Performax 240-3756 User manual

1
15A CHOP SAW
240-3756
Owner’s Manual
PRODUCT SPECIFICATIONS
Rating:
120 V, 60 Hz, AC
Amperes:
15 AMP
Speed:
3,800 RPM (no load)
Blade diameter:
14" (355 mm)
Blade thickness:
1/8" (3 mm)
Arbor:
1" (25.4 mm)
Maximum
workpiece size:
Vice miter gauge to front
Vice miter gauge to rear
5⅝x3⅝” deep (143x92
mm) Rectangular section
9”x3” deep (229x76 mm)
Rectangular section
4¾” (121 mm) Round pipe
4½” (114 mm) Round pipe
Weight:
34 lb (15.5 kg)
Need Assistance?
Call us on our toll free customer support line:
1-866-349-8665
Technical questions
Replacement parts
Parts missing from package

2
Product specifications ………….………………………………………………………………...
1
Table of contents ……………………………………………………………………...………….
2
General safety warnings ……………………………………………………………..……….....
3–4
Eye, ear & lung protection ……………………………………………………………………....
3–4
Electrical safety ……………………………………………………………………….……….....
4
Power tool safety ……………………………………………………………………...………....
5–6
General safety rules …………………………………………………………………..………....
5
Work area ………………………………………………………………….…………..……….....
5
Electrical safety ……………………………………………………………………….……….....
5
Personal safety ………………………………………………………………………..……….....
5–6
Power tool use and care .………………………………………………………..………...........
6
Service ………………………………………………………………………………………….....
6
Specific safety rules …………………………………………………………………..……….....
7
Extension cord safety ………………………………………………………….……..……….....
8
Symbols ………………………………………………………………………………..……….....
9
Know your chop saw ………………………………………………………………….………....
10
Assembly and operating ……………………………………………………………..……….....
11–17
Carrying the chop saw …………………………………………………………………………...
11
Selecting the work surface ………………………………………………………………………
11
Setting the depth stop ………………………………………………………………..……….....
11–12
Checking the automatic guard ……………………………………………………………….....
12
Checking the arbor cap screw ……………………………………………………..……….......
12–13
Setting the miter vice angle ………………………………………………………….……….....
13
Cutting 5” to 7” wide workpieces ………………………………………………………………..
13
Cutting 7”to 9”wide workpieces ………………………………………………………………..
14
Operating the vice quick release …………………………………………………………….....
14
LED worklight switch ……………………………………………………………………………..
14
ON/OFF switch ………………………………………………………………………..……….....
15
Replacing the cut off blade…………………………………………………………………........
15–16
Cutting metal …………………………………………………………………………..……….....
16–17
Maintenance …………………………………………………………………………..……….....
17–18
Exploded view ………………………………………………………………………...……….....
19
Parts listing …………………………………………………………………………….……….....
20–21
Warranty ……………………………………………………………………….……………….....
22
TABLE OF CONTENTS

3
EYE, EAR & LUNG PROTECTION
SAVE THESE INSTRUCTIONS FOR REFERENCE
This instruction manual includes the following:
General Safety Rules
Specific Safety Rules and Symbols
Functional Description
Assembly
Operation
Maintenance
Accessories
WARNING: Use hearing protection, particularly during extended
periods of operation of the tool, or if the operation is noisy.
!
SAVE THESE INSTRUCTIONS FOR REFERENCE
GENERAL SAFETY WARNINGS
WARNING: Before using this tool or any of its accessories, read this
manual and follow all Safety Rules and Operating Instructions. The important
precautions, safeguards and instructions appearing in this manual are not
meant to cover all possible situations. It must be understood that common
sense and caution are factors which cannot be built into the product.
!
!
ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA
REQUIREMENTS or ANSI SAFETY STANDARD Z87.1
FLYING DEBRIS can cause permanent eye damage. Prescription
eyeglasses ARE NOT a replacement for proper eye protection.
WARNING: Non-compliant eyewear can cause serious injury if
broken during the operation of a power tool.

4
EYE, EAR & LUNG PROTECTION –cont’d
ELECTRICAL SAFETY
WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN
OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.
WARNING: Dust that is created by power sanding, sawing, grinding,
drilling, and other construction activities may contain chemicals that are
known to cause cancer, birth defects, or other genetic abnormalities. These
chemicals include:
Lead from lead-based paints
Crystalline silica from bricks, cement, and other masonry products
Arsenic and chromium from chemically treated lumber
The level of risk from exposure to these chemicals varies, according to how
often this type of work is performed. In order to reduce exposure to these
chemicals, work in a well-ventilated area, and use approved safety
equipment, such as a dust mask that is specifically designed to filter out
microscopic particles.
!
SAVE THESE INSTRUCTIONS FOR REFERENCE
WARNING: To avoid electrical hazards, fire hazards or damage to
the tool, use proper circuit protection.
This tool is wired at the factory for 120 V AC operation. It must be
connected to a 120 V AC, 15 A circuit that is protected by a 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.
GENERAL SAFETY WARNINGS

5
WARNING: Read all safety warnings and
all instructions. Failure to follow the warnings
and instructions may result in electric shock, fire
and/or serious injury.
Save all warnings and instructions for future
reference.
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
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 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 earthed
(grounded) power tools. Unmodified plugs and
matching outlets will reduce risk of electric
shock.
Avoid body contact with earthed or
grounded surfaces such as pipes, radiators,
ranges and refrigerators. There is an
increased risk of electric shock if your body is
earthed or 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. See chart on Page 8.
If operating a power tool in a damp location
is unavoidable, use a ground fault circuit
interrupter (GFCI) protected supply. Use of a
ground fault circuit interrupter (GFCI) 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 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 dust mask, non-skid safety shoes, hard
hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
Prevent unintentional starting. Ensure the
switch is in the off-position before
connecting to power source and/or battery
pack, picking up or carrying the tool.
Carrying power tools with your finger on the
switch or energizing 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.
POWER TOOL SAFETY
SAVE THESE INSTRUCTIONS FOR REFERENCE
!

6
PERSONAL SAFETY –cont’d
Dress properly. Do not wear loose clothing
or jewellery. Keep your hair, clothing and
gloves away from moving parts. Loose
clothes, jewellery 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 dust collection 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 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 pack 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’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,
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.
Hold power tools by insulated gripping
surfaces when performing an operation
where cutting tool may contact hidden
wiring or its own cord. Contact with a "live"
wire will make exposed metal parts of the tool
"live" and shock the operator
Service
Have your power tool serviced by a qualified
repair person using only identical
replacement parts. This will ensure that the
safety of the power tool is maintained.
POWER TOOL SAFETY
SAVE THESE INSTRUCTIONS FOR REFERENCE

7
WARNING: Know your chop saw. Do
not plug the chop saw into the power source
until you have read and understand this
Instruction Manual. Learn the tool’s
applications and limitations, as well as the
specific potential hazards related to this tool.
Following this rule will reduce the risk of electric
shock, fire, or serious injury.
Always wear eye protection. Any
power tool can throw foreign
objects into your eyes and cause
permanent eye damage.
ALWAYS wear safety goggles (not glasses) that
comply with ANSI safety standard Z87.1.
Everyday glasses have only impact resistant
lenses. They ARE NOT safety glasses.
WARNING: Glasses or goggles not in
compliance with ANSI Z87.1 could cause
serious injury when they break.
DANGER: Always unplug the tool from
the power source before changing the
cutting blade or when cleaning the tool.
DANGER: Never place your hands or
fingers near the cutting blade while the tool
is running. Severe injury will result.
DANGER: Never install a saw blade on
this tool. It is designed ONLY for use with
abrasive cut off blades.
Use this chop saw for cutting steel only. Cutting
ceramic materials will create excessive dust and
cause damage to the motor.
Never turn the chop saw ON with the cut off
blade touching the work surface.
Use only cut off blades in compliance with ANSI
Standard B7.1 and rated for a speed greater
than 3600 RPM.
Do not use the chop saw if the blade flanges or
cap screw are missing or improperly installed.
Dust and abrasive materials should not be
allowed to build up in the workshop. Hot metal
sparks could start a fire.
Do not remove the soft paper in the centre of
the cut off blade.
Do not alter or enlarge the centre hole of the cut
off blade as this could result in the blade
shattering.
Always use a dust mask along with safety
goggles when operating the chop saw.
Always use hearing protection when operating
of the chop saw.
Do not wear gloves, neckties or loose clothing.
Do not cut material too small to be securely held
in the vice.
Always keep your hands out of the path of the
cut off blade. Avoid awkward hand positions
where a sudden slip could cause your hand to
move into the path of the cut off blade.
Secure the workpiece. Use the clamping system
provided with the chop saw. It is safer than
using your hand.
Make sure there are no foreign objects in the
part of the workpiece to be cut.
The cut off blade must be securely attached as
described in this Owner’s Manual before
connecting the tool to the power source. Failure
to do so will increase the risk of serious injury if
the cut off blade shatters or comes loose.
Make sure the guard is installed and in proper
working order before operating the chop saw.
Cut off blades must be stored in a dry location to
prevent deterioration.
Before attaching the cut off blade, inspect it for
visible defects. If cracked, chipped or warped,
do not install it.
Do not over tighten the clamp nut on the cut off
blade. Excessive tightening may cause the
blade to crack and possibly shatter during
operation.
SPECIFIC SAFETY RULES
!
!
SAVE THESE INSTRUCTIONS FOR REFERENCE
!
!
!

8
WARNING: Keep the extension cord
clear of the working area. Position the cord so
it will not get caught on the workpiece, tools or
any other obstructions while you are working
with the power tool.
Make sure any extension cord used with this
tool is in good condition. When using an
extension cord, be sure to use one of heavy
enough gauge to carry the current the tool will
draw. An undersized cord will cause a drop in
line voltage resulting in loss of power and
overheating.
The table at right shows the correct size to use
according to cord length and nameplate ampere
rating. If in doubt, use the next heavier gauge.
The smaller the gauge number the heavier the
cord.
Be sure your extension cord is properly wired
and in good condition. Always replace a
damaged extension cord or have it repaired by a
qualified electrician before using it. Protect your
extension cord from sharp objects, excessive
heat and damp or wet areas.
Use a separate electrical circuit for your power
tools. This circuit must not be less than 14
gauge wire and should be protected with either
a 15 A time delayed fuse or circuit breaker.
Before connecting the power tool to the power
source, make sure the switch is in the OFF
position and the power source is the same as
indicated on the nameplate. Running at lower
voltage will damage the motor.
MINIMUM GAUGE (AWG)
EXTENSION CORDS (120 V use only)
Amperage
rating
Total length
More
than
Not
more
than
25'
(7.5 m)
50'
(15 m)
100'
(30 m)
150'
(45 m)
0
6
18
16
16
14
6
10
18
16
14
12
10
12
16
16
14
12
12
16
14
12
Not Applicable
EXTENSION CORD SAFETY
!

9
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Litres
kg
Kilograms
H
Hours
N/cm2
Newtons per square
centimetre
Pa
Pascals
OPM
Oscillations per minute
Min
Minutes
S
Seconds
or a.c.
Alternating current
Three-phase alternating
current
Three-phase alternating
current with neutral
Read all safety warnings
and instructions
Direct current
No load speed
Alternating or direct
current
Class II construction
Splash-proof
construction
Watertight construction
Protective grounding at
grounding terminal,
Class I tools
Revolutions or
reciprocations per
minute
Diameter
Off position
Directional arrow
Warning symbol
Wear your safety
glasses
Wear hearing protection
SYMBOLS
WARNING: Some of the following symbols may appear on the chop saw. Study
these symbols and learn their meaning. Proper interpretation of these symbols will
allow for more efficient and safer operation of this tool.
!
This symbol designates that this tool is
listed with U.S. requirements by
Underwriters Laboratories.
Conforms to UL Std. 987-8-S.
61TN
E213739
JD1902U

10
KNOW YOUR CHOP SAW
Automatic guard
Vice adjustment
handle
Cut off blade
Vice miter
gauge
Vice quick
release
nut
Trigger switch
Arbor lock
Base
Swing arm
Main handle
Depth stop
screw
Safety
chain
Carrying
handle
LED worklight
Motor
end cap
17 mm Wrench

11
CARRYING THE CHOP SAW
When carrying the chop saw from one location
to another, always lower the swing arm (1) to its
lowest position and loop the lowest safety chain
link (2) over the pin (3) (Fig. 1). This will hold the
blade and swing arm in the “down” position for
easier lifting of the chop saw. Once the safety
chain has been placed over the pin, carefully lift
the chop saw using the carrying handle.
WARNING: The chop saw is very heavy.
For safety in carrying the chop saw, always lift it
using one hand on the carrying handle and the
other under the base.
WARNING: Always disconnect your
chop saw from the power source when
carrying it to another location, replacing the
cut off blade, clamping material in the vice,
adjusting the guard, cleaning or when not in
use. Disconnecting the chop saw will
prevent accidental starting that could cause
serious personal injury.
SELECTING THE WORK SURFACE
It is important to place the chop saw on a solid
flat work surface that will not shift during
operation of the chop saw. Locating the chop
saw near an electrical outlet will eliminate the
need for an extension cord.
WARNING: Never place the chop saw
near any flammable liquids or items that can
be damaged by the sparks thrown by the
chop saw during cutting. The hot sparks can
ignite flammable liquids.
Hot metal sparks and sharp metal pieces will
damage the work surface to some degree. Make
sure you consider this fact when selecting the
work surface. A non-flammable surface such as
a metal bench will be less likely to be damaged
during the cutting operation.
SETTING THE DEPTH STOP
The maximum cut depth is controlled by
adjusting the depth stop.
1. Lift the swing arm (1) upward as far as it
will go (Fig. 2).
2. Loosen the depth stop lock nut (2) by
turning it counter clockwise using a
14 mm wrench.
3. Turn the depth stop screw (3) to raise or
lower it. Adjust until the cut off blade enters
the base slot no more than 3/16" (5 mm)
when the swing arm is fully lowered and
contacts the top of the depth stop screw.
4. When the depth stop screw is correctly set,
lock it in place by tightening the lock nut
clockwise.
!
ASSEMBLY AND OPERATING
!
!
Fig. 1

12
SETTING THE DEPTH STOP –cont’d
CHECKING THE AUTOMATIC GUARD
The automatic guard must be checked to ensure
it is working properly.
WARNING: Always disconnect your
chop saw from the power source before
checking the automatic guard.
1. Lift the guard (1) upward approximately 3"
and then release it (Fig. 3). If the guard is
functioning correctly, it will freely drop
down to its original position.
2. Lower the swing arm and cutting blade
assembly until the lower edge of the guard
(2) touches the chop saw base. Continue
to lower the swing arm and cutting blade
assembly. The automatic guard should
freely rise as the cutting blade is lowered.
NOTE: The guard should always rise and
fall freely when the swing arm is lowered
and raised as outlined in #1 & #2 above. If
not, clean any cuttings out from around the
guard mechanism (3) (Fig. 4).
CHECKING THE ARBOR CAP SCREW
It is important to check the arbor cap screw to
make sure the cut off blade is fully tightened.
WARNING: Disconnect your chop saw
from the power source before checking the
arbor cap screw.
1. Lift swing arm fully upward as far as it will
go.
2. Lift the blade guard (1) fully upward until it
will stay in the upright position (Fig. 5).
3. Press and hold the arbor lock (2) to the
right while rotating the cut off blade by
hand.
4. When the arbor lock engages the arbor,
tighten the arbor cap screw (3) by turning it
clockwise using the 17 mm wrench
supplied.
NOTE: Do NOT over tighten the arbor cap
screw as you could crack the hub of the
cutting blade.
Fig. 2
ASSEMBLY AND OPERATING
!
Fig. 3
Fig. 4
!

13
CHECKING THE ARBOR CAP SCREW –
cont’d
5. When the arbor cap screw is fully
tightened, remove the wrench, release the
arbor lock and lower the blade guard.
SETTING THE MITER VICE ANGLE
The miter vice can be set for cutting at angles
from 90° to 45° either left or right.
1. Open the vice by turning the vice
adjustment handle (1) 5 or 6 turns counter
clockwise (Fig. 6).
2. Loosen the miter gauge cap screws (2) by
turning them counter clockwise using the
17 mm wrench supplied (Fig. 7).
3. Rotate the miter gauge to the left or right
until the desired cutting angle (3) lines up
with the alignment mark (4).
4. Tighten both miter gauge cap screws to
lock the miter gauge in place.
NOTE: Always make a test cut on a scrap
workpiece to verify the miter angle setting.
CUTTING 5” to 7” WIDE WORKPIECES
The vice is set up at the factory for cutting
workpieces up to 5” in width. This is the
preferred set-up. If it is necessary to cut
workpieces between 5”and 7”in width, the miter
gauge will have to be relocated on the chop saw
base.
1. Remove the front and rear miter gauge cap
screws (1) using the 17 mm wrench
supplied (Fig. 8).
2. Move the miter gauge (2) back
approximately 1½” until the hole and slot in
the miter gauge line up with the next two
holes (3) in the chop saw base.
3. Reinstall and tighten the miter gauge cap
screws in the two new holes.
ASSEMBLY AND OPERATING
Fig. 5
Fig. 6
Fig. 7

14
CUTTING 7” to 9” WIDE WORKPIECES
NOTE: To cut workpieces between 7”and 9”in
width, locate the miter gauge in the back two
holes (4) in the chop saw base.
OPERATING THE VICE QUICK RELEASE
The vice has a quick release feature that allows
for making major adjustments much quicker.
1. To operate the quick release system, turn
the vice adjustment handle (1) counter
clockwise 2 or 3 turns to loosen the vice
jaws (Fig 9).
2. Lift upward on the front of the quick release
nut (2) to release the vice screw (3).
3. While holding the quick release nut upward
in the released position, pull the vice
adjustment handle toward you to quickly
open the vice.
4. To quickly close the vice, release the quick
release nut and push the crank away from
you.
5. Use the crank to completely tighten the
vice on the workpiece.
WARNING: Always make sure the
workpiece is flat against the chop saw base
and securely held in the vice before turning
the saw ON.
LED WORKLIGHT SWITCH
This chop saw is equipped with an LED
worklight. To turn the LED worklight ON, press
the LED worklight switch (1) located in the main
handle (2) once (Fig. 10). To turn the LED
worklight OFF, press the LED Worklight switch a
second time.
ASSEMBLY AND OPERATING
!
Fig. 9
Fig. 10
Fig. 8

15
ON/OFF SWITCH
To turn the switch ON, squeeze the switch
trigger (1) until the chop saw starts Fig. 11). To
turn the chop saw OFF, release the switch
trigger.
WARNING: Always make sure the cut
off blade is NOT touching the workpiece
when the switch is being turned ON. Let the
motor come to full speed before beginning
to cut.
REPLACING THE CUT OFF BLADE
The cut off blade must be replaced when it has
become damaged in any way or it has worn
down to a diameter of less than 10”.
WARNING: Disconnect your chop saw
from the power source before attempting to
change the cut off blade.
1. Lift the swing arm fully upward.
2. Lift the guard (1) fully upward until it
exposes the arbor cap screw (2)
(Fig. 12).
3. Press and hold the arbor lock (3) to the
right while rotating the cut off blade by
hand.
4. When the arbor lock engages the arbor,
loosen the arbor cap screw by turning it
counter clockwise using the 17 mm wrench
supplied.
5. Remove the arbor cap screw, the small
outer washer (4), the large outer washer
(5), the cut off blade (6) and large inner
washer (7) from the arbor (8) (Fig. 13).
6. Use a clean dry brush or cloth to carefully
remove all cuttings from the arbor and the
motor housing.
7. Reinstall the washers, new cut off blade
and arbor cap screw in the same order in
which they were removed.
ASSEMBLY AND OPERATING
!
!
Fig. 11
Fig. 12
Fig. 13

16
REPLACING THE CUT OFF BLADE –cont`d
NOTES:
a) Make sure the LARGE outer surfaces of the
large and small washers are facing the cut off
disk.
b) Make sure the flats of the washer holes slide
over the matching flats of the arbor.
8. Engage the arbor lock and tighten the
arbor cap screw using the 17 mm wrench
supplied.
9. Carefully rotate the cut off disk by hand to
make sure it is firmly tightened, that it is not
damaged and that it does not wobble.
WARNING: Reset the depth stop as
shown in Fig. 2. The new blade will be larger
and will damage the work surface if the
depth stop is not readjusted.
10. With depth stop properly set and the guard
in the down position, turn the switch ON.
NOTE: If the cut off blade wobbles or vibrates,
turn the switch OFF immediately. Recheck to
make sure the cut off blade is installed correctly
and that the blade is not damaged.
CUTTING METAL
1. Lift the swing arm fully upward as far as it
will go.
2. Adjust the miter gauge as required.
3. Firmly lock the metal workpiece to be cut in
the vice.
4. Make sure you are wearing your safety
goggles, dust mask and hearing protection.
5. Lower the cut off blade until it is about 1”
above the workpiece.
NOTE: The cut off blade MUST NOT be
touching the workpiece when the motor switch is
turned ON.
6. While holding the chop saw handle firmly in
your right hand, turn the motor switch ON.
ASSEMBLY AND OPERATING
!
Have you read "GENERAL SAFETY
WARNINGS”, "POWER TOOL SAFETY",
"SPECIFIC SAFETY RULES",
"EXTENSION CORD SAFETY" and
"SYMBOLS" on pages 3, 4, 5, 6, 7, 8 & 9
of this Instruction Manual? If not, please
do it now before you operate this chop
saw. Your safety depends on it!
Every time you use the chop saw you
should verify the following:
1. Cord is not damaged.
2. Cut off blade is correct for the type
of material being cut.
3. Cut off blade is in good condition
and securely tightened onto the
arbor.
4. Safety glasses, dust mask and
hearing protection are being worn.
5. Guard is in good working order.
6. No flammable liquids are in the
vicinity.
Failure to adhere to these safety rules
can greatly increase the chances of
injury.
WARNING
!

17
CUTTING METAL –cont`d
7. Wait for motor to come up to its full speed.
Carefully lower the cut off blade until it
contacts the workpiece.
NOTE: Many sparks will be generated as soon
as the cut off blade touches the workpiece.
8. Apply only slight pressure to the chop saw
handle as it begins to cut through the
workpiece. DO NOT apply to much
pressure to the handle as this will cause
the motor to slow down. Doing so will slow
the cutting action and damage the motor.
9. When the cut off blade has completely cut
through the workpiece, release the trigger
switch immediately. Wait for the motor to
come to a complete stop before lifting the
cut off blade away from the workpiece.
WARNING: Never touch the workpiece
immediately after a cut is completed. The
metal in the cutting area will be red hot and
will cause severe burns to your skin
REPLACING CARBON MOTOR BRUSHES
The carbon motor brushes will wear down and
require replacing. The time intervals between
replacements will vary depending upon the type
of materials being cut and the hours of use. It is
recommended that the brushes be checked
after each 10 hours of use. When the length of
the carbon brush reaches 1/4" (6.35 mm), the
brushes should be replaced.
WARNING: Unplug the tool from the
power source.
1. Use a #2 screwdriver and remove four
screws (1) from the motor end cap (2)
(Fig. 14).
2. Pull the motor end cap from the motor
housing (3).
3. Use needle nose pliers to pull the spade
connector (4) from the spade (Fig. 15).
4. Use needle nose pliers to pull the brush
retainer spring (5) away from the carbon
brush (6).
5. While holding the brush retainer spring off
the carbon brush, pull the carbon brush out
of the brush bolder (7).
6. To install a new motor brush assembly,
reverse steps 3 through 6.
Replace the second carbon brush located on
the opposite side of the motor housing using the
procedure noted above. When new motor
brushes have been installed, reinstall the motor
end cap.
ASSEMBLY AND
OPERATING
!
MAINTENENCE
!
MAINTENENCE
Fig. 14
Fig. 14

18
GENERAL
WARNING: When servicing, use only
identical replacement parts. The
use of any other part may create a hazard or
cause damage to the product.
DO NOT use solvents when cleaning plastic
parts. Plastics are susceptible to damage from
various types of commercial solvents and may
be damaged by their use. Use a clean cloth to
remove dirt, dust, oil, grease etc.
WARNING: Do not allow brake fluids,
gasoline, petroleum-based products,
penetrating oils, etc. to come into contact
with plastic parts. These substances contain
chemicals that can damage, weaken or
destroy plastic.
Keep the air vents cleared of any built up dust to
prevent the motor from overheating. Remove
accumulated dust and debris regularly using a
soft DRY brush.
WARNING: Use safety goggles when
using an air jet to blow dust out of the chop
saw.
DO NOT abuse power tools. Abusive practices
can damage the tool and the workpiece.
WARNING: DO NOT attempt to modify
this chop saw or create accessories. Any
such alteration, modification or unintended
use is misuse and could result in a
hazardous condition leading to possible
serious injury. It will also void the warranty.
LUBRICATION
All of the bearings in this tool are lubricated with
a sufficient amount of high-grade lubricant for
the life of the unit under normal conditions.
Therefore, no further lubrication is required.
!
!
!
!
MAINTENANCE

19
EXPLODED VIEW

20
WARNING: When servicing, use only original equipment replacement parts. The use of any other
parts may create a safety hazard or cause damage to the chop saw.
Any attempt to repair or replace electrical parts on this chop saw may create a safety hazard unless
repairs are performed by a qualified technician. For more information, call the Toll-free Helpline, at
1-866-349-8665.
Always order by PART NUMBER, not by key number.
Key #
Part #
Part Name
Quantity
1
1280040002
Base
1
2
4050010046
Hex screw M8X16
1
3
2030280012
Spark arrestor
1
4
4050010038
Hex screw M16X170
1
5
2030280005
Connecting pipe cover
2
6
2050050034
Gemel torsional spring
1
7
2040320003
Connecting pipe
1
8
4060090011
Hex lock nut M16
1
9
2050050043
Hex screw M10X25
1
10
2030280002
Little flange plate
1
11
2030280001
Big flange plate
2
12
3140160001
Rubber
1
13
1270030037
Movable guard
1
14
2040320001
Screw M5
2
15
4040010036
Flat washer #8
2
16
4060090001
Hex lock nut M5
2
17
4020010024
Screw M5X20
4
18
4040030003
#5 spring washer
12
19
1270030036
Fixed guard
1
20
2040060001
Output shaft
1
21
4010010110
6204-2RS bearing
1
22
3140060031
Rubber cup
1
23
2020240006
Gear housing cover
1
24
4120020009
Woodruff key
1
25
2040320007
Output gear
1
PARTS LIST
!