Masterforce 5416 BOOST 20-Volt Brushless Cordless 6-1/2" Circular Saw - Tool Only

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User Manual

This is the main product document for model 5416.

The file format is pdf, 24 pages, you can download this manual here .

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241-0495
Cordless Circular Saw
For questions / comments, technical assistance or repair parts –
Please Call Toll Free: 1-866-917-4374 (M-F 8:30am-5:00pm EST).
OPERATOR’S MANUAL
WARNING:
To Reduce The Risk Of Injury, User Must Read And
Understand Operator’s Manual. Save These Instructions For Future
Reference.
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TABLE OF CONTENTS
Safety Symbols ......................................................... Page 2
Safety Instructions ...................................................... Page 3
Overview/Specifications ................................................. Page 9
Assembly ............................................................ Page 10
Operation ............................................................ Page 11
Maintenance .......................................................... Page 18
Troubleshooting ....................................................... Page 19
Warranty ............................................................. Page 22
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Page 2
Some of these following symbols may be used on this tool. Please study them and learn their
meaning. Proper interpretation of these symbols will allow you to operate the tool better and
more safely.
WARNING:
To ensure safety and reliability, all repairs should be performed by a
qualified service technician.
SAFETY SYMBOLS
Symbol
Name
Designation / Explanation
V Volts Voltage
A Amps Current
Hz Hertz Frequency (cycles per second)
W Watts Power
lbs Pounds Weight
.../min
Per minute
Revolutions, strokes, surface speed
orbits, etc., per minute
n
o
No-load speed Rotational speed at no load
or d.c.
Direct current Type or characteristic of current
To reduce the risk of injury, user must
read instruction manual.
To reduce the risk of injury, always wear
eye protection.
Read instruction
manual
Wear safety goggles
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Page 3
The purpose of safety symbols is to attract your attention to possible dangers. The
safety symbols, and the explanations with them, deserve your careful attention and
understanding. The symbol warnings do not, by themselves, eliminate any danger. The
instructions and warnings they give are no substitutes for proper accident prevention
measures.
WARNING:
Be sure to read and understand all safety instructions in this manual,
including all safety alert symbols such as “DANGER”, “WARNING” and “CAUTION” before
using this tool. Failure to following all instructions listed below may result in electric
shock, fire, and/or serious personal injury.
SYMBOL MEANING
SAFETY ALERT SYMBOL: Indicates DANGER, WARNING, OR CAUTION. May be used
in conjunction with other symbols or pictographs.
DANGER:
Indicates an imminently hazardous situation, which, if not avoided, will
result in death or serious injury.
WARNING:
Indicates a potentially hazardous situation, which, if not avoided,
could result in death or serious injury.
CAUTION:
Indicates a potentially hazardous situation, which, if not avoided,
could result in minor or moderate injury.
NOTICE:
(Without Safety Alert Symbol) Indicates a situation that may result in property
damage.
SAVE THESE INSTRUCTIONS!
SAFETY INSTRUCTIONS
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Page 4
GENERAL POWER TOOL SAFETY
WARNINGS
WARNING:
Read all safety
warnings, instructions, illustrations and
specifications provided with this power
tool. Failure to follow all instructions listed
below may result in electric shock, fire and/or
serious injury.
SAVE ALL WARNINGS AND INSTRUCTIONS
FOR FUTURE REFERENCE.
The term “power tool” in the warnings refers
to your mains-operated (corded) power tool
or battery-operated (cordless) power tool.
WORK AREA SAFETY
1. Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
2. Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power
tools create sparks which may ignite the
dust or fumes.
3. Keep children and bystanders away
while operating a power tool. Distractions
can cause you to lose control.
ELECTRICAL SAFETY
1. Power tool plugs must match the
outlet. Never modify the plug in any way.
Do not use any adapter plugs with earthed
(grounded) power tools. Unmodified plugs
and matching outlets will reduce risk of
electric shock.
2. Avoid body contact with earthed
or grounded surfaces, such as pipes,
radiators, ranges and refrigerators. There
is an increased risk of electric shock if your
body is earthed or grounded.
3. Do not expose power tools to rain or
wet conditions. Water entering a power tool
will increase the risk of electric shock.
4. Do not abuse the cord. Never use the
cord for carrying, pulling or unplugging the
power tool. Keep cord away from heat, oil,
sharp edges or moving parts. Damaged or
entangled cords increase the risk of electric
shock.
5. When operating a power tool outdoors,
use an extension cord suitable for outdoor
use. Use of a cord suitable for outdoor use
reduces the risk of electric shock.
6. If operating a power tool in a damp
location is unavoidable, use a ground fault
circuit interrupter (GFCI) protected supply.
Use of a GFCI reduces the risk of electric
shock.
PERSONAL SAFETY
1. 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.
2. Use personal protective equipment.
Always wear eye protection. Protective
equipment such as a dust mask, non-skid
safety shoes, hard hat or hearing protection
used for appropriate conditions will reduce
personal injuries.
3. Prevent unintentional starting. Ensure
the switch is in the off-position before
connecting to power source and/or battery
pack, picking up or carrying the tool.
Carrying power tools with your finger on the
switch or energizing power tools that have
the switch on invites accidents.
4. Remove any adjusting key or wrench
before turning the power tool on. A wrench
or a key left attached to a rotating part of the
power tool may result in personal injury.
5. Do not overreach. Keep proper footing
and balance at all times. This enables better
control of the power tool in unexpected
situations.
6. Dress properly. Do not wear loose
clothing or jewelry. Keep your hair and
clothing away from moving parts. Loose
clothes, jewelry or long hair can be caught
in moving parts.
7. If devices are provided for the
connection of dust extraction and collection
facilities, ensure these are connected and
properly used. Use of dust collection can
reduce dust-related hazards.
8. Do not let familiarity gained from
frequent use of tools allow you to become
complacent and ignore tool safety
principles. A careless action can cause
SAFETY INSTRUCTIONS
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Page 5
SAFETY INSTRUCTIONS
severe injury within a fraction of a second.
8. Do not let familiarity gained from
frequent use of tools allow you to become
complacent and ignore tool safety
principles. A careless action can cause
severe injury within a fraction of a second.
POWER TOOL USE AND CARE
1. Do not force the power tool. Use the
correct power tool for your application. The
correct power tool will do the job better and
safer at the rate for which it was designed.
2. Do not use the power tool if the switch
does not turn it on and off. Any power tool
that cannot be controlled with the switch is
dangerous and must be repaired.
3. Disconnect the plug from the power
source and/or remove the battery pack,
if detachable, from the power tool before
making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk
of starting the power tool accidentally.
4. Store idle power tools out of the reach
of children and do not allow persons
unfamiliar with the power tool or these
instructions to operate the power tool.
Power tools are dangerous in the hands of
untrained users.
5. Maintain power tools and accessories.
Check for misalignment or binding of
moving parts, breakage of parts and
any other condition that may affect the
power tool’s operation. If damaged, have
the power tool repaired before use. Many
accidents are caused by poorly maintained
power tools.
6. Keep cutting tools sharp and clean.
Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are
easier to control.
7. Use the power tool, accessories
and tool bits etc. in accordance with
these instructions, taking into account
the working conditions and the work to
be performed. Use of the power tool for
operations different from those intended
could result in a hazardous situation.
8. Keep handles and grasping surfaces
dry, clean and free from oil and grease.
Slippery handles and grasping surfaces do
not allow for safe handling and control of the
tool in unexpected situations.
BATTERY TOOL USE AND CARE
1. Recharge only with the charger
specified by the manufacturer. A charger
that is suitable for one type of battery pack
may create a risk of fire when used with
another battery pack.
2. Use power tools only with specifically
designated battery packs. Use of any other
battery packs may create a risk of injury and
fire.
3. When battery pack is not in use, keep
it away from other metal objects, like
paper clips, coins, keys, nails, screws or
other small metal objects, that can make
a connection from one terminal to another.
Shorting the battery terminals together may
cause burns or a fire.
4. Under abusive conditions, liquid may
be ejected from the battery; avoid contact.
If contact accidentally occurs, flush with
water. If liquid contacts eyes, additionally
seek medical help. Liquid ejected from the
battery may cause irritation or burns.
5. Do not use a battery pack or tool that
is damaged or modified. Damaged or
modified batteries may exhibit unpredictable
behavior resulting in fire, explosion or risk of
injury.
6. Do not expose a battery pack or tool
to fire or excessive temperature. Exposure
to fire or temperature above 100 °C (212 °F)
may cause explosion.
7. Follow all charging instructions and
do not charge the battery pack or tool
outside the temperature range specified
in the instructions. Charging improperly or
at temperatures outside the specified range
may damage the battery and increase the
risk of fire.
SERVICE
1. Have your power tool serviced by a
qualified repair person using only identical
replacement parts. This will ensure that the
safety of the power tool is maintained.
2. Never service damaged battery
packs. Service of battery packs should
only be performed by the manufacturer or
authorized service providers.
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SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS FOR ALL
SAWS
CUTTING PROCEDURES
DANGER:
Keep hands away from
cutting area and the blade. Keep your
second hand on auxiliary handle, or motor
housing. If both hands are holding the saw,
they cannot be cut by the blade.
1. Do not reach underneath the workpiece.
The guard cannot protect you from the blade
below the workpiece.
2. Adjust the cutting depth to the
thickness of the workpiece. Less than a
full tooth of the blade teeth should be visible
below the workpiece.
3. Never hold the workpiece in your hands
or across your leg while cutting. Secure
the workpiece to a stable platform. It is
important to support the work properly to
minimize body exposure, blade binding, or
loss of control.
4. Hold the power tool by insulated
gripping surfaces, when performing an
operation where the cutting tool may
contact hidden wiring or its own cord.
Contact with a “live” wire will also make
exposed metal parts of the power tool “live”
and could give the operator an electric shock.
5. When ripping, always use a rip fence
or straight edge guide. This improves the
accuracy of cut and reduces the chance of
blade binding.
6. Always use blades with correct size
and shape (diamond versus round) of arbor
holes. Blades that do not match the mounting
hardware of the saw will run off-center,
causing loss of control.
7. Never use damaged or incorrect blade
washers or bolt. The blade washers and
bolt were specially designed for your saw,
for optimum performance and safety of
operation.
FURTHER SAFETY INSTRUC-
TIONS FOR ALL SAWS
KICKBACK CAUSES AND
RELATED WARNINGS
- Kickback is a sudden reaction to a pinched,
jammed or misaligned saw blade, causing
an uncontrolled saw to lift up and out of the
workpiece toward the operator;
When the blade is pinched or jammed
tightly by the kerf closing down, the blade
stalls and the motor reaction drives the unit
rapidly back toward the operator;
If the blade becomes twisted or misaligned
in the cut, the teeth at the back edge of the
blade can dig into the top surface of the
wood causing the blade to climb out of the
kerf and jump back toward the operator.
Kickback is the result of saw misuse and/
or incorrect operating procedures or
conditions and can be avoided by taking
proper precautions as given below.
1. Maintain a firm grip with both hands on
the saw and position your arms to resist
kickback forces. Position your body to
either side of the blade, but not in line with
the blade. Kickback could cause the saw
to jump backwards, but kickback forces
can be controlled by the operator, if proper
precautions are taken.
2. When blade is binding, or when
interrupting a cut for any reason, release
the trigger and hold the saw motionless
in the material until the blade comes to a
complete stop. Never attempt to remove
the saw from the work or pull the saw
backward while the blade is in motion or
kickback may occur. Investigate and take
corrective actions to eliminate the cause of
blade binding.
3. When restarting a saw in the workpiece,
center the saw blade in the kerf so that
the saw teeth are not engaged into the
material. If a saw blade binds, it may walk
up or kickback from the workpiece as the
saw is restarted.
4. Support large panels to minimize the
risk of blade pinching and kickback. Large
panels tend to sag under their own weight.
Supports must be placed under the panel on
both sides, near the line of cut and near the
edge of the panel.
5. Do not use dull or damaged blades.
Unsharpened or improperly set blades
produce narrow kerf causing excessive
friction, blade binding and kickback.
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SAFETY INSTRUCTIONS
6. Blade depth and bevel adjusting
locking levers must be tight and secure
before making the cut. If blade adjustment
shifts while cutting, it may cause binding
and kickback.
7. Use extra caution when sawing into
existing walls or other blind areas. The
protruding blade may cut objects that can
cause kickback.
LOWER BLADE GUARD FUNCTION
1. Check the lower guard for proper
closing before each use. Do not operate
the saw if the lower guard does not move
freely and close instantly. Never clamp or
tie the lower guard into the open position.
If the saw is accidentally dropped, the lower
guard may be bent. Raise the lower guard
with the retracting handle and make sure it
moves freely and does not touch the blade or
any other part, in all angles and depths of cut.
2. Check the operation of the lower guard
spring. If the guard and the spring are not
operating properly, they must be serviced
before use. Lower guard may operate
sluggishly due to damaged parts, gummy
deposits, or a build-up of debris.
3. The lower guard may be retracted
manually only for special cuts such as
“plunge cuts” and “compound cuts”.
Raise the lower guard by the retracting
handle and as soon as the blade enters the
material, the lower guard must be released.
For all other sawing, the lower guard should
operate automatically.
4. Always observe that the lower guard is
covering the blade before placing the saw
down on bench or floor. An unprotected,
coasting blade will cause the saw to walk
backwards, cutting whatever is in its path. Be
aware of the time it takes for the blade to stop
after switch is released.
IMPORTANT SAFETY
INSTRUCTIONS
1. To reduce the risk of electric shock
or damage to the chargers and batteries,
use only with the MASTERFORCE
®
battery
packs and chargers listed.
Battery pack Charger
252-8029 (1.5Ah)
252-8031 (2.0Ah)
252-8030 (2.5Ah)
252-8003 (2.5Ah)
252-8034 (4.0Ah)
252-8035 (5.0Ah)
252-8005 (5.0Ah)
252-8027 (7.5Ah)
252-8007 (7.5Ah)
252-8025
252-8037
252-8026
2. For best results, your battery and tool
should be stored, charged and used in a
location where the temperature is more
than 5°C (41°F) but less than 40°C (104°F).
Do not store outside or in vehicles.
DANGER:
People with electronic
devices, such as pacemakers, should
consult their physician(s) before using this
product. Operation of electrical equipment
in close proximity to a heart pacemaker
could cause interference or failure of the
pacemaker.
WARNING:
Some dust created by power sanding,
sawing, grinding, drilling, and other
construction activities contains chemicals
known to the state of California to cause
cancer, birth defects, or other reproductive
harm. Some examples of these chemicals
are:
–Lead from lead-based paints
–Crystalline silica from bricks, cement, and
other masonry products
–Arsenic and chromium from chemically-
treated lumber
• Your risk from these exposures varies,
depending upon how often you do this type
of work. To reduce your exposure to these
chemicals:
–Work in a well-ventilated area.
–Work with approved safety equipment,
such as dust masks that are specially
designed to filter out microscopic particles.
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SAFETY INSTRUCTIONS
–Avoid prolonged contact with dust from
power sanding, sawing, grinding, drilling,
and other construction activities. Wear
protective clothing and wash exposed
areas with soap and water. Allowing dust
to get into your mouth or eyes or to lie
on the skin may promote absorption of
harmful chemicals.
SAVE THESE INSTRUCTIONS!
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OVERVIEW
Lock-Off Button
Main Handle
Wrench
Lower-Blade-
Guard Lever
Blade
Spindle-Lock
Button
Edge-Guide
Locking Knob
Auxiliary Handle
Bevel Angle Scale
Upper Blade Guard
LED Worklight
Depth Scale
Depth-Adjustment Lever
SPECIFICATIONS
Rated Voltage
20V
No-load Speed 5600 /min
Blade Diameter 6-1/2'' (165mm)
Blade Arbor 5/8" (16 mm)
Cutting Depth at 90° 2-3/16" (55 mm)
Cutting Depth at 45° 1-11/16" (42.5 mm)
Bevel Angle Adjustable 0–50°
Tool Weight 5 lbs 15 oz.
Lower Blade Guard
Trigger Switch
Bevel-Adjustment
Lever
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WARNING:
If any part is broken or
missing, DO NOT attach the battery pack
or operate the tool until the broken or
missing part is replaced. Failure to do so
could result in possible serious injury.
WARNING:
Do not attempt to
modify this tool or create accessories not
recommended for use with this tool. Any
such alteration or modification is misuse
and could result in a hazardous condition
leading to possible serious injury.
WARNING:
Your tool should
never be connected to battery pack
when you are assembling parts, making
adjustments, cleaning, or when it is not in
use. Disconnecting the tool will prevent
accidental starting, which could cause
serious personal injury.
CONTENTS
- Cordless circular saw
- 24-tooth saw blade
- Wrench (attached on the tool)
- Vacuum adaptor
- Screw for the vacuum adaptor
- Instruction manual.
UNPACKING
1. Carefully remove the tool and any
accessories from the carton. Make sure
that all items listed above are included.
2. Inspect the tool carefully to make sure
that no breakage or damage occurred
during shipping.
3. Do not discard the packing material
until you have carefully inspected and
satisfactorily operated the tool.
ASSEMBLY
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TO INSTALL OR CHANGE THE
BLADE (FIG. 1)
3
2
1
1
FIG. 1
Wrench
Blade
1. Detach the battery pack from circular
saw.
2. Depress the spindle-lock button, insert
the blade wrench into the blade bolt and
rotate it back and forth until you feel the
spindle-lock button depresses deeper.
This action locks the blade in position
so that the blade bolt can be removed.
3. With the spindle-lock button firmly
depressed, turn the blade bolt clockwise
to loosen it.
4. Use the lower-blade-guard lever to raise
the lower blade guard and hold it in the
raised position with the lever.
5. Remove the blade bolt, the outer
washer, and the blade.
6. The remaining, inner flange, that fits
around the spindle shaft, does not need
to be removed.
7. Clean the spindle, washers, upper
guard, and lower guard to remove any
dirt and sawdust.
8. Make sure that the blade teeth and the
arrow on the blade point in the same
direction as the arrow on the upper
guard. Slide the new saw blade inside
the upper blade guard, onto the spindle
shaft and against the inner washer.
9. Replace the outer washer.
10. Depress and hold the spindle-lock
button as you replace the blade
and hand-tighten the bolt in a
counterclockwise direction. Use the
blade wrench to tighten the blade bolt
securely.
11. Return the blade wrench into the
storage area. Make sure the wrench is
securely placed.
NOTICE: Do not use a blade wrench with
a longer handle, since it may lead to over
tightening of the blade bolt.
WARNING:
Be sure to wear
protective work gloves while handling
a saw blade. The sharp teeth can injure
unprotected hands.
TO ATTACH BATTERY PACK (FIG. 2)
FIG. 2
Battery-
Release
Button
Detach
1. Align the raised rib on the battery pack
with the grooves on the tool, then slide
the battery pack onto the tool.
2. Ensure that the battery-release button
on the battery pack snaps into place
and the battery pack is secured to the
tool before beginning operation.
NOTICE: When placing the battery pack
on the tool, be sure that the raised rib on
the battery pack aligns with the groove on
the tool and the latches snap into place
properly. Improper assembly of the battery
pack can cause damage to internal
components.
OPERATION
Outer Flange
Blade Bolt
Attach
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OPERATION
TO DETACH BATTERY PACK (FIG. 2)
1. Press the battery-release button to
release the battery pack.
2. Pull the battery pack to remove it from
the tool.
LED WORKLIGHT (FIG. 3)
FIG. 3
LED Worklight
The LED worklight will illuminate when the
trigger switch is depressed. This provides
additional light on the surface of the
workpiece. The light will automatically turn
off within 10 seconds after releasing the
trigger.
VACUUM ADAPTOR (FIG. 4)
FIG. 4
Vacuum Adaptor
Screw Holes
Your tool is shipped with a vacuum adaptor
for connecting vacuum cleaner hose with
Ø1-1/4".
1. To attach the vacuum adaptor to the
saw, insert it into the slot of the upper
blade guard and then use the screw
(included) to secure it.
2. To remove the vacuum adaptor from the
saw, loosen the screw on the vacuum
adaptor.
ELECTRIC BRAKE
The saw has an electric brake to quickly
stop the blade rotation. The electric brake
engages when the trigger switch is released.
BLADE GUARD SYSTEM (FIG. 5)
FIG. 5
Lower blade guard is in the up
position when making a cut.
The lower blade guard attached to your
circular saw is there for your protection
and safety. It should never be altered for
any reason. If it becomes damaged or
begins to return slowly or sluggishly, do not
operate the saw until the blade guard has
been repaired or replaced. Always leave the
guard in its correct operating position when
using the saw.
WARNING:
Do not allow familiarity with the
circular saw to cause a lack of
alertness. A fraction of a second of
carelessness is enough to cause
severe injury.
Never attach battery pack to the
circular saw when you are assembling
parts, making adjustments, installing
or removing cutting blade, cleaning,
or when it is not in use. Detaching
the battery pack will prevent the saw
from accidental starting, which could
cause serious personal injury.
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OPERATION
KICKBACK (FIG. 6)
FIG. 6
DIRECTION OF CUT
Kickback occurs when the blade stalls
rapidly and the saw is driven back towards
the operator. Blade stalling is caused by
any action that pinches the blade in the
wood. Loss of control can lead to serious
injury.
WARNING:
Use only 6-1/2” saw blades rated
5600/min (RPM) or greater. Never use
a blade that is so thick that it prevents
the outer blade washer from engaging
with the flat side of the spindle. Using
a blade not designed for the saw may
result in serious personal injury and
property damage.
If the blade comes in contact with
the workpiece before it reaches full
speed, it could cause the saw to
“kickback” towards you, which could
result in serious injury.
When using the saw, always stay alert
and exercise control. Do not remove
the saw from the workpiece while the
blade is moving.
DANGER:
When sawing through
a workpiece, the lower blade guard does
not cover the blade on the underside of
the workpiece. Since the blade is exposed
on the underside of the workpiece, keep
hands and fingers away from the cutting
area. Any part of your body coming in
contact with a moving blade will result in
serious injury.
NOTICE: Never use the saw when the
guard is not operating properly. The guard
should be checked for correct operation
before each use. If you drop your saw,
check the lower blade guard and bumper
for damage at all depth settings before
using.
SAW BLADES
In order to cut efficiently, all saw blades
need to be kept clean, sharp and properly
set. Using a dull blade places a heavy load
on the saw and increases the danger of
kickback. Keep extra blades on hand, so
sharp blades are always available. Gum
and wood pitch hardened on the blade
slows the saw down. Use gum and pitch
remover, hot water or kerosene to remove
them. Do not use gasoline.
NOTICE: The circular saw is mainly
intended for cutting wood. It’s
recommended to use wood-cutting blade.
WARNING:
Do not use abrasive
blades with the circular saw. Abrasive
dust may cause lower guard to not
operate properly.
KICKBACK
Blade is set
too deep
Correct blade
depth
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TO GUARD AGAINST KICKBACK,
FOLLOW THESE INSTRUCTIONS
(FIG. 7, FIG. 8)
FIG. 7
No more than 1/4'' (6mm)
FIG. 8
Correct Support
1. Keep the blade at the correct depth
setting. The depth setting should not
exceed 1/4” (6mm) below the material
being cut (FIG. 7).
2. Inspect the workpiece for knots or nails
before cutting. Never saw into a knot or
nail.
3. Make straight cuts. Always use a
straight edge guide when rip cutting.
This helps prevent twisting of the blade.
4. Use clean, sharp and properly set
blades. Never make cuts with dull
blades.
5. Support the workpiece properly before
beginning a cut (FIG. 8).
6. Use steady, even pressure when making
a cut. Never force a cut.
7. Do not cut warped or wet lumber.
8. Hold the saw firmly with both hands and
keep your body in a balanced position
so as to resist the forces if kickback
should occur.
WARNING:
To avoid kickback,
release the trigger switch immediately if
blade binds or saw stalls. Kickback could
cause you to lose control of the saw. Loss
of control can lead to serious injury.
DEPTH OF CUT ADJUSTMENTS
Always keep the correct blade-depth
setting. The correct blade-depth setting
for all cuts should not exceed 1/4” (6mm)
below the material to be cut. Excess blade
depth will increase the chance of kickback
and cause the cut to be rough. One blade
tooth below the material to be cut works is
best for efficient cutting.
TO ADJUST THE CUTTING
DEPTH (FIG. 9)
FIG. 9
Depth Scale
Depth-
Adjustment
Lever
1. Detach the battery pack.
2. Raise the depth-adjustment lever to
release it.
3. Hold the base shoe against the
workpiece and raise or lower the saw
until the indicator mark on the saw
aligns with the desired depth on the
depth scale.
OPERATION
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Page 15
OPERATION
4. Lower the depth-adjustment lever to
lock the saw in this depth position.
BEVEL ADJUSTMENTS
The angle of cut can be adjusted to
any desired setting between 0°and 50°.
Because blade thicknesses vary and
different angles require different settings,
always make a trial cut in scrap material
along a guideline to determine how much
you should offset the guideline on the
workpiece to be cut.
TO ADJUST BEVEL SETTING
(FIG. 10)
FIG. 10
0–50° BEVEL SETTING
1. Detach the battery pack.
2. Loosen the bevel-adjustment lever by
rotating the lever clockwise.
3. Tilt the base until the bevel indicator
reaches the desired setting on the bevel
scale.
4. Tighten the bevel-adjustment lever by
rotating the lever counterclockwise.
0° BEVEL STOP
The saw has a 0° bevel stop that has been
adjusted before shipment to assure that the
blade is perpendicular to the base at the 0°
bevel setting.
WARNING:
Attempting a bevel
cut without fully tightening the bevel-
adjustment lever can result in serious
injury.
TO CHECK 0° BEVEL STOP (FIG. 11)
FIG. 11
Blade
Carpenter’s
Square
1. Detach the battery pack.
2. Using a carpenter’s square (available
separately), make sure that the saw
blade is perpendicular to the base of the
saw.
TO ADJUST 0° BEVEL STOP (FIG. 12)
FIG. 12
1. Detach the battery pack.
Bevel Angle
Scale
Bevel-
Adjustment
Lever
Base
Adjusting
Screw
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Page 16
2. Loosen the bevel-adjustment lever.
3. Use a 2.5mm hex wrench (available
separately) to turn the adjusting screw
until the base is perpendicular to the
saw blade.
4. Tighten the bevel-adjustment lever by
rotating the lever counterclockwise.
WARNING:
Attempting to make
cuts without the bevel-adjustment lever
securely tightened can result in serious
injury.
TURNING THE SAW ON AND OFF
(FIG. 13)
Trigger
Switch
Lock-Off Button
FIG. 13
1. Attach the battery pack to the saw.
2. To turn the saw ON, depress the lock-
off button from either side and then
depress the trigger switch.
3. To turn the tool OFF, release the trigger
switch.
OPERATING THE SAW
It is important to understand the correct
method for operating the saw.
Refer to the figures and instructions in this
section to learn the correct and incorrect
ways for handling the saw.
DANGER:
When lifting the saw from the
workpiece, the blade is exposed on
the underside of the saw until the
lower blade guard closes. Make sure
the lower blade guard is closed before
setting the saw down.
WARNING:
Allow the blade to come to a complete
standstill before setting the circular
saw down.
To make sawing easier and safer,
always maintain proper control of the
saw. Loss of control could cause an
accident resulting in possible serious
injury.
Always clamp and support the
workpiece securely. Always maintain
proper control of the saw. Failure to
clamp and support the workpiece and
loss of control of the saw could result
in serious injury.
TO MAKE THE BEST POSSIBLE CUT:
1. Always use your saw with your hands
positioned correctly, with one hand
on the main handle and operating the
trigger switch and the other hand on
the auxiliary handle. Avoid placing your
hand on the workpiece while making a
cut.
2. Position your body to either side of the
blade, but not in line with the blade.
3. Support the workpiece near the cut.
4. Clamp the workpiece securely so that
the workpiece will not move during the
cut.
5. Always place the saw weight on the
workpiece that is supported, not on the
“cut off” piece.
6. Place the workpiece with the “good”
side down.
7. Draw a guideline along the desired line
of cut before beginning your cut.
NOTICE: The “good” side of the
workpiece is the side where appearance
is important.
OPERATION
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Page 17
OPERATION
MAKING CROSS CUTS AND RIP
CUTS (FIG. 14)
FIG. 14
When making a cross cut or rip cut, align
your line of cut with the center of the
notch by the 0° indicator. Because blade
thicknesses vary, always make a trial cut
in scrap material along a guideline to
determine how much, if any, the guideline
must be offset to produce an accurate cut.
MAKING RIP CUTS (FIG. 15)
FIG. 15
Workpiece
The combination blade provided with your
saw is for both cross cuts and rip cuts.
Ripping is cutting lengthwise along the grain
of the wood.
When rip cutting a large sheet, use a straight
edge (available separately).
1. Secure the workpiece.
2. Use clamps (available separately) to
clamp a straight edge to the workpiece.
3. Carefully guide the saw along the
straight edge to achieve a straight rip
cut.
MAKING A BEVEL CUT (FIG. 16)
1
1
/2
1 0 45 1 3 4
1
/4
FIG. 16
45°Indicator
1. Secure workpiece with clamps.
2. Draw a line of cut on the workpiece.
3. Detach the battery pack.
4. Adjust and secure the saw at desired
bevel angle.
5. Attach the battery pack.
6. When making a bevel cut, hold the saw
firmly with both hands.
7. Rest the front edge of the base on the
workpiece. Depress the lock-off button
and trigger switch to start the saw.
Allow the saw to reach full speed before
attempting to make a cut.
8. After completing the cut, release the
trigger switch and allow the blade to
come to a complete stop. After the
blade has stopped, remove the saw
from the workpiece.
NOTICE: There is a notch in the saw base
to help you line up the blade with the line
of cut when making 45° bevel cuts. Align
your line of cut with the center of the
notch by the 45° indicator.
0° Indicator
Line of Cut
Guideline
Clamp
Line of Cut
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Page 18
MAINTENANCE
MAINTENANCE
1. Inspect the circular saw, the lock-
off button, trigger switch and the
accessories for damage.
2. Check for damaged, missing, or worn
parts.
3. Check for loose screws, misalignment
or binding of moving parts, or any other
condition that may affect the operation.
4. If abnormal vibration or noise occurs,
turn the tool off immediately and have
the problem corrected before further
use.
5. Detach the battery pack before cleaning
or performing any maintenance. Using
compressed air may be the most
effective cleaning method. Always wear
safety goggles when cleaning tools
using compressed air.
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.
Do not at any time let brake fluids,
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.
When servicing, use only identical
replacement parts. The use of any
other parts may create a hazard or
cause damage to the product.
Use only accessories that are
recommended for this circular saw
by the manufacturer. Accessories
that may be suitable for one tool may
become hazardous when used with
another tool.
Maintain tools with care. Keep cutting
tools sharp and clean. Properly
maintained tools with sharp cutting
edges are less likely to bind, and are
easier to control.
To ensure safety and reliability, all
repairs should be performed by a
qualified service technician.
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Page 19
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
The tool does not start. The battery is depleted. Charge the battery.
The blade does not follow a
straight line.
1. Teeth are dull. This
is caused by hitting a
hard object such as a
nail, dulling teeth on
one side. The blade
tends to cut to the side
with the sharpest teeth.
1. Replace with a new sharp
blade.
2. Edge guide or
straight edge is not
being used.
2. Use an edge guide or
straight edge.
The blade binds or smokes from
friction.
1. Blade is dull. 1. Replace with a new sharp
blade.
2. Blade is on
backwards.
2. Install the blade correctly.
3. Blade is bent. 3. Replace with a new blade.
4. Workpiece is not
properly supported.
4. Clamp the workpiece
correctly and tightly.
5. Incorrect blade is
being used.
5. Use the correct blade.
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Page 20
NOTES
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Page 21
NOTES
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Page 22
SAVE YOUR RECEIPTS
THIS WARRANTY IS VOID WITHOUT THEM
Brushless Circular Saw
WARRANTY
90-DAY MONEY BACK GUARANTEE:
This MASTERFORCE
®
brand power tool carries our 90-DAY Money Back
Guarantee. If you are not completely satisfied with your MASTERFORCE
®
brand
power tool for any reason within ninety (90) days from the date of purchase, return
the tool with your original receipt to any MENARDS
®
retail store, and we will provide
you a refund – no questions asked.
3-YEAR LIMITED WARRANTY:
This MASTERFORCE
®
brand power tool carries our famous No Hassle 3-Year
Limited Warranty to the original purchaser. If, during normal use, this
MASTERFORCE
®
power tool breaks or fails due to a defect in material or
workmanship within three (3) years from the date of original purchase, simply bring
this tool with the original sales receipt back to your nearest MENARDS
®
retail store.
At its discretion, MASTERFORCE
®
agrees to have the tool or any defective part(s)
repaired or replaced with the same or similar MASTERFORCE
®
product or part
free of charge, within the stated warranty period, when returned by the original
purchaser with original sales receipt. Not withstanding the foregoing, this limited
warranty does not cover any damage that has resulted from abuse or misuse of
the Merchandise. This warranty: (1) excludes expendable parts including but not
limited to blades, brushes, belts, bits, light bulbs, and/or batteries; (2) shall be void
if this tool is used for commercial and/or rental purposes; and (3) does not cover any
losses, injuries to persons/property or costs. This warranty does give you specific
legal rights and you may have other rights, which vary from state to state. Be
careful, tools are dangerous if improperly used or maintained. Seller’s employees
are not qualified to advise you on the use of this Merchandise. Any oral
representation(s) made will not be binding on seller or its employees. The rights
under this limited warranty are to the original purchaser of the Merchandise and
may not be transferred to any subsequent owner. This limited warranty is in lieu of all
warranties, expressed or implied including warranties or merchantability and fitness
for a particular purpose. Seller shall not be liable for any special, incidental, or
consequential damages. The sole exclusive remedy against the seller will be for the
replacement of any defects as provided herein, as long as the seller is willing or able
to replace this product or is willing to refund the purchase price as provided above.
For insurance purposes, seller is not allowed to demonstrate any of these power
tools for you.
For questions / comments, technical assistance or repair parts –
Please Call Toll Free: 1-866-917-4374 (M-F 8:30am-5:00pm EST).
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3/2021
© 2021 Menard, Inc., Eau Claire, WI 54703

Specifications

Indexed Terms: Circular Saw, Cordless Saw

Masterforce 5416 Questions and Answers

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