protech 7208 User manual

INSTRUCTION MANUAL Type [I
Miter Saw
For Your Own Safety, Read Instruction Manual
Before Starting Operations.
Record the Model No, and Serial No. and date
ot purchase in your manuat for future reference.
Model No.
Serial No.
Date of Purchase
y2 o8Z --/_-O

Uontents i'"
GENERAL SAFETY RULES ........................ ..i'_,..iii_"'i'i.2 _i_li Arm and Clamp ............ 13
SPECIALSAFETY o Jn, !!i.OMeBlade...................iiii....14
MOTOR _ ____RSAWOPERATION ........... i"" 15
Body:land Hand Position ..................................... 15
... 6
,7
.,=_8
I,,,...L. ...................... :.........g
Mounting the saw ......... i............................................... 9
Assembling the Lower Blade Guard ........................... 9
Blade Square to Table ............................................... 10
Checking and Adjusting Blade Square ...................... 11
Travel Pivot Adjustment ............................................. 12
Bevel Pivot Adjustment .............................................. 12
Fence Positions ........................................................... 12
Miter/Bevel Cut ..................................... 16
Compound Cut ............................................................ 17
Cutting Bowed Mater al ............................................ 17
Workpiece Support ..................................................... 18
Auxiliary Fence ........................................................... 18
Filler Blocks for Cutting Crown Moldings .................. 19
Vertical Bevel Cutting ................................................. 19
MAINTAINING YOUR MITER SAW ............................. 21
CONTENT PARTS,,_ ..................................................... 22
TROUBLE SHOOTING ................................................. 27
General Safety Rules
1,Know Your Power Tool
Read and understand the owner's manual and
labels affixed to the tool. Learn its application
and limitations as well as the specific potential
hazards peculiar to this tool.
2.Ground all Tools
This tool is DOUBLE INSULATED to give you
added protection. Double insulation does not
take the place of normal safety precautions
when operating this tool. When servicing this
double insulated tool, use only identical parts,
3.Keep Guards in Place
In working order, and in proper adjustment and
alignment.
4.Remove Adjusting Keys and Wrenches
Form a habit of checking to see that keys and
adjusting wrenches are removed from tool
before turning it on.
5,Keep Work Area Clean
Cluttered areas and benches invite accidents.
Floor must not be slippery due to wax or
sawdust.
6.Avoid Dangerous Environment
Don't use power tools in damp or wet locations
or expose them to rain. Keep work area well
lighted. Provide adequate surrounding work
space.
7,Keep Children Away
All visitors should be kept a safe distance from
work area.
8.Make Workshop Child Proof
With padlocks, master switches, or by removing
starter keys.
9.Don't Force Tool
It will do the job better and safer at the rate for
which it was designed.
10.Use Right Tool
Don't force tools or attachment to do a job it
was not designed for.
11,Wear Proper Apparel
Do not wear loose clothing, gloves, neckties or
jewelry (rings, wrist watches) which may get
caught in moving parts. NONSLIP footwear is
recommended, Wear protective hair covering to
contain long hair. Roll long sleeves above the
elbow.
2
12.Use Safety Goggles
Wear safety goggles (must comply with ANStZ
87.1) at all times. Everyday eyeglasses only
have impact resistant lenses, they are NOT
safety glasses, Also, use face or dust mask if
cutting operation is dusty, and ear protectors
(plugs or muffs) during extended periods or
operation.
13,Secure Work
Use clamps or a vise to hold work when
practical. It's safer than using your hands and
frees both hands to operate tool.
14.Don't Overreach
Keep proper footing and balance at all times,
15.Maintain Tools with Care
Keep tools sharp and clean for best and safest
performance. Follow instructions for lubricating
and changing blades, bits, cutters, etc.
16.Disconnect Tools
Before servicing, when changing accessories
such as blades, bits, cutters, etc,
17.Avotd Accidental Starting
Make sure switch is in "OFF" position before
plugging in,
18.Use Recommended Accessories
Consult the owner's manual for recommended
accessories. Follow the instructions that accom-
pany the accessories. The use of improper
accessories may cause hazards.
19.Never Stand on Tool
Serious injury could occur if the tool is tipped or
if the cutting tool is accidentally contacted.
Do not store materials above or near the tool
such that it is necessary to stand on the tool to
reach them,
2O.Check Damaged Parts
Before further use of the tool, aguard or other
part that is damaged should be carefully
checked to ensure that it will operate properly
and perform its intended function, Check for
alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any
other conditions that may affect its operation. A
guar_ or other part that is damaged should be
properly repaired or replaced.
21,Never Leave Tool Running Unattended
Turn power off, Don't leave tool until it comes to
a complete stop.

Special
BEFORE USING THE SAW:
1. Assembly and alignment.
2. Learn the function and proper use of:
A. The on-off switch.
B. The upper and lower blade guards.
C, The arbor lock and handle latch.
D. The bevel clamp, fence clamps, and miter
lock handle.
3. Read and understand all safety instructions and'
operating procedures throughout the manual.
4. Read the warning label on the miter saw,
WHEN INSTALLING OR MOVING
THE SAW:
1, To avoid injury from unexpected saw movement'.
A. Place the saw on a firm level surface where
there is plenty of room for handling and
properly supporting the workplace.
B. Support the saw so the table is level and the
saw does not rock.
C. Bolt or clamp the saw to its support,
2, Before moving the saw, lock the miter, bevel
and power-head positions. Unplug electric cord.
3, To avoid back injury, get help when you need to
lift the saw more than 10 inches. Hold the tool
close to your body. Bend your knees so you can
lift with your legs, not your back. Lilt by using
the hand-hold areas at the bottom of the base.
Never carry the tool by the cord or power head
handle. Damage to insulation could cause an
electric shock. Damage to wire connections
could cause a fire.
BEFORE EACH USE:
1. Inspect your saw. If any part of this miter saw is
missing, or bent, or has failed in any way, or
any electrical parts don't work properly, turn the
saw off and unplug the saw. Replace damaged,
missing, or failed parts before using the saw
again.
2. Plan Your Work to protect your eyes, hands,
face, and ears.
A. Wear safety goggles (not glasses) that
comply with ANStZ87,1(shown on package).
Using any power tool can result in foreign
objects being thrown into the eyes, which
can result in permanent eye damage. Safety
goggles are available at stores. Use of
glasses or use of goggles not in compliance
with ANSiZ87.1 could result in severe injury
from breakage of the eye protection.
WEAR YOUR
B. For dusty operations, wear a face shield
along with safety goggles.
C. To avoid injury from jams, slips or thrown
pieces:
@Choose the right 10-inch diameter blade for
the material and the type of cutting you
ptan to do. Use this miter saw to cut only
wood, wood-like products or soft metals
like aluminum. Other materials may sha-
tter, grab at the blade, or create other
dangers.
eMake sure the direction of rotation arrow
on the blade matches the direction arrow
on the saw. The blade teeth should always
point downward at the front of the saw.
eMake sure the blade is sharp, undamaged
and properly aligned. With the saw un-
plugged, push the power-head all the way
down, Hand spin the blade and check for
clearance. Tilt the power-head to 45 degree
bevel and repeat the check, if the blade hits
anything, make the adjustments shown in
the Maintaining Maximum Cutting Capacity
section,
eMake sure the blade and arbor collars are
clean.
• Make sure the collars' recessed sides are
facing toward the blade.
eMake sure the recessed side of the blade
washer (just under the arbor screw head)
faces the collar.
eUsing 1/2-inch box end wrench, make sure
the arbor cap screw retaining the blade
collars is firmly hand tightened.
eMake sure all clamps and locks are tight
and there is no excessive play in any parts.
• Never cut FREEHAND:
a. Brace your workplace solidly against the
fence and table top so it will not rock or
twist during the cut. Make sure no
debris is caught beneath_the workpiece.
b. Make sure no gaps between the work-
piece, fence and table will let the
workpiece shift after it is cut in two.
co Use jigs, fixtures or a different tool for
unstable workpieces.
3

• Never cut more than one workplace at a time.
• Make sure the cut off piece C_n move
sideways after it's cut off. Otherwise, it could
get wedged against the blade and thrown
violently. .............._ ,_;_
blocks, etc,)for any workpieces large enou-
gh to tip when not held down to the tabte
top.
b. Do not use this saw to cut pieces too small
to let you easily hold the work while you
keep the thumb side of your index (poi-
nter) finger against the outside edge of the
fence.
c. When cutting irregularly shaped work*
pieces, plan your work so it will not slip
and pinch the blade. A piece of motding,
for example, must lie flat or be held by a
fixture or jig that will not let it twist, rock
or slip while being cut.
d. Properly support round material such as
dowel rods, or tubing. They have a
tendency to roll while being cut, causing
the blade to _bite. _ To avoid this, always
use a fixture designed to properly hold
your work piece.
• Make sure there are no nails or foreign
objects in the part of the workpiece to be cut.
• Make sure bystanders are clear of the tool and
workpiece. Keep them clear of the area behind
the saw where debris will be thrown.
• Never turn your miter saw _ON_ before
clearing everything except the workpiece and
related support devices off the table.
D. To avoid risk of hearing damage, wear ear
plugs or muffs during extended periods of
operation.
E, To avoid being suddenly pufled into the blade:
1. Do not wear gloves.
2. Remove all jewelry and loose clothing.
3. Tie back long hair.
4. Rol! long sleeves above the elbow.
G, To avoid an electrical shock, make sure your
fingers do not touch the metal prongs on the
plug when inserting or removing the plug to
or from a live outlet.
H. Never put lubricants on the blade while it's
spinning,
1.To avoid burns or other fire damage, never
use the saw near flammable liquids, vapors or
gases.
J. To avoid injury from unsafe accessories, use
only accessories shown on the recommended
accessories list in this manual.
WHENEVER SAW IS RUNNING:
ii =ii i i =========lllll
I WARNING: Don't allow familiarity (gained trom
Irequent use of your miter saw) to cause a careless
mistake. Always remember that a careless fraction
....#fa second is enough,, t,o cause a severe injury.
1. Before actually cutting with the saw, let it run
for a while. If your saw makes an unfamiliar
noise or if it vibrates excessively, stop immedi-
ately. Turn the saw off. Unplug the saw. Do not
restart until finding and correcting the problem,
2. Never confine the piece being cut off. Never
hold it, clamp it, touch it, or use length stops
against it. It must be free to move sideways. If
confined, it could get wedged against the blade
and thrown violently.
3. Avoid awkward hand positions where a sudden
slip could cause a hand to move into the blade.
4, Let the blade reach ful! speed before cutting.
5. Feed the saw into the workpiece only fast
enough to let the blade cut without bogging
down or binding,
6. Before freeing jammed material, release switch
and unplug the saw. Wait for all moving parts to
stop.
7. After finishing a cut, keep holding the power-
head down, release the switch, and wait for all
moving parts to stop before moving your hands,
f
4

Motor
POWER SUPPLY
Motor Specifications
:The AC motor, u_ed _!n this saw is a universal,
nonreversible type having the following specifica-
tions:
Maximum Developed H.P .............................. 3
Voltage ............................................................ 120
Amperes ...................................................... 15
Hertz (Cycles) ................................................ 60
Phase .................................... :.:_...................... Single
RPM ................................................................... 4500
Rotation of Shaft ....................................... Clock wise
Brake ........................................................... Automatic
-- i JJL
WARNING: To avoid electrical hazards, fire
hazards, or damage to the tool, use proper circuit
protection. Your saw is wired at the factory for 120v
operation, Connect to a 120v, 15-amp, branch
circuit and use a 15-amp time delay fuse or circuit
breaker. To avoid shock or fire, if power cord is
worn or cut, or damaged in any way, have it
:replaced immediately.
I,i ii ii ,,,i, ,11
DOUBLE INSULATED
The miter saw is double insulated to provide a
double thickness of insulation between you and the
tool's electrical system. All exposed metal parts
are isolated from the internal metal motor compo-
i nents with protective insulation,
Your unit has a plug that looks like the one shown
below
This power tool is equipped with a 2-conductor
cord listed by Underwriters Laboratories (UL). The
plug permits you to use any conventional 120-volt
electrical outlet without necessity for maintaining a
ground connection.
CAUTION: Double insulation does not take the
place of normal safety precautions when operating
this tool.
DANGER: To avoid electrocution:
1. Use only identical replacement parts when
servicing a tool with double insulation. Servicing
should be performed by a qualified service
technician,
2. Do not use in rain or where floor is wet,
This toot is intended for indoor residential use
only.
MOTOR SAFETY PROTECTION
CAUTION: Toavoid motor damage, this motor
should be blown out or vacuumed frequently to
keep sawdust from interfering with normal motor
ventilation.
1, Connect this tool to a 120V, 15-amp branch
circuit with a 15-amp time delay fuse or circuit
breaker.Using the wrong size fuse can damage
the motor.
2. If the motor won't start, release the trigger
switch immediately. UNPLUG THE TOOL, Check
the saw blade to make sure it turns freely. If the
blade is free, try to start the motor again. If the
motor still does not start, refer to the "MotOr
Trouble-Shooting Chart."
3, It the motor suddenly stalls while cutting wood,
release the trigger switch, unplug the tool, and
free the blade from the wood, Then you may
restart the motor and finish the cut.
4 Fuses may "blow"or circuit breakers may trip
frequently if:
a, MOTOR IS OVERLOADED-Overloading can
occur if you feed too rapidly or make too
many start/stops in a short time,
b. Voltages not more than 10_ above or below
the nameplate voltage can handle normal
loads. For heavy loads, however, the voltage
at motor terminals must equal the voltage
specified on nameplate
5 Most motor troubles may be traced to loose or
incorrect connections, overload, tow voltage
(such as small size wire in the supply circuit) or
to overly long supply circuit wire, Always check
the connections, the load and the supply circuit
whenever motor doesn't work well. Check wire
sizes and length with the Wire Size Chart below,
WIRE SIZES
The use of any extension coro ¢ilt cause some
toss of power. To keep this to a minimum and to
prevent overheating and motor burn-out, use the
table below to determine the minimum wire size
(A.W.G.) extension cord.
For circuits that are farther than 100 feet away
from electrical service box, the wire size must be
increased proportionately in order to deliver ample
voltage to the saw motor.
Length of the Wire Sizes Required For 120V
Conductor (American Wire Gage Number)
0-25Ft No, 16
26-50Ft No,14
51-100Ft No. 12

Getting To Know Your
1. Warning label
3. Fence
Lock Screws
Handle Latch
Bevel
LoCk Halndle
Power Cord
Upper
Blade
Guard
Lock Off Button
/7. Miter
Saw Handle
Sawdust
Ejection
Port \
ger Switch
Changing Blade
Wrench Bevel Scale
6. Lower
Blade Guard
Fence o
Warning Line Miter Scale
Index Spring
Miter
Lock Handle
6

Getting To Know
1. Warning label
2. Handle Latch
The miter saw can be locked in the lowered
position for compact storage
3. Fence Lock Screws
The fence has two positions for increased
crosscut capacity. The lock screws secure the
fence to the base. The saw is shipped with the
fence in the rear position.
4. Miter Lock Handle
The miter lock handle securely locks the miter
saw at a desired miter angle, Index points have
been provided at 0°,15°R/L, 22.5°R/L,30°RiL,and
45°RiL.
.
=
The bevel lock handle locks the miter saw at a
desired bevel angle.
Lower Blade Guard
The blade guard helps protect your hands from
the blade in the raised position. To avoid
binding on the workpiece, it retracts as the
blade is lowered.
Miter Saw Handle
The saw handte contains the trigger switch with
a lock-off button, The blade is lowered into the
workpiece by pushing down on the handle. The
saw will return to it's upright position when the
handle is released.
iiiiiiiiiiiiiiii IIIIHIII I HIHIII II I Hill
Glossary of
Arbor
The shaft on which acutting tool is mounted,
Bevel Cut
An angle cutting operation made through the face
of the workpiece.
Compound Cut
A simultaneous bevel and miter cutting operation.
Grosscut
A cutting operation made across the width of the
workpiece.
Freehand
Performing a cut without the use of fence (guide),
hold down or other proper device to prevent the
workpiece from twisting during the cutting operat-
ion. Twisting of the worl<piece can cause it to be
thrown.
Revolutions Per Minute (RPM)
The number of turns completed by aspinning
object in one minute.
Sawblade Path
The area of the workpiece or table top directly in
line with either the travel of the blade or the part of
the workpiece which will be, or has been, cut by
the blade.
Set
The distance that the tip of the sawblade tooth is
bent (or set) outward from the face of the blade.
Gum
A sticky, sap based residue from wood products.
Heel
Misalignment of the btade.
Kerr
The.amount of material removed by the blade in a
through cut or the slot produced by the blade in a
nonthrough or partial cut.
Miter Cut
An angle cutting operation made across the width
of the workpiece.
Resin
A sticky, sap based substance that has hardened.
Workplece
The item on which the cutting operation is being
performed. The surfaces of aworkpiece are
commonly referred to as faces, ends, and edges.
EDGE
FACE
END
7

n al
U packing
TOOLS IBLY
MEDIUM SCREWDRIVER
#2 PHILLIPS SCREWDRIVER
COMBINATION SQUARE
ADJUSTABLE WRENCH
6ramHEX,"L"WRENCH
COMBINATION SQUARE MUST GE TRUE
Stratgh! Edge of Board
3/4"'Thtck, This Edge Must Be
Draw Light Line On
°o.,,.,oo0,,,.V0. :i
t.
ShOuld Be No Gap Or Overlap
Here When Square Is Flipped
Over In Doffed Position,
_Perlectly Straight.
A
The Miter Saw is shipped complete in one carton.
Separate all parts from packing materials and check
each item with illustration and =Table of Loose
Parts." Make certain all items are accounted for,
before discarding any packing material.
,,,ll i iiiiiiiiiii i ,,,,,l_lul,iii ii i
l WARNING: If any parts are missing, do not try
I to assemble the miter saw, plug in the power cord
I or turn the switch on until the missing parts are
obtained and installed correctly.
ITEM QTY.
A
B
C
D
E
F
G
H
I
J
TABLE OF LOOSE PARTS
Basic Saw Assembly .................
Lower Guard Assembly .............
Instruction Manual .....................
Dust Bag .....................................
Clamp Assembly
Slide Extension Arm ..................
_U_ Bracket/screw .....................
Stop Block/Wing Screw .............
Stop Fence Plate ........................
Wing Screw ................................
1
1
1
1
I
2
2
1
1
1
8

,q sern u Ey et
MOUNTING THE SAW
1: Before moving the saw, lock the miter, bevel and Rear
power-head positions. Unplug electric cord. Mounting
2. To avoid back injury, get help when you need to Holes
lift the saw more than 10 inches. Hold the toot
close to your body. Bend your knees so you can
lift with your legs, not your back. Lilt by using the
hand-hold areas at the bottom of the base
3 Never carry the miter s3w by the power cord or
the plastic handle. Carrying the tool bv the powe;
cord could cause damage to the insWatior, or the
wire Connec-tions re-suiting in electric shock or
fire.
4. Place the saw so other people cannot stand
behind it Thrown debris coutcl miure people in its
path.
5_ Place the saw or_ afirm. level surface where there
is plenty of room for handling and properly
supporting the workpiece.
6 Support the saw so the table is levet and the saw
does not rock,
7. Bolt or clamp the saw to _ts support
Place the saw in the desired Iocat=on e_ther on a
work bench or the recommended leg set The base
of the saw has four holes to mount the miter saw
(see illustration) I! the saw is to be used _,n one
location, lasten tt to the work beqch or leg set.
Forward
Mounting
Holes
ASSEMBLING THE LOWER BLADE GUARD
WARNING: To avoid injury from unexpected
starting or electrical shock, do not plug the saw in
until all aGsembly and alignment steps are com-
plete. The power cord must remain unplugged
whenever you are working on the saw,
NOTE: For compact shipment the lower blade
guard has been disconnected.
1 The miter saw is equipped with ahandle latch
used to lock the miter saw in the lowered
position. To release, push the handle down
slightly and pull the handle latch to the other
side.
2. Release the handle latch and raise the saw to
its up position.
3. Loosen screw A and remove screw 8
Rear
Mounting
Holes
Forward
Mounting
Holes
Handle Latch
9

4.Remove the screw C and spacer in the lower
guard.
5,Slide slotted end of lower guard mounting
bracket under screw head and rotate lower
guard mounting bracket until hole in bracket
lines up with threaded hole ;n upper guard.
Threaded Hole
Mounting Bracket
Slotted & Spacer
6.Replace' screw B, that was removed in step 3.
Tighten screw A and screw B.
7. Replace screw C and spacer, that were
removed in step 4. Tighten the screw C and
spacer through the slot.
NOTE: With the blade guard attached, the guard
should raise as the blade is lowered towards
the work table and drop to cover the blade as
the power head is raised.
\
Screw B
IIIIIIIIIIIIH II III IIIIIII -
BLADE SQUARE TO TABLE
NOTE: The miter saw was assembled aligned and
inspected before shipment. Alignment should be
checked and any adjustments made to insure
accurate cuts,
!. Check miter lock handle setting. The miter lock
handle should be at the 0° position, To reset the
miter angle, turn the miter lock-handle counter
clockwise and press down the index spring.
2 Lower the blade and lock the handle latch, Use
the combination square to check blade square-
ness to table, If the blade does not contact the
full length of the square, follow the alignment
procedure.
a, Loosen the bevel lock handle.
b. Grasp the metal upper guard and move the
cutting head to the left as far as it will go,
10