Getting the most out of your tool. Please tke time to rea this manual and pay particular attention tothe safety rules we've provided for your protection. Don't forget to send in your owner's registration card If you have any questions about your tool ease cl 1-800-9-BD TOOL (1-800-923-8665) TRIGGER SWITCH (WHEEL LOGK LEVER BRUSH CAP WHEEL GUARD WHEEL y a hee ES WARNING: When using Electric Tools, basi safety precautions should always be followedto reduce te risk offre, shock, and personal injury, inciding the following READ ALL INSTRUCTIONS. 1. _ KEEP GUARDS IN PLACE and in working order 2, REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that keys and adjusting ‘wrenches are rerioved from tol before turning ion 3, KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents, DON'T USE IN DANGEROUS ENVIRONMENT. Don't use power toos in damp or wet lcations, or ‘expose them to rain, Keep work area wel ight, KEEP CHILDREN AWAY. Al visitors should be kept at safe stance from work area, MAKE WORKSHOP KiD PROOF with paclocs, master switches, or by removing starter keys. DONT FORCE TOOL. t wil do the ob better and be safer tthe rate for which was designed, USE RIGHT TOOL. Don't force tol or attachment to do a job fr which twas not designed \WEAR PROPER APPAREL. No loose clothing, gloves, neckties, ings, bracelets, or oer Jewelry to get ‘aught in moving pats. Nonsip footwear is recommended, Wear protective hair covering fo contain Tong hai, 10, ALWAYS WEAR SAFETY GLASSES. Also use face or dust mask if cuting operation is dusty, Everday eyeglasses have only impact resistant lenses. They are NOT safety lasses 11. SECURE WORK. Use clamps or vse to old work when practical I's safer than using your hand and it frees both hands to operate oo. 12. DON'T OVERREACH. Keep proper fotin and balance at altimes, 18. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance, Follow Instructions for lubricating and changing acessories, 14, DISCONNECT TOOLS before servicing; when changing accessories suchas blades, bts, cutters, 15. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switchs in OFF postion before pag: ‘ing in, 16. USE RECOMMENDED ACCESSORIES. Consult the instruction manual for recommended accessories. The use of improper accessories may cause risk of injury to person. 17, NEVER STAND ON TOOL. Serious injury could accu the too is tpped orf the cutng tol is unin: ‘entionaly contacted. 18. CHECK DAMAGED PARTS. Before further use of the tool, a quard or othr part that is damaged should be carefully checked to determine that wil operate propery and perform is intended function — ‘heck for allnment of moving parts, binding of moving pats, breakage of part, mounting and any ter conditions tht mayafect is operation. A guard or other part that damaged shouldbe proper Iy repaired or replaced, 19, DIRECTION OF FEED. Feed work into a blade or cutter agains the direction of rotation ofthe blade or cutter oly, 20, NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’ leave too until it comes to@ ‘complete stop 21. DO NOT OPERATE ELECTRIC TOOLS NEAR FLAMMABLE LIQUIDS OR IN GASEOUS OR EXPLOSIVE "ATMOSPHERES. Motors in these tools may spark and ignite fumes.RAM le TT Grounding GROUNDED 10. " 12, 13. 14 15. ‘Aways wear safety gogoes or other eye protection wien using ths too Do nat remove or loosen chain. Check tat the chain is always tightly secured to the base and am, Before using, inspect each cutting wheel for cracks or flaws. Ifa crack or flaw is evident— scar the whee! The whee! should also be inspected vhenever you think the tool may have been dropped. ‘When starting the tool (with a new or replacement whee! installed) place the too! in a wel protected area. If the veel has an undetected crack or flaw, it should burst in less than one minute. Never start the tool with @ person in ine withthe wieel. This includes the operator. Im operation, avoid bouncing the wheel or giving trough treatment. If his occurs, stop te tol and inspect the whee. {Gtean your chop saw periodically folowing the procedure on page 4 ‘Do not remove whee quad, ‘vay use the vise to clamp work Use only wheels rated at 4100 rpm or higher ‘low cut of parts to cool before handling Do not attempt to cut wood or masonry with this tool, NEVER CUT MAGNESIUM WITH THIS TOOL. Use chop saw ina wol-ventilated area ‘Tur chop saw off before removing any pieces from the base. [NEVER USE A CIRCULAR SAW BLADE IN THIS CHOP SAW. DO NOT USE TOOTHED BLADES. ‘SAVE THESE INSTRUCTIONS FOR FUTURE USE a OUTLET BOX {nthe event of malfunction or breakdown, grounding pro- vides a path of east resistance for electric current to reduce the risk of elactic shack. This too is equipped wih an ec ‘ric cord having an equipment-grounding conductor and a rounding pig. The plug must be plugged int a matching GRouNDED outlet thats prep installed and grounded in accordance PRONG IS ih local codes and ordinances. LONGEST OF ‘Do not modify the plug provided. If it will not fit the outlet, THES PRONES have the proper ut installed by a qualified electrician. B ROUNDED ‘This tools intended for use on a circuit that has an outlet lke the oneilusrated in sketch A. The tool has a grounding plug that looks Ike the plug illustrated in sketch A ‘temporary adapter, which looks ike the adapterilustated in sketches B ard C, may be used to connec this plug toa 2-pole receptacle as shown in sketch 8 ifa properly (rounded outlet isnot available. The temporary adapter should be used only until a propery grounded outlet can be © installed by a qualified electrician. The green-colored rigid eat, lug, and te lke, extending from the adapter must be connected to a permanent ground such as a properly (rounded outletbox. ADAPTER SHOWN IN FIGURES B & C ISNOTFORUSE|N CANADA. 120 Volt Operation Be sure your power supply agrees with the nameplate marking, 120 Volts, 60H2 means alternating current (normal 120 vo, 62 house current). ‘Avoltage decrease of more than 10% wil cause a loss of power and overheating Extension Cords “Tools that have 3 wire cords requiring grounding must only be used with extension cords that have 3- rong grounding type plugs and 3-polereceptaces, Only round jacketed extension cords should be used, and we recommend that they be listed by Underwriters Laboratories (UL) (C.S.A in Canada). If ‘the extension wil be used ouside, the cord must be suitable for outdoor use. The letters “WA onthe cord jacket indicate that tis suitable for outdoor use. Any cord marked as outdoor can also be used {or indoor work. ‘An extension cord must have adequate wie size (AWG or American Wire Gauge) for safety, and to prevent loss of 2ower and overheating The smaler the gauge number ofthe wie, the greater the capacity ofthe cable, that is 16 gauge has more capacity than 18 gauge. When using more than one ‘extension to make up the total length, be sure each individual extension contains atleast the minimum ire size. To determine the minimum wire size required, refer tothe following char GROUNDING MEANS ADAPTER(CHART FOR MINIMUM WIRE SIZE (AWG) OF EXTENSION CORDS NAMEPLATE TOTAL EXTENSION CORD LENGTH-FEET RATING-AMPS 25 5075100125 150_—175_—_—200 0-00 18 ~CSSC~<~ OC‘ !!;*~*dCSC*~«‘z SSC‘2«SC«D 11-130 1606 aR 131-150 1404 Before using an extension cord, inspect it for loose or exposed wires, damaged insulation, and detec- tive fitings, Make any needed repais or replace the cord if necessary. B&D has extension cords aval- able thatare UL. (C.S.. in Ganad) sted for outdoor use. Features and Benefits + AG/DG permits use witha DC power source such as a welder. + Switch handle is human engineered fr maximum convenience when the sawis used ona bench, (ron the floor. Lightweight, sure-grip carrying handle, and fld-down design combine to make it easy to cary the machine from job to ob. Rugged stel base with rubber padded feet provide durability and reduced vibration operation for stable cutting Pivoting fence for convenience and accuracy in making mite cuts. Right position graduations for 0°, 15", 30° and 45°, Left postion graduations for O*, 15° and 30°. ‘+ Wheelock simplifies and speeds whee changing + WheelFence wrench is conveniantly stored in holder at rear of base + Spark shield over vise threads. ‘+ Tough tee wheel uard protects operator from the whee. Spark chute in base minimizes escap- ing sparks and protects surroundings. ‘+ Heavy duty brush system extends brushite. ‘+ High efficiency cooling fan and improved housing design assure high aiflow for cooler operation and ong ite ‘+ 8’ power supply cord with separable cord protectors convenient and simplifies. servicing ‘+ 100% ball and rol bearing construction fo longer tol it. Standard Equipment 1. 40278 Metal Cutting Abrasive Wheel Use high strength organic bonded wheels only. (Aluminum Oxide) 1) WheelFence wrench ee ‘Switch To start the tol, depress the trigger switch shown in Figure 1. To tur the tool of, release th trigger switch, Removal and Installation of Wheels 1, Be sure tool is disconnected from power supply TRIGGER SWITCH Figure 1 2. Push in whee! look lever (Figure 1) and rotate ‘whee! by hand untl whee! lock lever engages slot in inside flange to lock wheel. Loosen the hex. head bolt in the center ofthe abrasive wheel with the wrench provided at rear of base. Bolt has right hand thread, A Kw wooceven Reve te bo, washer, ouside fane adapta, an ol hea. (gr 2) Intl the new abrasive whe by reversing the above step, Make sue adapters on spindle Shatand canteen whee 5. Donotovertgten ot WARNING: Checkthe work sucht he chap saw rests on when replacing wih anew abrasive ‘wheel. It's possible thatthe whee! may contact the work surface (through the base) when the arm {is flly lowered. Figure 2 [ABRASIVE WHEEL HEX HEAD BOLT WASHER SPINDLE SHAFT DO NOT MAKE ANY ADJUSTMENT WHILE THE WHEEL ISIN MOTION. DO NOT MAKE ANY ADJUSTMENT WHILE CHOP SAW IS PLUGGED INTO POWER SUPPLY.To Adjust Vise Stop ‘CUTTING ANGLE Use the wrench to loosen the two hex bolts (Figure 3) (D0 not remove the bolts). The fence can be rotated in ether direction, Securely tighten both the bots before use. (OPENING ADJUSTMENT Aemove both fence bos. Move fence forvard or backvard to desired locaton. Install oth bots Tighten both bolts. To Carry Fold down unit to position where you can attach chain to pin on tool arm. (Figure 4) Cutting Capacity ‘The wide vise opening and high pivot point provide cutting capacity for many large pieces. Use this chart to determine total maximum sizeof cuts that can be made with a new wheel. Recommended applications are: metal studs, electrical conduit upto 4” diameter, bar stock and reinforcing bar upto 3/4 diameter, Note that ascuting width increases, cutting height decreases. ‘CAUTION: CERTAIN LARGE, CIRCULAR OR IRREGULARLY SHAPED OBJECTS MAY REQUIRE [ADDITIONAL HOLDING MEANS IF THEY CANNOT BE HELO SECURELY IN VISE. ‘CAUTION: DO NOT CUT MAGNESIUM WITH THIS TOOL. [NOTE: CAPACITY SHOWN ON FOLLOWING CHART ASSUMES NO WHEEL WEAR. SL Ss Fence BOLTS ~~ SS ~~ cura caper Cuan rence at ronwano . posmon qo wecext ‘| next “ POSITION. i. bs Maximum Cutting Depth ‘To obtain maximum cuting depth, move the fence tothe rear poston. (See Figure 5) NOTE: A new wheel, when pushed all the vay down, vil extend below the base and ct into the work surface Degree Setting ‘Align the index ine stamped in the base with the appropriate degre forthe desired angle of cut. (See Figure 6) For very accurate cuts, usea protractor. Figure 6 INDEX LINELubrication Closed-type, grease-sealed ball bearings are used throughout. These bearings have sufclent ubrca- ton packed in them atthe factory to last the fife of the bearing, Gears shouldbe relubricated every 60 to 90 days, depending upon use This lubrication should only be attempted by experienced power tool repairpersons like the mechanics at BAD service centers. The gear case should be wiped clean and 24 oz (20 grams) of B&D Lubricant PartNo, 790206 (6 cz tube) shouldbe placed inthe gear case Blowing dust and rt out ofthe main housing by means of an ar hose is recommended and may be done as often as dit is seen collecting in and around the ar vents. Motor Brushes e sure too! is unplugged before inspecting brushes. Brushes should be regularly inspected for ‘wear. To inspect brushes, unscrew the plastic brush caps (located in the sides ofthe motor housing) and the spring and brush assemblies may be removed from the tol. Keep brushes clean and sliding froolyin their guides. Ifthe brushes are worn down to 0.3" length, they must be replaced. New brush assembles are available at B&D service centers. See TOOLS, ELECTRIC inthe Yellow Pages. (See Figure7) Procedure For Permanent Mounting 1. Drill four holes, 5/16" diameter minimum, through the work surface. (Figure 8) 2. Remove screws from feet. 3. Insert 1/4-20 screws through underside of work surface, through feet, nto holes in too base The ‘roper screw length ts equal to the thickness ofthe work surace plus 1 inch (25 mm, Figure 7 Figure 8 16-318 Cradle Mounting 1, Gut two boards 20"long x2"=3*high x4 wide. 2, Ptace chop saw at desired work locaton, 3, Place boards tightly along side, and nail work sur- face. (Fgute 9) ‘ALWAYS WEAR SAFETY GLASSES. ALWAYS SECURE WORKIN VISE. DISCONNECT TOOL FROM POWER SUPPLY BEFORE ‘CHANGING WHEEL.Accessories ‘Recommended accessories for use with your tol are available at extra cost from your cistibutor oF local service center. A complet listing of service centers is included with your too. ‘CAUTION: The use of any non-recommended accessory may be hazardous. Htyou need any assistance in locating any accessory call 1-200-9-80 TOOL (1-800-923-8668) or con- tact Black & Decker (US.) nc., Consumer Service Department, P.O. Box 618, 626 Hanover Pike, Hampstead, MD 21074. IMPORTANT! To assure product safety and relablty, particulary for Double Insulated tools, repairs, maintenance and adjustment (excluding maintenance described in this manual) should be performed by B&D ser- vice centers or authorized service centers, using identical B&D replacement pars. ‘One Year Service/Safety Check ‘AILB&D tools for Industry and Construction are covered under a service/sfety check program where B&D will inspect your tol fr safety and provide necessary maintenance or repairs, including normal \wear and tear parts, for one year, FREE OF CHARGE, Full Warranty ‘All B&D tools for Industry and Construction are warranted to be fre of any defects in materials or ‘workmanship. Upon thorough examination of tol, B&D wil repair or eplce, at our option any prd- uct thats determined tobe defective Conditions ‘The servce/saf'y check and the warranty donot apply to: repairs made or attempted by anyone other than an authorized B&D service location; misuse, abuse, neglect, improper application ofthe tool; missing parts; o° normal wear and ter (aftr fist year of ownership). Please return the complet uit, transportation repaid, to any B&D factory owned or B&D authorized service center location (ist pro- vided with tool er see Vellow Pages under “Tools Electric), He hteereetrene a B pater