Chicago Electric Saw 41903 User Manual

6-1/2” (18V)  
CIRCULAR SAW  
41903  
ASSEMBLY & OPERATING INSTRUCTIONS  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
©
®
Copyright 1999 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.  
For technical questions and replacement parts, please call 1-800-444-3353  
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Work Area  
TO AVOID RISK OF PERSONAL INJURY, EQUIPMENT DAMAGE, FIRE AND SHOCK, MAKE SUREYOUR  
WORK AREA IS:  
Free of damp, wet or rainy conditions.  
Free of flammable gasses or liquids.  
Free of children (never let them handle tools or machinery).  
Well-lit.  
Clean and uncluttered.  
Well-ventilated.  
Before Operating  
Before operating your Circular Saw check for damaged parts. Before using any tool, any part that appears  
damaged should be carefully checked to determine that it will operate properly and perform its intended  
function.  
DO NOT exceed the tools maximum capacity.  
Never force the tool or attachment to do the work of a larger industrial tool. It is designed to do the job better  
and more safely at the rate for which it was intended.  
Do not try to use inappropriate attachments in an attempt to exceed the tool’s capacity. Approved accessories  
are available from Harbor FreightTools.  
Make sure all clamps, locks and bolts are tight.  
MAKE CERTAINTOTURN OFFTHE SAW, AND REMOVETHE BATTERY PACKWHEN MOVING OR  
LOADING ORWHEN DOING ANY MAINTENANCE. THETOOL SHOULD ALWAYS BETURNED OFFWHEN  
NOT IN USE.  
Do not reach over or across running machines.  
Battery Precautions  
Read all instructions and warnings on the battery before charging the battery.  
To avoid accidents, charge the supplied battery only. Do not use a different charger with this battery.  
Note: Always switch to a fresh battery when tool  
Do not expose the battery to rain or wet conditions.  
performance begins to diminish. Severe heat is most  
destructive to a battery; the more heat generated, the faster  
the battery loses power. A battery that gets too hot can be  
permanently damaged. Never over-discharge a battery by  
using the tool even after tool performance is decreasing. Never  
attempt to discharge a tool’s battery by continuing to pull the  
tool trigger. When tool performance begins to diminish,  
stop the tool, recharge the battery and use the fresh  
battery for optimal performance.  
To avoid damage of cable and plug, never pull the cable to  
disconnect the charger.  
Do not use the charger if the cable or plug are damaged.  
Repairs should be carried out by experts only  
Do not touch the battery poles with any conductive source.  
Do not store the battery in a box with other metal objects.  
Do not throw the battery in a fire. Ni-Cd Battery must be recycled or disposed of properly.  
Note: The operation time of a new battery will ramp up as it is properly used and recharged. It will take  
about 5 cycles before the battery is at maximum efficiency. Warning: If two or more batteries are to  
be charged, allow the Quick Charger time to cool down between charges. Charging room temperature:  
50°F - 104° F.  
REV 10/03  
SKU 41903  
For technical questions, please call 1-800-444-3353.  
Page 3  
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Warning: Never charge more than 2 hours continuously. Chargers  
should not be left plugged in or charging for more than 2 hours.  
Charging the Battery Pack  
The Battery Pack (part #14) does not come charged from the factory. Charge it before using.  
Step 1)  
Insert the Battery Pack (#14) into the Quick Charger. The Battery Pack will only  
fit in one way.  
Step 2)  
Step 3)  
Plug the Quick Charger into a wall socket.  
When the Quick Charger is plugged into a wall socket, the GREEN light will go on.  
This shows that all circuitry is working properly and that the Charger is ready.  
Step 4)  
Press the SET button to start charging. The RED light will go on and will continue  
to be on while the Battery Pack is charging. When the RED light goes off, the  
Battery pack charge is complete. It will take approximately 1 to 1-1/2 hours to fully charge the  
Battery Pack.  
Step 5)  
Step 6)  
Step 7)  
Step 8)  
After charging, unplug the Quick Charger from the wall outlet.  
Remove the Battery from the Quick Charger.  
Insert the Battery Pack (part #14) into Saw body as shown in Figure 1.  
When removing the Battery Pack from the Saw body, press down on the  
locking tabs located on each side of the Battery Pack and pull straight out from  
the body.  
Figure 1-Installing the Battery Pack  
Assembly  
Your Circular Saw may require some assembly. Information on installation is included below for your reference.  
Please refer to the photos and illustrations as well as the Assembly Diagram located on page 9 of this manual.  
The Parts List is located on page 8.  
It is important that you read the entire manual to become familiar with the unit BEFORE you use it. Be sure  
that you have all parts described in the Parts List. For assistance with assembly please refer to the assembly  
diagram and the parts list on page.  
Warning:  
Remove the Battery Pack (part #14) before making any adjustments to the Saw.  
Installing the Cutting Blade - Note: Loosen the Hex Wrench Knob as shown in Figure 4, and remove the Hex  
Wrench.  
Step 1)  
Step 2)  
Remove the Battery Pack (part #14).  
Press down on the Stop Button located on the top of the Saw while slowly moving the blade.  
The tip of the Stop Button will engage in a cutout in the blade to stop the blade from moving.  
REV 05/02  
SKU 41903  
For technical questions, please call 1-800-444-3353.  
Page 4  
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Step 3) While continuing to hold down the Lock Button, use  
the 4 mm Hex Wrench to loosen and remove the  
Arbor Bolt (part #38). Remove the SpringWasher  
(part #37) and the Flange (part #36).  
Press Stop Button  
Step 4) Rotate the Retractable Guard (part #32) clockwise  
to allow entry of the Saw Blade (part #35).  
Arbor Bolt (#38)  
Hex Wrench  
Step 5) Insert the Saw Blade (#35) up through the  
Shoe (part #53) with the teeth facing forward  
and up, until the center hole of the Saw Blade fits  
over the Main Shaft (part #25) - (See Figure 3).  
Figure 2-Installing the Saw Blade  
Warning:  
Make certain that the arrow on the Retractable Guard (#32) and the Saw Blade  
are facing the same direction as in Figure 3.  
Directional Arrows  
Teeth face up  
Figure 3  
Step 6)  
Step 7)  
While pressing on the Lock Button, replace the Flange (#36), Washer (#37) and  
Arbor Bolt (#38). Tighten into place with the Hex Wrench. When finished, make  
certain that the Lock Button has been returned to the up (unlocked) position.  
Slide the Hex Wrench into its storage slot and tighten it into place with the  
Hex Wrench Knob (See Figure 4).  
Bevel Adjustment  
Knob (#50)  
Hex Wrench  
Knob  
Depth Adjustment  
Knob  
Angle Scale  
Hex Wrench  
Shoe  
Figure 4  
SKU 41903  
For technical questions, please call 1-800-444-3353.  
Page 5  
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Adjusting the Saw Prior to Cutting  
Step 1)  
To adjust the angle of the Saw Blade up to 50° loosen the Bevel Adjustment  
Knob (part #50) and move the Shoe (part #53) down paying attention to the  
degrees indicated on the angle scale (See Figure 4). Once set, retighten the  
Bevel Adjustment Knob (part #50).  
Step 2)  
To adjust the depth of the cut, loosen the Depth Adjustment Knob (part #7)  
(See Figure 4). Move the Shoe (#53) down while observing the amount  
of Saw Blade exposed under the Shoe (#53). Once adjusted, tighten the  
Depth Adjustment Knob (#7).  
Prepare Material Before Cutting  
Step 1)  
Support large panels to minimize the risk of pinching the Saw Blade and to  
reduce the risk of kickback.  
Step 2)  
Step 3)  
Step 4)  
Use the Rip Fence (part #49) when ripping material.  
Securely clamp the work piece to be cut to the workbench.  
Make sure the Saw does not cut into the supports or the workbench.  
Note:  
Use the appropriate type of Saw Blade for the material you are cutting.  
Operation  
Before operating your Circular 6-1/2" Saw, it will be helpful to refer to each of the photos and illustrations shown  
in this manual, as well as to the Parts List on page 8 and Assembly Diagram on page 9.  
Cutting  
Step 1)  
Step 2)  
Position the Rip Fence (part #49) to guide the Saw on a straight path.  
With your left hand resting on the front portion of the Body (part #9/13), position your right hand  
on the upper portion of the handle portion of the Body (directly above theTrigger/Safety).  
Step 3)  
Step 4)  
Place the front edge of the Shoe (part #53) on the front edge of the material to be cut. Align  
the front notch (right notch aligns with the Saw Blade) on the cut line.  
Pull the Safety (part #18) back with the middle finger and squeeze the Trigger  
(part #20) with the index finger. Do this before the Saw Blade touches the  
work piece.  
Step 5)  
Step 6)  
With the Saw at full speed, move it slowly forward to start the cut.  
When the cut is complete, release the Trigger (part #20). Do not set the  
Saw down until the Saw Blade stops turning.  
SKU 41903  
For technical questions, please call 1-800-444-3353.  
Page 6  
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Maintenance  
CLEANING:  
Before remounting the Saw Blade, remove all sawdust that has accumulated  
around the Retractable Guard (part #32) and the Spacer (part #22), Bolts and  
Washers.  
Regularly clean the work surface with a vacuum cleaner or a dry brush. At the end  
of every work session, remove sawdust from the motor vents. Prevent wood, dust  
and debris from accumulating in the working area.  
Keep the Saw Blade (#35) clean and sharp. A sharp blade will minimize stalling  
and kickback.  
STORAGE:  
Child-proof the machine and work area. Use of padlocks and master switches are  
recommended. Store the Circular Saw in its Case.  
IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE, DO NOT OPERATE THE TOOL.  
PLEASE READTHE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS  
MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER NOR DISTRIBUTOR  
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYERTHAT HE OR SHE  
IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO  
REPLACE ANY PARTS OFTHE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBU-  
TOR EXPRESSLY STATESTHAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDER-  
TAKEN 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 PARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLA-  
TION OF REPLACEMENT PARTSTHERETO.  
SKU 41903  
For technical questions, please call 1-800-444-3353.  
Page 7  
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Unpacking  
UNPACK AND CHECK CONTENTS  
When unpacking your Circular 6-1/2", 18V Saw, check to make sure the following parts are included. If any  
parts are missing or broken, please call HARBOR FREIGHTTOOLS at 1-800-444-3353.  
Parts List-#41903  
Part #  
1
2
3
4
5
6
7
8
Description  
Screw ST 2.9 x 25  
Stud Screw M5 x 50  
SnapWasher  
StudWasher  
Screw ST2.9 x 19  
Screw ST2.9 x 13  
Depth Adjustment Knob  
Washer  
Quantity Part #  
Description  
SnapWasher  
Gear Box  
Stud Screw M4 x 8  
Spring  
Retractable Guard  
Washer  
Adapter  
Saw Blade  
Flange  
SpringWasher  
Arbor Bolt  
Stud Screw M4 x 10  
Washer  
Collar  
Screw  
Washer  
SpringWasher  
Screw Cap  
Plate  
Connecting Bar  
Bolt M6 X 80  
Rip Fence  
Quantity  
2
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
9
Left Body  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
Back Case  
SnapWasher  
Motor Base  
Right Body  
Battery Pack  
Motor  
Battery Clip  
Spring  
Safety  
Spring  
Trigger  
Switch  
Guard  
23  
24  
25  
26  
27  
Ball Bearing  
Master Gear  
Main Shaft  
Stud Screw  
Spacer  
1
1
1
1
1
50  
51  
52  
53  
54  
55  
56  
Bevel Adjustment Knob  
Washer  
Guard Bar  
Shoe  
Hex Wrench Knob  
Charger  
1
1
1
1
1
1
1
4mm HexWrench  
SKU 41903  
For technical questions, please call 1-800-444-3353.  
Page 8  
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Assembly Diagram - 41903  
38  
37  
36  
35  
34  
33  
49  
39  
40  
32  
31  
30  
29  
28  
27  
26  
25  
41  
42  
48  
43  
44  
50  
51  
45  
54  
46  
47  
24  
23  
22  
52  
53  
21  
20  
19  
13  
15  
18  
17  
12  
11  
10  
9
16  
6
5
4
3
14  
2
8
7
Note: Charger (#55) is not shown.  
4mm Hex Wrench (#56) is not shown.  
1
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