Chicago Electric 94596 User Manual
TWIN CUTTER SAW
®
94596 /
94896
ASSEMBLY AND OPERATION INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND
ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
Copyright© 2006 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.
PRODUCT SPECIFICATIONS
E194601E194601
Motor 120 V~ / 60 Hz / 5.6 A / n0 5,500/min 120 V~ / 60 Hz / 7.8 A / n0 4,600/min
Power Switch Slider Button with Automatic Shut-Off
Power Cord 18 AWG x 2C SJT / 2-Prong Polarized Plug
Saw Blades
(Qty. 2, Included)
Maximum Cutting
Depth
Overall Dimensions 13” Long x 6” Wide x 73/8” High 13” Long x 61/2” Wide x 8” High
Unit Weight 7 lb. 11.2 lb.
MODEL 94896 - 5” Twin Cutter Saw MODEL 94596 - 61/8” Twin Cutter Saw
47/8” Diameter / 32 Teeth
0.05” Individual Thickness
Minimum 5,500 RPM Rating
Carbide Tipped / Teflon® Coated
11/8” Wood
1
/8” Mild Steel (Tubing & Sheets)
1
/8” Plastic (Tubing & Sheets)
1
/8” Copper, Stainless Steel,
Aluminum, Cast Iron (Tubing & Sheets)
61/8” Diameter / 36 Teeth
0.064” Individual Thickness
Minimum 4600 RPM Rating
Carbide Tipped / Teflon® Coated
11/2” Wood
1
/8” Mild Steel (Tubing & Sheets)
3
/16” Plastic (Tubing & Sheets)
1
/8” Copper, Stainless Steel,
Aluminum, Cast Iron (Tubing & Sheets)
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this manual and invoice in a safe and dry place for future reference.
1.
2.
3.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
Do not operate power tools in explosive atmospheres, such as in the pres-
ence of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 2SKUs
ELECTRICAL SAFETY
1.
2.
3.
4.
5.
Grounded tools must be plugged into an outlet properly installed and grounded
in accordance with all codes and ordinances. Never remove the grounding
prong or modify the plug in any way. Do not use any adapter plugs. Check with
a qualified electrician if you are in doubt as to whether the outlet is properly
grounded. If the tools should electrically malfunction or break down, grounding
provides a low resistance path to carry electricity away from the user.
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. Double insulation eliminates the need for the three wire grounded
power cord and grounded power supply system.
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.
Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
Do not abuse the Power Cord. Never use the Power Cord to carry the tools or
pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp
edges, or moving parts. Replace damaged Power Cords immediately. Dam-
aged Power Cords increase the risk of electric shock.
6.
1.
2.
3.
When operating a power tool outside, use an outdoor extension cord marked
“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the
risk of electric shock.
PERSONAL SAFETY
Stay alert. Watch what you are doing, and use common sense when operat-
ing a power tool. Do not use a power tool while tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
Avoid accidental starting. Be sure the Power Switch is off before plugging
in. Carrying power tools with your finger on the Power Switch, or plugging in power
tools with the Power Switch on, invites accidents.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 3SKUs
4.
Remove adjusting keys or wrenches before turning the power tool on. A
wrench or a key that is left attached to a rotating part of the power tool may result
in personal injury.
5.
6.
1.
2.
3.
4.
Do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enables better control of the power tool in unexpected situations.
Use safety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
TOOL USE AND CARE
Use clamps (not included) or other practical ways to secure and support the
workpiece to a stable platform. Holding the work by hand or against your body
is unstable and may lead to loss of control.
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.
Do not use the power tool if the Power Switch does not turn it on or off. Any
tool that cannot be controlled with the Power Switch is dangerous and must be
replaced.
Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
5.
6.
7.
8.
1.
2.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools sharp and clean. Properly main-
tained tools with a sharp cutting edge are less likely to bind and are easier to control.
Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.
Check for misalignment 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 accidents are caused by poorly maintained tools.
Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instruc-
tions in the “Inspection, Maintenance, And Cleaning” section of this manual.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 4SKUs
Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.
SPECIFIC SAFETY RULES
1.
2.
3.
4.
5.
DANGER! Keep hands away from cutting area and 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.
Keep your body positioned to either side of the saw blade, but not in line with
the saw blade. KICKBACK could cause the saw to jump backwards. (See “Causes
and Operator Prevention of Kickback.”)
Do not reach underneath the work. The guard can not protect you from the blade
below the work.
Check lower guard for proper closing before each use. Do not operate saw if
lower guard does not move freely and close instantly. Never clamp or tie the
lower guard into the open position. If saw is accidentally dropped, 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.
Check the operation and condition 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 buildup
of debris.
6.
7.
8.
9.
10.
Lower guard should be retracted manually only for special cuts such as
“Pocket Cuts” and “Compound Cuts.” Raise lower guard by Retracting Handle.
As soon as blade enters the material, lower guard must be released. For all other
sawing, the lower guard should operate automatically.
Always observe that the lower guard is covering the blade before placing
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.
NEVER hold piece being cut in your hands or across your leg. It is important
to support the work properly to minimize body exposure, blade binding, or loss of
control.
Hold 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 tool “live” and shock the operator.
When ripping always use a rip fence or straight edge guide. This improves the
accuracy of cut and reduces the chance for blade binding.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 5SKUs
11.
Always use blades with correct size and shape (diamond vs. round) arbor
holes. Blades that do not match the mounting hardware of the saw will run eccen-
trically, causing loss of control.
12.
13.
14.
15.
16.
17.
Never use damaged or incorrect blade washers or bolts. The blade washers
and bolt were specially designed for your saw, for optimum performance and safety
of operation.
Always wear safety impact eye goggles when using the Twin Cutter
Saw. Always wear heavy duty work gloves when changing Saw Blades.
Using personal safety devices reduces the risk for injury. A leather apron
and arm protection may be advisable to protect from sparks created
when cutting metal.
Maintain a safe working environment. Keep the work area well lit. Make sure
there is adequate surrounding workspace. Always keep work area free of obstruc-
tions, grease, oil, trash, and other debris. Do not use a power tool in areas near
flammable chemicals, dusts, and vapors. Do not use in a damp or wet location.
Avoid unintentional starting. Make sure you are prepared to begin work before
turning on the Twin Cutter Saw.
Do not force the Twin Cutter Saw. This tool will do the work better and safer at
the speed and capacity for which it was designed. Do not force the Saw Blades
into the workpiece being cut.
Never leave the Twin Cutter Saw unattended when it is plugged into an electri-
cal outlet. Turn off the tool, and unplug it from its electrical outlet before leaving.
18.
19.
20.
21.
22.
23.
24.
Before using the Twin Cutter Saw, check to make sure the Saw Blades are
properly mounted on the Arbor Adapter. Make sure the Saw Blades are sharp,
and are not cracked or bent.
Industrial applications must follow OSHA guidelines.
When cutting a large workpiece, make sure its entire length is properly sup-
ported. If necessary, use a roller stand (not included).
To avoid electrical shock, do not handle the Twin Cutter Saw or its Power Cord
Plug with wet hands.
Make sure the workpiece is free from nails and any other foreign objects which
can damage the Saw Blades.
Always check to make sure there are no electrical wires or cables in the cut-
ting path of the Twin Cutter Saw.
Allow the Blades to run up to full speed before feeding them into a workpiece.
When turning off the Twin Cutter Saw, allow the Saw Blades to stop on their own.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 6SKUs
25.
Turn off the Twin Cutter Saw and allow the Saw Blades to completely stop if
the Saw Blades are to be backed out of an uncompleted cut.
26.
27.
28.
Never attempt to remove material stuck in the moving parts of the Twin Cutter
Saw while it is plugged in and running.
Always unplug the Twin Cutter Saw from its electrical outlet before performing
any inspection, maintenance, or cleaning procedures.
KICKBACK PRECAUTIONS
Causes and operator prevention of “KICKBACK”: Kickback is a sudden reaction
to pinched, bound, or misaligned Saw Blades, causing an uncontrolled Twin Cutter
Saw to lift up and out from the workpiece toward the operator. When the Saw Blades
are pinched or bound tightly by the kerf closing down, the Saw Blades stall and the
motor reaction drives the Twin Cutter Saw rapidly back toward the operator. If the
Saw Blades become twisted or misaligned in the cut, the teeth at the front edge of
the Saw Blades can raise the Twin Cutter Saw (walk up) toward the operator. Kick-
back is a result of tool misuse and/or incorrect operating procedures or conditions
and can be avoided by taking proper precautions as follows:
Maintain a firm grip with both hands on the saw and position your body
•
and arm to allow you to resist KICKBACK forces. KICKBACK forces can be
controlled by the operator, if proper precautions are taken.
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.
When restarting the Twin Cutter Saw on a workpiece, center the Saw Blades
•
in the pre-cut kerf and check that the Saw Teeth are not engaged into the
workpiece. If the Saw Blades are binding, the Twin Cutter Saw may walk up or
kickback as the Saw is restarted.
When restarting a saw in the workpiece, center the saw blade in the kerf and
•
check that saw teeth are not engaged into the material. If saw blade is binding,
it may walk up or KICKBACK from the workpiece as the saw is restarted.
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.
Do not use dull or damaged blades. Unsharpened or improperly set blades
•
produce narrow kerf causing excessive friction, blade binding and KICKBACK.
Blade depth and bevel adjusting locking levers must be tight and secure
•
before making cut. If blade adjustment shifts while cutting, it may cause binding
and KICKBACK.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 7SKUs
Use extra caution when making a “Pocket Cut” into existing walls or other
•
blind areas. The protruding blade may cut objects that can cause KICKBACK.
Push the Saw Blades past the workpiece prior to releasing the Power
•
Switch.
Make sure to check the Blade Guard for proper operation. Never disable the
•
Guard. Do not use the Twin Cutter Saw if the Guard assembly does not operate
properly. Before each use, make sure the Blade Guard does not touch the Saw
Blades.
Make sure the workpiece is free from nails, metal rebar, and any other foreign
•
objects that could damage the Saw Blades or cause “kickback”.
29.
30.
31.
32.
CAUTION! When cutting metal, the Twin Cutter Saw produces extremely hot
chips (rather than sparks). Use caution to avoid accidental fire and/or injury to the
operator.
WARNING! Some dust created by power sanding, sawing, grinding, drilling,
and other construction activities, contain chemicals known (to the State of California) to cause cancer, birth defects or other reproductive harm. 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.)
WARNING! People with pacemakers should consult their physician(s) before
using this product. Electromagnetic fields in close proximity to a heart pacemaker
could cause interference to or failure of the pacemaker.
WARNING! The warnings and cautions discussed in this 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.
94596 &
94896
SAVE THESE INSTRUCTIONS
For technical questions, please call 1-800-444-3353.
Page 8SKUs
GROUNDING
WARNING!
Improperly connecting the grounding wire can result in the risk of 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.
2.
3.
Tools marked “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet. If tool should
electrically malfunction, grounding provides a low resistance path to carry electricity
away from the user, reducing risk of electric shock. (See Figure A.)
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 Figure A.)
Your 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 Figure A.)
FIGURE A
FIGURE B
DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS
1.
2.
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 Standard
Association, and the National Electrical Code. (See Figure B.)
Double insulated tools may be used in either of the 120 volt outlets shown in the
preceding illustration. (See Figure B).
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 9SKUs
EXTENSION CORDS
1.
2.
3.
4.
5.
6.
7.
Grounded tools require a three wire extension cord. Double Insulated tools can
use either a two or three wire extension cord.
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 Figure C, next page.)
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 Figure C.)
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 Figure C.)
If you are using one extension cord for more than one tool, add the nameplate am-
peres and use the sum to determine the required minimum cord size.
(See Figure C.)
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.
Make sure your 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 extension cords from sharp objects, excessive heat, and damp or wet areas.
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 10SKUs
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 OR 240 VOLT)
NAMEPLATE
AMPERES
(at full load)
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 - - -
FIGURE C
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
EXTENSION CORD LENGTH
SYMBOLOGY
Double Insulated
Canadian Standards Association
V~
A
n0 xxxx/min.
Underwriters Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions per Minute
(RPM)
94596 &
94896
For technical questions, please call 1-800-444-3353.
Page 11SKUs
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List on page
16 are included. 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.
PRODUCT FEATURES
FIGURE E
POWER
CORD/PLUG
1.
2.
SIDE HANDLE
POWER SWITCH
HOUSING
UPPER GUARD
LUBRICATING
UNIT KNOB
WAX TUBE
LOWER GUARD
Power Switch: The Power Switch is a simple “slider” switch that when pressed
and held turns on the Twin Cutter Saw. To turn off the Saw, release pressure on the
Power Switch and the switch will automatically return up to its “OFF” position.
Power Cord/Plug: The Power Cord/Plug must only be connected to a 120 volt,
grounded, electrical outlet. Do not pull on the Cord to remove the Plug from its
electrical outlet.
3.
4.
5.
Side Handle and Housing: The Side Handle allows for increased control of the
Twin Cutter Saw and additional safety. When using the Saw, always maintain a firm
grip on the Side Handle and Housing.
Lower Guard and Upper Guard: Before each use of the Twin Cutter Saw, always
check to make sure the Lower Guard and Upper Guard are operating properly. Also,
make sure the Saw Blades do not touch either Guard.
Wax Tube and Lubricating Unit Knob: Always use a lubricating Wax Tube when
cutting aluminum, copper, stainless steel, and cast iron. When cutting, these materials tend to soften and adhere to the Saw Blades and can diminish the performance
of the Twin Cutter Saw. To use a Wax Tube, insert the Wax Tube into the Lubricating Unit Dispenser. Turn the Lubricating Unit Knob to apply lubricant to the Saw
94596 &
For technical questions, please call 1-800-444-3353.
Page 12SKUs
94896
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