drillmaster 120 Volt 6″ Cut-Off Saw User Manual
- June 6, 2024
- drillmaster
Table of Contents
120 Volt 6″ Cut-Off Saw
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.
21b
Grinding Wheel Sold Separately Visit our website at: http://www.harborfreight.com Email our technical support at: productsupport@harborfreight.com
When unpacking, make sure that the product is intact and undamaged. If any
parts are missing or broken,
please call 1-888-866-5797 as soon as
possible.
Copyright© 2019 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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table of contents
Safety ………………………………………………… 2 Specifications ……………………………………… 6 Setup …………………………………………………. 6 Operation……………………………………………. 7
Maintenance ………………………………………. 10 Parts List and Diagram ………………………… 14 Warranty ……………………………………………. 16
WarninG SyMBOLS anD DEFinitiOnS This is the safety alert symbol. It is used to
alert you to potential personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death. Indicates a hazardous
situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury.
Addresses practices not related to personal injury.
iMpOrtant SaFEty inFOrMatiOn
General tool Safety Warnings
read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.
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 removed from tool before turning it on.
3. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
4. DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet
locations, or expose them to rain. Keep work area well lighted.
5. KEEP CHILDREN AWAY. All visitors should be kept safe distance from work
area.
6. MAKE WORKSHOP KID PROOF with padlocks, master switches, or by removing
starter keys.
7. DON’T FORCE TOOL. It will do the job better and safer at the rate for
which it was designed.
8. USE RIGHT TOOL. Don’t force tool or attachment to do a job for which it
was not designed.
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General tool Safety Warnings (cont.)
table a: rEcOMMEnDED MiniMuM WirE GauGE FOr EXtEnSiOn cOrDS (120 VOLt)
naMEpLatE aMpErES
(at full load)
EXtEnSiOn cOrD LEnGtH
0 6
18 16 16 14
6.1 10
18 16 14 12
10.1 12
16 16 14 12
12.1 16
14 12 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. 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.
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.
13. DON’T OVERREACH. Keep proper footing and balance at all times.
14. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest
performance. Follow instructions for lubricating and changing accessories.
15. DISCONNECT TOOLS before servicing; when changing accessories, such as
blades, bits, cutters, and the like.
16. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off
position before plugging in.
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.
20. 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
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tO prEVEnt ELEctric SHOcK anD DEatH FrOM incOrrEct GrOunDinG WirE cOnnEctiOn
rEaD anD FOLLOW tHESE inStructiOnS:
110-120 Vac 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.
2. Do not modify the plug provided if it will not fit the outlet, have the
proper outlet installed by a qualified electrician.
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 equipmentgrounding conductor to a live terminal.
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.
5. Use only 3-wire extension cords that have 3-prong grounding plugs and
3-pole receptacles that accept the tool’s plug.
6. Repair or replace damaged or worn cord immediately.
Grounding pin
125 Vac 3-prong plug and Outlet (for up to 125 Vac and up to 15 a) 7. This
tool is intended for use on a circuit that has an outlet that looks like the
one illustrated above in 125 Vac 3-prong plug and Outlet. The tool has a
grounding plug that looks like the plug illustrated above in 125 Vac 3-prong
plug and Outlet. 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.
cut-Off Saw Safety Warnings
For your Own Safety read instruction Manual Before Operating Grinder.
9. Do not grind with side of wheel unless wheel is specifically designed for that type of grinding.
1. Wear eye protection. 2. Use grinding wheel suitable for speed of grinder.
3. Replace cracked wheel immediately. 4. Always use guards and eye shields. 5.
Do not overtighten wheel nut. 6. Use only flanges furnished with the grinder.
7. Frequently clean grinding dust from beneath grinder. 8. Wear a full face
shield over ANSI-
approved safety goggles during use.
10. DO nOt OpEratE WitH any GuarD DiSaBLED, DaMaGED, Or rEMOVED. Moving
guards must move freely and close instantly.
11. The use of accessories or attachments not recommended by the manufacturer
may result in a risk of injury to persons.
12. When servicing use only identical replacement parts.
13. Only use safety equipment that has been approved by an appropriate
standards agency. Unapproved safety equipment may not provide adequate
protection. Eye protection must be ANSI-approved and breathing protection must
be NIOSH-approved for the specific hazards in the work area.
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cut-Off Saw Safety Warnings (cont.)
14. 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.
15. Industrial applications must follow OSHA guidelines.
16. Maintain labels and nameplates on the tool. These carry important safety
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
17. Avoid unintentional starting. Prepare to begin work before turning on the
tool.
18. 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.
19. 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:
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.
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.
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 Motor No Load Speed Max Accessory Diameter Arbor Size Cutting Capacity Cutting Angle
120VAC / 60Hz / 5.5A 10,000 RPM 6″ 5/8″, 7/8″ (changeable) 1″ 0-45°
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.
note: For additional information regarding the parts listed in the following
pages, refer to the Assembly Diagram near the end of this manual.
Functions
Safety Button (on other side
of handle)
trigger
Handle
Stationary Guard
Vise Knob
Swing Guard
angle Guide
Vise clamp
Base
cut-Off Wheel (Grinding)
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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
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OpEratiOn
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 a cut-Off (Grinding) Wheel
1. The Grinding Wheel MUST be: · rated to at least 10,000 RPM. · no larger than 6″ in diameter. · fitted with a 5/8″, 7/8″ (changeable) round arbor hole. · suitable for edge grinding, not surface grinding. · dry and clean. · proven undamaged by inspection and by the ring-test explained below.
2. Closely inspect the new wheel before mounting it. Perform a ring-test on
the wheel XQOHVVZKHHOLVVPDOOHUWKDQDVIROORZV
a. Suspend wheel using a dowel or finger through the arbor hole.
Hang Wheel from Dowel
45°
45°
V E r t i c a L
tap Wheel Here
c E n t E r
45°
45°
3. Release the Safety Chain from the securing pin (see Figure a) and guide
the Housing to rest at its full upward position.
Safety chain
Figure a: Safety chain
Securing pin
4. Open the Swing Guard all the way, exposing the Grinding Wheel, Outer Flange (29) and Arbor Bolt (30).
5. As shown in Figure B, use the supplied Flat Wrench (44) to hold the Spindle in place and use the supplied Sleeve Wrench to loosen the Arbor Bolt.
Flat Wrench
Swing Guard
b. Tap the flat side of the wheel with a light nonmetallic 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).
c. Rotate the wheel 90° and repeat the test until the entire wheel has been
checked.
d. An undamaged wheel will ring with a clear tone. If cracked, there will be a
dead sound and not a clear ring.
Sleeve Wrench
Figure B: removing the arbor Bolt
6. Remove the Arbor Bolt, the Outer Flange and the old Grinding Wheel, noting
the orientation of each.
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note: Two Adapters are supplied with this saw, 5/8″ (61) and 7/8″ (62). The
Adapter used for the old wheel may be the wrong size for the new wheel. Use
the Adapter that fits the new Grinding Wheel.
inner Flange Spindle with no adapter
9. For wheels with paper gaskets (blotters) or metal gaskets: Slip the
grinding wheel onto the Arbor 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.
WarninG: to prevent serious injury, gaskets must be used for all grinding
wheels they are provided with. Gaskets help prevent grinding wheel damage and
wheel slippage, causes of wheel failure.
10. Lower the Housing and replace the Safety Chain.
7/8″ adapter
5/8″ adapter
Figure c: adapters
7. The Adapter should be on the Spindle and against the Inner Flange. Install the new Grinding Wheel onto the Adapter.
8. Replace the Outer Flange onto the Spindle; thread the Arbor Bolt onto the Spindle and tighten them in place with the Sleeve Wrench.
adjusting cut angle
1. To cut at various angles (up to 45º), adjust the Angle Guide by loosening
the two Bolts that attach the Guide to the Base.
2. Adjust the Angle Guide to the desired setting and then tighten both Bolts.
3. To reposition the Angle Guide for a differentsized workpiece, remove both
of the Bolts, and reattach the Angle Guide at the other set of screw holes.
See Figure D.
angle Guide
Bolt (hidden)
Bolt
Screw Holes Figure D: repositioning the angle Guide
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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. There must not be objects, such as utility lines, nearby that will present a hazard while working.
using the Vise
Secure loose work pieces using the Vise to prevent movement while working: See Figure E.
Quick release
Vise clamp
1. Turn the Vise Knob counterclockwise a quarter turn and lift up the Quick Release.
2. Slide the Vise Clamp open as far as needed.
3. Position the workpiece against the Angle Guide.
4. Push the Quick Release down onto the Vise threads.
5. Push the Vise Knob until the Vise Clamp is up against the workpiece.
6. Tighten the Vise Knob clockwise to secure the workpiece.
Vise Knob
Figure E: Vise components
angle Guide
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.
1. Release the Safety Chain and guide the Housing to rest at its full upward
position.
2. Adjust the Angle Guide as needed.
3. Place the workpiece against the Angle Guide and clamp in place using the
Vise.
4. Plug the Power Cord into a grounded, 120VAC electrical outlet.
5. Press the Safety Button, then squeeze and hold the Trigger to start the
Saw. Allow the Grinding Wheel to attain full speed.
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 Trigger and raise the Saw.
8. Wait until the Wheel comes to a complete stop, then remove the workpiece.
9. To prevent accidents, turn off the tool and disconnect its power supply
after use. Lower the Saw and secure with the Safety Chain. Clean, then store
the tool indoors out of children’s reach.
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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 condition of the tool. Check for: ·
loose hardware, · misalignment or binding of moving parts, · cracked or broken
parts, · damaged electrical wiring, and · any other condition that may affect
its safe operation.
2. aFtEr uSE, wipe external surfaces of the tool with clean cloth.
3. Periodically, wear ANSI-approved safety goggles and NIOSH-approved
breathing protection and blow dust and grit out of the motor vents using dry
compressed air.
4. WarninG! tO prEVEnt SEriOuS inJury: if the supply cord of this power tool
is damaged, it must be replaced only by a qualified service technician.
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
Tool will not start.
possible causes
1. Cord not connected. 2. No power at outlet.
3. Internal damage or wear. (Carbon Brushes or switch, for example.)
Tool operates slowly. Extension cord too long or wire size too small.
Performance
1. Wheel worn or dull.
decreases over time.
Excessive noise or rattling. Overheating.
2. Carbon brushes worn or damaged. Internal damage or wear. (Carbon Brushes or bearings, for example.) 1. Forcing machine to work too fast.
2. Wheel worn or dull.
3. Blocked motor housing vents.
4. Motor being strained by long or small diameter extension cord.
Likely Solutions
1. Check that cord is plugged in. 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. Have
technician service tool.
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 wheel as needed. 2. Have technician replace brushes. Have technician
service tool.
1. Allow machine to work at its own rate. 2. Keep cutting accessories sharp.
Replace wheel as needed. 3. Wear ANSI-approved safety goggles and
NIOSH-approved dust mask/respirator while blowing dust out of motor using
compressed air. 4. 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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Page 11
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. Specify UPC 193175364210 when
ordering parts.
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parts List and Diagram
parts List
part
Description
Qty part
Description
Qty
1 Power Cord
1
32 Roll Pin
1
2 Cord Protector
1
33 Angle Guide
1
3 Cord Clamp
1
34 Hinge Bolt
1
4 Trigger
1
35 Vise Clamp
1
5 Left Housing
1
36 Clip Pin
1
6 Right Housing
1
37 Vise Feed Screw
1
7 Stator
1
38 Vise Lock Handle
1
8 Carbon Brush Cap
2
39 Vise Mount
1
9 Carbon Brush Holder
2
40 Roll Pin
1
10 Carbon Brush
2
41 Vise Knob
1
11 Rotor
1
42 Base
1
12 Fan
1
43 Rubber Foot
4
13 Roll Pin
1
44 Flat Wrench
1
14 Drive Gear
1
45 Sleeve Wrench
1
15 Bearing 627
1
46 Hex Wrench
1
16 Bearing 609
1
47 Screw
1
17 Bearing 607
1
48 Flat Washer
1
18 Bearing 6201
1
49 Spring Washer
1
19 Spindle
1
50 Nut
1
20 Driven Gear
1
51 Screw
7
21 Bearing Cover
1
52 Flat Washer
4
22 Key
1
53 Spring Washer
4
23 Gear Housing Cap
1
54 Screw
4
24 Stationary Guard
1
55 Flat Washer
4
25 Swing Guard
1
56 Spring Washer
4
26 Spring
1
57 Bolt
2
27 Inner Flange
1
58 Bolt
2
28 Grinding Wheel (sold separately)
1
59 Screw
2
29 Outer Flange
1
60 Safety Chain (not shown)
1
30 Arbor Bolt
1
61 Adapter 5/8″ (not shown)
1
31 Spring
1
62 Adapter 7/8″ (not shown)
1
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assembly Diagram
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1
2
23 51
16
10 9 8
8 9 10
11 3 47
19
6 17
12 15 13 14 48 49 50
54
53
22
52
18 21
20
7 5
4
25 26 24
30 29
28 27
42
49 31 32 49
57 56 55
59 43 50
34 35
38 37 33
36 48
58 56 55
39 41
40
44 45 46
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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.
26541 agoura road · calabasas, ca 91302 ·
1-888-866-5797
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