Craftsman 28617589 User manual

Operator'sManual

5-in.TWIN CUTTER SAW

Model No.

286.17589

CAUTION: Read, understand and follow

all Safety Rules and Operating Instructions

in this manual before using this product.

• SAFETY

• OPERATION

• MAINTENANCE

• ESPANOL, PAGE25

Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.

Warranty. ...................................................................... Page 2

Safety Instructions ..................................................... Pages 3-8

Safety Symbols ....................................................... Page 8

Description .................................................................... Page 9

Operation .................................................................. Pages 10-19

Removing and Installing Blades ................................... Pages 17-19

Maintenance ................................................................. Pages 19-20

Troubleshooting ............................................................ Page 21

Accessories .................................................................. Page 21

Repair Parts .................................................................. Pages 22-23

Service Numbers .......................................................... Back Cover

ONE YEAR FULL WARRANTY ON CRAFTSMAN TOOL

If this Craftsman Tool fails to give complete satisfaction within one year

from the date of purchase, RETURN ITTOTHE NEAREST SEARS

STORE OR SEARS PARTS AND REPAIR CENTER INTHE UNITED

STATES, and Sears will repair it, free of charge.

If this Craftsman Tool is used for commercial or rental purposes, this

warranty applies for only 90 days from the date of purchase.

This warranty gives you specific legal rights, and you may also have other

rights which vary from state to state.

Sears, Roebuck and Co., Dept. 817 WA, Hoffman Estates, IL 60179

SAVETHESE INSTRUCTIONS!

READ ALL INSTRUCTIONS!

2

/_, WARNING: BE SURE to readand understandallinstructions. Failure to

follow all instructionslisted below may result in electric shock,fire and/or

serious personal injury.

WORK AREA SAFETY

1.ALWAYS keep your work area clean and well lit. Clutteredbenchesand dark

areas inviteaccidents.

2. DO NOT operate power tools in explosive atmospheres, such as in the

presence of flammable liquids, gases, or dust. Powertoolscreate sparks which

may ignitethe dustor fumes.

3. ALWAYS keep bystanders, children, and visitors away while operating a

power tool. Distractions can causeyou to lose control

ELECTRICAL SAFETY

1. Double Insulated tools are equipped with a polarized plug (one blade is

wider than the other.) This plug will fit In a polarized outlet only one way.

If the plug does not fit fully In the outlet, reverse the plug. If it still does not

fit, contact a qualified electrician to install a polarized outlet. Do not change

the plug In any way.

2. Doubleinsulation Deliminates the need for the three-wiregroundedpower cord

and groundedpowersupplysystem.ApplicableonlytoClass II (doubleinsulated)

tools.

3. Beforeplugginginthe tool, BE SURE that theoutletvoltagesuppliedis withinthe

voltagemarked on thetool'sdata plate,DO NOT use"AC only" rated toolswith a

DC powersupply.

4. ALWAYS avoid body contact with grounded surfaces, such as pipes,

radiators, ranges and refrigerators. There isan increasedrisk ofelectricshock

if your body is grounded.

5. If operating the power tool in damp locations Is unavoidable, ALWAYS use a

Ground Fault Circuit Interrupter to supply power to your tool. ALWAYS wear

electrician's rubber gloves and footwear in damp conditions.

6. DO NOT expose power tools to rain or wet conditions. Water enteringa power

toolwillincreasethe risk of electricshock.

7, DO NOT abuse the cord, NEVER use the cord to carry the tools or pull the

plug from the outlet. Keep cord away from heat, o11,sharp edges or moving

parts. Replace damaged cords immediately, Damaged cordsincreasethe risk

of electricshock.

8. When operatinga powertooloutside,ALWAYS use an outdoorextensioncord

marked'_V-A"or '_N".These cordsare ratedfor outdooruseand reducethe risk

ofelectricshock.

NOTE: The extensioncord musthaveadequate wire size AWG (American Wire

Gauge) for safe, efficientuse. Smaller gaugewires, havegreatercapacity(16 gauge

wire has morecapacity than 18 gauge wire),

PERSONALSAFETY

1.ALWAYSstayalert,watchwhatyouaredoingandusecommonsensewhen

operatingapowertool.DONOTusetoolwhiletiredorundertheInfluenceof

drugs,alcohol,ormedication.Amoment of inattention whileoperatingpower

toolsmay resultin seriouspersonalinjury.

2. ALWAYS dress properly. DO NOT wear loose clothing or jewelry. Pull back

long hair. Keep your hair, clothing, and gloves away from moving parts.

Looseclothes,jeweFry,or longhaircan be caughtin movingparts.

3. ALWAYS avoid accidental starting. BE SURE switch Is In the "Off" position

before plugging in. DO NOT carry toolswithyourfingeron the switch.Carrying

toolswithyourfinger on the switchor pluggingintoolsthathavethe switchinthe

"On"positioninvitesaccidents.

4. ALWAYS remove adjusting keys or wrenches before turning the tool "On".

A wrenchor akey that isleftattached to a rotatingpart ofthe toolmay resultin

personalinjury.

5. DO NOT overreach. ALWAYS keep proper footing and balance at all times.

Properfooting and balance enables bettercontrolofthe toolinunexpected

situations.

6. ALWAYS use safety equipment. Always wear eye protection. Dust mask,

non-skid safety shoes,hardhat, or hearing protection must be used forappropriate

conditions,

TOOL USE AND CARE SAFETY

1. ALWAYS use clamps or other practical ways to secure and support the

workplece to a stable platform. Holdingthework byhand or againstyourbody

isunstableand may lead to loss ofcontrol.

2. DO NOT force the tool. Use the correct tool for your application, The correct

tool will do the job better and safer at the rate for which it is designed,

3. DO NOTuse the tool If the switch does not turn It "On" or "Off". Any tool that

cannot be controlled with the switchis dangerous and must be repaired.

4. ALWAYS disconnect the plug from the power source before making any

adjustments, changing accessories or storing the tool. Suchpreventivesafety

measures reducethe riskof startingthetoolaccidentally.

5. ALWAYS store Idle tools out of the reach of children and other untrained

persons. Toolsare dangerous in the handsof untrainedusers.

6. ALWAYS maintain tools with care. Keep cutting tools sharp and clean.

Properlymaintained toolswith sharp cuttingedges ere lesslikelyto bindand are

easier tocontrol,

7. ALWAYS check for mlsalignment or binding of moving parts, breakage of

parts, and any other condition that may affect the tool's operation. If

damaged, have the tool serviced before using. Many accidentsare caused by

poorly maintained tools.

/'_ WARNING; USE OFACCESSORIESTHATARE NOT RECOMMENDED I

FOR USE WITH THIS TOOL MAY CREATEA HAZARDOUS CONDITION

8. ALWAYS use only accessories that are recommended for this tool.

Accessoriesthatmay be suitablefor one toolcan become hazardouswhen used

on anothertool.

4

SERVICESAFETY

1.Ifanypartofthissawismlsslng or should break, bend, or fall In any way; or

should any electrical component fall to perform properly: ALWAYSshut offthe

powerswitchand removethesaw plugfrom the powersourceand havethe missing,

damagedor failed partsreplaced BEFORE resumingoperation.

2. Tool service must be performed only at a Sears Parts and Repair Center.

Service or maintenanceperformedbyunqualifiedpersonnelcouldresurtina riskof

injury.

SAFETY RULES FOR SAWS

•'_ DANGERf Keep hands away from cutting area and blades. Keep your I

second hand on the auxiliary handle or motor housing. Ifbothhandsare

I

holding the saw, theycannot be cutby the blades.

1. ALWAYS keep your body positioned to either side of the saw blades, but not

in line with the saw blades.

2. DO NOT reach underneath the work. The guardcannotprotectyoufromthe

bladesbeneath thework.

3. ALWAYScheck guard for proper closing BEFORE each use. DO NOT operate

the saw if the guard does not move freely and close instantly. Never clamp or

tie the blade guard In the open position. Ifthe saw isaccidentallydropped,the

guard may be bent.Raisethe guardand make surethat itmovesfreely and does

nottouchthebladesoranyotherpart.

4. ALWAYScheck the operation and condition of the guard spring. If the guard

and the spring are not operating properly,they MUST be serviced before use,

The blade guard may operatesluggishly,due todamaged parts, gummy deposits,

or a buildupofdebris.

5. The guard should be retracted manually ONLY for making special cuts, such

as pocket or compound cuts. ALWAYS raise the guard by retracting the

handle. As soon as the blade enters the material, the guard MUST be

released. Forall othersawing,theguard shouldoperateautomatically.

6. ALWAYS make sure that the guard Is covering the blades BEFORE placing the

saw down on a work bench or floor. An unprotectedmoving bladeswillcausethe

saw towalkbackwards,cuttingwhateveris in itspath.Make noteofthetime ittakes

for thebladestostopspinningaftertheswitchisreleased.

7. NEVER hold the piece being cut In your hands or across your legs.It is

important tosupporttheworkproperlyinorderto minimizebodyexposure,blade

binding, or lossofcontrol

g. ALWAYS hold tool by Insulated gripping surfaces when performing an

operation where the cutting tool may contact hidden wiring or Itsown cord.

Contactwitha 'live"wirewillmake theexposedmeta]parts ofthetool"live" and

shockthe operator.

9. DO NOT leave the saw running when carrying It In your hand.The lower blade

guard may be opened by contact with your clothing. Accidentalcontactwiththe

spinningsaw bladescouldresult inseriouspersonalinjury.

10. DO NOT use the tool If the switch does not turn "On" or "Off". Anytoolthat

cannotbe controlledwiththeswitchis dangerousand must be repaired.

SAFETYRULESFORSAWScont.

11.Whenremovingthebladesfromthetool,ALWAYSwearprotectivegloves when

graspingthe bladesor accessory.Accessoriesmay be hot afterprolongeduse.

KICKBACK..,WHAT CAUSES IT AND WAYSTO PREVENT IT

The Causes of Kickback

1. Kickbackis a sudden reaction to a pinched, bound or misaligned saw blades,

which cause the uncontrolled saw to lift up and out of the workpiece and towards

the operator.

2. When the blades are pinched or bound tightly by the kerr closing down, the blades

stall and the motor reaction drives the unit rapidly back towards the operator.

3. ifthe blades become twisted or misaligned in the cut, the teeth at the back edges

of the blades can dig into the top surfaceof the wood, This causes the blades to

climb out of the kerf and jump back towardsthe operator.

4. Kickback is a result of tool misuse and/orincorrect operating procedures or

conditions, It can be avoided by taking the proper precautions, as listed below.

Ways to Prevent Kickback

1. ALWAYS maintain a firm grip with both hands on the saw and position your

body and arms to allow you to resist KICKBACK forces, KICKBACKforcescan

be controlledby the operator, if the proper precautions are taken,

2. Ifthe blades are binding, or when you are Interrupting a cut for any reason,

ALWAYS turn off the saw and hold the saw motionless in the material until

the blades come to a complete stop. NEVER attempt to remove the saw from

the work or pull the saw backward while the blades are in motion or

KICKBACK may occur. ALWAYS checkand be readyto take corrective actionto

eliminate the cause of blade binding.

3.When restarting the saw In the workpiece, ALWAYS center the blades In the

kerf and check to be sure that the saw teeth are not engaged Into the

material. Ifthe saw blades are binding,they maywalk upor KICKBACKfromthe

workpiece when the saw isrestarted.

4. ALWAYS support large panels to minimize the risk of blades pinching and

KICKBACK. Large panelstendto sag undertheirown weight.SupportsMUST be

placed underthe panel on bothsides,near the line ofcut and near the edge ofthe

panel.

5. DO NOT use a dull or damaged blades, Unsharpened or improperly set blades

produce narrow kerf which causes excessive friction, blade binding and

KICKBACK.

6.ALWAYS use extra caution when making a "Pocket Cut" Into existing walls or

other blind areas. The protruding bladesmay outobjectsthat can cause

KICKBACK.

7. ALWAYS havethe saw blades at fullspeed beforecontactingworkpiece

8. ALWAYS keepyourbody positioned to eitherside ofthe saw blades, but not in line

with the saw blades. KICKBACKcouldcause the saw tojump backwards towards

the operator.KICKBACK forcescan be controlled bythe operator, ifproper

precautions are taken.

ALWAYS hold tool by insulated gripping surfaces when performing an

operation where the cutting tool may contact hidden wiring or its own cord.

Contactwith a "live" wirewillmake theexposedmetal parts of the tool"live" and

shock the operator. 6

ADDITIONAL RULES FOR SAFE OPERATION

I Z_ WARNING: BE SURE to read and understandallinstructions.Failureto I

followall instructions listedbelow may resultin electric shock,fireand/or serious

personal injury.

1. Know your power tool. Read operator's manual carefully. Learn the

applications and limitations, as well as the specific potential hazards related

to this tool. Followingthis rule willreducethe riskof electric shock,fireor serious

injury.

2. ALWAYS wear safety glasses or aye shields when using this saw. Everyday

eyeglasses have only Impact-resistant lenses; they are NOT safety glasses.

Followingthis rulewillreducethe riskofseriouspersonalinjury.

3. ALWAYS protect your lungs.Wear a face mask or dust mask if the operation

is dusty. Following thisrule willreduce the risk of seriouspersonal injury.

4. ALWAYS protect your hearing.Wear hearing protection during extended

periods of operation. Following this rulewill reducethe riskof seriouspersonal

injury.

5. ALWAYS Inspect the tool cords periodically and if damaged have them

repaired at your nearest Sears Service Center or other Authorized Service

Facility.ALWAYS be aware of the cord location. Followingthis rulewitlreduce

the risk of electricshockor fire.

6. ALWAYS check for damaged parts. Before further use of the tool, a guard or

other part that is damaged should be carefully checked to determine if it will

operate properly and perform Its Intended function. Check for miaalignment

or binding of moving parts, breakage of parts, and any other condition that

may affect the tool's operation. A guard or other part that Is damaged, should

be properly repaired or replaced at a Sears Service Center. Followingthis rule

willreduce the risk of electricshock,fire or serious injury,

7. DO NOT abuse the cord. NEVER use the cord to carry the tool or pull the

plug from the outlet. Keep cord away from heat, o11,sharp edges or moving

parts. Replace damaged cords Immediately. Damaged cordsincreasethe risk

ofelectricshock.Followingthis rulewillreducethe riskofelectricshockor fire.

8. ALWAYS make sure that your extension cord Is in good condition.When

using an extension cord be sure to use one that Is heavy enough to carry the

current that your tool will draw. A wire gauge size (A.W.G.) of at least 16 is

recommended for an extension 100 feet or less in length. Using an extension

cord that is over 100 feet Inlength is not recommended. If in doubt, use the

next heavier gauge. Smaller gauge wires, have greater capacity (16 gauge

wire has more capacity than 18 gauge wire). An undersizedcordwillcausea

dropin line voltage, resultingin lossof powerand overheating.

9. DO NOT use the tool while tired or under the influence of drugs, alcohol or

any medication. Following this rule will reduce the risk ofelectric shock,fire or

serious personalinjury.

10. SAVETHESE INSTRUCTIONS. Refer to them frequently and use them to

Instruct others who may use this tool. Ifsomeone borrows this tool, make

sure they have these Instructions also.

ADDITIONALRULESFORSAFEOPERATIONcont.

,/_ WARNING: Some dust particles created by power sanding, sawing,

grinding, drilling and other construction jobs contains chemicals known

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 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 those dust masks that are

specially designed to filter out microscopic particles.

WEAR YOUR

Z_ WARNING: The operation of any saw can result in

foreign objects being throwninto your eyes, whichcan result in

severe eye damage. Before beginning powertool operation,

ALWAYSwear safety goggles or safety glasses with side shield

and a full face shield when needed. We recommend A Wide

Vision Safety Mask for use over eyeglasses or standard safety

glasses with side shield, available at Sears Retail Stores.

The label on your tool may Include the following symbols.

V.......................................................................Volts

A......................................................................Amperes

Hz....................................................................Hertz

W.....................................................................Watts

mln..................................................................Minutes

....................................................................Alternating current

................................................................... Direct current

no....................................................................No-loadspeed

[] ....................................................................Class IIconstruction

,../mln..............................................................Revolutionsor Strokssper minute

Z_, ....................................................................Indicates danger,warning or caution.

It means attention! Your safetyis involved,

IMPORTANT! READ ALL INSTRUCTIONS

Beforeattempting to use any tool, be sureto familiarize withall the operating

features and safety instructions.

I Z_ WARNING" 90 NOT letfamiliarity withyoursaw make youcareless.

Rememberthata carelessfraction ofa secondis sufficienttocausesevereLnjury.

KNOWYOUR SAW (SEE Fig. 1)

YourTwinCuttersaw has many built-in conveniencefeatures for fast, efficientcutting.

These features includea innovative 2-blade systemwith specialblades that spinin

oppositedirectionstoprovidesmooth,clean cuts. Italso includesa pre-instailed

blade lubricating system for usewhen cuttingaluminum, copper,stainlesssteeland

cast iron.The auxiliaryhandle mountson thetop ofthe saw to providemaximum

supportand ease of handling.

Foryourconvenience,there isno assemblyrequiredfor yourTwinCutter Saw.The

special2-blade cuttingsystem and thewax lubricatingsystem are already installed.

UpperBladeGuard

AssistHandle,_

LowerSlade

_/'/( '_° '_ GuardHandle_ _--_/1

o j wax

_,_,J j Lubricatingf _)e..>'._-_

Stick _ f[

LockNut WaxLubdcating /_= \

SystemKnob i:_

Wrench_ Blades

Fig. 1

On/OffSwitch

Ni,li[o]o]l[q _"]"J_[_o,E_i[i]_ [,,_

Input

Output

BladeDiameter

Rating

No-load Speed

Maximum Depth of Cut

6 Amps

,96-Peak HP

5 in.(127mm)

120volls,60 HzAC

5500 RPM

wood (1 inch) metal (with a wall or sheet thickness of 1/16 in.)

UNPACKING

Your TwinCutterSaw has been shippedcompletelyassembled. Inspectthe saw

carefullyto make sure thatno breakage or damage has occurredduringshipping.

Ifany parts are damaged or missing returnthe saw toyournearest Sears Store to

have it replaced.

,/ik, WARNING: If anyparts are missing, DO NOT operate this saw until the

missing parts are replaced. Failure to do socould result in possible serious

personal injury

9

SAWBLADES

Eventhebestsawbladeswillnot cut efficientlyiftheyare not keptclean, sharpand

properlyset. Using dullbladeswill placea heavy loadon yoursaw and increasethe

dangerof kickback.Keep extrabladeson hand, so sharpbladesare alwaysavailable.

Gum and wood pitchhardenedon yourbladeswillslowyour saw down. Use gum

and pitchremover, hotwater or keroseneto removethese accumulations,

DO NOT usegasoline.

I /_, WARNING: This TwinCutter saw uses specially designed 5-in. blades I

and noother typos or sizes of blades shouldeverbe used. Other typos and sizes of

blados will not operate safely in this saw and could result in serious personal injury.

To order extra blades or to replace the blades that came with the saw, see page 21

of this manual for ordering instructions. To install new blades onto to your saw see

the specialinstructions on pages 17 to 19 of this manual for proper removal and

insta]lation of blades.

BLADE GUARD SYSTEM

The lower blade guard, attached to your 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 your saw until the

problem has been corrected or the damaged part has been replaced. ALWAYS

leave the guard in itscorrect operating position when using the saw.

./K DANGER: When sawingthrougha

workpiece, the lower blade guard does not

coverthe blade onthe undersideofthe

workpiece.Since the blade isexposedon the

undersideofthe workpiece,ALWAYS keep

yourhandsand fingersawayfrom the cutting

area (see Fig.2). Any part of yourbody

comingin contactwiththe movingblade will

result in seriousinjury.

Lower Blade Guard is in UP position when

making a cut. Blades are exposedon underside

of workpiece.

\ Fig.2

Z_ WARNING: NEVER use the sawwhen the guard isnot operatingproperly.

The guardshouldbe checkedfor correctoperationbeforeeach use.Ifyou drop your

saw,checkthe lowerblade guardfor damage beforeusing,

NOTE:The guardisoperatingproperlywhen itmoves freely and then readily

returnsto theclosedposition.If,for any reason,your lowerbladeguarddoes not

closefreely, take ittoyour nearest Sears RepairCenterfor servicebeforeusingit.

10

KICKBACK

Kickbackoccurswhenthebladesstall rapidlyand the saw isdrivenbacktowards

you. Bladestallingis caused byany actionwhichpinchesthe blade inthe material

beingcut.

IMPORTANT:The best guard against kickback is to avoid dangerous practices.

/_, DANGER: ALWAYS turn OFF powerto saw immediatelyif the bladesbind I

or the saw stalls,Kickbackcouldcauseyou to lose control of the saw.Loss of

I

control can lead to serious injury.

ALWAYS provide proper support for the workpleoe and hold the saw with

both hands

Kickback is Caused By:

1. Twistingthe blades while making a cut,

2. Making a cutwitha dull,gummed up, or

improperlyset blades,

3. Not providingpropersupportfor workpiece,

ALWAYS providepropersupportasshown

in Fig.3.

4. Forcinga cut.

5. Cuttingwarped or wet lumber.

6 Toolmisuse or incorrectoperatingprocedures.

7. Contactingthe workpiecewith bladesat less

than full speed.

To Lessen the Chance of Kickback

1. ALWAYS approachthe workpiecewith

the saw at an angle ofapproximately

30° tothe workpiece.(see Fig. 4.)

2. ALWAYS make straightcuts.

This willhelp prevent twistingthe

blade in the cut,

3. ALWAYS use clean, sharp and

properlyset blades.NEVER make

cutswith dullblades.

4. ALWAYS properlysupportthe

workpiece before beginning a cut,This willhelp you avoid pinching the blades

(see Fig.3).

5. ALWAYS use steady,even pressure when making a cut. NEVER force the cut,

6. DO NOT cut wet or warped lumber.

7. ALWAYS hold the saw firmly with both hands and keep your body in a balanced

position. ALWAYS keep your body positioned to either side of the saw blades, but

not in line with the saw blades.This will help you resist the forces of kickback,

shouldit occur.

IMPORTANT:When using your saw, ALWAYS stay alert and exercise control.

DO NOT remove your saw from the workplece, while the blade Is moving.

11

STARTINGACUT

IMPORTANT:

BEFOREusingtheTwinCutterSawforthefirst time,ALWAYS familiarize yourself

withthe saw bymakingpracticecuts inscrapmaterials.

The weightofthis saw helpstomake thecutssmoother.Learn howto safely handle

and controlthe weightofthe saw.

ALWAYS besure that you positionthe blades perpendiculartothe planeof the

workpiece.Make the cutat an approximate30° angle to the workpiecesurface.

(See Fig. 5).

Practice the properfeed speed rate for the materialsbeing cut.The bladesspinat a

consistent5500 RPM (no-loadspeed).

Engage the on/offswitchto startthe saw.Toengage, pressdownon the backofthe

switch,then pushforward. ALWAYS let the bladesreachfull speed beforeyou begin

the cut intotheworkpiece.

IMPORTANT: When using your saw, ALWAYS stay alert and exercise control.

DO NOT remove your saw from the workpiece, while the blade Is moving.

Blades perpendicular to workplece

Approximately 30°

/_ WARNING: ALWAYS

maintain propercontrolofthe saw

tomake sawing safer and easier.

Lossof control of the saw could

causean accident resulting in

possible seriousinjury.

Fig. 7

NEVER hold the saw withjust

one hand (see Fig. 6).

Correct

ALWAYS holdsaw bymotorbodyand

assisthandle (see Fig.7).

12

TOHELPMAINTAINCONTROL

1.ALWAYSsupporttheworkpiecenearthecut.

2.ALWAYSsupporttheworkpiecesothecutwillbeonyourright.

3.ALWAYSclamptheworkpiecesoitwillnot moveduringthe cut.

Place the workpiecewith the goodside down.NOTE: The good sideisthe side

where appearance isimportant.

Beforestartinga cut,draw a guidelinealongthe desiredlineofcut.Then place the

front edge ofthe saw bladeson the part ofthe workpiecethat issolidlysupported.

4. NEVER place the saw on the part ofthe workpiecethatwillfall offwhen the cutis

made.

5. ALWAYS keep the cordaway from the cuttingarea, ALWAYS place the cordsoit

does nothang up on theworkpiecewhen makinga cut.

Z_ DANGER: If the cord hangs up on the workpieceduring a cut, release the

on/offswitchimmediately.Unplugthesaw and movethe cordto prevent itfrom

! hanging up again.

I

,/K DANGER" Usingthe saw with a damaged cordcouldresult in serious

injury or death. If the cord has been damaged, have it replaced before using the

saw again.

Z_ WARNING: If the blades come in contact withthe workpiece before they

reach fu!l speed, itcould cause the saw to kickback towardsyou, resulting in

serous nlury.

When making a cut, ALWAYS use steady,even pressure. Forcingthe saw causes

roughcutsand couldshortenthe lifeofthe saw or causekickback.

,/_, DANGER: When sawing through the workpiece, the lower blade guard

does not cover the blades.The blades are exposed on the under side of the

workpiece. ALWAYS keep your hands and fingers away from the cutting area.

Any part of your body coming in contact with the moving blades will result

in serious injury.

After completingyourcut, release the on/offswitchand allowthebladesto cometo a

completestop.DO NOT remove the saw from the workplece while the blades

are moving.

I Z_ CAUTION: Whenever you liftyour saw from the workpiece,the blades are

exposed on the under side of the saw until the lower blade guard closes. ALWAYS

MAKE SURE that the lower blade guard is closed before setting the saw down on

work surface.

13

CUTTINGINSTRUCTIONS

NOTE:ThelifespanofthebladesonyourTwinCuttersawandthequalityofthe

cuttingedgesisdependentonkeepingvibrationstoaminimum.

ALWAYSsecurelyclamptheworkpiece

BEFOREbeginningacut.Thenfeed the

bladethroughthe materialat an angle

of approximately 30° (see Fig.8).

This saw produces hot chips, not

sparks, when cutting metal.

It is recommended that you wear a

face shield over safety glasses to

protect your face,

FEED SPEED

F,0.

Feed speed ishow quickly you push the saw blades throughthe material being cut,

The correct feed speed is totally determined by the hardness and the thickness of

the material being cut,

IMPORTANT: FeedingmustALWAYS be done withthe bladesperpendicular tothe

planeof theworkpiece (See Fig.A). Feedingat an angle can burn the blade and

damage the bladeteeth (See Fig. B).

Selecting the correct feed speed Is important.

If the feed speed Is too slow:

1. The blades will onlypress downon the material rather than cuttingit,

2. The bladeedges glideand wear downthe material.

3. A poorcut willresultand cause excessivewear on the blades

If the feed speed Is too fast:

1. There isa definite riskthatthe cut mFghtsplitand the splinteredopeningofthecut

winnot be sufficientto divertthe woodshavings.

2. A poor cutwillresultwith a significantdischargeof woodshavingson the lower

side ofthe cut.

Correct

F,g'. J

ong

14

CUTTING INSTRUCTIONS cont.

WHAT IT CUTS

The blades supplied with the saw are universal In application and will give clean,

smooth cuts in:

• Wood up to a maximum depth of 1 inch.

• Mild steel tubing or sheets with a maximum wall or sheet thickness of 1/16 inch.

• Copper, stainless steel, aluminum, cast Iron tubing or sheets with a wall thickness of

1/16 inch.When cutting these materials, the wax lubricatingsticks MUST BE USED.

• Plastic pipe or sheets of a wall thickness of 1/16 inch.

IMPORTANT: The Twin Cutter WILL NOT CUT masonry, cement or brick material.

IMPORTANT: Once the blades become worn, chipped or dull, they MUST BE replace

immediately.

CUTTING ALL MATERIALS

1. ALWAYS have the saw blades at full speed before contacting workpiece.

2. ALWAYS hold the saw so the blades feed perpendicularly into the workpiece. Hold

the saw at an approximate 30° angle.

3. ALWAYS keep your body positioned to either side of the saw blades, but not in line

with the saw blades.

4. Feed the blades into the workpiece untilthe desired cut is made.

5. The kerf (width of the cut) ofthe twin blades Isapproximately 3/16th of an inch.

Always be sure to allow for this kerr width.

ThlaTwln Cutter Saw with It's special blades and cutting action is s highly

versatile tool that quickly and efficiently provides smooth, efficient cuts In a

wide variety of materials:

/

//

Rat Iron Bar Corner Piece U-Section

RectangularPIpe

Thin Pfate Shaped Platl Pipes

Cutting other materials may require even more

special handling.These Include cutting aluminum,

copper, stainless steel and cast Iron or shaped

plates

Cutting Aluminum, Copper, Stainless Steel

and Cast, Iron up to 1/16-in. thick. (See Fig. 9).

1. ALWAYS use the wax lubricating device (included)

when cutting these materials because they have a

tendency to soften and adhere to the blades.

15

Wax Lub_cating Device Stick

LUBRICATING INSTRUCTIONS

(See Figure C)

The bladesof your Twin Cutter saw are

equippedwith"dry cutteeththat under

normal cuttingconditionsdo not need to

be lubricated.However,in extremecutting

conditions,suchas whenyou are sawing

into aluminum,copper, stainless steel and

cast Iron, the wax lubricating device must

be used.

1. Insert wax lubricating stick into wax

lubricating device.

2. Turn feeder wheel to apply lubricant to "

blade. A 1/4turn should provide adequate lubrication.

CUTTING INSTRUCTIONS cont.

Cutting Shaped Plates

up to 1116-in.thick (See Fig. 10)

1.When cuttingshaped metal plate

ALWAYS supportthe plate evenlyon

bothsides and in the middlewith

supportblocks. Thiswillkeep itfrom

flexing when cutting.This shouldbe

done, whetheryou'reusing aclamping

table, or using adjustable clamps on a

flat work table.

Fig. 10 1

S_ck

PLUNGE CUT'rING (See Figure 11)

1. Raise the retractable guardinto the

open positionwith yourleft hand,

2. Use the thumbof your lefthand to hold

the guard in theopen positionwhile

grippingthe saw'sassisthandle.

3. Turn on the saw and plungetheblades

into the material to be cut.

4. Push the saw forward to complete

the cut.

5.Turn off saw, allow blades to stop

completely, then remove saw from

workpiece.

6. Clean out the corners of thecutwith a hand saw or sabre saw, depending

on project.

NOTE: When cutting building materials, blades must be kept clean with a tar and

pitch blade cleaning solvent

16

REMOVINGBLADESFROMSAW(SeeFigs,12-16)

1.Unplugthesawandallow bladesto cool.

/'lk WARNING: Failureto unplugthe saw Couldresultin accidental starting I

causing possibleserious personal injury,

I

2, Rotate the blades untilthe holes in both blades arealigned. Then place pin

attached to the wrench through holes in blades. Unscrew Lock Nut

counterclockwise and remove (see Fig. 12),

3. Open the retractable guard (see Fig. 13).

4. Lift up and remove Blade "B" (see Fig. 14),

5. Remove the arbor adapter (see Fig. 15).

6. Lift up and remove Blade "A" (see Fig, 16).

Fig. 13

Retracted

Fig. 15

rbor

Adapter

Fig. 16

17

A'I-rACHING REPLACEMENT BLADES TOTHE SAW (See Figs. 17 - 20)

,/_ WARNING: ThisTwinCuttersaw usesspeciallydesigned5-in. blades

and no othertypesor sizes of bladesshouldever be used.Othertypesand sizes

of.bladeswillnot operatesafelyin thissaw and couldresultinseriouspersonal

injury.

See the accessories section of this manual for the proper replacement blades

that are needed for this saw.

1, Unplugthe saw,

,/_ WARNING: Failureto unplugthe saw couldresultin accidentalstarting

causingpossibleserious personalinjury,

2, Laythe saw clown withthe blade arborpointingupward.

3, Place blade"A" ontothe bladeflange withthe"A" clearlyvisible(see Fig. 17).

4.Alignthe holeson the bladewiththe pinson the flangeand securelyfitthe blade

on theflange (see Fig, 18),

5.Take the arboradapter "1"and pushitdownontotheflangewiththe "1" clearly

visible.Make sure thatthe adapter isproperlyseated overtheflat sidesofthe

flange.(see Fig,18),

6, Place blade "B" onto the adapterwiththe "B" easily visible,then thread lock nut

onto shaft. DO NOT tighten, (see Fig. 19).

7. Turn the blades so that the holes in both blades are lined up.

Flange

Fig. 18

I

Fig. 19

18

A'I-I'ACHtNGREPLACEMENT BLADES TO THE SAW cont. (See Figs. 17 -20)

8, Place the pin(includedwiththe

wrench)intothe lined up holes, Fig, 20

9, Tightenthe lock nut clockwisewith

the wrenchand then remove the pin

from the blades(see Fig.20), This will

allow the bladestoturn freely.

10.Carefully turn blades withyour hand

to be sure they easily turn in

opposite directions.

Lock Nut

GENERAL

/_ WARNING: To avoidaccidents,ALWAYS disconnectthetoolfrom the IpowersourceBEFORE cleaningor performingany maintenance.

Allparts representan importantpart ofthe doubleinsulationsystemand shouldbe

servicedonlyat a Sears Service Center.

Avoidusingsolventswhen cleaningplasticpads. Most plasticsare susceptibleto

damage from varioustypesofcommercialsolventsand may bedamaged bytheiruse.

Use clean clothsto remove dirt,carbondust,etc.

/_ WARNING: DO NOT at anytimeletbrakefluids,gasoline,petroleum-based I

products,penetratingoils,etc.to comeincontactwith plasticparts.They contain

I

chemicalsthat can damage,weaken or destroyplastic.

Itis a knownfact thatelectrictoolsare subjectto acceleratedwear and possible

prematurefailure whentheyare usedtoworkon fiber glassboatsandsportscars,

wallboard,specklingcompoundsor plaster.The chipsand grindingsfrom these

materials are highlyabrasiveto electricaltoolparts,such as bearings,brushes,

commutators,etc.Consequently,itisnot recommendedthatthistoolbe usedfor

extendedworkon any fiber glassmaterial,wallboard,spacklingcompound,or piaster.

Duringany useonthese materials,it isextremelyimportantthatthetoolis cleaned

frequentlyby blowingwithan air jet.

•/1\ WAR NING: ALWAYSwearsafetygogglesor safetyglasseswithsideshields I

orface shieldwhenblowingdustfrom toolwhencleaningit.Ifoperationisdusty,also

wears dustmask.

19

LUBRICATION

Allofthebearingsinthistoolare lubricatedwitha sufficientamountofhigh-grade

lubricantfor the life ofthetoolunder normaloperatingconditions.Therefore, no

further lubricationis required.

DOUBLE INSULATION

Doubleinsulation isa conceptin safety inelectricpowertools,whicheliminatesthe

need for the standard 3-wire groundedpowercord.Allexposedmetal parts are

isolatedfrom the internal motorcomponentswith protectveinsulation.Double

insulatedtoolsdo not need tobe grounded.

IMPORTANT

The servicingof a toolwith doubleinsulationrequiresextreme care and knowledge

of thesystem and shouldbe performedonlybya qualifiedservicetechnician.For

service,we recommendthat you returnthetooltoyournearest Sears Service Center

for repair.ALWAYS useoriginalfactory replacementpartswhen servicing.

EXTENSION CORDS

The useof any extensioncord willcause some loss ofpower.Tokeepthe lossat a

minimum and to preventoverheating,use an extensioncordthat isheavy enoughto

carrythe currentthat the toolwilldraw.

A wire gauge (AWG) of at least 16 is recommendedfor an extensioncord 100 feet or

less inlength. When workingoutdoorsALWAYS use an extensioncord that is

suitablefor outdooruse.The cord'sjacketwillbe marked WA.

I/_ CAUTION: Keepextensioncordsaway from the cuttingarea, and position I

I

the cord so itwillnot getcaughton lumber,tools, etc.during the cuttingoperation

I

I/K DANGER: Check extension cordsbefore each use. if damaged, replace I

I

it immediately. NEVER use a tool with a damaged cord because touching the

I

damaged area could cause electrical shock, resulting in serious injury.

Extension cords that are suitablefor use with your saw are available at your nearest

Sears Store.

20

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