SteelMax S9 XP User manual

SM-S-9 XP Operator’s Manual 2017 Version 1.01
MODEL S9 XP
(Part Number: SM-S-9 XP)
9” METAL CUTTING CIRCULAR SAW
OPERATOR’S MANUAL
TO REDUCE THE RISK OF INJURY , READ AND THOROUGHLY UNDERSTAND THIS
OPERATOR’S MANUAL .
Always Wear Eye and Never Place Line Voltage
Ear Protection Hands Near Present
Cutting Area
WWW.STEELMAX.COM

SM-S-9 XP Operator’s Manual - i - 2017 Version 1.01
Steelmax S9 XP Portable Metal Cutting Circular Saw
Congratulations on your purchase of a Steelmax
®
portable metal cutting saw. Please register your product on our
web site at www.steelmax.com/product-registration. Doing so will validate your machine’s warranty period and ensure
prompt service if needed. We sincerely thank you for selecting a product from Steelmax.
CONTENTS
Intended Use and General Safety Guidelines .................................................................................1
Specific Safety Rules for Metal Cutting Saws.................................................................................4
Exploded Parts Diagram ..................................................................................................................8
Parts List ..........................................................................................................................................9
Steelmax S9 XP Operation
Included items....................................................................................................................11
Saw Blade Installation/Replacement .................................................................................12
Making Plunge Cuts...........................................................................................................14
Setting Bevel Angle for Bevel Cuts ...................................................................................15
Laser Guide Use and Adjustment ......................................................................................15
Aligning Laser Guide Line ................................................................................................16
Using LED Light................................................................................................................18
Cutting Depth Adjustment .................................................................................................18
Saw Trigger Switch Operation...........................................................................................19
Proper Saw Operation ........................................................................................................19
Overload Protection ...........................................................................................................20
Saw Guide ruler .................................................................................................................20
Sighting Notch ...................................................................................................................21
Chip Removal ....................................................................................................................21
Saw Maintenance...........................................................................................................................22
Troubleshooting .............................................................................................................................24
Saw Specifications.........................................................................................................................25
Warning Symbols and Precautions ................................................................................................26

SM-S-9 XP Operator’s Manual - ii - 2017 Version 1.01
STEELMAX LIMITED WARRANTY
Within twelve (12) months from the original date of purchase Steelmax will repair or replace any machine tool found
to be defective in materials or workmanship, provided the product working registration card has been returned to
Steelmax within thirty (30) days of the purchase date. This warranty is void if the tool being returned has been used
beyond the recommendations in this Operator’s Manual or if the machine has been damaged by accident, neglect,
improper service, or other causes not arising out of defects in materials or workmanship. This warranty does not apply
to machines and/or components which have been altered, changed, or modified in any way, or subjected to use beyond
recommended capacities and specifications. Electrical components are subject to respective manufacturers warranties.
All goods returned defective shall be returned prepaid freight to Steelmax, which shall be the buyer’s sole and
exclusive remedy for defective goods. Steelmax reserves the right to optionally repair or replace the machine with
the same or equivalent item. There is no warranty for any consumable items, including, without limitation, saw blades,
annular cutters, abrasive belts and cutting inserts. All machines must have the consumables used when the machine
failed installed to determine if the machine has been overused or if it falls under Steelmax’s warranty replacement
program for defects in material and workmanship. In no event shall Steelmax be liable for loss or damage resulting
directly or indirectly from the use of the merchandise or from any other cause. Steelmax is not liable for any costs
incurred on such goods or consequential damages. No officer, employee or agent of Steelmax is authorized to make
oral representations of fitness or to waive any of the foregoing terms of sale and none shall be binding on Steelmax.
STEELMAX RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO DESIGN AND
SPECIFICATIONS WITHOUT PRIOR NOTICE. IN ADDITION, STEELMAX RESERVES THE RIGHT TO
MODIFY THESE TERMS AND CONDITIONS WITHOUT PRIOR NOTICE.

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Intended Use and General Safety Guidelines
The Steelmax S9 XP Metal Cutting Saw is designed to rapidly cut mild steel and other similar
materials without heating either the saw blade or the material being cut. The S9 XP can easily cut
mild steel sheet metal up to ¼” (6 mm) thick.
WARNING! To reduce the risk of injury, read and thoroughly understand this Operator’s
Manual.
WARNING! Read all safety warnings and all instructions thoroughly and carefully. Failure
to follow the warnings and instructions may result in electric shock, fire and/or severe injury.
SAVE THIS OPERATOR’S MANUAL 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 of the saw or the material being cut.
Electrical Safety
•Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or modify
the plug in any way. Do not use adapter plugs. Check with a qualified electrician if you
are in doubt as to whether the outlet is properly grounded. If the tool should electrically
malfunction or break down, grounding provides a low resistance path to carry
electricity away from the user.
•Don't 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 to carry the tools or pull the plug from the outlet.
Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords
immediately. Damaged cords increase the risk of electric shock.
•When operating a power tool outside, use an outdoor extension cord marked "W-A" or
"W." These cords are rated for outdoor use and reduce the risk of electric shock.
•When using an extension cord, be sure to use one heavy enough to carry the current
your product will draw. An undersized cord will cause line voltage to drop,
resulting in loss of power and overheating. The recommended minimum is a 14-
gauge extension cord not exceeding 50 feet.

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Personal Safety
•Stay alert, watch what you are doing and use common sense when operating a power tool.
Do not use tool while tired or under the influence of drugs, alcohol, or medication. A mo men t of
ina ttenti on whil e op erating power tools may result in serious personal injury.
•Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair,
clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair
can be caught in moving parts.
•Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools
with y our fi ng er on the switch or plugging in tools that have the switch on invites
accidents.
•Remove adjusting keys or switches before turning the tool on. A wrench or a key that
is left attached to a rotating part of the tool may result in personal injury.
•Do not overreach. Keep proper footing and balance always. Prop er footing and
balance enables b etter control of the tool.
•Use safety equipment. Always wear eye and ear protection. Dust mask, non-skid safety
shoes and hard hat should be used as appropriate for conditions.
Tool Use and Care
•Use clamps or other practical way to secure and support the workpiece to a stable platform.
H o l d i n g t h e w o r k b y h a n d o r a g a i n s t y o u r b o d y i s u n s t a b l e a n d
m a y l e a d t o l o s s o f c o n t r o l .
•Do not force tool. Use the correct tool for your application. The correct tool will do
the job better and more safely.
•Do not use tool if switch does not turn it on or off. Any 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 the tool. Such preventive safety measures reduce the risk of
starting the tool accidentally.
•Store idle tools out of reach of children and other untrained persons. Tools are dangerous
in the hands of untrained users.
•Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained
tools, with sharp cutting edges are less likely to bind and are easier to
control.
•Check for misalignment or binding of moving parts, breakage of parts, and any other
condition that may affect the tools operation. If damaged, have the tool serviced before
using. Many accidents are caused by poorly maintained tools.
•Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool may become hazardous when used on
another tool.

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Service
•Tool service must be performed only by qualified repair personnel. Servic e or
maintenance performed b y unqualified personnel could result in a risk of injury.
•When servicing a tool, use only identical replacement parts. Follow instructions in the
Maintenance section of this manual. Use of unauthorized parts or failure to follow
Maintenance Instructions may create a risk of electric shock or injury and will void
the warranty.

SM-S-9 XP Operator’s Manual - 4 - 2017 Version 1.01
Specific Safety Rules for Metal Cutting Saws
•Only use Steelmax® saw blades. Unauthorized blades may be dangerous!
•Keep saw blades securely fastened. Check blade flanges for debris before installing a new
blade.
•Do not use dull or broken blades. Check blades often for condition and wear.
•Check chip collector cover for proper fit to minimize the risk of flying debris.
•Beware of ejecting chips. They become HOT during cutting.
•Always make provisions for safe handling of excess material.
•Keep bottom of base plate free from dirt and other debris.
Additional copies of this manual are available on our web site at: www.steelmax.com or by
contacting us directly at [phone]
- DANGER! Keep hands and body away from and to the side of the blade. Contact with
blade will result in severe injury.
- WARNING! To reduce the risk of injury, check lower guard. It must close quickly and
automatically. Hold saw with both hands. Support and clamp work. Wear eye and ear
protection.
Additional Specific Safety Rules:
DANGER! Keep hands away from cutting area and blade. Keep your second hand on auxiliary
handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
• Keep your body positioned to either side of the saw blade, but not in line with the saw blade.
KICKBACK could cause the saw to jump backwards. (See "Causes and Prevention of
Kickback.")
• Do not reach underneath the work. The guard cannot protect you from the blade below the
work.
• Check lower guard for proper closing before each use. Do not operate saw if lower guard
does not move freely and close automatically. Never clamp or tie the lower guard into the
open position. If saw is accidentally dropped, lower guard may be bent. Raise the lower
guard and make sure it moves freely and does not touch the blade or any other part, in all
angles and depths of cut.
• Check the operation and condition of the lower guard spring. If the guard and the spring
are not operating properly, they must be serviced before use. Lower guard may operate
sluggishly due to damaged parts, gummy deposits, or a buildup of debris.
• Always observe that the lower guard is covering the blade before placing saw down on bench
or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting

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whatever is in its path. Be aware of the time it takes for the blade to stop after switch is
released.
• NEVER hold piece being cut in your hands or across your leg. It is important to support the
work properly to minimize body exposure, blade binding, or loss of control.
• Hold tool by 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. This improves the accuracy of
cut and reduces the chance for blade binding.
• Always use blades with correct size and shape (diamond vs. round) arbor holes. Blades that
do not match the mounting hardware of the saw will run eccentrically, causing loss of
control.
• Never use damaged or incorrect blade washer or bolts. The blade washer and bolt were
specially designed for your saw, for optimum performance and safety of operation.
LASER ALIGNMENT GUIDE PRECAUTIONS
DANGER! LASER RADIATION. AVOID DIRECT EYE EXPOSURE. DO NOT
STARE INTO THE LASER LIGHT SOURCE.
Never aim light at another person or object other than the workpiece. Laser light can
damage your eyes.
WARNING!
DO NOT USE TINTED GLASSES TO ENHANCE THE LASER LIGHT. Tinted glasses will
reduce overall vision for the application and interfere with the normal operation of the tool.

SM-S-9 XP Operator’s Manual - 6 - 2017 Version 1.01
WARNING!
NEVER AIM THE BEAM AT A WORKPIECE WITH A REFLECTIVE SURFACE. Highly
polished or similar reflective surfaces are not recommended for laser use where eye exposure is
possible due to reflection. These surfaces could reflect the beam back toward the operator or
bystanders. ALWAYS CONSIDER THE PATH OF POSSIBLE BEAM DEFELCTION.
CAUSES AND PREVENTION OF KICKBACK
Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing 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 (saw cut) 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 material causing the blade
to climb out of the kerf and the saw to jump back toward operator. Kickback is the result of tool
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 body and arm to allow you to
resist KICKBACK forces. KICKBACK forces can be controlled by the operator, if proper
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 saw teeth
are not engaged into the material. If saw blade is binding, it may walk up or KICKBACK from
the workpiece as the saw is restarted.
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.
Never attempt to cut with a dull or damaged blade. Dull or improperly set blades produce a narrow
kerf which leads to excessive friction, blade binding and KICKBACK.
Blade depth and bevel adjusting locking levers must be tight and secure before making a cut. If
blade adjustment shifts while cutting, it may cause binding and KICKBACK.
Lower Guard Safety Instructions
• Check lower guard for proper closing before each use. Do not operate the saw if lower guard
does not move freely and close instantly. Never clamp or tie the lower guard into the open

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position. If saw is accidentally dropped, lower guard may be bent. Raise the lower guard with
the retracting handle and make sure it moves freely and does not touch the blade or any other
part, in all angles and depths of cut.
• Check the operation of the lower guard spring. If the guard and the spring are not operating
properly, they must be serviced before use. Lower guard may operate sluggishly due to
damaged parts, gummy deposits, or a build-up of debris.
• Lower guard manually only for special cuts such as “plunge cuts” and “compound cuts.” Raise
lower guard by retracting handle. As soon blade enters the material, release the lower guard.
For all other sawing, the lower guard should operate automatically.
• Always observe that the lower guard is covering the blade before placing saw down on bench
or floor. An unprotected, spinning 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 switch is released.
Additional Safety Instructions
• Use clamps or another practical way to secure and support the workpiece to a stable platform.
Holding the work by hand or against your body leaves it unstable and may lead to loss of
control.
• Keep your body positioned to either side of the blade, but not in line with the saw blade.
KICKBACK could cause the saw to jump backwards (see Causes and Operator Prevention of
Kickback and KICKBACK).
• Make sure nothing interferes with the movement of the lower blade guard.
• Make sure the saw is clean before use.
• Stop using this saw and have it properly serviced if any unusual noise or abnormal operation
occurs.
• Be sure all components are mounted properly and securely before using tool.
• Wait until the motor has reached full speed before starting a cut.
• Keep handles dry, clean and free of oil and grease. Hold the tool firmly with both hands when
in use.
• Always be alert, especially during repetitive, monotonous operations. Always be sure of
position of your hands relative to the blade.
• Stay clear of end pieces that may fall after cutting off. They may be sharp and/or heavy. Serious
personal injury may result.
• Replace or repair damaged cords. Make sure your extension cord is in good condition. Use
only 3-wire (minimum 14 gauge) extension cords that have 3-prong grounding-type plugs and
3-pole receptacles that accept the tool’s plug.

SM-S-9 XP Operator’s Manual - 8 - 2017 Version 1.01
S9 XP Parts Diagram

SM-S-9 XP Operator’s Manual - 9 - 2017 Version 1.01
Steelmax S9 XP Parts List

SM-S-9 XP Operator’s Manual - 10 - 2017 Version 1.01
Steelmax S9 XP Parts List (Cont’d)

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STEELMAX S9 XP OPERATION
Your Steelmax
®
S9 XP
®
saw is shipped complete and protected inside a reusable carrying case.
Remove all contents from the case and inspect to ensure no damage occurred during shipping.
INCLUDED ITEMS
DESCRIPTION
PART NUMBER
QUANTITY
S9 XP METAL CUTTING SAW
SM-S-9 XP
1
9” TCT SAW BLADE FOR MILD STEEL
SM-BL-09
1
OPERATOR’S MANUAL
N/A
1
CARRYING CASE
SMS9XP-901
1
SAFETY GOGGLES
SMS9XP-910
1
EARPLUGS (2)
SMS9XP-911
1
REPLACEMENT CARBON BRUSHES
SMS9XP-912
2
6MM ALLEN WRENCH
SMS9XP-162
1
EDGE GUIDE RULER
SMS9XP-93
1
WARNING:
For your own safety, never connect the plug to a power source outlet until all assembly steps are
complete and you have read and understood the safety and operating instructions. The safety cover
is attached to the saw for your protection. Should the safety cover become damaged, do not use
the saw until the damaged cover has been replaced. If the safety cover becomes dirty, or chips
adhere to it, clean the safety cover carefully with a damp cloth.

SM-S-9 XP Operator’s Manual - 12 - 2017 Version 1.01
Installing a New Saw Blade
WARNING: To prevent an accident or personal injury, always turn off the trigger switch and
disconnect the power plug from the receptacle before removing or installing a blade. Only use
Steelmax
®
blades designed for metal cutting saws. DO NOT USE ABRASIVE WHEELS OR
WOOD SAW BLADES ON YOUR METAL CUTTING SAW. USE ONLY STEELMAX 9”
METAL CUTTING SAW BLADES. USE OF ABRASIVE WHEELS, WOOD SAW BLADES
OR SMALLER OR LARGER SAW BLADES WILL VOID YOUR PRODUCT WARRANTY
AND MAY RESULT IN PERSONAL INJURY.
Check that the blade to be used is flat, sharp and free of damage or defects.
Blade Removal and Installation
1. Loosen lower guard lever (A). Fig. 1.
2. Open guide plate to maximum extent (B). Fig. 2.

SM-S-9 XP Operator’s Manual - 13 - 2017 Version 1.01
3. Use the included open-end wrench and Allen wrench
to loosen the shaft screw (counter-clockwise). Fig. 3.
4. Remove wrenches and open blade guard to remove arbor
screw, flange and blade. Fig. 4.
5. Install the new blade, flange and arbor screw in
proper order and check for proper blade
orientation. Fig. 5.

SM-S-9 XP Operator’s Manual - 14 - 2017 Version 1.01
Making Plunge Cuts
Plunge or pocket cuts are made in the middle of a work piece when a cut cannot be started at the
edge of the workpiece. Make certain that there are no hidden hazards under the workpiece before
making a plunge or pocket cut.
1. Line up the saw sight line with your
cutting line. Tilt the saw forward, firnly
fixing the guide plate on the workpiece.
The blade should be just above the the
cutting line, but not touching the
workpiece. Raise the lower blade guard
(B) using the guard lever (A). Fig. 6.
2. Start the saw and allow the blade to reach
maximum speed before beginning your
cut.Use the front of the guide palte as a
hinge and slowly lower the blade into the
workpiece and release the guard lever
(A).
3. Once the blade has fully penetrated the
workpiece, advance the cut until
complete. Release the trigger switch and
let the blade come to a full stop before
removing it from the workpiece.

SM-S-9 XP Operator’s Manual - 15 - 2017 Version 1.01
Setting Bevel Angle for Bevel Cuts
Release the lock lever (A) and the wing nut (B) to change the bevel plate angle between 0˚ and
45˚. Once the angle is set, re-tighten the lock and lever and wing nut. Fig. 7.
Laser Guide Use and Adjustment
1. Plug power cord into appropriate
power supply and press the
bottom of the left button (A) to
turn on the laser. Press again to
turn laser off. Fig.8.

SM-S-9 XP Operator’s Manual - 16 - 2017 Version 1.01
2. Laser guide automatically follows bevel angle. The laser will align with notch (B) at 0˚ and
will align with notch (C) at 45˚. Fig. 9.
Aligning the Laser Guide Line
DANGER: Laser radiation. Avoid direct eye contact with light source.
WARNING: Use of controls or adjustments or performance of procedures other than those
specified herein may resuit in hazardous radiation exposure. When adjusting the laser guide,
make sure the saw trigger is not inadvertently engaged. Fig. 10. Serious injury could result.

SM-S-9 XP Operator’s Manual - 17 - 2017 Version 1.01
1. Adjusting the laser: Use an M2 Allen wrench
to tighten or loosen the laser adjustment screw
(A) to adjust the laser beam width. Fig.11
2. Use a small flat blade screw driver to tighten or
lossen the the direction adjustment screw (B) to
align the laser beam with the actual cut line.
Fig.12.
3. Calibrate the saw with the laser by adjusting the
guide plate bevel scale to 0˚ when the laser is
aligned with the appropriate notch on the guide
plate. Fig.13.