OPERATING MANUAL 12-in.Compound Miter Saw with Dual-Laser line 240-0024 IMPORTANT : Carefully read this Owner’s Manual before using this tool. Pay close attention to all Safety Instructions, Warnings, and Caution sections. Use this tool properly, and only for its intended use. Safety symbols in this manual are used to flag possible dangers. The safety symbols and their explanations require the operator’s full understanding.
TABLE OF CONTENTS Specifications.................................................................................................. Page 2 Rules for Safe Operation............................................................................... Page 3 Description....................................................................................................... Page 11 Adjustments..................................................................................................... Page 15 Operation..........
RULES FOR SAFE OPERATION KNOW YOUR TOOL Before operating this tool, carefully read this operating manual and all of the labels affixed to the router. Keep this manual available for future reference. IMPORTANT This tool should only be serviced by a qualified service technician. READ ALL INSTRUCTIONS THOROUGHLY GENERAL SAFETY RULES FOR ALL POWER TOOLS WARNING! Read and understand all instructions.
Recommended sizes of extension cords Tool’s Ampere rating Volts 0-6 6-10 10-12 12-16 120V~ Total length of cord in feet Cord size in A.W.G.(minimum) 25’ 50’ 100’ 150’ 18 16 16 14 18 16 14 12 16 16 14 12 14 12 Not Recommended 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.
20. DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only. 21. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’t leave tool until it comes to a complete stop. DOUBLE-INSULATED TOOLS 1. R eplacement Parts When servicing use only identical replacement parts. 2. P olarized Plugs T o reduce the risk of electric shock, this equipment has a polarized plug (one blade is wider than the other).
VOID body contact with grounded surfaces, such as pipes, radiators, A ranges and refrigerators. There is an increased risk of electric shock if your body is grounded. O NOT expose power tools to rain or wet conditions or use power tools in D wet or damp locations. Water entering a power tool will increase the risk of electric shock. This tool is intended for indoor use only.
WARNING: The use of optical instruments such as, but not limited to, telescopes or transits to view the laser beam will increase eye hazard. 1. T he laser shall be used and maintained in accordance with the manufacture’s instruction. 2. N ever aim the beam at any person or an object other than the work piece. 3. A lways ensure the laser beam is aimed at a sturdy work piece without reflective surface. I.e. wood or rough coated surface are acceptable.
11. ALWAYS be sure that the blade clears the workpiece. NEVER start the saw with the blade touching the workpiece. ALWAYS allow the motor to come up to full speed BEFORE starting a cut. 12. SUPPORT long workpieces when cutting to minimize the risk of blade pinching or kickback. The saw may slip, walk or slide while cutting long or heavy boards. 13. NEVER use a length-stop on the free (scrap end) of a clamped workpiece, NEVER hold onto or bind the free scrap end of the workpiece in any operation.
24. DO NOT turn the motor switch on and off rapidly. This could cause the blade to loosen, which could create a hazard. Should this ever occur, stand clear and allow the saw blade to come to a complete stop. Disconnect the saw from the power source and securely tighten the blade bolt. 25. ALWAYS turn off the saw before disconnecting it to avoid accidental starting when reconnecting the saw to a power supply. NEVER leave the saw unattended while connected to a power supply. 26.
ALWAYS check the tool for damaged parts. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine if it will operate properly and perform its intended function. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. A guard or other part that is damaged should be properly repaired or replaced by qualified person. INSPECT and remove all nails from lumber before sawing.
DESCRIPTION KNOW YOUR MITER SAW (Fig. 1a) Fig.
WARNING: Your saw should NEVER be connected to the power source when you are assembling parts, making adjustments, installing or removing blades, cleaning or when it is not in use. Disconnecting the saw will prevent accidental starting, which could cause serious personal injury. Laser On/Off Switch To turn on/off laser, press the laser button. Work Light On/Off Switch To turn on/off the work light, press the work light button.
bevel scale. The blade can be positioned at any angle, from a 90° straight cut (0° on the scale) to a 48° left and right bevel (Fig. 1a). Tighten the bevel lock knob to secure the saw head. NOTE: It is necessary to adjust the 48° left and right bevel angle specially. Miter Fence The miter fence is in two pieces, with numbered ruler on the left and right side and a slightly taller left and right side for additional support. Hold the workpiece securely against the miter fence when making all cuts.
ASSEMBLY MOUNTING THE MITER SAW TO WORK SURFACE (Fig. 2) To prevent your miter saw from Fig. 2 sliding, falling or tipping during operation, the saw must be permanently mounted to a firm, stable supporting surface, such as a workbench or piece of plywood. Four bolt holes have been provided in the saw base (one in each corner) for mounting purposes. Each of these four mounting holes should be securely bolted using machine bolts, lock washers and hex nuts (not included).
SAWDUST EJECTION PORT Fig. 3 This miter saw comes with a dust bag to help you keep the work area clean. The dust bag is ideal for smaller jobs. Dust Ejection Use a 2 1/2-in. vacuum hose adapter Port to hook up your saw to a wet/dry vacuum (sold separately). To install dust bag squeeze the metal collar wings located at the opening of the dust bag. Place the dust bag neck opening around the Fig. 3a sawdust ejection port (located on saw arm, behind upper blade guard) (Fig.
4. I f the blade is not 90° to the fence, unscrew the fence locking knobs completely out and remove the fence extensions. Fig. 4a 5. L oosen all hex-head bolts (Fig.4a). Rotate the fence until the protractor is flush over its entire length. Retighten the hexhead bolts. Remount the fence extensions. Hex-head bolts NOTE: If the saw has not been used recently, recheck blade squareness to the fence and readjust if necessary. MITER ANGLE INDICATOR ADJUSTMENT (Fig.
SQUARING THE BLADE TO THE MITER TABLE (Fig. 6, Fig.6b) WARNING: Failure to unplug your saw could result in accidental starting causing serious injury. 1. S et the bevel and miter angle scales to 0°and lock in place. Fig. 6 2. L ower and lock the saw arm into the “DOWN” position. 3. P lace a combination square on the miter table with the rule against the table and heel of the square against the saw blade.
BEVEL ANGLE INDICATOR ADJUSTMENT (Fig. 7) If Necessary 1. C heck to see if the bevel angle indicator is pointing to 0° on the bevel scale. Fig. 7 2. I f the indicator is not on 0°, loosen the bevel angle indicator screw, adjust the indicator to 0° on bevel angle scale, and tighten screw. ADJUSTING THE BLADE TO THE MITER TABLE 45° Bevel, 0° MITER (Fig. 8) WARNING: Failure to unplug your saw could result in accidental starting causing serious injury. 1. R aise the saw arm. Fig. 8 2.
These setting bolt are to your left and right as you face the back of the saw. (Fig.9) Fig. 9 6. L ift up to unlock the bevel angle lock knob (Fig.10),then adjust the blade to 45°by adjusting the setting bolt clockwise or counterclockwise. You may have to move the saw arm left or right by hand while you turning the setting bolt. 7. O nce the angle is set, tighten the setting bolt and bevel lock knob. Stop Pawl Fig. 10 ADJUSTING THE BEVEL STOP TO 33.9° NOTE: Adjust the 33.
OPERATION CAUTION: ALWAYS make sure the arbor lock button is released so the blade can rotate freely. MAKE SURE that the locking pin is loose and that the saw head moves freely up and down. ENSURE that all clamps and locks are tightly in place and that there is no excessive play in any parts. HOW TO USE THE DUAL LASER LINE (Fig.11) 1. M ark your workpiece with a pencil line at the point to be cut. Fig. 11 2. P ush the Laser ON/OFF switch “On” to activate the “bright red laser line”.
SUPPORTING LONG WORKPIECES (Fig.11a) Long workpieces require extra Fig. 11a supports. The supports should be placed along the workpiece so it does not sag. The support should allow the workpiece to lay flat on the base of the saw and work table during the cutting operation. Use the hold down clamp to secure the workpiece. CAUTION: NEVER use another person as an additional support for a workpiece that is longer or wider than the basic saw table, or to help feed, support, or pull the workpiece.
1. Release the tightening knob counterclockwise, and separate the two parts. (Fig.12a, Fig12b). Fig. 12a 2. Insert the hold down clamp in the hole as shown, press the lock button to adjust the the width according to the workpiece. (Fig.12c) 3. Tighten the hold down clamp knob clockwise. NOTE: When you do the bevel 45°cutting, You must pull to extend Fig. 12b the fence by releasing the fence locking knob to prevent from scratching with the saw arm.
USING THE MITER SAW CAUTION: Always hold the cutting handle firmly when making a cut, because the starting and stopping action of the motor may cause the handle to move up or down slightly. NOTE: Make the ON/OFF trigger switch childproof. Insert a small padlock or chain with padlock through the holes in the ON/OFF trigger switch, locking the switch and preventing children or other unauthorized users from turning on the saw (Fig. 13). Fig. 13 CROSSCUTTING (Fig.
To Crosscut With Your Miter Saw WARNING: Failure to unplug your saw could result in accidental starting causing serious injury. 1. U nplug the saw. 2. L ock the saw arm in the down position by pushing in the locking pin. 3. R aise miter lock lever and Fig. 14a release the detent locking knob by pressing it down to loosen the miter table. (Fig.14a) 4.
11. When cutting long workpieces, pull out extension wing for extra support for the long workpieces. (Fig. 14b) Fig. 14b CAUTION: NEVER use another person as an additional support for a workpiece that is longer or wider than the basic saw table, or to help feed, support, or pull the workpiece. WARNING: To avoid serious personal injury, ALWAYS keep your hands outside the “no hands zone”, as marked on the saw table, which is at least 3 inches from the blade.
BEVEL CUTTING (Fig. 15) A bevel cut is a cut made across the grain of the workpiece with the blade at an angle to the workpiece. A straight bevel cut is made with the miter table set in the 0° position and the saw arm set at a bevel angle between 0° and 45°. Fig. 15 45°Bevel Cut To Bevel Cut with Your Miter Saw 1. U nplug the saw. WARNING: Failure to unplug your saw could result in accidental starting causing serious injury. 2.
CAUTION: NEVER use another person as an additional support for a workpiece that is longer or wider than the basic saw table, or to help feed, support, or pull the workpiece. WARNING: To avoid serious personal injury, ALWAYS keep your hands outside the “no hands zone”, as marked on the saw table, which is at least 3 inches from the blade. Also, NEVER perform any cutting operation “freehand” (i.e.
3. S plintering typically happens due to incorrect blade style, dull blade, thinness of workpiece, or improperly dried wood. NOTE: Always perform a dry run cut so you can determine if the operation being attempted is possible before power is applied to miter saw. 4. P lace the workpiece flat on the miter table with one edge securely against the fence. If the board is warped, place the convex side against the fence.
To Make a Compound Miter Cut with your Miter Saw 1. Unplug the saw. WARNING: Failure to unplug your saw could result in accidental starting causing serious injury. 2. R elease the saw arm by pulling out the locking pin. 3. R aise miter lock lever and pressing the detent locking knob to loosen the miter table. 4. H old the base of the saw arm firmly and rotate the miter table on the miter lock lever by pressing the detent locking knob while holding the saw base steady. 5.
WARNING: To avoid serious personal injury, ALWAYS keep your hands outside the “no hands zone”, as marked on the saw table, which is at least 3 inches from the blade. Also, NEVER perform any cutting operation “freehand” (i.e. without holding the workpiece against the fence); the blade could grab the workpiece, causing it to slip and twist. 14. M ake sure that there will be no obstructions to interfere with when making the cut. 15.
Each B (Bevel) and M (Miter) Setting is listed to the closest 0.005° COMPOUND-ANGLE SETTINGS FOR POPULAR STRUCTURES *Pitch of Side = Angle of side from vertical. Example: ƾPITCH OF SIDE 0 o 5o 10o 15o 20o 25o 30o 35o 40o 45o 50o 55o 60o 65o 70o 75o 80o 85o 90o 3 M-45.00o B- 0.00o M-44.89o B- 3.53o M-44.56o B- 7.05o M-44.01o B-10.55o M-43.22o B-14.00o M-42.19o B-17.39o M-40.89o B-20.70o M-39.32o B-23.93o M-37.45o B-27.03o M-35.26o B-30.00o M-32.73o B-32.80o M-29.84o B-35.40o M-26.57o B-37.76o M-22.
CUTTING CROWN MOLDING (Fig. 18) Your miter saw is ideal for cutting crown molding. In order to fit properly, crown molding must be compound-mitered with extreme accuracy. To fit flat against the ceiling and wall, the sum of the angles of the crown molding’s two connecting surfaces must equal 90°(Fig.18) Fig.
COMPOUND BEVEL /MITER SETTINGS Key IL Bevel Setting 33.9° Left Miter Setting 31.6°Right Type of cut Inside corner - Left side 1. Position top of molding against fence. 2. Miter table set at RIGHT 31.6° IR 33.9° Right 31.6°Left 3. LEFT side is finished piece. Inside corner - Right side 1. Position top of molding against fence. 2. Miter table set at LEFT 31.6° OL 33.9° Right 31.6°Left 3. Right side is finished piece Outside corner - Left side 1. Position top of molding against fence. 2.
CUTTING WARPED MATERIAL (Fig.19 and 20) WARNING: To avoid kickback Fig. 19 and to avoid serious personal injury NEVER position the concave side of bowed or warped material against the fence. When cutting warped material, BE CERTAIN that the material to be cut is positioned on the miter table with the convex side against the fence, as shown (Fig. 19). If the warped material is positioned the wrong way, (Fig. 20), it will pinch the blade near the end of the cut. Top View Wright Fig.
WARNING: Always wear safety goggles or safety glasses with side shields during power tool operations, or when blowing dust. If operation is dusty, also wear a dust mask. ROUTINE MAINTENANCE WARNING: DO NOT at any time let brake fluid, gasoline, petroleum-based products, penetrating oils, etc. come in contact with plastic parts. Chemicals can damage, weaken or destroy plastic, which may result in serious personal injury. Periodic maintenance allows for long life and trouble-free operation.
WARNING: To prevent personal injury, ALWAYS disconnect the plug from power source BEFORE assembling parts, making adjustments or changing blades. WARNING: Be sure to wear protective work gloves while handling a saw blade. The blade can injure unprotected hands. 1. R aise the saw arm. 2. U se Phillips screwdriver, loosen but do not remove screw on the arbor screw guard by turning counterclockwise. 3. R otate arbor guard to expose the arbor. 4.
REPLACEMENT OF CARBON BRUSHES (Fig. 22, 23) The factory installed carbon Fig. 22 brushes in the motor assembly inspect it regularly by unplugging tool. Keep brushes clean and sliding freely in their guides. Always replace a used brush in the Plastic Cap same orientation in the holder as it was prior to its removal. 1. First unplug the saw before inspecting or replacing brushes. 2. Replace both carbon brushes when either has less than 1/4-in.
LOWER BLADE GUARD WARNING: DO NOT use the saw without the lower blade guard. The lower blade guard is attached to the saw for your protection. Should the lower blade guard become damaged, do not use the saw until the damaged guard has been replaced. Check the lower blade guard regularly; making certain that it is in proper working order. CAUTION: When cleaning the lower blade guard, unplug the saw from the power source receptacle to avoid unexpected startup.
TROUBLE SHOOTING PROBLEM PROBLEM CAUSE SUGGESTED CORRECTIVE ACTION Brake does not stop blade within 5 seconds. Motor brushes not sealed or lightly sticking Inspect/clean/ replace brushes See MAINTENANCE section Motor brake overheated from use of defective or wrong size blade or rapid ON/OFF cycling. Use a recommended blade. Arbor bolt loose. Retighten. Fuse. Check time delay fuse or circuit breaker. Brush worn. Replace brushes. See MAINTENANCE section Motor does not start.
Exploded View 40
Part List No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Part Name Base Pad Screw M4X10 Foot Rubber Ring Bevel Bracket 45 Bevel Override Lever Screw M6X30 Nut M6 Screw M6X10 Screw M10X25 Screw M5X10 D Handle Up D Handle Down Miter Lock Cam D Handle Support Screw ST4.2X16 Bolt M5X28 Nut M5 Spring Washer 5 Detent Stop Support Detent Stop Handle Detent Stop Pole Pin Washer Ø10XØ20X0.
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Bevel Lock Baffle Bevel Lock Bracket Cam Cam Shaft Bevel Lock Pole Nut M6 Bevel Change Pole Bevel Change Knob Turn Table Gasket Ø105X1 Bevel Lock Linker Miter Lock Pad 33.
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 E Ring 9 Screw M12X12 Screw M5X16 Bolt M8X30 Nut M8 Gear Case Cover Arbor Lock Pin Plate Pinion Arbor Lock Pin Spring Screw M4x8 Rolling Bearing 6201-2RS Needle Bearing HK1010 Big Gear Gear Shaft Key 5X10 Twins Laser Set LED Snake Light LED Mount Gear Case Horizontal Adjusting Support Laser Cover Dust Support Adjusting Support Bearing Cover Spring Plate Adjusting Spacer Shaft Big Pulley Spring Spring Scre
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 Inner Wire Trough Dust Board Washer Ø13xØ22x0.
135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 Torsion Spring Bolt M6X16 Washer 6 Control PCB Switch PCB Switch Panel Switch Knob Transparent Cover Screw ST2.
169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 Miter Pointer Bevel Pointer Inner Flange Outter Flange Flange Screw Pivot Shaft Turn table Axis Lock Down Pin Shoulder Screw Shoulder Screw Quick Lock Screw(L) Quick Lock Screw(R) Miter Scale Bevel Scale Torsion Spring Tighten Screw Inner Wire Fixed Cover Spring Spring V-Belt Blade-60T Power Cord & Plug Main Cord Guard Cord Anchorage Micro-Switch Power Supply Indicator Con
203 204 205 206 207 208 209 210 211 212 213 Dust Spout Left Sliding Base Extend Pole Right Sliding Base Wrench Dust Bag Set Work Piece Clamp Screw Terminal Spring Screw M4X6 1 1 4 1 1 1 1 2 2 2 2 B A A A A A A B B B A WARRANTY If, during normal use, this MASTERFORCETM power tool breaks or fails due to a defect in material or workmanship within three years from the date of original purchase, simply bring this tool and its sales receipt back to your nearest Menards® retail store for a free equivalent repl
