! Hold the saw with both hands. Support and clamp
the work. Always wear eye protection. Always wear a dust mask. Always wear
hearing protection.
A_, DANGER: Keep hands away from the cutting area and the blade. Keep one
hand on the main handle and your other hand on the auxiliary handle or motor
housing. If both hands are holding the saw, they cannot be cut by the blade.
• Do not use abrasive wheels with this saw.
•Do not reach underneath the workpiece. The guard cannot protect you
from the blade below the workpiece.
• Adjust the cutting depth to the thickness of the workpiece. Less than a
full tooth of the blade should be visible below the workpiece.
31024 Manual Revised 11-0629 Page 7

•Never hold the piece being cut in your hands or across your leg. Secure
the workpiece to a stable platform. It is important to support the work
properly to minimize body exposure, blade binding or loss of control.
• Hold the power tool by its insulated gripping surfaces when performing
an operation where the cutting tool may contact hidden wiring or its
own cord. Contact with a "live" wire will also make exposed metal parts of
the tool "live" and shock the operator.
• When ripping, always use a rip fence or straight edge guide (sold
separately). This improves the accuracy of the cut and reduces the chance
of blade binding.
• Always use blades with the arbor holes that are the correct size and
shape. Blades that do not match the mounting hardware of the saw will run
erratically, causing loss of control.
• Never use damaged or incorrect blade washers or bolt. The blade
washers and bolt were specially designed for your saw for optimum
performance and safety of operation.
CAUSES AND OPERATOR PREVENTION OF KICKBACK:
• Kickback is a sudden reaction to a pinched, bound or misaligned saw blade,
which causes an uncontrolled saw to lift up and out of the workpiece toward
the operator.
• When the blade is pinched or bound tightly by the kerf closing down, the blade
stalls and the motor reaction drives the unit rapidly back toward the operator.
• If the blade becomes twisted or misaligned in the cut, the teeth at the back
edge of the blade can dig into the top surface of the wood, causing the blade
to climb out of the kerf and jump back toward the operator.
• Kickback is the result of misuse and/or incorrect operating procedures or
conditions and can be avoided by taking proper precautions, as given below:
• Maintain a firm grip with both hands on the saw and position your arms
to resist kickback forces. Position your body to either side of the blade,
but not in line with the blade. Kickback could cause the saw to jump
backwards, but kickback forces can be controlled by the operator if proper
grip and positioning precautions are taken.
• When blade is binding, or when interrupting 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 attempt to remove the saw
from the work or pull the saw backward while the blade is in motion or
kickback may occur. Investigate and take corrective actions to eliminate
the cause of blade binding.
• When restarting a saw in the workpiece, center the saw blade in the kerf
and check that the saw teeth are not engaged into the material. If the
saw blade is binding, it may walk up or kickback from the workpiece when
the saw is restarted.
31024Manual Revised 11-0629 Page8

•Support large panels to minimize the risk of blade pinching and
kickback. Large panels tend to sag under their own weight. Supports must
be placed under the panel on both sides, near the line of cut and near the
edge of the panel.
• Do not use dull or damaged blades. Unsharpened or improperly set blades
produce a narrow kerr, causing excessive friction, blade binding and kickback.
• Blade depth and bevel adjusting locking levers must be tight and secure
before making a cut. If the blade adjustment shifts while cutting, it may
cause binding and kickback.
• Use extra caution when making a "plunge cut" into existing walls or other
blind areas. The protruding blade may cut objects that can cause kickback.
SAFETY INSTRUCTIONS FOR LOWER BLADE GUARD
• Check the lower guard for proper closing before each use. Do not
operate the saw if the lower blade guard does not move freely and
close instantly. Never clamp or tie the lower blade guard into the open
position, if the saw is accidentally dropped, the lower blade guard may be
bent. Raise the lower blade guard with the retracting handle. Make sure that
it moves freely and does not touch the blade or any other part, in all angles
and all depths of cut.
• Check the operation of the lower blade guard spring. If the blade guard
and the spring are not operating properly, they must be serviced before
use. The lower blade guard may operate sluggishly due to damaged parts,
gummy deposits or a build-up of debris.
• The lower blade guard should be retracted manually only for specific
cuts, such as "plunge cuts" and "compound cuts". Raise the lower
blade guard with the retracting handle. As soon as the blade enters the
material, the lower guard must be released. For all other sawing, the lower
blade guard should operate automatically.
•Always ensure that the lower blade guard is covering the blade before
placing the saw down on a bench or the floor. An unprotected, coasting
blade will cause the saw to walk backwards, cutting whatever is in its path. Be
aware of the time it takes for the blade to stop after the switch is released.
SAFETY RULES FOR POWER UNIT
_I, WARNING: Read and understand all instructions. Failure to follow all
instructions listed below may result in electric shock, fire and/or serious
personal injury.
Before using the power unit, read all instructions and cautionary markings in
this manual, on the power unit, and the product using battery to prevent misuse
of the products and possible injury or damage.
_I, CAUTION: To reduce the risk of electric shock or damage to the power unit
and tool, charge only this Ni-Cd rechargeable tool. Other types of batteries may
burst, causing personal injury or damage.
31024Manual Revised 11-0629 Page9

• Do not use the power unit outdoors or expose it to wet or damp conditions.
Water entering the power unit will increase the risk of electric shock.
• Use of an attachment not recommended or sold by the manufacturer
may result in a risk of fire, electric shock or injury. Following this rule will
reduce the risk of electric shock, fire or serious personal injury.
• Do not abuse the cord or power unit. Never use the cord to carry the
power unit. Do not pull the cord rather than the plug to disconnect the plug
from the receptacle. Damage to the cord or power unit could occur and
create an electric shock hazard. Replace damaged cords immediately.
•Make sure that the cord is located so that it will not be stepped on,
tripped over, come in contact with sharp edges or moving parts or
otherwise be subjected to damage or stress. This will reduce the risk of
accidental falls, which could cause injury and damage to the cord, and could
result in electric shock.
Keep the cord and power unit from heat to prevent damage to housing
or internal parts.
Do not let gasoline, oils, petroleum-based products, etc. come in
contact with plastic parts. They contain chemicals that can damage,
weaken or destroy plastic.
An extension cord should not be used unless absolutely necessary.
Use of improper extension cord could result in a risk of fire and electric
shock. If an extension cord must be used, make sure that:
1. Pins on the plug of the extension cord are the same number, size and
shape as those on the plug on the power unit.
2. The extension cord is properly wired and in good electrical condition;
3. The wire size is large enough for AC ampere rating of charger as specified
below:
Cord Length (Feet) 25' 50' 100'
Cord Size(AWG) 16 16 16
NOTICE: AWG = American Wire Gauge
• Do not operate the power unit with a damaged cord or plug, which could
cause shorting and electric shock. If damaged, have the cord and plug
repaired or replaced by a qualified service technician.
• Do not operate the power unit if it has received a sharp blow, been
dropped or otherwise damaged in any way. Take it to a qualified service
technician for an electrical check to determine if the power unit is in good
working order.
• Do not disassemble the power unit. Replace if damaged or malfunctioning.
• Disconnect the power unit from the electrical outlet when it is not in
use. This will help prevent damage to the power unit during a power surge.
31024Manual Revised 11-0629 Page 10

•Risk of electric shock. Do not touch the uninsulated portion of the output
connector or the uninsulated battery terminal.
IMPORTANT SAFETY INSTRUCTIONS
• Save these instructions.
• Before using the power unit, read all instructions and cautionary markings
on the battery, power unit, and product using battery.
_1, CAUTION: To reduce the risk of injury, charge only this tool. Other types of
batteries may burst, causing personal injury or damage.
_, WARNING: When using electric appliances, basic precautions should
always be followed, including the following.
a) To reduce the risk of injury, close supervision is necessary when an appliance
is used near children.
b) Only use attachments recommended for this product.
c) Do not use outdoors.
d) To reduce the risk of electrical shock, do not put the Circular Saw and Battery
Pack in water or other liquid. Do not place or store the appliance where it can
fall or be pulled into a tub or sink.
A_, WARNING: Contains nickel-cadmium battery. Battery must be recycled or
disposed of properly.
_, WARNING: Do not dispose of this product in fire, batteries in this product
may explode or leak.
31024Manual Revised 11-0629 Page 11

ID]=_.'_o_[[o_]
KNOW YOUR CIRCULAR SAW (Fig. 1)
Trigger Switch Main Handle
Front Handle
Upper Blade Guard
Bevel Scale Blade Guard Lever
Edge Guide
Locking Knob _Blade screw
45°Blade Guide _lade
0°Blade (_ \Lower Blade Guard
Depth Scale Lock-Off button
,_ , _ Spindle-Lock Button
_, __,, _ Bevel Adjustment
nob
Depth-of-cut Quick ;P
_Base Plate
Adjustment Clamp
Lever
Saw blade
PRODUCT SPECIFICATIONS
Motor 18.0 Volt DC
No load speed 4500 RPM
Blade diameter 5-1/2 inches
Blade arbor 3/8 inch (10 mm)
Cutting depth at 90 ° 1-1/2 inches (38 mm)
Cutting depth at 45 ° 1-1/16 inches (27 mm)
Bevel angle Adjustable 00-50 °
Charging time 5 -7 hours
Saw weight (without battery) 4.83 Ibs.
31024Manual Revised 11-0629 Page 12

Battery type Ni-Cd
Battery voltage 18.0 Volt DC
Model No.: HYCH0092400250U
Power unit Input: 120V AC 60Hz
Output: 24V DC 250mA
_, WARNING: The safe use of this product requires an understanding of the
information on the tool and in this operator's manual as well as knowledge of the
project you are attempting. Before use of this product, familiarize yourself with all
operating features and safety rules.
PLASTIC UPPER AND LOWER BLADE GUARD WITH ANTI-SNAG FEATURE
Lightweight blade guards provide protection from the blade. The self-retracting
lower blade guard features an anti-snag design for more efficient cutting.
ELECTRIC BRAKE
The saw has an electric brake to quickly stop the blade rotation.
0° TO 50 ° BEVEL ADJUSTMENT
The bevel adjustment knob allows you to set the circular saw for bevel cuts from
0° to 50 °.
INTEGRATED RIP AND CROSSCUT RULERS
The base has integrated rip and crosscut rulers for quick reference when making
repetitive cuts.
ERGONOMIC DESIGN
The design of the saw allows proper two-handed control when cutting. It has
been designed to be comfortable and easy to grasp.
SPINDLE-LOCK BUTTON
The spindle-lock button allows you to secure the blade when turning the blade screw.
LOCK-OFF BUTTON
The lock-off button reduces the possibility of accidental starting. The button can
be used on either the left or right of the trigger switch.
DEPTH ADJUSTMENT LEVER
The depth adjustment lever adjusts the cutting capacity from 0 to 1-1/2 inches at
90 ° and 0 to 1-1/16 inches at 45°.
31024Manual Revised 11-0629 Page 13

_, WARNING: If any parts are broken or missing, do not attach battery pack
to the saw or operate the circular saw until the broken or missing parts are
replaced. Failure to do so could result in serious injury.
_, WARNING: Do not attempt to modify this circular saw or create accessories
not recommended for use with this circular saw. Any such alteration or
modification is misuse and could result in a hazardous condition leading to
possible serious injury.
_, WARNING: To prevent accidental starting that could cause serious personal
injury, always remove the battery pack from the saw when assembling parts.
UNPACKING
When unpacking the box, do not discard any packing materials until all of the
contents are accounted for:
1. Carefully lift the circular saw (with blade installed) out of carton and place it
on a stable, flat surface.
2. Open the carton to locate the following:
• Hexwrench
• Manual
3. Inspect the items carefully to make sure that no breakage or damage has
occurred during shipping. If any of the items is missing or damaged, return
the tool to the store where purchased for replacement.
31024Manual Revised 11-0629 Page 14

HOW TO CHARGE THE BATTERY PACK (Fig. 2)
Detach the battery pack from the
circular saw.
Insert the power unit jack into the
charging socket, making sure that
it is properly connected.
Power unit can be used with
normal house voltage of 120
volts, 60 Hz, AC only.
Connect the power unit plug to
an electrical outlet. The indicator
light on the battery pack shines
red when the power unit is
plugged into a power source.
Charge the battery for at least 7
hours before the first use.
Fig. 2
Charging socket
Power unit
For best results, do not recharge the battery for less than 5 hours or more than 7
hours after each use.
Do not place the power unit in an area of extreme heat or cold. It works best at
normal room temperature.
The base of the battery or power unit may become warm during charging.
This is normal.
TO ATTACH BATTERY PACK (Fig. 3)
1. Make sure that the circular
saw is turned off. Fig. 3
2. Align the raised platform on
the battery pack with the
grooves on the bottom of the
saw main handle, and then
slide the pack into the handle.
See Fig. 3.
NOTICE: When inserting the
battery pack into the tool, make
sure that the raised platform on
the pack aligns with the grooves
on the bottom of the tool main Attach
handle, and that the latches snap
properly into place. Improper
assembly of the battery pack can cause damage to internal components.
Battery pack
release button
31024Manual Revised 11-0629 Page 15

TO DETACH BATTERY PACK (Fig. 3)
1. Make sure that the circular saw is turned off.
2. Depress the battery release buttons located on the front of the battery pack
to release the battery pack.
3. Pull forward on the battery pack to remove it from the tool.
A_, WARNING: Battery tools are always in operating condition. Therefore, the
circular saw should always be turned off when not in use or when carrying the
tool at your side.
BLADE GUARD SYSTEM (Fig. 4)
The lower blade guard attached
to your circular saw is there for
your protection and safety. It
should never be altered for any
reason. If it becomes damaged
or begins to return slowly or
sluggishly, do not operate the
saw until the lower blade guard
has been repaired or replaced.
Always leave the lower blade
guard in its correct operating
position when using the saw.
_, DANGER: When sawing
through a workpiece, the lower
blade guard does not cover
Fig. 4 Lower blade guard is in up
position when making a cut
m --1
Blade exposed o'[-nunderside of workpiece
the blade on the underside of the workpiece. Since the blade is exposed on
the underside of the workpiece, keep hands and fingers away from the cutting
area. Any part of your body coming in contact with a moving blade will result in
serious injury.
_, WARNING: Never use the saw when the guard is not operating properly.
The guard should be checked for correct operation before each use. If you drop
your saw, check the lower blade guard and bumper for damage at all depth
settings before using.
A_, WARNING When using the saw, always stay alert and exercise control. Do
not remove the saw from the workpiece while the blade is moving.
SAW BLADES
Even the best of saw blades will not cut efficiently unless it is kept clean, sharp
and properly set.
Using a dull blade places a heaw load on the saw and increases the danger of
kickback. Keep extra blades on hand, so sharp blades are always available.
Gum and wood pitch hardened on the blade slows the saw down. Use gum and
pitch remover, hot water or kerosene to remove them. DO NOT USE GASOLINE.
31024Manual Revised 11-0629 Page 16

_, WARNING: A 5-1/2 inch blade is the maximum blade capacity of your saw.
A blade larger than 5-1/2 inches will come in contact with the blade guards.
Never use a blade that is so thick that it prevents the outer blade washer from
engaging with the flat side of the spindle. Blades that are too large or too thick
can result in an accident causing serious injury.
KICKBACK (Fig. 5)
Fig. 5
_,- Direction of cut <_
Blade is set tool deep Correct blade depth
_Kickback _._
Kickback occurs when the blade stalls rapidly and the saw is driven back towards
you. Blade stalling is caused by any action which pinches the blade in the wood.
Loss of control can lead to serious injury.
To guard against kickback, avoid unsafe practices such as the following:
• Setting blade depth incorrectly.
• Sawing into knots or nails in the workpiece.
• Twisting the blade while
making a cut. Fig. 6
• Making a cut with a dull,
gummed up or improperly
set blade.
• Supporting the workpiece
incorrectly (Fig. 6).
• Forcing a cut. f3
• Cutting warped or wet lumber.
• Operating the tool incorrectly
or misusing the tool.
• Attempting to cut with blade
at less than full speed. Incorrect support
_, WARNING: If the blade
comes in contact with the workpiece before it reaches full speed, it could cause
the saw to "kickback" towards you, which could result in serious injury.
31024Manual Revised 11-0629 Page 17

To lessen the chance of kickback:
1. Keep the blade at the correct
depth setting. The depth
setting should not exceed 1/4
inch below the material being
cut (Fig. 7).
2. Inspect the workpiece for
knots or nails before cutting.
Never saw into a knot or nail.
4. Make straight cuts. Always
use a straight edge guide
(sold separately) when rip
cutting. This helps prevent
twisting of the blade.
5. Use clean, sharp and
properly set blades. Never
make cuts with dull blades.
6. Support the workpiece
properly before beginning a
cut (Fig. 8).
7. Use steady, even pressure
when making a cut. Never
force a cut.
8. Do not cut warped or
wet lumber.
9.
Fig. 7
Correct blade depth setting is 1/4-in.
maximum or less on underside
of workpiece
....................................- ........................-- t
t-1/4-in.
Maximum
Fig. 8
Hold the saw firmly with both
hands and keep your body in
a balanced position so as to Correct support
resist the forces if kickback
should occur.
_, WARNING: To avoid kickback, release the trigger switch immediately if
blade binds or saw stalls. Kickback could cause you to lose control of the saw.
Loss of control can lead to serious injury.
31024Manual Revised 11-0629 Page 18

LOCK-OFF BUTTON (Fig. 9}
The lock-off button reduces the
possibility of accidental starting.
The lock-off button is located
on the handle above the trigger
switch. The lock-off button
must be depressed before you
squeeze the trigger switch to
start the saw.
NOTICE: The lock-off button can
be operated from either the left
or right side.
Fig. 9
Lock-off button
\
Trigger switch
STARTING/STOPPING THE
SAW (Fig. 9)
To start the saw:
1. Depress the lock-off button.
2. Depress the trigger switch. Always let the blade reach full speed, and then
guide the saw into the workpiece.
To stop the saw:
1. Release the trigger switch.
After you release the trigger switch, allow the blade to come to a complete stop.
Do not remove the saw from the workpiece while the blade is moving.
ELECTRIC BRAKE
The saw has an electric brake to quickly stop the blade rotation. The electric
brake engages when the trigger switch is released. When the brake is
functioning properly, sparks may be visible through the vent slots in the motor
housing. This is normal and is the action of the brake.
_, WARNING: If the electric brake repeatedly fails to quickly stop the blade
rotation, the saw should be repaired by a qualified technician.
WARNING: Always remove the battery pack from the tool when assembling
parts, changing the blade and making adjustments. Failure to obey this warning
could cause serious personal injury.
DEPTH-OF-CUT ADJUSTMENTS
Always use the correct blade-depth setting. The correct blade-depth setting for
all cuts should not be more than 1/4 inch below the material being cut. Greater
blade depth will increase the chance of kickback and cause the cut to be rough.
Your saw is equipped with a depth-of-cut scale that enables you to accurately
set the depth-of-cut.
31024Manual Revised 11-0629 Page 19

TO ADJUST BLADE DEPTH
(Fig. 10)
1. Remove the battery pack
from the saw.
2. Loosen the depth-of-cut quick
adjustment clamp lever.
3. Hold the base flat against
the workpiece and raise
or lower the saw until the
indicator aligns with the
desired depth on the scale.
4. Tighten the depth-of-cut
quick adjustment clamp
lever securely.
Fig. 10
Depth scale
Depth-of-cut quick
adjustment clamp lever
USING EDGE GUIDE (sold
separately) (Fig. 11)
Always use a guide when making
long or wide rip cuts with your
saw. You can use either a
straight edge or use an edge
guide (sold separately).
NOTICE: The edge guide can be
used on the left or right side of
the blade (Fig. 11).
_lk WARNING: Always remove
the battery pack from the
saw when assembling parts,
changing blades and making
Fig. 11
Edge
i,
guide locking knob U I
Edge guide
adjustments. Failure to obey this warning could cause serious personal injury.
1. Remove the battery pack from the saw.
2. Position the edge guide (sold separately) so that the arm with the ruler side
is facing up. Slide the arm of the edge guide through the mounting slots at
the front of the saw base.
3. Adjust the edge guide to the desired width of cut.
4. Tighten the edge guide locking knob.
5. When using an edge guide, position the face of the edge guide firmly
against the edge of the workpiece. This will help make a true cut without
binding the blade. The edge of the workpiece must be straight for the cut to
be straight. Use caution to prevent the blade from binding in the cut.
_, WARNING: Do not bind the blade in the cut. It could cause the saw to
"kickback" towards you, which could result in serious injury.
31024Manual Revised 11-0629 Page20