14" Abrasive Chop Saw

14" Abrasive Chop Saw Operation and Safety Instructions Model 99174 ® For your safety WARNING: Read and understand all instructions. Failure to fol...
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14" Abrasive Chop Saw

Operation and Safety Instructions Model 99174

®

For your safety WARNING: Read and understand all instructions. Failure to follow all instructions may result in electric shock, fire, and/or serious injury.

IMPORTANT INFORMATION INTRODUCTION

SPECIFICATIONS

Your new Wilton 14-inch Abrasive Chop Saw is a rugged, dependable tool that will cut metal and other materials with extreme accuracy and repeatability. Easy to operate, it’s the ideal saw for the serious DoIt-Yourselfer.

MODEL NUMBER ................................................99174 Motor Power Source............................120V AC, 60 Hz, 15 A Horsepower...........................................................2-1/2 Speed ...........................................2800 RPM (no load) Cutting disc..............................................14" (35.6 cm) Arbor .............................................................1" (2.5 cm) Swiveling vise clamp assembly .............0 – 45˚ right; 0 – 30˚ left Maximum cutting diameter ................4 1/2" (11.4 cm) Net weight........................................46 lbs 3 oz (21 kg)

®

Take time to read these Operation and Safety Instructions. A thorough understanding of your saw will enable you to use it to its full potential.

LIMITED WARRANTY Wilton Power Tools are warranted against defects in workmanship and material for a period of two (2) years from the date of purchase. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair or alterations, lack of maintenance, or use for purposes other than those for which the tool was designed. This warranty does not cover products used for commercial, industrial or educational purposes. Any return must be preauthorized, so please contact our Consumer Relations Department with warranty claims at 1-800-274-6848 for further instructions. If it is determined that the product is within this warranty, replacement parts or complete product replacement will be made at our discretion. WMH TOOL GROUPTM LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. WMH TOOL GROUPTM 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 PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

TABLE OF CONTENTS IMPORTANT INFORMATION ....................................2 Introduction ..........................................................2 Specifications.......................................................2 LIMITED WARRANTY ...............................................2 SAFETY .....................................................................3 General Safety Warnings.....................................3 Special Safety Rules for Chop Saws...................4 Electrical Requirements.......................................6 BEFORE YOU START...............................................8 Know Your Chop Saw..........................................8 Unpacking the Chop Saw ....................................9

ASSEMBLY..............................................................10 OPERATION ............................................................11 On/Off Switch .....................................................11 Swiveling Vise Clamp Assembly ........................11 Angle Plate.........................................................11 Remove/Install Cutting Disc ..............................12 Adjust Cutting Depth..........................................12 Cut a Workpiece ................................................13 MAINTENANCE.......................................................14 SERVICE..................................................................15

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SAFETY Wear the proper apparel – and non-slip footwear when operating power tools. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may become caught in moving parts. Keep long hair away from your face and tied back. Roll long sleeves above the elbow.

Read, understand, and follow all operating instructions, safety operations and symbols in this manual and warning labels on the saw before operating, maintaining, and cleaning your power tool.

WARNING: Indicates the presence of a hazardous situation which CAN cause SEVERE personal injury.

Use safety goggles at all times – which comply with ANSI Z87.1. Normal safety glasses only have impact resistant lenses and are not designed for safety. Wear a face or dust mask when working in a dusty environment. Use ear protection, such as plugs or muffs, during extended periods of operation.

CAUTION: Indicates the presence of a hazardous situation which WILL or CAN cause MINOR or MODERATE PERSONAL injury, or could cause machine damage. Note: Indicates installation, operation, or maintenance information which is important but not hazard-related.

GENERAL SAFETY WARNINGS WARNING: Failure to read all instructions and follow the

Secure your work – using clamps or a vise when practical. It frees both hands and is safer to operate the tool.

general safety warnings and other safety warnings and cautions may result in serious personal injury.

Do not overreach – and keep proper balance and footing at all times.

Know your power tool – read the instruction manual. Understand your power tool’s application, limitations, and potential hazards.

Maintain your tools with care – keeping them clean for best and safest performance.

Ground all tools – this tool is equipped with a 3-prong plug. It must be plugged into a properly grounded receptacle.

Disconnect your tool – unplug the power cord from the electrical source when making adjustments, changing parts, cleaning, or working on the tool.

Keep safety guards in place – and in working order with proper adjustment and alignment.

Avoid accidental starting – by ensuring the ON/OFF switch is in the OFF position and the power cord is unplugged from the electrical outlet.

Keep work area clean – prevent accidents. Take time to clean the tool, the work area, and especially the floor. The floor can become slippery from sawdust, wax and other materials.

Use recommended accessories – by the tool’s manufacturer. Read, understand and follow the instructions supplied with accessories. Using incorrect accessories may be hazardous.

Avoid dangerous environments – do not use power tools in damp or wet environments. Select a work area with proper lighting.

Never stand on the tool – or store materials above or near it. Standing on the tool to reach materials could result in serious injury if it tips or is accidentally contacted.

Keep children away – from the work area. Children and others should be a safe distance from the work area.

Check any damaged parts – discontinue using a damaged tool until the part is carefully checked. Ensure that all parts will operate and perform properly. Check for alignment of moving parts, jamming, breakage, improper mounting, and any other condition that may affect the tool’s operation. Any part that is damaged should be properly repaired or replaced before use.

Make the workshop childproof – use padlocks and master switches. Remove starter keys from power tools when not in use. Do not force the tool – beyond its designed rate. For a better and safer job, allow the tool to work within manufacturer’s recommendation. Use the right tool – for the job. Do not force a tool or its attachments to perform a task that it is not designed to do.

SAVE THESE SAFETY INSTRUCTIONS 3

SAFETY Never leave the tool unattended while it’s running – turn OFF the power. Do not leave the tool unattended until it reaches a complete stop.

Avoid injury from jams, slips, or thrown pieces

Drugs, alcohol, medication – are not to be used when operating the tool.





Wear a face mask or dust mask – when sawing. Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contain chemicals known to cause cancer, birth defects, or other reproductive harm. Examples of these chemicals include: – Lead from lead-based paints – Crystalline silica from bricks, cement, and other masonry products – Arsenic and chromium from chemically treated lumber. To reduce your exposure to these chemicals: work in a well-ventilated area, use approved safety equipment, and use dust masks that are specially designed to filter out microscopic particles.



● ●

Do not cut freehand ●





SPECIAL SAFETY RULES FOR CHOP SAWS



completely assembled and installed according to the instructions. Read and understand the following operating instructions and safety warnings in the manual and on the saw.



Check for proper assembly and proper alignment of moving parts.

● ●

Understand the function and proper use of:

● ● ●

Allow room so the cut-off workpiece can move after it is cut. It could create a hazard by becoming wedged against the disc.

Avoid contact with a rotating cutting disc

Before Operating Your Chop Saw



Verify the workpiece will not rock or twist when it is being cut. The area between the workpiece and the saw must be free from debris. Make sure there is no gap between the workpiece, angle plate, and base of the saw. A gap could allow the workpiece to move when it is being cut. Use vise clamps to hold the workpiece. Do not secure waste piece.

Do not cut more than one workpiece at a time

WARNING: Do not use or plug in your saw until it is



Use the correct 14-inch cutting disc for the material and type of cut. Do not cut wood with this saw. Replace cracked cutting disc immediately. Handle disc carefully. and inspect for cracks before each use. Tighten spindle bolt enough to hold the disc firmly. Use only the disc flanges provided with your saw. Make sure cutting disc is properly installed. Make sure the arbor screw and washer are properly installed and tightened. Ensure all clamps and locks are tight. Verify there is no excessive play in any parts. Allow the disc to reach full speed before cutting.

Trigger switch/start switch Lower guard Spark deflector Wheel lock lever Quick-release latch



Do not wear gloves, loose clothing, or jewelry. Tie back long hair and roll long sleeves above the elbow. Do not allow anyone to stand behind the saw or close to the workpiece where debris can be thrown. Operate your saw in a clear, safe environment.

Avoid injury from accidental starting of saw. Unplug the power cord from the electrical source: ● ● ●

Know the condition of your saw. If any part is missing, bent, or does not operate properly, replace the component before you continue to use your saw. Determine the type of work you are going to be doing before you operate your saw. Properly protect your body including your eyes, hands, face, and ears.

Disconnect the lower guard. Install or remove the disc. Perform maintenance or make adjustments.

Avoid injury from electrical shock ●

Do not touch the metal blades on the power cord plug when inserting or removing the plug from an electric outlet.

Avoid injury from a fire hazard ●

Do not operate the saw near flammable liquids, vapors, or gases.

SAVE THESE SAFETY INSTRUCTIONS 4

SAFETY Use care when cutting

When Operating Your Saw



Avoid injury from unexpected saw movement ● ●

Use the saw on a firm level surface with adequate space for handling and supporting the workpiece. Be sure the saw cannot move when operated.

● ●

Before moving the saw ● ●

Avoid awkward operation

Unplug the power cord from the electrical source. Lock the handle in the down position using the handle latch.

● ●

Avoid back injury ● ● ●

Obtain help when it is necessary to raise the saw more than 10 inches (254 mm). Bend your knees when lifting the saw. Carry your saw by the carrying handle or base. Do not carry your saw by the power cord or the trigger handle. Carrying the saw by the power cord could cause damage to the insulation or the wire connections resulting in electric shock or fire.

Make sure your hand is never closer than 4 inches (102 mm) from the disc. Do not cross your arms in front of the disc while operating the saw.

Do not force the disc through the workpiece ●

Lower the disc through the workpiece fast enough to allow it to cut without binding or bogging down.

Before removing obstructed material ●

Whenever the Saw is Running WARNING: Do not make a careless error just because you operate the saw frequently. A neglectful moment can cause a severe injury.

Release the trigger switch/start button, wait for the disc to stop moving, and unplug the power cord from the electric outlet.

After completing a cut ●

Prior to cutting a workpiece ●

Flying sparks will occur when cutting. They can cause injury and ignite flammable materials. Never use a circular saw blade or tooth-type blade in the chop saw. Use only abrasive cutting discs rated at 3500 RPM or higher.



Test the operation of your saw. If you feel excessive vibration or hear an unusual noise, immediately stop operating the saw. Correct the problem before using.

Keep the handle in the down position. Release the trigger switch/start button and wait for the disc to stop moving. Do not touch workpiece after cutting. It is hot and could burn skin.

Allow movement of the waste portion of the workpiece ●

Do not hold it, clamp it, touch it or use a length stop against it. The cut-off waste portion must be free to move. It could become wedged against the disc causing a hazard.

SAVE THESE SAFETY INSTRUCTIONS 5

SAFETY ELECTRICAL REQUIREMENTS

In the event of a malfunction or breakdown, grounding provides the path of least resistance for electric current and reduces the risk of electric shock. This tool is equipped with an electric cord that has an equipment grounding conductor and a grounding plug. The plug MUST be plugged into a matching receptacle that is properly installed and grounded in accordance with ALL local codes and ordinances.

WARNING:

• Use only manufacturer’s recommended replacement parts, or equivalent, when servicing this tool.

• Do not touch the metal blades on the power cord plug when removing or installing the plug into an electrical outlet.

• To avoid electrical hazards, fire hazards, or damage to the

Improper connection of the equipment grounding conductor can result in risk of electric shock. The conductor with the green insulation (with or without yellow stripes) is the equipment grounding conductor.

tool, use proper circuit protection. Your saw is wired at the factory for 120V operation. Connect to a 120V, 15 Amp time delayed fuse or circuit breaker. To avoid shock or fire, replace power cord immediately if it is worn, cut, or damaged in any way.

If repair or replacement of the electric cord or plug is necessary, DO NOT connect the equipment grounding conductor to a live terminal.

Use a separate electrical circuit for your tools. This circuit must not be less than a #12 wire and should be protected with a 15 Amp time delayed fuse. Before connecting the motor to the power line, make sure the switch is in the OFF position and the electric current is rated the same as the current stamped on the motor nameplate. Running at a lower voltage will damage the motor.

Check with a qualified electrician or service personnel if you do not completely understand the grounding instructions, or if you are not sure the tool is properly grounded.

WARNING: This saw is for indoor use only. Do not expose to rain or use in damp locations. This tool must be grounded while in use to protect the operator from electrical shock.

Do not modify the power cord plug. If it does not match the electrical outlet, have the proper outlet installed by a qualified electrician. This tool is intended for use on a circuit that has a receptacle like the one illustrated: a 3-prong electrical plug (1) and a receptacle (2) that has a grounding conductor. If a properly grounded receptacle is not available, have a certified electrician check the receptacle.

1

2

SAVE THESE SAFETY INSTRUCTIONS 6

SAFETY Use only 3-wire extension cords that have 3-prong plugs and 3-prong outlets that accept the tool’s plug.

Guidelines for Extension Cords 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 cause overheating. The table below shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Be sure your extension cord is properly wired and in good operating condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it. Protect your extension cords from sharp objects, excessive heat and damp or wet areas. Repair or replace damaged or worn cord immediately.

Minimum Gauge for Extension Cords (AWG) (when using 120 volts only) Ampere Rating

Total Length of Cord in Feet (meters)

More Than

Not More Than

25 (7.6)

50 (15.2)

100 (30.4)

150 (45.7)

0

6

18

16

16

14

6

10

18

16

14

12

10

12

16

16

14

12

12

16

14

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SAVE THESE SAFETY INSTRUCTIONS 7

Not Recommended

BEFORE YOU START KNOW YOUR CHOP SAW 1

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3 4

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18

5

6

17 7 8 16

9 15 10 14 12

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Figure 1

1 2 3 4 5 6 7 8 9 10

Trigger switch D-handle Arbor lock Upper guard Lower guard 14" metal cutting disc Angle plate Vise pressure plate Quick-release latch Vise handle

11 12 13 14 15 16 17 18 19

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Vise wheel Vise screw Rubber feet (4) Base Spark deflector Depth stop bolt Wheel lock lever Carbon brush cap Carrying handle

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BEFORE YOU START UNPACKING THE CHOP SAW

1. Carefully unpack the abrasive chop saw and all its components.

WARNING: To avoid injury:

2. Inspect the contents and compare to the list below.

• Do not plug the power cord into the power source during unpacking or assembly. • If any part is missing or damaged, do not connect the saw to the power source until the missing or damaged part is replaced and assembly is complete. • Avoid fire and toxic reaction. Never use gasoline, naphtha, acetone, lacquer, thinner or any volatile solvents to clean the saw.

1

2

4 3

Figure 2

1 2 3 4

14" abrasive chop saw Vise handle knob Threaded bolt and nut Adjusting wrench

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ASSEMBLY ASSEMBLING THE CHOP SAW

WRENCH STORAGE

Your saw requires these minor assembly tasks. Once assembled, complete the adjustment procedures before using the saw.

Store the wrench provided with your saw in the slots at the rear of the saw.

INSTALL THE VISE CRANK 1. Insert the bolt (1) through the vise handle (2). 2. Tighten the nut (3) on the bolt. 3. Insert the assembled handle into the opening (4) on the vise wheel and turn it clockwise to secure the handle to the wheel.

1

2 4 3

Figure 5

2 1

Figure 3

RAISE/LOWER THE SAW 1. Pull out the wheel lock lever (1) and use the handle to raise or lower the saw. 2. Push in the wheel lock lever (1) in to lock the saw in the raised or lowered position.

1

Figure 4

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OPERATION ON/OFF SWITCH

SWIVELING VISE CLAMP ASSEMBLY AND QUICK RELEASE LATCH

To start the saw, press the trigger switch (1). To stop the saw, release the trigger switch. Allow the disc to come to a complete stop before using the saw again or making adjustments.

Always secure the workpiece between the angle plate and the vise pressure plate when cutting. 1. Place the workpiece between the angle plate (1) and the vise pressure plate (2).

1

1

2 3 4

5

Figure 6

Figure 7 2. Push the vise screw (4) toward the angle plate and turn the vise wheel (5) clockwise to secure. 3. To release, turn the wheel counterclockwise two turns, raise the quick-release latch (3) and pull the vise screw toward you.

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OPERATION ANGLE PLATE

REMOVE/INSTALL CUTTING DISC

The angle plate can be moved forward, backward, or rotated for angle cutting. 1. To move the angle plate, loosen the two bolts (1) and place the angle plate (2) in the desired position. Retighten the bolts.

1. Unplug the saw. 2. Push the arbor lock lever (1) toward the cutting disc (2) and slowly turn the disc (either direction) until it locks. 1 2

1 2

Figure 10

Figure 8

3. Loosen the hex bolt (5) in the center of the disc with the wrench. Remove the bolt, washer (4), flange (3), and disc (2).

2. To set a cutting angle, loosen the bolts and rotate the angle plate (2) up to 45˚ right or 30˚ left. Align the index with the left edge of the angle plate slot. Retighten the bolts.

2 3 4 5

3

2

Figure 11 4. To install a new cutting disc, reverse the process in step 3. Do not over tighten the bolt. 5. Make sure all guards are in place and the disc rotates freely. 6. Adjust the depth stop bolt (Fig. 12). 7. Return the wrench to the storage slot (Fig. 5). 8. Plug in the saw. 9. Run the saw and check to make sure the disc is in good condition. When testing a new disc, run the saw for 3 minutes. When testing an existing disc, run the saw for 1 minute.

Figure 9 3. Always center the workpiece over the table slotweb to maximize cutting depths. Move the angle plate (2) toward the vise pressure plate (3) until the workpiece is centered over the web. Tighten angle plate bolts (1) and vise pressure plate (3).

Note: Always stand to one side when turning on the saw.

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OPERATION ADJUST THE CUTTING DEPTH

CUT A WORKPIECE

The depth stop bolt must be adjusted as the diameter of the cutting disc decreases with use. This will prevent the disc from cutting the work surface below the saw table.

1. Set the angle plate (1) to the desired cutting angle. 2. Make sure the workpiece lies flat on the saw table. 3 Use the vise (2) to secure the workpiece to the table.

1. Loosen the lock nut (2). 2. Turn the stop bolt (1) to set the downward travel of the disc.

1 1

2

2

Figure 13 4. Pull the trigger switch.

Figure 12

5. After the motor reaches full speed, lower the disc into the center of the workpiece.

3. Re-tighten the lock nut when the disc is at the desired depth.

6. Using a smooth, firm, and gentle downward motion, make a clean cut through the workpiece. Do not allow the disc to bump or jump when making contact with the workpiece; this may damage both the workpiece and the disc. 7. Keep consistent pressure when coming to the bottom of the cut to avoid forming a heavy burr and overheating the workpiece. 8. Raise the disc completely from the workpiece before releasing the trigger switch and allow the motor to stop before removing the workpiece. Note: A long workpiece should be supported on both ends with blocks of a non-flammable materials, so the workpiece is level to the saw table.

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MAINTENANCE REPLACING CARBON BRUSHES

WARNING: • Before performing any maintenance or cleaning on your saw, unplug the power cord from the power source. The power cord must remain unplugged whenever you are working on your saw. • To prevent electrical shock, fire or injury, use only identical replacements parts with equivalent characteristics, including type, strength and material. Be sure to assemble replacement parts exactly as the original components to reduce the risk of electrical shock. • If the power cord is worn, cut or damaged, have it replaced immediately.

WARNING: Be sure to unplug the power cord from the power source before inspecting the carbon brushes. Check the condition of the carbon brushes after 50 hours of use of your new saw. If the brushes are worn to 1/4 inch (6 mm) in length, replace them. To inspect the carbon brushes: 1. Loosen and remove the two brush caps (1) using a slotted screwdriver.

WARNING: Never use flammable or combustible

2. Carefully remove the caps from the motor. The caps are spring loaded from the spring on the brush.

solvents around tools. When servicing, use only identical Wilton replacement parts. Use of any other parts may create a hazard or cause product failure.

3. Pull out one brush at a time. Inspect the brush and replace them if necessary. Be sure to replace both brushes even if only one is damaged.

WARNING: Dust generated from certain materials can be hazardous to your health. Always operate the saw in wellventilated areas and provide proper dust removal. Use dust collection systems whenever possible. Wear a face mask when operating the saw.

1

GENERAL MAINTENANCE Before each use, inspect guards, switches, power cord, and extension cord. Check for loose screws, jamming, broken parts and any other condition that may affect the safe operation of the saw. If an unusual operating noise or vibration occurs, turn the saw off and immediately correct the problem before using the saw again.

Figure 14 Note: If you are not installing new brushes, be sure to re-install the brushes into the same positions they were removed from. 4. Position the brushes into the motor.

CLEANING

5. Tighten the brush caps snugly. Do not over-tighten.

Clean dust and debris from vents, table top, and vise screw. Use a dry, clean rag to clean all areas of the saw. Never use solvents or other harsh chemicals for cleaning as they are harmful to plastic and other insulated parts. Petroleum-based products, brake fluid, thinners, and ammonia detergents are also harmful to your saw.

LUBRICATION All the ball bearings are permanently lubricated and do not require lubrication.

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SERVICE REPLACEMENT PARTS When servicing your Wilton® product, use only Wilton® replacement parts. Use of any other parts may cause product damage. All servicing of the tool should be performed by a qualified service technician. When requesting service or ordering parts, always provide the model number, part number and description.

Customer Replacement Parts Part Number TS-2286252 TS-1550041 99174N003 TS-1540061 TS-1490111 TS-1491013 99174N013 TS-2361101 TS-1550071 TS-1550071 99174N016 99174N018 99174N029 99174N030 TS-1550061 99174N032 TS-2288502 99174N052 99174N053 99174N063 TS-2285352 99174N067 99174N090 99174N091 99174N093 99174N095 99174N098 99174N099 99174N102 99174N103 99174N107 M99174

Item Phillips screw at rubber foot, M6x25 Flat washer at rubber foot, M6 Rubber foot Nut, M8 Depth stop hex bolt, M8x60 Angle plate hex bolt, M10x25 Disc hex bolt, M10x25 Angle plate lock washer, M10 Angle plate flat washer, M10 Disc bolt small washer, M10 Angle plate Vise pressure plate Vise wheel spring pin, 4x20 Vise tension wheel Vise flat washer, M8 Vise tension handle Vise handle screw, M8x50 Motor brushes (set of 2) Brush covers (set of 2) Return spring cover (plastic) Phillips screw, carry handle, M5x35 Carry handle Spring support cover Lower guard return spring Lower guard Lower guard roller Disc flange Bushing, 1" cut-off disc Disc bolt large washer Spark deflector Wrench, hex bolt Manual

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SERVICE FOR REPLACEMENT PARTS AND SERVICE In the U.S.:

WMH TOOL GROUP Consumer Relations 427 Sanford Road Lavergne, TN 37086 Phone: 1-800-274-6846 (technical assistance) 1-800-274-6848 (parts) www.wmhtoolgroup.com

In Canada:

WMH TOOL GROUP LTD Customer Service 212A Wilkinson Road Brampton, Ontario L6T 4M4 CANADA Phone: 1-800-689-9928 www.wmhtoolgroup.com

99174 A 0904

©WMH Tool Group

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Printed in China