electric Saw blade

sharpener
Model 96687
Set up And Operating Instructions

Diagrams within this manual may not be drawn proportionally.

Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.
Save this manual.
Copyright© 2007 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 or replacement parts, please call 1-800-444-3353.
 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.

Important SAFETY Information

In this manual, on the labeling, and all other information
provided with this product:

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.

DANGER indicates a hazardous situation

Danger which, if not avoided, will result in death or
serious injury.
WARNING indicates a hazardous situation
WARNING which, if not avoided, could result in death
or serious injury.
CAUTION, used with the safety alert
Caution symbol, indicates a hazardous situation
which, if not avoided, could result in minor
or moderate injury.
NOTICE is used to address practices not
Notice related to personal injury.
CAUTION, without the safety alert symbol,
Caution is used to address practices not related to
personal injury.

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 General Safety Rules
WARNING! Read all instructions
Failure to follow all instructions listed below may result in electric shock,
fire, and/or serious injury. The term “power tool” in all of the warnings listed
below refers to your mains-operated (corded) power tool or battery-operated
(cordless) power tool.
SAVE THESE INSTRUCTIONS
1. Work area safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. 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.
c. Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
2. Electrical safety
a. Power tool plugs must match the outlet. Never modify the plug in any way.
Do not use any adapter plugs with grounded power tools. Unmodified plugs
and matching outlets will reduce risk of electric shock.
b. Avoid body contact with grounded surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
c. Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
d. 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.
e. 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.
3. Personal safety
a. 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.
b. Use safety equipment. Always wear eye protection and a full face
shield. Safety equipment such as dust mask, non-skid safety
shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
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 c. Avoid accidental starting. Ensure the switch is in the off-position before
plugging in. Plugging power tools in with the switch on invites accidents.
d. 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.
e. Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
f. Dress properly. Do not wear loose clothing or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
4. Power tool use and care
a. 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.
b. 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.
c. Disconnect the plug from the power source before making any
adjustments, changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting the power tool
accidentally.
d. 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.
e. Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tools
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
f. Use the power tool in accordance with these instructions and in the manner
intended for the particular type of power tool, 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.
. Service
a. 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.

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 Specific Safety Rules
1. Maintain labels and nameplates on the tool. These carry important safety
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
2. Avoid unintentional starting. Prepare to begin work before turning on the tool.
3. Do not leave the tool unattended when it is plugged into an electrical outlet. Turn
off the tool, and unplug it from its electrical outlet before leaving.
4. This product is not a toy. Keep it out of reach of children.
. 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. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked on.
• Properly maintain and inspect to avoid electrical shock.
• Any power cord must be properly grounded. Ground Fault Circuit Interrupter
(GFCI) should also be implemented – it prevents sustained electrical shock.
6. 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 and cement or other masonry products
Arsenic and chromium from chemically treated lumber
Your risk from these exposures varies, depending on how often you do this type
of work. To reduce your exposure to these chemicals: work in a well ventilated
area, and work with approved safety equipment, such as those dust masks that
are specially designed to filter out microscopic particles. (California Health &
Safety Code § 25249.5, et seq.)
7. Always operate with shields in place.
8. 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.

Save these instructions.

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 Grounding
Improperly connecting the grounding wire can result in
WARNING electric shock.
Check with a qualified electrician if you are in doubt as to
whether the outlet is properly grounded. Do not modify
the power cord plug provided with the tool. Never remove
the grounding prong from the plug. Do not use the tool if
the power cord or plug is damaged. If damaged, have it
repaired by a service facility before use. If the plug will not
fit the outlet, have a proper outlet installed by a qualified
electrician.

Grounded Tools: Tools with Three Prong Plugs

1. Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If
the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user, reducing the risk of electric
shock. (See 3-Prong Plug and Outlet.)
2. The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached
to an electrically “live” terminal. (See 3-Prong Plug and Outlet.)
3. The tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
should look like those in the following illustration.
(See 3-Prong Plug and Outlet.)

3-Prong Plug and Outlet Outlets for 2-Prong Plug

Double Insulated Tools: Tools with Two Prong Plugs

1. Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satisfies OSHA requirements and complies
with the applicable standards of Underwriters Laboratories, Inc., the Canadian

SKU 96687 For technical questions, please call 1-800-444-3353. Page 

 Standard Association, and the National Electrical Code.
(See Outlets for 2-Prong Plug.)
2. Double insulated tools may be used in either of the 120 volt outlets shown in the
preceding illustration. (See Outlets for 2-Prong Plug.)

Extension Cords
1. Grounded tools require a three wire extension cord. Double Insulated tools can
use either a two or three wire extension cord.
2. As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool damage.
(See Table A.)
3. The smaller the gauge number of the wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
(See Table A.)
4. When using more than one extension cord to make up the total length, make
sure each cord contains at least the minimum wire size required. (See Table A.)
. If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size.
(See Table A.)
6. If you are using an extension cord outdoors, make sure it is marked with the
suffix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
7. Make sure the extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified
electrician before using it.
8. Protect the extension cords from sharp objects, excessive heat, and damp or wet
areas.

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RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE EXTENSION CORD LENGTH
AMPERES
(at full load)
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A * Based on limiting the line voltage drop to five volts at 150% of the rated amperes.

Symbology

Double Insulated
V~ Volts Alternating Current

Canadian Standards Association

A Amperes

No Load Revolutions per Minute

Underwriters Laboratories, Inc. n0 xxxx/min. (RPM)

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 Specifications
Electrical Requirements 120 V~ / 60 Hz
Load Current 1.19A (no load)
Rotations Per Minute 3800
Arbor Diameter 10mm
Power Cord 6’ 18 AWG 3C
Sharpens Blade Sizes 3-1/2” - 15-3/4” Diameter
Angle Gauge Range 0 - 25º Left/Right
Mounting Hole Size 3/8” Diameter (4 holes)

Unpacking
When unpacking, check to make sure that the item is intact and undamaged. If
any parts are missing or broken, please call Harbor Freight Tools at the number shown
on the cover of this manual as soon as possible.

Set Up 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.
Risk of accidental starting; resulting in serious personal
WARNING injury. Turn the Power Switch of the tool to its “OFF”
position and unplug the tool from its electrical outlet before
assembling or making any adjustments to the tool.
Note: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram near the end of this manual.

Mounting
1. Only mount the Blade Sharpener on a solid, level surface capable of bearing the
weight and vibration of the equipment while it is running. Verify that there are
no hidden wires, utility lines, or hardened surfaces beneath the surface of the
intended mounting area before drilling.
2. Using the holes in the Base (74) as a template, mark the area where the Blade
Sharpener is to be mounted.
3. Drill four 3/8” holes in the surface and secure Blade Sharpener with appropriate
hardware (not included).

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 Functions
1. The Saw Blade Sharpener is designed to sharpen circular saw blades up to a
diameter of 15-3/4”, and 120 teeth.

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.

General operating instructions

1. Risk of serious personal injury from accidental starting or electric shock. Turn
the Power Switch of the tool to its “OFF” position and unplug the tool from its
electrical outlet before attaching the saw blade to be sharpened.

Installing the Grinding Wheel

1. Remove the three Screws (27) then take off the Disk Cover (26).
2. Insert the hex key wrench into the hole, turn the wrench counterclockwise to un-
screw the M10 nut (25).

3. Remove the Grinding Wheel Base (24) and the Grinding Wheel (23), then take
off the Grinder Lock Cap (22).
4. Put one of the washers onto the Arbor (19) and install the thick emery grinding
wheel on the arbor (19). The bevel edge of the grinding wheel should face the
M10 nut (25); adjust to fit properly. Place the other washer onto the Arbor (19).

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. Fasten the M10 nut (25) clockwise, put on the Disk Cover (26), secure using the
three Screws (27).
6. Remove the hex key wrench. Never operate tool before taking off the hex key
wrench or without the Disk Cover (26) mounted.
7. Remove Lock Nut (83), Spring (82), Pressure Bushing (81) and all washers from
Blade Rest (80). Assemble saw blade onto the Screw as shown in Figure 1.
Figure 1
Lock Nut (83)

Washer (84)

Spring (82)
Washer (84)
Pressure Bushing (81) Blade Rest (80)
Saw Blade

8. Center the saw blade and secure it in place. Do not overtighten; the Blade
should still be able to turn. Make sure the blade is level (perpendicular to axis of
the screw).

Grinder Lock Grinding Grinding Wheel

Cap (22) Wheel (23) Base (24)

9. The shaft of diamond grinding wheel is 20mm diameter, and is mounted on the
Arbor (19) using the Grinder Lock Cap (22) and the Grinding Wheel Base (24).
10. Adjust the Swivel Arm (63) of the Saw Sharpener to compensate for the size of
the saw blade. Loosen the Lock Nut (83), and rotate and/or extend the Swivel
Arm as necessary, so that the saw blade face or the cutting edge is mounted
towards the Grinding Wheel (23). To make room for larger blades, the motor may
also have to be moved.
11. To move the motor, loosen the Screws (71) that secure it to the Base (74) and
slide it along the track to the new position. Tighten Screws. The Motor can be

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 moved to a variety of positions, depending on the intended size of the blade to be
sharpened, as shown in Figure 2.
Figure 2
To sharpen a
3-1/2” (90mm)
blade the motor
must be moved
backward.

Swivel
Arm (63)

To sharpen a 9”
(230mm) saw
blade the motor
must be moved
forward to avoid To sharpen a 15-1/2” (400mm)
contact with the saw blade the motor must be
Swivel Arm (63). moved forward and the Swivel Arm
adjusted so that the Lock Nut (83)
does not contact the saw blade.

12. For greater stability and accuracy, position the Saw Blade Support (66) as close
as possible to the Grinding Wheel.
13. Position the blade according to which saw surface will be sharpened, the tooth
face, or the tooth back, as shown in Figure 3.
Figure 3

Position the Grinding Wheel Position the Grinding Wheel here

here to sharpen the tooth face. to sharpen the tooth back.

14. Loosen the Set Screw (39) in the middle of the Depth Gauge (40) and adjust the
saw blade so that the Grinding Wheel (23) is positioned to sharpen the tips, but
does not touch the tooth bottom.

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 Depth Gauge (40) Angle Guide Pointer (45)
and Set Screw (39) Left (33)

1. The Motor can be tilted to set an angle in the saw blade or to sharpen blades with
set teeth. Loosen the screws set in both sides to the Angle Guide (33, 46) and
move the Motor to set the desired angle.
16. After all adjustments are complete, position the Blade Stop (79) lightly against
the saw blade.
17. Plug the Saw Blade Sharpener into a standard 120V electrical outlet. Wearing
safety goggles, face guard and protective clothing, secure the saw blade and flip
the Switch (2) to the “ON” position.
18. Use the Handle (60) to apply the Grinding Stone to the saw blade until it reaches
the Depth Gauge (40).
19. Pull the Handle back, turn the saw blade, and sharpen the next tooth. Repeat
this process until all saw teeth are sharpened.
20. To prevent accidents, turn off the tool and disconnect its power supply after use.
Clean, then store the tool indoors out of children’s reach.

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 Maintenance And Servicing
Risk of serious personal injury from accidental starting
WARNING or electric shock. Turn the Power Switch of the tool to its
“OFF” position and unplug the tool from the electrical outlet
before performing any inspection, maintenance, or cleaning
procedures.
Damaged equipment can fail, causing serious personal
injury. 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 screws, 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, clean external surfaces of the tool with clean, moist cloth.
3. Make sure all ventilation slots are kept clear to prevent motor damage.
4. Replace Grinding Wheel when it becomes worn.
. WARNING! If the supply cord of this power tool is damaged, it must be
replaced only by a qualified service technician.

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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 PARTS LIST
Part Description Part Description Part Description
1 Motor Cover 30 Screw 58 Left Bushing Guide
2 Switch 31 Power Cord Protector 59 Washer
3 Power Cord Support 32 Power Cord 60 Handle
4 Screw 33 Left Angle Guide 61 Screw
5 Switch Circuit Board 34 Steel Bushing 62 Shaft
6 Screw 35 Nut 63 Swivel Arm
7 Washer 36 Motor Retainer 64 Swivel Arm Arbor
8 Motor 37 Screw 65 Washer
9 Motor Housing 38 Rear Guide Rod 66 Saw Blade Support
10 Motor Neck 39 Set Screw 67 Screw
12 Connector 40 Depth Gauge 68 Washer
13 Bearing Bushing 41 Right Bushing Guide 69 Rubber Feet
14 Retaining Pin 42 Screw 70 Washer
15 Pin 43 Screw 71 Screw
16 Bearing 44 Screw 72 Retaining Ring
17 Retaining Ring 45 Angle Gauge 73 Saw Blade Catch
18 Bearing 46 Right Angle Guide 74 Base
19 Arbor 47 Right Guide 75 Screw
20 Screw 48 Screw 76 Swivel Arm
21 Protection Cover 49 Screw 77 Washer
22 Grinder Lock Cap 50 Steel Bushing 78 Ring
23 Grinding Wheel 51 Screw 79 Blade Stop
24 Grinding Wheel Base 52 Front Bushing Guide 80 Blade Rest
25 Screw 53 Adjust Base 81 Pressure Bushing
26 Disk Cover 54 Screw 82 Spring
27 Screw 55 Screw 83 Lock Nut
28 Screw 56 Pull Rod 84 Mounting Washer
29 Protection Plate 57 Screw

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.

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 ASSEMBLY DIAGRAM

84

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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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

SKU 96687 For technical questions, please call 1-800-444-3353. Page 17