Chicago Electric 41903 Quick reference guide

6-1/2” (18V)

41903

ASSEMBLY & OPERATING INSTRUCTIONS

CIRCULAR SAW

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit ourWeb site at http://www.harborfreight.com

any artwork contained herein may be reproduced in any shape or form without the express

written consent of Harbor FreightTools.

For technical questions and replacement parts, please call 1-800-444-3353

SKU 41903 Page 2For technical questions, please call 1-800-444-3353.

THANKYOU for choosing a HARBOR FREIGHTTOOLS product. For future reference, please complete the

owner’srecordbelow:

Model______________ Serial No.____________ PurchaseDate__________

SAVETHE RECEIPT,WARRANTY ANDTHESE INSTRUCTIONS. It is important that you read the entire

manual to become familiar with the unit BEFORE you begin assembly.

Technical Specifications

Tool Name:6-1/2" 18V Circular Saw

SKU: 41903

CuttingCapacity: 2-1/16"@90degrees,1-1/2"@ 45 degrees

MotorRPM: 3,000RPM

ArborSize: 5/8"

Safety Switch: 2 Action

Blade: 6-1/2"X24TC-2TipwithHardness89-92HRC

Max. Blade RPM: 7000

Also Included: Quick Charger with U.L.Approved Adapter, 18V Battery, 4 mm HexWrench,

BlowMoldCase.

Warning: The warnings, cautions and instructions discussed in this instruction manual

cannot cover all possible conditions and situations that may occur. It must

beunderstoodbythe operatorthat COMMON SENSE AND CAUTIONARE

FACTORSWHICH CANNOTBEBUILTINTOTHIS PRODUCT,BUT

MUST BE SUPPLIED BYTHE OPERATOR.

TheOperator

PLEASE REMEMBER:

Do not operate the product if under the influence of alcohol or drugs. Read warning labels on prescriptions to determine

if your judgment/reflexes might be impaired.

Do not wear loose clothing or jewelry as they can be caught in moving

parts.

Protective gloves and nonskid footwear is recommended.

Wear restrictive hair covering to contain long hair.

Use eye and ear protection. Always wear ANSI approved impact

safety goggles and a dust mask or respirator when working around

metal, wood and chemical dusts and mists.

Wear a full face shield if you are producing metal or wood filings.

Maintain proper footing and balance at all times.

Keep hands out of the cutting area and away from the blade.

Make certain that the piece being cut is properly supported; do not support the piece being cut with your hands or by

bracing with your leg.

Avoid carrying the Saw with your fingers on the Handle. Your fingers may touch the Switch and Safety trigger and start

the Saw.

REV 02/01; 10/03; 12/04; 02/05

WARNING: Some dust created by power

sanding, sawing, grinding, drilling, and other

construction activities, contain chemicals

known [to the State of California] to cause

cancer, birth defects or other reproductive

harm. Someexamplesofthesechemicalsare:

• Leadfrom lead-based paints

• Crystalline silica from bricks and

cementorothermasonry products

• Arsenicandchromiumfrom

chemicallytreatedlumber

(CaliforniaHealth & Safety Code 25249.5,

seq.

)

SKU 41903 Page 3For technical questions, please call 1-800-444-3353.

Work Area

TO AVOID RISK OF PERSONAL INJURY, EQUIPMENT DAMAGE, FIRE AND SHOCK, MAKE SUREYOUR

WORKAREA 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.

Cleanand uncluttered.

Well-ventilated.

BeforeOperating

Before operating your Circular Saw check for damaged parts.Before using any tool, any part that appears

damagedshould be carefully checked todetermine that it willoperate properly and performits 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

areavailablefromHarborFreightTools.

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.

Donot reach over or across running machines.

BatteryPrecautions

Readallinstructions and warnings on thebattery beforecharging the battery.

To avoid accidents, charge the supplied battery only. Do not use a different charger with this battery.

Do not expose the battery to rain or wet conditions.

To avoid damage of cable and plug, never pull the cable to

disconnectthecharger.

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

becharged,allow the QuickChargertime to cooldownbetween charges. Chargingroomtemperature:

50°F - 104° F.

Note: Always switch to a fresh battery when tool

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

usingthetool even aftertool performance isdecreasing. 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.

REV 10/03

SKU 41903 Page 4For technical questions, please call 1-800-444-3353.

Charging the Battery Pack

The Battery Pack (part #14) does not come charged from the factory. Charge it before using.

Step1) Insert the Battery Pack (#14) into the Quick Charger. The Battery Pack will only

fit in one way.

Step 2) Plug the Quick Charger into a wall socket.

Step3) 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.

Step4) 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) After charging, unplug the Quick Charger from the wall outlet.

Step 6) Remove the Battery from the Quick Charger.

Step7) Insert the Battery Pack (part #14) into Saw body as shown in Figure 1.

Step8) 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.

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 HexWrench Knob as shown in Figure 4, and remove the Hex

Wrench.

Step1) Remove the Battery Pack (part #14).

Step2) 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.

Figure 1-Installing the Battery Pack

Warning: Nevercharge morethan2 hours continuously. Chargers

should not be left plugged in or charging for more than 2 hours.

REV 05/02

SKU 41903 Page 5For technical questions, please call 1-800-444-3353.

Step 3) While continuing to hold down the Lock Button, use

the 4 mm HexWrench to loosen and remove the

ArborBolt(part#38). RemovetheSpringWasher

(part #37) and the Flange(part #36).

Step4) RotatetheRetractableGuard (part#32) clockwise

to allow entry of the Saw Blade (part #35).

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).

Warning: Make certain that the arrow on the Retractable Guard (#32) and the Saw Blade

are facing the same direction as in Figure 3.

Step6) WhilepressingontheLockButton, 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.

Step7) Slide the HexWrench into its storage slot and tighten it into place with the

HexWrench Knob (See Figure 4).

Figure 2-Installing the Saw Blade

Press Stop Button

Hex Wrench

Arbor Bolt (#38)

Directional Arrows

Figure 3

Teeth face up

Depth Adjustment

Knob Hex Wrench

Hex Wrench

Knob

Bevel Adjustment

Knob (#50)

Shoe

Figure 4

Angle Scale

SKU 41903 Page 6For technical questions, please call 1-800-444-3353.

Adjusting the Saw Prior to Cutting

Step1) 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).

Step2) To adjust the depth of the cut, loosen the Depth Adjustment Knob (part #7)

(SeeFigure4). MovetheShoe(#53) down while observing the amount

of Saw Blade exposed under the Shoe (#53). Once adjusted, tighten the

DepthAdjustment Knob (#7).

Prepare Material Before Cutting

Step1) Support large panels to minimize the risk of pinching the Saw Blade and to

reduce the risk of kickback.

Step2) UsetheRipFence(part #49) when ripping material.

Step3) Securely clamp the work piece to be cut to the workbench.

Step4) 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

Step1) Position the Rip Fence (part #49) to guide the Saw on a straight path.

Step2) 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).

Step3) 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.

Step 4) Pull the Safety (part #18) back with the middle finger and squeeze theTrigger

(part #20) with the index finger. Do this before the Saw Blade touches the

workpiece.

Step5) With the Saw at full speed, move it slowly forward to start the cut.

Step6) When the cut is complete, release theTrigger (part #20). Do not set the

Saw down until the Saw Blade stops turning.

SKU 41903 Page 7For technical questions, please call 1-800-444-3353.

Maintenance

CLEANING: Before remounting the Saw Blade, remove all sawdust that has accumulated

aroundtheRetractableGuard (part #32)andtheSpacer (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

anddebrisfromaccumulatingintheworkingarea.

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.Storethe Circular Saw in its Case.

IF THERE IS ANY QUESTION ABOUT ACONDITION BEING SAFE OR UNSAFE, DO NOT OPERATE THE TOOL.

PLEASEREADTHE FOLLOWINGCAREFULLY

THEMANUFACTURERAND/OR DISTRIBUTORHAS PROVIDEDTHE PARTSDIAGRAMINTHIS

MANUALASAREFERENCETOOLONLY. NEITHERTHEMANUFACTURERNOR DISTRIBUTOR

MAKES ANY REPRESENTATION ORWARRANTY OF ANY KINDTOTHE BUYERTHAT HE OR SHE

IS QUALIFIEDTO MAKE ANY REPAIRSTOTHE PRODUCT ORTHAT HE OR SHE IS QUALIFIEDTO

REPLACE ANY PARTS OFTHE PRODUCT. IN FACT,THE MANUFACTURER AND/OR DISTRIBU-

TOREXPRESSLY STATESTHAT ALL REPAIRS ANDPARTS REPLACEMENTSSHOULD BE UNDER-

TAKEN BY CERTIFIED AND LICENSEDTECHNICIANS AND NOT BYTHE BUYER.THE BUYER

ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRSTOTHE ORIGINAL

PRODUCTOR REPLACEMENTPARTSTHERETO,OR ARISING OUTOF HIS OR HER INSTALLA-

TIONOFREPLACEMENTPARTSTHERETO.

SKU 41903 Page 8For technical questions, please call 1-800-444-3353.

Unpacking

UNPACKAND 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.

PartsList-#41903

Part # Description Quantity Part # Description Quantity

1 Screw ST 2.9 x 25 2 28 SnapWasher 1

2 Stud Screw M5 x 50 4 29 GearBox 1

3 SnapWasher 4 30 Stud Screw M4 x 8 1

4 StudWasher 4 31 Spring 1

5 Screw ST2.9 x 19 1 32 RetractableGuard 1

6 Screw ST2.9 x 13 1 33 Washer 1

7 DepthAdjustmentKnob 1 34 Adapter 1

8 Washer 1 35 SawBlade 1

9 Left Body 1 36 Flange 1

10 Back Case 1 37 SpringWasher 1

11 SnapWasher 1 38 Arbor Bolt 1

12 MotorBase 1 39 Stud Screw M4 x 10 1

13 Right Body 1 40 Washer 1

14 Battery Pack 1 41 Collar 1

15 Motor 1 42 Screw 1

16 Battery Clip 1 43 Washer 1

17 Spring 1 44 SpringWasher 1

18 Safety 1 45 Screw Cap 1

19 Spring 1 46 Plate 1

20 Trigger 1 47 ConnectingBar 1

21 Switch 1 48 Bolt M6 X 80 1

22 Guard 1 49 RipFence 1

23 BallBearing 1 50 Bevel Adjustment Knob 1

24 MasterGear 1 51 Washer 1

25 Main Shaft 1 52 GuardBar 1

26 Stud Screw 1 53 Shoe 1

27 Spacer 1 54 HexWrench Knob 1

55 Charger 1

56 4mmHexWrench 1

SKU 41903 Page 9For technical questions, please call 1-800-444-3353.

23456

1112

222324

2829

3031

3233

3536

Assembly Diagram - 41903

Note: Charger (#55) is not shown.

4mm HexWrench (#56) is not shown.

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