Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual
near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and
the receipt in a safe and dry place for future reference.
email our technical support at: [email protected]
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-800-444-3353 as soon as possible.
©
®
Copyright 2012 by Harbor Freight Tools . All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
Save thiS manual.
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General tool Safety Warnings (cont.)
13. DON’T OVERREACH. Keep proper
table a: ReCOmmenDeD minimum WiRe GauGe
FOR eXtenSiOn CORDS
footing and balance at all times.
(120 vOlt)
14. MAINTAIN TOOLS WITH CARE. Keep tools sharp
and clean for best and safest performance. Follow
instructions for lubricating and changing accessories.
eXtenSiOn CORD
lenGth
nameplate
ampeReS
(at full load)
25′
50′ 100′ 150′
15. DISCONNECT TOOLS before servicing;
when changing accessories, such as
blades, bits, cutters, and the like.
0 – 6
18
18
16
14
16
16
16
12
16
14
14
14
12
12
6.1 – 10
10.1 – 12
12.1 – 16
16. REDUCE THE RISK OF UNINTENTIONAL
STARTING. Make sure switch is in
off position before plugging in.
Do not use.
9. USE PROPER EXTENSION CORD. Make sure your
extension cord is in good condition. 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 a drop in line
voltage resulting in loss of power and overheating.
Table A shows the correct size to use depending
on cord length and nameplate ampere rating.
If in doubt, use the next heavier gauge.
17. USE RECOMMENDED ACCESSORIES.
Consult the owner’s manual for recommended
accessories. The use of improper accessories
may cause risk of injury to persons.
18. NEVER STAND ON TOOL. Serious injury
could occur if the tool is tipped or if the
cutting tool is unintentionally contacted.
19. CHECK DAMAGED PARTS. Before further use
of the tool, a guard or other part that is damaged
should be carefully checked to determine 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 guard or other part that is
damaged should be properly repaired or replaced.
The smaller the gauge number, the heavier the cord.
10. WEAR PROPER APPAREL. Do not wear
loose clothing, gloves, neckties, rings, bracelets,
or other jewelry which may get caught in moving
parts. Nonslip footwear is recommended.
Wear protective hair covering to contain long hair.
11. ALWAYS USE SAFETY GLASSES. Also use
face or dust mask if cutting operation is dusty.
Everyday eyeglasses only have impact resistant
lenses, they are NOT safety glasses.
20. DIRECTION OF FEED. Feed work into
a blade or cutter against the direction of
rotation of the blade or cutter only.
12. SECURE WORK. Use clamps or a vise to hold
work when practical. It’s safer than using your
hand and it frees both hands to operate tool.
21. NEVER LEAVE TOOL RUNNING UNATTENDED.
TURN POWER OFF. Don’t leave tool
until it comes to a complete stop.
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Grounding instructions
tO pRevent eleCtRiC ShOCk anD Death FROm inCORReCt GROunDinG WiRe COnneCtiOn
ReaD anD FOllOW theSe inStRuCtiOnS:
110-120 v~ Grounded tools: tools with three prong plugs
1. In the event of a malfunction or breakdown,
grounding provides a path of least resistance for
electric current to reduce the risk of electric shock.
This tool is equipped with an electric cord having an
equipment-grounding conductor and a grounding
plug. The plug must be plugged into a matching
outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
6. Repair or replace damaged or worn cord immediately.
Grounding
pin
2. Do not modify the plug provided – if it will
not fit the outlet, have the proper outlet
installed by a qualified electrician.
125 v~ 3-prong plug and Outlet
(for up to 125 v~ and up to 15 a)
3. Improper connection of the equipment-grounding
conductor can result in a risk of electric shock.
The conductor with insulation having an outer
surface that is green with or without yellow
stripes is the equipment-grounding conductor.
If repair or replacement of the electric cord or
plug is necessary, do not connect the equipment-
grounding conductor to a live terminal.
7. This tool is intended for use on a circuit that has
an outlet that looks like the one illustrated above in
125 v~ 3-prong plug and Outlet. The tool has a
grounding plug
that looks like the plug illustrated above
in 125 v~ 3-prong plug and Outlet.
4. Check with a qualified electrician or service
personnel if the grounding instructions are
not completely understood, or if in doubt as
to whether the tool is properly grounded.
8. The outlet must be properly installed and grounded
in accordance with all codes and ordinances.
9. Do not use an adapter to connect
this tool to a different outlet.
5. Use only 3-wire extension cords that
have 3-prong grounding plugs and 3-pole
receptacles that accept the tool’s plug.
Cut-Off Saw Safety Warnings
1. For Your Own Safety Read instruction
manual Before Operating Grinder
11. DO nOt OpeRate With anY GuaRD DiSaBleD,
DamaGeD, OR RemOveD. moving guards
must move freely and close instantly.
2. Wear eye protection.
12. The use of accessories or attachments not
recommended by the manufacturer may
result in a risk of injury to persons.
3. Use grinding wheel suitable for speed of grinder.
4. Replace cracked wheel immediately.
5. Always use guards and eye shields.
6. Do not overtighten wheel nut.
13. When servicing use only identical replacement parts.
14. Only use safety equipment that has been approved
by an appropriate standards agency. Unapproved
safety equipment may not provide adequate
7. Use only flanges furnished with the grinder.
8. Frequently clean grinding dust from beneath grinder.
protection. Eye protection must be ANSI-approved
and breathing protection must be NIOSH-approved
for the specific hazards in the work area.
9. Wear a full face shield over ANSI-
approved safety goggles during use.
10. Do not grind with side of wheel unless wheel is
specifically designed for that type of grinding.
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Cut-Off Saw Safety Warnings (cont.)
15. 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.
20. WARNING: Some dust created by power sanding,
sawing, grinding, drilling, and other construction
activities, contains chemicals known [to the State
of California] to cause cancer, birth defects or
other reproductive harm. Some examples of these
chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and cement or other
masonry products
• Arsenic and chromium from
chemically treated lumber
Your risk from these exposures varies, depending
on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well
ventilated area, and work with approved safety
equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
(California Health & Safety Code § 25249.5, et seq.)
16. Industrial applications must follow OSHA guidelines.
17. Maintain labels and nameplates on the tool.
These carry important safety information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
18. Avoid unintentional starting.
Prepare to begin work before turning on the tool.
19. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
21. WARNING: Handling the cord on this product will
expose you to lead, a chemical known to the State
of California to cause cancer, and birth defects or
other reproductive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
22. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.
vibration Safety
This tool vibrates during use. Repeated or long-term
exposure to vibration may cause temporary or permanent
physical injury, particularly to the hands, arms and
shoulders. To reduce the risk of vibration-related injury:
2. Do not smoke during use. Nicotine reduces
the blood supply to the hands and fingers,
increasing the risk of vibration-related injury.
3. Use tools with the lowest vibration when there
is a choice between different processes.
1. Anyone using vibrating tools regularly or for an
extended period should first be examined by a
doctor and then have regular medical check-ups
to ensure medical problems are not being caused
or worsened from use. Pregnant women or
people who have impaired blood circulation to
the hand, past hand injuries, nervous system
disorders, diabetes, or Raynaud’s Disease should
not use this tool. If you feel any medical or
physical symptoms related to vibration (such as
tingling, numbness, and white or blue fingers),
seek medical advice as soon as possible.
4. Include vibration-free periods each day of work.
5. Grip tool as lightly as possible (while still keeping
safe control of it). Let the tool do the work.
6. To reduce vibration, maintain the tool as
explained in this manual. If any abnormal
vibration occurs, stop use immediately.
Save theSe inStRuCtiOnS.
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Specifications
Electrical Rating
120V~ / 60Hz / 5.5A
5000 RPM
Motor No Load Speed
Max. Accessory Diameter 6"
Arbor Size 5/8"
3150240
Setup - Before use:
Read the entiRe impORtant SaFetY inFORmatiOn section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
tO pRevent SeRiOuS injuRY FROm aCCiDental OpeRatiOn:
Release the trigger and unplug the tool from its electrical outlet before
assembling or making any adjustments to the tool.
note: For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
Functions
Handle
Trigger
Stationary
Guard
Moveable Guard
Angle Guide
Clamp
Blade
Base
Figure a
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Operating instructions
Read the entiRe impORtant SaFetY inFORmatiOn section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
tool Set up
tO pRevent SeRiOuS injuRY FROm aCCiDental OpeRatiOn:
Release the pressure and unplug the tool from its electrical outlet before
assembling or making any adjustments to the tool.
tO pRevent SeRiOuS injuRY:
DO nOt OpeRate With anY GuaRD DiSaBleD, DamaGeD, OR RemOveD.
installing the Wheel
1. The Grinding Wheel MUST be:
• rated to at least 5000 RPM.
3. Release the Safety Chain and guide the
Housing to rest at its full upward position.
• no larger than 6" in diameter.
• fitted with a 5/8" round arbor hole.
• suitable for edge grinding, not surface grinding.
• dry and clean.
• proven undamaged by inspection and
by the ring-test explained below.
Moveable Guard
Swing open
2. Closely inspect the Grinding Wheel before mounting.
Perform a ring-test on the wheel
Nut
(unless wheel is smaller than 4″) as follows:
a. Suspend wheel using a dowel or
finger through the arbor hole.
Figure B
45°
45°
hang
Wheel
from
4. Loosen the Knob on the Moveable Guard and
swing it open, exposing the Blade and Flange.
v
e
R
t
i
C
a
l
5. Using the included wrenches, hold the Spindle
in place with the flat Wrench and loosen
the Outer Flange with the Pin Wrench.
Dowel
tap
Wheel
here
6. Remove the Outer Flange and Blade,
noting the orientation of each.
C
e
n
t
e
R
7. For wheels with paper gaskets (blotters) or
metal gaskets: Slip the grinding wheel onto the
Spindle with the gasket first. The gasket should be
centered on the grinding wheel and the wheel and
gasket should rest flat against the Inner Flange.
45°
45°
WaRninG: to prevent serious
injury, gaskets must be used for all
b. Tap the flat side of the wheel with a light non-
metallic object, such as a screwdriver handle,
at a point 45° from the vertical center line on
each side of the wheel and 1 – 2 inches from
the edge of the wheel (see Illustration).
grinding wheels they are provided with.
Gaskets help prevent grinding wheel damage
and wheel slippage, causes of wheel failure.
8. Thread the Outer Flange onto the Spindle
and tighten in place with the Wrenches.
c. Rotate the wheel 90° and repeat the test
until the entire wheel has been checked.
9. Swing the Moveable Guard back in
place and tighten the Knob.
d. An undamaged wheel will give a clear tone.
If cracked, there will be a dead sound
and not a clear ring.
10. Lower the Housing and replace the Safety Chain.
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Angle Guide
Bolt
Clamp Knob
Flip open
Two Locations
Quick Release
Figure C
The Clamp and Angle Guide are used together to hold the workpiece securely in place.
The Angle Guide can be adjusted from 0 to 45° for straight or angled cuts. Adjust the
Angle Guide first, then secure the workpiece in place with the Clamp.
1. To adjust the Angle Guide:
a. Loosen both Bolts.
2. To secure a workpiece in the Clamp:
a. Turn the Handle counterclockwise a quarter turn.
b. Flip up the Quick Release.
b. Turn the Angle Guide to the desired angle.
c. Retighten the bolts.
c. Slide the clamp out as far as needed.
d. Position the work piece against the angle Guide.
note: The Angle Guide can be positioned
in either pair of holes in the Base.
e. Flip the Quick Release down
onto the Clamp threads.
f. Push the Clamp against the workpiece.
g. Tighten the Handle clockwise to
secure the workpiece.
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Work piece and Work area Set up
1. Designate a work area that is clean and well-lit.
The work area must not allow access by children
or pets to prevent distraction and injury.
2. Route the power cord along a safe route to reach
the work area without creating a tripping hazard or
exposing the power cord to possible damage. The
power cord must reach the work area with enough
extra length to allow free movement while working.
3. Secure loose work pieces using the clamp
to prevent movement while working.
General Operating instructions
CautiOn! Friction from cutting will heat both the
Wheel and the workpiece. Be careful when handling
the workpiece and do not overwork the Cut-Off Saw as
the Wheel can become damaged from overheating.
6. With one hand on the Handle and the other hand
clear, slowly bring the Saw down, letting the Saw
do the work. Do not apply excessive force.
7. After making the cut, release the Power
Switch and raise the Saw.
1. Release the Safety Chain and guide the
Housing to rest at ifs full upward position.
8. Wait until the unit comes to a complete
stop then remove the workpiece.
2. Adjust the Angle Guide as needed.
3. Place the workpiece against the Angle
Guide and the Clamp in place.
9. To prevent accidents, turn off the tool and disconnect
its power supply after use. Lower the Housing
and secure with the Safety Chain. Clean, then
store the tool indoors out of children’s reach.
4. Plug the Power Cord into a 120V~
grounded, electrical outlet.
5. Squeeze and hold the Trigger to start the Saw.
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maintenance and Servicing
procedures not specifically explained in this manual must
be performed only by a qualified technician.
tO pRevent SeRiOuS injuRY FROm aCCiDental OpeRatiOn:
Release the trigger and unplug the tool from its electrical outlet before
performing any inspection, maintenance, or cleaning procedures.
tO pRevent SeRiOuS injuRY FROm tOOl FailuRe:
Do not use damaged equipment. if abnormal noise or vibration
occurs, have the problem corrected before further use.
Cleaning, maintenance, and lubrication
1. BeFORe eaCh uSe, inspect the general
2. aFteR uSe, wipe external surfaces
condition of the tool. Check for:
of the tool with clean cloth.
• loose hardware,
3. Check and change the Carbon Brushes as needed.
• misalignment or binding of moving parts,
• cracked or broken parts,
4.
WaRninG! if the supply cord of this
power tool is damaged, it must be replaced
only by a qualified service technician.
• damaged electrical wiring, and
• any other condition that may
affect its safe operation.
Changing Carbon Brushes
3. Slide out the Carbon Brushes, noting the
direction of wear of each brush.
Carbon Brush location
Cap
4. If they are worn to 3mm or less
they need to be replaced.
5. Insert new Carbon Brushes and
secure in place with the Caps.
6. If they are still in good condition, replace
the brushes in the same orientation and
secure in place with the Caps.
Figure D
1. The two Carbon Brushes are located on either
side of the back of the Saw near the Base.
note: When replacing Carbon Brushes,
always replace both brushes.
2. Remove the Caps with a Screwdriver
(sold separately).
Cut-off Wheel Storage and handling
1. Handle Cut-off Wheels carefully to prevent
dropping or bumping. Do not use wheels
that have been dropped or bumped.
2. Store Cut-off Wheels in shelves, racks, boxes, or
drawers. Storage area must be kept dry, and above
freezing. Any grinding or cut-off wheels exposed to
humidity or freezing temperatures must not be used.
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troubleshooting
problem
possible Causes
likely Solutions
Tool will not start. 1. Cord not connected.
1. Check that cord is plugged in.
2. No power at outlet.
2. Check power at outlet. If outlet is unpowered,
turn off tool and check circuit breaker.
If breaker is tripped, make sure circuit is right
capacity for tool and circuit has no other loads.
3. Internal damage or wear. (Carbon
3. Check and replace Carbon Brushes
Brushes or switch, for example.)
Extension cord too long or
wire size too small.
or have technician service tool.
Tool operates
slowly.
Eliminate use of extension cord. If an extension cord
is needed, use one with the proper diameter for its
length and load. See table a on page 3.
1. Keep cutting accessories sharp. Replace as needed.
Performance
decreases
over time.
1. Accessory dull or damaged.
2. Carbon brushes worn or damaged. 2. Replace brushes.
Excessive noise Internal damage or wear. (Carbon
Check and replace Carbon Brushes or
have technician service tool.
or rattling.
Brushes or bearings, for example.)
Overheating.
1. Forcing machine to work too fast.
1. Allow machine to work at its own rate.
2. Accessory misaligned.
2. Check and correct accessory to
fence and/or table alignment.
3. Accessory dull or damaged.
4. Blocked motor housing vents.
3. Keep cutting accessories sharp. Replace as needed.
4. Wear ANSI-approved safety goggles and
NIOSH-approved dust mask/respirator while
blowing dust out of motor using compressed air.
5. Motor being strained by long or
small diameter extension cord.
5. Eliminate use of extension cord. If an extension cord
is needed, use one with the proper diameter for
its length and load. See table a on page 3.
Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.
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pleaSe ReaD the FOllOWinG CaReFullY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
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Record product’s Serial number here:
note: if product has no serial number, record month and year of purchase instead.
note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
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parts list and Diagram
parts list
part
Description
Qty
1
1
1
1
1
3
3
1
1
1
4
1
1
1
3
3
1
1
1
1
5
2
1
1
1
1
2
2
2
1
1
2
part
Description
Qty
2
2
2
1
1
1
3
3
3
3
1
1
1
1
1
1
2
2
2
1
1
1
2
2
2
1
1
1
2
1
1
1
1
2
3
4
5
6
7
8
9
Knob
33 5X14 Hexagonal Screw
34 Ф5 Spring Washer
35 Terminal
Mechanical Spring
Moveable Guard
Outer Flange Nut
Inner Flange
Ф5x12 S/T Screw
Ф5 Spring Washer
Grinder Cover
Output Shaft
36 Pin
37 Spring
38 Support/Base Plate
39 Machine Foot
40 Gasket
41 M4 Nut
42 Ф4x30 S/T Screw
43 Chain
10 2.9X10 Semicircle Key
11 4X55 Self-Tapping Screw
12 Bearing Seat
13 201# Bearing
14 201# Triangle Press Cover
15 Ф4 Spring Washer
16 Ф4x10 S/T Screw
17 Gear
18 Ф10 Retaining Ring
19 17# Bearing
20 Right Motor Housing
21 Ф4x20 S/T Screw
22 Ф4x12 S/T Screw
23 Trigger
24 Left Motor Housing
25 19# Bearing
26 Rotor
27 Brush Holder
28 Brush
29 Cap
44 Screw Pole
45 2X20 Cotter Pin
46 4X24 Spring Pin
47 Nut Holder
48 Quick Release Nut
49 Ф6x16 S/T Screw
50 Ф6 Spring Washer
51 Ф6 Washer
52 Straight Pin
53 Small Clamp Plate
54 Large Clamp Plate
55 6X14 Hexagon Screw
56 Ф6 Spring Washer
57 Ф6 Washer
58 Cable Guard
59 Power Cord
60 Cable Press Plate
61 Ф4x14 S/T Screw
62 Ф20 Flange
30 18# Bearing
31 Stator
32 100# Pull Spring
63 Pin Wrench
64 Flat Spanner
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assembly Diagram
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limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
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