3-3/8 INCH BLADE TOE KICK SAW
94626
ASSEMBLY AND OPERATING INSTRUCTIONS
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright© 2006 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.
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Electrical Safety
4.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges,
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
5.
6.
Do not expose power tools to rain or wet conditions. Water entering a power tool
will increase the risk of electric shock.
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 any adapter plugs. Check with
a qualified electrician if you are in doubt as to whether the outlet is properly
grounded. If the tools should electrically malfunction or break down, grounding
provides a low resistance path to carry electricity away from the user.
7.
Double insulated tools are equipped with a polarized plug (one blade is wider
than the other). This plug will fit in a polarized outlet only one way. If the plug
does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install a polarized outlet. Do not change the plug in any
way. Double insulation
eliminates the need for the three wire grounded power
cord and grounded power supply system.
8.
9.
Do not abuse the Power Cord. Never use the Power Cord to carry the tools or
pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp
edges, or moving parts. Replace damaged Power Cords immediately. Damaged
Power Cords increase the risk of electric shock.
When operating a power tool outside, use an outdoor extension cord marked
“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the risk
of electric shock.
Personal Safety
10. Stay alert. Watch what you are doing, and use common sense when operating a
power tool. Do not use a power tool while tired or under the influence of drugs,
alcohol, or medication. A moment of inattention while operating power tools may
result in serious personal injury.
11. 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.
12. Avoid accidental starting. Be sure the Power Switch is off before plugging in.
Carrying power tools with your finger on the Power Switch, or plugging in power tools
with the Power Switch on, invites accidents.
13. Remove adjusting keys or wrenches before turning the power tool on. A wrench
or a key that is left attached to a rotating part of the power tool may result in personal
injury.
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14. Do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enables better control of the power tool in unexpected situations.
15. Use safety equipment. Always wear ANSI-approved eye protection. Dust mask,
non-skid safety shoes or hearing protection must be used for appropriate conditions.
Tool Use and Care
16. Use clamps (not included) or other practical ways to secure and support the
workpiece to a stable platform. Holding the work by hand or against your body is
unstable and may lead to loss of control.
17. Do not force the tool. Use the correct tool for your application. The correct tool
will do the job better and safer at the rate for which it is designed.
18. Do not use the power tool if the Power Switch does not turn it on or off. Any tool
that cannot be controlled with the Power Switch is dangerous and must be replaced.
19. Disconnect the Power Cord 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.
20. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
21. Maintain tools with care. Keep cutting tools sharp and clean. Properly
maintained tools with a sharp cutting edge are less likely to bind and are easier to
control. Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.
22. Check for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
23. 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.
Service
24. Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
25. When servicing a tool, use only identical replacement parts. Follow instructions
in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of
unauthorized parts or failure to follow maintenance instructions may create a risk of
electric shock or injury.
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SPECIFIC SAFETY RULLES FOR THIS PRODUCT
1.
2.
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 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 instantly. 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.
3.
4.
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 whatever is in its path. Be aware of the time it takes for the blade to
stop after switch is released.
5.
6.
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. Contact with a “live” wire will also make
exposed metal parts of the tool “live” and shock the operator.
7.
8.
Always use 3-3/8” 18-tooth carbide tipped blades. Blades that do not match the
mounting hardware of the saw will not run properly, causing loss of control.
Never use damaged or incorrect blade washers or bolts. The blade washers and
bolts were specially designed for your saw, for optimum performance and safety of
operation.
9.
Do not use dull or damaged blade. Unsharpened or improperly set blades produce
narrow kerf causing excessive friction, blade binding, and kickback.
10. Causes and Operator 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 closing down, the blade stalls and the motor reaction drives the unit rapidly
back toward the operator.
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If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of
the blade can dig into the top surface of the wood causing the blade to climb out of the
kerf and jump back toward the operator. Kickback is the result of tool misuse and/
or incorrect operating procedures or conditions and can be avoided by taking proper
precautions as given below:
Maintain a firm grip on the saw and position your body and arm in a way that
allows 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 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.
11. Use extra caution when making a “Pocket Cut” into existing walls or other blind
areas. The protruding blade may cut objects that can cause kickback.
12. Maintain labels and nameplates on the Saw. These carry important information. If
unreadable or missing, contact Harbor Freight Tools for a replacement.
13. Always wear ANSI-approved safety impact eye goggles, heavy work gloves, and
appropriate work clothes and shoes when using the Saw. Using personal safety
devices reduce the risk for injury. Safety impact eye goggles and heavy work gloves
are available from Harbor Freight Tools.
14. Maintain a safe working environment. Keep the work area well lit. Make sure there
is adequate surrounding workspace. Always keep the work area free of obstructions,
grease, oil, trash, and other debris. Do not use a power tool in areas near flammable
chemicals, dusts, and vapors. Do not use this product in a damp or wet location.
15. Avoid unintentional starting. Make sure you are prepared to begin work before
turning on the Saw.
16. Do not force the Saw. This tool will do the work better and safer at the speed and
capacity for which it was designed.
17. Always unplug the Saw from its electrical outlet before performing any
inspection, maintenance, or cleaning procedures.
18. Never leave the Saw unattended while running. Turn power off and unplug the
power cord if you have to leave the Circular Saw.
19. Before each use, check all nuts, bolts, and screws for tightness.
20. Keep extension cord off the ground and away from water.
21. Always connect the Power Cord to a Ground protected electrical outlet.
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WARNING!
People with pacemakers should consult their physician(s) before using this
product. Operation of electrical equipment in close proximity to a heart
pacemaker could cause interference or failure of the pacemaker.
Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities, contain 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.)
GROUNDING
WARNING!
Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualified electrician if you are in doubt as to whether
the outlet is properly grounded. Do not modify the power cord plug provided
with the tool or product. Never remove the grounding prong from the plug.
Do not use the tool if the power cord or plug is damaged. If damaged, have
it repaired by a service facility before use. If the plug will not fit the outlet,
have a proper outlet installed by a qualified electrician.
Grounded Tools with Three Prong Plugs
1.
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If the tool
should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user, reducing the risk of electric shock. (See
Figure A.)
2.
3.
The grounding prong in the plug is connected through the green wire inside the cord
to the grounding system in the tool. The green wire in the cord must be the only
wire connected to the tool’s grounding system and must never be attached to an
electrically “live” terminal. (See Figure A.)
Your tool must be plugged into an appropriate outlet, properly installed and grounded
in accordance with all codes and ordinances. The plug and outlet should look like
those in the following illustration. (See Figure A.)
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Figure B
Figure A
Double Insulated Tools with Two Prong Plugs
4.
This product has a polarized plug (one blade is wider than the other) as a feature to
reduce the risk of electric shock. This plug will fit in a polarized outlet only one way. If
the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact
a qualified electrician. Never use with an extension cord unless plug can be fully
inserted. Do not alter the plug.
5.
6.
Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satisfies OSHA requirements and complies with
the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard
Association, and the National Electrical Code. (See Figure B above.)
Double insulated tools may be used in either of the 120 volt outlets shown in the
following illustration. (See Figure B above.)
EXTENSION CORDS
1.
2.
Grounded tools require a three wire extension cord. Double Insulated tools can use
either a two or three wire extension cord.
As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a serious
drop in voltage, resulting in loss of power and possible tool damage. (See Table A.)
3.
The smaller the gauge number of the wire, the greater the capacity of the cord. For
example, a 14 gauge cord can carry a higher current than a 16 gauge cord. (See
Table A.)
4.
5.
6.
7.
When using more than one extension cord to make up the total length, make sure
each cord contains at least the minimum wire size required. (See Table A.)
If you are using one extension cord for more than one tool, add the nameplate amps
and use the sum to determine the required minimum cord size. (See Table A.)
If you are using an extension cord outdoors, make sure it is marked with the suffix “W-
A” (“W” in Canada) to indicate it is acceptable for outdoor use.
Make sure your extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified electrician
before using it.
8.
Protect your extension cords from sharp objects, excessive heat, and damp or wet
areas.
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SYMBOLOGY
Table B
UNPACKING
When unpacking, check to make sure that all the parts are included. The unit comes fully
assembled. Refer to the Assembly section, and the Assembly Drawing and Parts List at the
end of this manual. If any parts are missing or broken, please call Harbor Freight Tools at
the number on the cover of this manual as soon as possible.
OPERATING INSTRUCTIONS
The Flush Cut Saw is used to cut flooring, or in other areas that need to be cut flush against
a vertical surface (at a toe-kick area or where a wall meets the floor or countertop). The fol-
lowing steps give you guidelines on using the Flush Cut Saw.
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Controls
Trigger Switch (49)
Safety Button
Spindle Shaft Lock (33)
Making Flush Cuts
1.
Place the Saw where the flush cut is to be made. See photo below.
When making a cut under a toe-kick (i.e., under a cabinet), insert the Saw at an angle,
then lower it to the floor surface. See illustrations on the next page.
2.
3.
4.
5.
Plug the Power Cord (54) into the electrical outlet.
Grab the Forward Handle with your left hand.
Grab the Rear Handle with your right hand.
To begin cutting, press in (and hold) the Safety Button with your thumb, and at the
same time, pull the Trigger Switch (49) with your index finger.
When the Motor starts turning, release the Safety Button. As the Motor reaches full
speed, begin to move the Saw slowly forward and away from your body to complete
the cut. If a loud grinding noise is heard, the Saw Blade is contacting the cement
foundation. Immediately raise the Saw Blade.
6.
When the flush cut is complete, release the Trigger and hold the Saw in place until the
Saw Blade comes to a complete stop. Unplug the Power Cord (54) from the electrical
outlet.
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Caution: Never pull the Saw backwards since the Saw Blade will climb out of the cut
and kickback will occur.
INSPECTION, MAINTENANCE, AND CLEANING
WARNING!
Make sure the Trigger Switch of the Flush Cut Saw is in its “OFF” position,
and that the tool is unplugged from its electrical outlet, before performing
any inspection, maintenance, or cleaning procedures.
1.
2.
Before each use, inspect the general condition of the Saw. Check for loose
screws, misalignment or binding of moving parts, cracked or broken parts, damaged
electrical wiring, and any other condition that may affect its safe operation. If
abnormal noise or vibration occurs, have the problem corrected before further use.
Do not use damaged equipment.
Before remounting the Saw Blade (2), remove all sawdust that has accumulated
around the Safety Guard (6) and Blade Guard Frame (9).
3.
4.
5.
6.
7.
Regularly inspect and tighten all mounting screws and knobs.
Keep Saw Blade clean and sharp. Sharp blades minimize stalling and kickback.
Keep guards in good working order.
Keep motor air vent clean of dust and debris. Vacuum periodically.
If the tool is not operating normally, making unusual noises, or appears defective, stop
using it immediately and get it repaired.
8.
Clean tool with a damp cloth and light detergent. Do not use solvents as they can
damage and crack the plastic parts.
Replacing the Carbon Brushes
Unscrew the Carbon Brush Covers (38).
1.
2.
Pull out the Carbon Brush (36) from each side of the Motor and examine them.
If they are worn more than half way down, replace them. (An extra set is included.) It
could be that they are simply dirty. They can be cleaned using an ink eraser.
3.
Replace the Carbon Brushes (36) and Brush Covers (38).
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Installing the Saw Blade
1.
2.
3.
4.
Use only a 3-3/8 inch Saw Blade (2) rated to at least 4500 RPM.
Unplug the Saw Power Cord (54) from the electrical outlet.
Wearing work gloves, raise the Blade Guard (6) as far as possible.
Hold the Blade Guard up and press the spindle Shaft Lock (33) with one hand.
Rotate the Saw Blade until the spindle Shaft Lock catches and the blade stops.
5.
Using Hex Wrench (55) in the other hand, loosen (counterclockwise) the Screw (1).
Remove the Screw (1), then the Saw Blade (2).
Saw Blade (2)
Arbor Adaptor Plate (3)
6.
7.
Clean out Blade Guard Frame (9) of any debris.
Replace the new Saw Blade over the Arbor Adaptor Plate (3), and hole. Make sure
Arbor Adapter Plate is properly seated on the Shaft (11). Guide the Saw Blade onto
the pins of the Arbor Adaptor Plate.
The Saw Blade teeth at the bottom of the Saw Blade should be pointing toward the
front of the Saw.
8.
Press the spindle Shaft Lock (33) with one hand, and tighten the Blade Screw (1)
clockwise using the Hex Wrench with the other hand.
TROUBLESHOOTING
Symptom
Possible Cause
Remedy
Saw does not start when
Trigger Switch (49) is
pulled.
1. No power to Power Cord.
2. Safety Button not pushed in while 2. Press in Safety Button while
pulling Trigger Switch.
3. Defective switch.
4. Carbor Brushes dirty or worn
down.
1. Check electrical outlet for power.
pulling Trigger.
3. Replace switch.
4. Clean or replace carbor brushes.
While Cutting, saw slows
down.
Carbon brushes dirty or worn down.
Clean or replace carbon brushes.
Securely tighten Screw (1)
Saw blade slips while
cutting.
Saw Blade Screw (1) loose.
Blade Guard sticks or does Debris buildup in the Blade Guard
Remove Saw Blade and clean our
Blade Guard Frame.
not open easily.
Frame (9).
Wood burns or smokes
while cutting.
Saw Blade dull.
Sharpen or replace Saw Blade.
REV 07i
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PARTS LIST
NO. DESCRIPTION
QTY NO. DESCRIPTION
QTY
2
2
1
1
1
1
1
2
2
2
4
4
1
1
2
2
4
1
1
2
1
1
1
5
2
1
1
1
2
3
4
5
6
7
8
9
Screw
1
1
1
1
1
1
1
3
1
1
1
1
1
1
4
7
7
3
1
1
1
1
1
1
1
1
2
1
29 Spring Washer (D4)
30 Flat Washer 9D4)
31 Motor Stator
Saw Blade 3-3/8”-18T
Arbor Adaptor Plate
Bushing (L)
32 Shaft Lock Spring
33 Shaft Lock
Retaining Ring D36
Blade Guard
34 Rotor Retainer
35 Motor Housing
36 Carbon Brush
37 Brush Retainer
38 Brush Cover
Coil Spring
Screws M5*8
Blade Guard Frame
10 Guard Frame Connector
11 Shaft
39 Flat Washer D5
40 Bolt M5*55
12 Key 4*4*14mm
13 Bearing 6201
14 Retaining Ring D12
15 Screws M5*20
16 Spring Washer D5
17 Flat Washer D5
18 Screw M5*10
19 Shaft Housing
20 Bearing 6201
21 Gear
41 End Cover
42 Rear Supporter
43 Flat Washer D4
44 Nut M4
45 Screw ST4.2*13C
46 Handle (Part 1)
47 Cord Stopper
48 Screw ST4.2*13C
49 Switch, Trigger
50 Cord Thimble
51 Handle (Part 2)
52 Screw ST4.2*16C
53 Dscrew M4*25
54 Power Cord
22 Retaining Ring D10
23 Bushing (S)
24 Front Cover
25 Needle Bearing 6001-2R
26 Motor Rotor
27 Bolt D4*65
55 Hex Wrench
28 Bearing 627
NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS
MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER NOR 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 STATESTHAT 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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ASSEMBLY DRAWING
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LIMITED 90 DAY WARRANTY
Harbor FreightTools 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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