Page 1
COPYRIGHT ©
2010
ALL
RIGHTS RESERVED BY KING CANADA TOOLS INC.
6-3/8” “DOUBLE CUTTM”SAW
COUNTER-ROTATING TWIN BLADE TECHNOLOGY
INSTRUCTION MANUAL
MODEL: KC-9160
WARRANTY INFORMATION
2-YEAR
LIMITED WARRANTY
FOR THIS “DOUBLE CUT
TM
” SAW
PROOF OF PURCHASE
Please keep your dated proof of purchase for warranty and servicing purposes.
REPLACEMENT PARTS
Replacement parts for this product are available through our authorized King
Canada service centers across Canada.
LIMITED TOOL
WARRANTY
King Canada makes every effort to ensure that this product meets high quality and
durability standards. King Canada warrants to the original retail consumer a 2-year
limited warranty as of the date the product was purchased at retail and that each
product is free from defects in materials. Warranty does not apply to defects due
directly or indirectly to misuse, abuse, normal wear and tear, negligence or
accidents, repairs done by an unauthorized service center, alterations and lack of
maintenance. King Canada shall in no event be liable for death, injuries to persons
or property or for incidental, special or consequential damages arising from the use
of our products.
To take advantage of this limited warranty, return the product at your expense
together with your dated proof of purshase to an authorized King Canada service
center. Contact your retailer or visit our web site at www.kingcanada.com for an
updated listing of our authorized service centers. In cooperation with our authorized
serviced center, King Canada will either repair or replace the product if any part or
parts covered under this warranty which examination proves to be defective in
workmanship or material during the warranty period.
NOTE TO USER
This instruction manual is ment to serve as a guide only. Specifications and
references are subject to change without prior notice.
KING CANADA
INC. DOR
V
AL, QUÉBEC, CANADA
H9P
2Y4
www.kingcanada.com
Page 2
1. KNOW YOUR TOOL
Read and understand the instruction manual and labels affixed to the tool. Learn its
application and limitations as well as its specific potential hazards.
2. Don’t use power tools in damp or wet locations or expose them to rain. Keep work area
well lit and provide adequate surrounding work space.
3. USE RIGHT TOOL.
Don’t force the tool or the attachment to do a job for which it was not designed.
4. WEAR PROPER APPAREL.
Do not wear loose clothing, gloves, neckties or jewelry (rings, watch) because they could
get caught in moving parts. Non-slip footwear is recommended. Wear protective hair
covering to contain long hair. Roll up long sleeves above the elbows.
5. MAINTAIN TOOL WITH CARE.
Keep tool clean for best and safest performance. Follow instructions for operation and
changing accessories.
6. DISCONNECT TOOLS.
Before servicing, when changing accessories or attachments.
7. AVOID ACCIDENTAL STARTING.
Make sure the switch is in the ‘’OFF’’ position before plugging in.
8. USE RECOMMENDED ACCESSORIES.
Consult the manual for recommended accessories. Follow the instructions that
accompany the accessories. The use of improper accessories may cause hazards.
9. CHECK FOR DAMAGED PARTS.
Before further use of the tool, a guard or other parts that are damaged should be
carefully checked to ensure they will operate properly and perform their intended
function. Check for alignment of moving parts, breakage of parts, mounting, and any
other conditions that may affect its operation. A guard or other parts which are damaged
should be properly repaired or replaced.
Specific Safety Instructions
1. If possible, use clamps
or any other practical way 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.
2. Do not use the tool if switch does not turn it on or off. Any tool that cannot be controlled
with the switch is dangerous and must be repaired.
3. Do not allow the power cord to contact the rotating accessory as the cord may
become quickly tangled. If this happens, turn the tool off immediately, unplug from the
power source and untangle the power cord.
4. Remove arbor key before turning the power tool on. Personal injury will result if the
power tool is turned on with the arbor key installed on the arbor bolt.
5. Hold the tool by its insulated gripping surfaces when performing an operation where
cutting tools may contact hidden “live” wiring or its own cord. Contact with a “live” wire
will make exposed metal parts of the tool “live” and shock the operator
.
6. Do not abuse the power cord. Do not use it to carry, pull or unplug the tool from the
power source. Keep power cord away from heat, oil, moving parts and sharp edges.
A
damaged power cord will increase the risk of electric shock.
GENERAL & SPECIFIC
SAFETY INSTRUCTIONS
DOUBLE CUT SAW
SAFETY INSTRUCTIONS
1. Always keep your second hand on the control handle or motor housing. With both hands
holding the saw this way, they cannot be cut by the blades. Keep your body positioned
to either side of the saw blade, but not in line with the saw blade.
2. Do not attempt to remove cut material while the blade is moving. Always check the lower
guard is properly closed 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 guard handle lever and make sure it moves freely and does not
touch the blade or any other part, in all angles.
3.The lower guard may operate sluggishly due to damaged parts, gummy deposits or a
build up of debris. Disconnect the plug from the power source. Periodically remove the
blades, clean the upper and lower guards and the hub area with kerosene and wipe it
dry, or blow it clean with compressed air.
4. The lower guard should be retracted manually only for making special cut such as
“pocket cuts” and “compound cuts”. Always raise the lower guard using the lower guard
handle lever. As soon as the blade enters the material, the lower guard must be released
for all other sawing. The lower guard should operate automatically.
5. Always make sure that the lower guard is covering the blade before placing the saw
down on the bench or floor. Left unprotected, coasting blade will cause the saw to jump,
cutting whatever is in its path. Be aware of the time it takes for the blade to stop after its
switch is released.
6. Never hold the piece being cut in your hands or across your leg. It is important to
support the work properly to minimize body exposure, blade jamming, or loss of control.
7. Do not use any other blades than the King Canada blades specially designed for this
tool. Never use blades that do not match the mounting hardware.
8. Never attempt to operate the saw with only one blade. Kickback will occur and send the
saw towards you resulting in serious injury.
Causes and Operator Prevention from Kickback
1. Kickback is a sudden reaction to a pinched, bound or misaligned saw blade, causing an
uncontrolled saw to lift up and out of the workpiece.
2. When the blade is pinched or bound tighly by the kerf closing down, the blade stalls and
the motor reaction drives the unit rapidly out of the workpiece.
3. If a 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 workpiece causing the blade to climb out of the
kerf.
4. Kickback is the result of tool misuse and/or incorrect operating procedures or conditions
and can be avoided by taking proper precautions as given below:
• 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.
• Support large panels to minimize the risk of blades 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.
• 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.
Page 3
WARNING: YOUR DOUBLE CUT SAW MUST BE CONNECTED TO A 120V, 15-AMP
CIRCUIT. FAILURE TO CONNECT IN THIS WAY CAN RESULT IN INJURY FROM
SHOCK OR FIRE.
DOUBLE INSULATION TOOLS. Double Insulation is a design concept used in electric
power tools which eliminates the need for the three wire grounded power cord and
grounded power supply system. It is a recognized and approved system by Underwriter’s
Laboratories, CSA and Federal OSHA authorities.
IMPORTANT: Servicing of a tool with double insulation requires care and knowledge of the
system and should be performed only by a qualified service technician. WHEN
SERVICING, USE ONLY IDENTICAL REPLACEMENT PARTS OR THOSE
RECOMMENDED BY THE MANUFACTURER.
POLARIZED PLUGS: Your tool is 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 the
proper outlet. To reduce the risk of electric shock, do not change the plug in any way.
EXTENSION CORDS. The use of any extension cord will cause some loss of power. Use
the following chart to determine the minimum wire gauge (A.W.G-American Wire Gauge)
extension cord. Only use polarized extension cords (one prong wider than the other) which
have 2-prong type plugs and 2-hole receptacles which accept the tool’s plug.
For circuits that are further away from the electrical circuit box, the wire gauge must be
increased proportionately in order to deliver ample voltage. Refer to chart for wire length
and size.
ELECTRICAL INFORMATION
WARNING!: If any parts are missing, do
not operate until missing parts are
replaced. Failure to do so could result in
serious personal injury.
WARNING!: Do not use this product as a
component of others products. Also, do not
use attachments or accessories not recommended for use with this product. Any such
use could result in possible serious injury.
Tool’s
Amperage
Rating
3-6
6-8
8-10
10-12
12-16
Cord Size in A.W.G.
Cord Length in Feet
25 50 100 150
18 16 16 14
18 16 14 12
18
16
14 12
18 16 14 12
14 12 - -
Technical Specifications
Blade size ..........................................................................................................6-3/8”
Depth of cut ......................................................................................................1-3/8”
Voltage................................................................................................................120V
Amperage ............................................................................................................10A
R.P
.M. ................................................................................................................4,200
Cycle/Phase ........................................................................................60Hz, 1 phase
GETTING TO KNOW YOUR
DOUBLE CUT SAW
1. On/Off switch
2. Carbon brush cover (1 of 2)
3. Motor housing
4. Control handle
5. Lubrication system
6. Lubrication system feed wheel
7. Lower blade guard
8. Arbor flange
9. Arbor flange hex. bolt
10. Lower blade guard lever
11. Arbor adjustment key
12. Lubricating wax sticks (10)
13. Spindle lock button
14. Switch lock button
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OPERATIONAL GUIDELINES
& LUBRICATION SYSTEM
Operation guidelines
1. Even the best saw blades would not cut efficiently if they are not kept clean and sharp.
Using a dull blade will place a heavy load on your saw and increases the risk of
kickback. Keep extra blades on hand, so sharp blades are always available.
2. Gum and pitch hardened on your blade will slow your saw down. Use gum and pitch
remover, hot water or keronsene to remove these accumulations. Do not use gasoline.
3. The lower blade guard is there for your protection and safety. It should NEVER be
altered for any reason. If it becomes damaged of begins to return slowly, DO NOT
operate your saw until the damage has been repaired or replaced. ALWAYS leave the
guard in its correct operating position when using the saw.
4. CAUTION: NEVER use the saw when the guard is not operating correctly. The guard
should be checked for correct operation before each use. If you drop your saw, check
the lower blade guard for damage.
5. The lower blade guard is operating properly when it moves freely and then returns to the
closed position. If it is not operating properly, have it repaired.
6. If the blades comes in contact with the workpiece before they reach full speed, it could
cause the saw to kickback towards you, resulting in serious injury.
7. When making a cut, always use steady, even pressure. Forcing the saw causes rough
cuts and could shorten the life of the saw or cause kickback.
8. Always use the lubricating system (wax stick) when cutting aluminum, copper, stainless
steel and cast iron materials, because these have a tendency to smear and adhere to
the blades.
9. Feeding must be parallel to the blade. Feeding at an angle can burn the blades and
damage blade teeth.
Lubrication System
Warning!
The supplied blades have “drycut”
teeth , always use the lubricating system (wax
stick) or cutter paste when cutting aluminum,
copper, stainless steel and cast iron materials,
they have a tendency to smear and adhere to the
blades. This will also reduce overheating and
warping.
1. Insert the lubricating wax stick (A) Fig.1 into
the lubricating feeder wheel housing (B) as
shown.
2. Start the saw, turn the feeder wheel to
introduce the wax stick into the saw and begin
operation, turn feeder wheel to lubricate as
needed.
FIGURE 1
FEED SPEED &
CUTTING TECHNIQUES
Correct Feed Speed Is Important
1. Feed speed is how quickly you push the saw blades through the material being cut. The
correct feed speed is totally determined by the hardness and the thickness of the
material being cut.
2. For thin materials, feed the blades down with the teeth protruding about 1/2” below the
material, then move forward or backward to cut.
3.
If the feed speed is too slow, the blades will only press down on the material rather
than cut it. The blade edges will glide and wear down the material. This will produce a
poor cut and cause excessive wear on the blades.
4.
If the feed speed is too fast, there is a risk that the cut might split and the splinter
opening’s volume will not be sufficient to divert all the shavings. The result is a poor cut
with significaant discharge on the lower side of the material.
5. Feeding must be parallel to the blade. Feeding at an angle can burn the blade and
damage the blade teeth.
Various Cutting Techniques
FIGURE 2
Page 5
CHANGING BLADES
Removing blades
Warning!
Unplug the saw from the power source
before attempting to remove blades.
1. Press and hold the spindle lock button (A)
Fig.3 to lock the blade spindle.
2. Undo the arbor nut (A) Fig.4 using the
supplied adjustment tool (B). Turn adjustment
tool in a counterclockwise direction.
3. Remove the arbor bolt (A) Fig.5 and the arbor
flange (B) and open the lower blade guard.
4. Lift and remove the top “B” blade (C) and then
lift and remove the bottom “A” blade (D).
Installing blades
Warning!
Unplug the saw from the power source
before attempting to install blades.
1. Open the lower blade guard.
2. Position the bottom “A” blade (D) Fig.5 onto
the outer blade spindle, turn the blade until its
cutouts fit perfectly into the backing plate.
3. Position the top “B” blade (C) Fig.5 onto the
inner blade spindle, turn the blade until its
cutouts fit perfectly into the backing plate.
4. Position the arbor flange (B) Fig.5 over the top
“B” blade and hand tighten the arbor bolt (A).
5. Press and hold the spindle lock button (A)
Fig.3 to lock the blade spindle.
6. Using the supplied adjustment tool, turn arbor
bolt in a clockwise direction to secure the
blades.
Optional accessories
A variety of optional accessories are available for
your Double Cut Saw. Listed below are the
available King Canada accessories;
• 6-3/8” TCT Universal blade set (KW-9161)
• 6-3/8” Diamond stone blade set (KW-9162)
• Pivoting base & edge guide (KW-9166)
• Laser attachment (KW-9111)
• 25pc. lubricating wax sticks (KW
-91
12)
Contact your local King Canada distributor for more information on these accessories.
FIGURE 3
FIGURE 4
FIGURE 5
MAINTENANCE
INSPECTING/REPLACING CARBON BRUSHES
Warning! Only use identical replacement carbon
brushes, both carbon brushes should be
replaced at the same time, normally after 50
hours of operation.
Unscrew and remove the carbon brush covers
(A) Fig. 6 (one on each side) which secure the
carbon brushes (B) inside the tool. Take out the
carbon brushes and inspect them. If the wear of
the carbon brushes has gone past the side limit
mark, install new brushes. Reinstall all parts in
reverse order.
FREQUENT INSPECTION AND MAINTENANCE
The tool should be inspected and maintained frequently. Check and make sure the power
cord, internal wires, plug and switch are in good condition. Make sure the insulation
resistance is within normal limits, contact between the brushes and the commutator are
good, and that there is no short-circuit or breakage of the armature and stator windings.
Check the blades, bearings and driving parts also.
Do not allow brake fluid, gasoline, petroleum-based products such as penetrating oils to
come in contact with plastic parts. They contain chemicals which can damage, weaken or
destroy the motor housing, thus compromising the intergrity of the double insulation.
Inspect mounting screws regularly, making sure they are properly tightened. Tighten all
loose screws before operating.
It is a known fact that electric tools are subject to accelerated wear and possible
premature failure when they are used to work on fibre glass and drywall or plaster. The
chips and grindings from these materials are highly abrasive to electrical parts, such as
bearings, brushes and commutators. Consequently clean the tool even more intensely
after working these materials.
Due to the double insulation of this tool, the service should only be done by a qualified
service technician using identical replacement parts.
P
ARTS DIAGRAM & P
ARTS LISTS
Refer to the Parts section of the King Canada web site for the most updated parts diagram
and parts list.
FIGURE 6
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