5” PROFESSIONAL DOUBLE-CUT SAW
241-9870
SAVE THIS MANUAL
You will need this manual for safety instructions, operating procedures and warranty.
Put it and the original sales receipt in a safe dry place for future reference.
Operator’s Manual
For questions about this product, Please call 1-866-915-8626
2
IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electric tools, machines or equipment, basic safety
precautions should always be followed to reduce the risk of fire, electric
shock, and personal injury.
READ ALL INSTRUCTIONS BEFORE USING THIS TOOL
1. KEEP WORK AREA CLEAN. Cluttered areas can cause injuries.
2. CONSIDER WORK AREA ENVIRONMENT. Don’t use power tools in damp,
wet, or poorly lit locations. Don’t expose tools to the rain. Keep the work area
well lit. Don’t use tools in the presence of flammable gases or liquids.
3. KEEP CHILDREN AND BYSTANDERS AWAY. All children should be kept
away from the work area. Don’t let them handle machines, tools or extension
Bystanders can be a distraction and can be injured.
cords.
4.
GROUNDED TOOLS must be plugged into an outlet that is properly
installed and grounded. Grounding provides a low-resistance path to carry
electricity to the ground away from the operator, should the tool malfunction elec--
trically. Do not remove the grounding prong from the plug or alter the plug in
any way. If in doubt as to whether the outlet is properly grounded according
to code, check with a qualified electrician.
5. OBSERVE PROPER PRECAUTIONS REGARDING DOUBLE INSULATION. This tool is double insulated. It is equipped with a polarized plug.
One blade is wider than the other, so it will fit into a polarized outlet only one
way. If you have difficulty inserting the plug, try reversing it. If it still doesn’t
fit , do not alter the plug; have a qualified electrician install a polarized outlet.
6. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded
surfaces: pipes, radiators, ranges, and refrigerator enclosures. When your
body is grounded the risk of electric shock increases. When working wherever “live” electrical wires may be encountered, try to ascertain whether
there is a danger of shock. DO NOT TOUCH ANY METAL PARTS
OF THE TOOL while using it. Hold the tool only by the plastic grip to prevent
electric shock if you contact a live wire.
7.
DO NOT MISUSE THE CORD. Never carry your tools by the cord or pull on
the cord to unplug it. Protect the cord from potential sources of damage:
heat, oil & solvents, sharp edges, or moving parts. Replace damaged cords
immediately.
WHEN WORKING OUTDOORS, USE AN OUTDOOR-RATED EXTENSION
8.
CORD.
“W”.
DO NOT EXPOSE ELECTRICAL POWER TOOLS TO MOISTURE. Rain or
9.
wet conditions can cause water to enter the tool and lead to electric shock.
10. ENSURE THE EXTENSION CORD YOU USE IS OF SUFFICIENT GAUGE
FOR ITS LENGTH.
An extension cord rated for outdoor use must be marked “W-A” or
Recommended Minimum Wire Gauge for Extension Cords
Amps
from
Tool Nameplate
0-5 amps 16 ga.
5.1-8 amps 16 ga. 16 ga. 14 ga. 12 ga. 10 ga. Do Not Use
8.1-12 amps 14 ga. 14 ga.
12.1-15 amps 12 ga. 12 ga. 10 ga.
15.1-20 amps 10 ga. 10 ga. 10 ga.
25’ length
16 ga. 16 ga. 14 ga. 12 ga. 12 ga.
50’ length 75’ length 100’ length 150’ length 200’ length
12 ga. 10 ga. Do Not Use Do Not Use
10 ga. Do Not Use Do Not Use
Do Not Use Do Not Use Do Not Use
11. STORE IDLE EQUIPMENT. Store equipment in a dry area to inhibit rust.
Equipment also should be in a high location or locked up to keep out of
reach of children.
12. DON’T FORCE THE TOOL. It will do the job better and more safely at the
rate for which it was intended.
13. USE THE RIGHT TOOL. Don’t force a small tool or attachment to do the
work of a larger industrial tool. Don’t use a tool for a purpose for which it was
not intended.
14. DRESS PROPERLY. Don’t wear loose clothing or jewelry; they can be
caught in moving parts. Protective, non-electrically conductive gloves, protective
eyewear and non-skid footwear are recommended. Wear protective hair
covering to contain long hair and keep yourself from harm.
IMPORTANT SAFETY INSTRUCTIONS
15. USE EYE PROTECTION. Use a full-face mask if the work you’re doing
produces metal filings, dust or wood chips. Goggles are acceptable in other
situations. Wear a clean dust mask if the work involves creating a lot of fine
or coarse dust.
16. SECURE WORK. Use clamps or a vise to hold the work. It’s safer than using
your hands and it frees both hands to operate the tool.
17. DON’T OVERREACH. Keep proper footing and balance at all times. Do not
reach over or across machines that are running.
MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and
18.
safer performance. Follow instructions for lubricating and changing accessories.
For safe performance, keep handles dry, clean and free from oil and grease.
19. AVOID UNINTENTIONAL STARTING. Be sure the switch is in the
tion before plugging in.
20. ALWAYS CHECK AND MAKE SURE TO REMOVE ANY ADJUSTING KEYS
OR WRENCHES before turning the tool on. Left attached, these parts can fly
off a moving part and result in personal injury.
DO NOT USE THE TOOL IF IT CANNOT BE SWITCHED ON OR OFF.
21.
Have your tool repaired before using it.
22. DISCONNECT THE PLUG FROM POWER BEFORE MAKING ANY AD
JUSTMENTS. Changing attachments or accessories can be dangerous if
the tool could accidentally start.
23. STAY ALERT. Watch what you are doing & use common sense. Don’t operate
any tool when you are tired.
24. CHECK FOR DAMAGED PARTS. Before using this tool, any part that is
damaged should be carefully checked to determine that it will operate prop-
erly and perform its intended function. Check for alignment of moving parts,
binding of moving parts, breakage of parts, mountings, and other conditions
that may affect its operation. Inspect screws and tighten any ones that are
loose. Any part that is damaged should be properly repaired or replaced by
an authorized service center unless otherwise indicated elsewhere in the in-
struction manual. Have defective switches replaced by an authorized service
center. Don’t use the tool if switch does not turn it on and off properly.
25. REPLACEMENT PARTS. When servicing, use only identical replacement
parts.
26. SERVICE AND REPAIRS should be made by qualified repair technicians at
an authorized repair center. Improperly repaired tools could cause serious
shock or injury.
OFF posi
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SAFETY RULES FOR DOUBLE CUT SAW
DANGER ! KEEP HANDS AWAY FROM CUTTING AREA AND BLADE.
Always keep your second hand on auxiliary handle or motor housing. With both
hands holding the saw (machine), they cannot be cut by the blades. Keep your body
positioned to either side of the saw blade, but not stand in line with the saw blade
Hold the saw firmly to prevent loss of control. Do not reach underneath the work.
The guard cannot protect you from the blade below the work. Do not attempt to
remove cut material when blade is moving. Always allow Lower Guard to properly
close 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 at 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 build up of debris. Disconnect the
plug from power source. Periodically remove the blade, clean the upper, Lower
Guards and the hub area with kerosene and wipe it dry, or blow it clean with
compressed air.
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SAFETY RULES FOR DOUBLE CUT SAW
The Lower Guard should be retracted manually only for making special cuts such
as“Pocket cuts” and “Compound Cuts”. Always Raise Lower Guard by Lower Guard
Handle Lever. 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, moving 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 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 jamming, or loss of
control.
Always hold tool by the 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.
DO NOT use any other blades than the WORKSITE Blades specially designed for this
tool. Other blades do not match the mounting hardware & will cause loss of control.
Never use damaged or incorrect flanges (drivers) or bolts. The flanges (drivers) &
bolts are specially designed for your saw, for optimum performance and safety of
operation.
DO NOT run the saw while carrying it. Lower Guard may be opened by a contact
with your clothing. Accidental contact with the spinning saw blade could result
in serious personal injury.
“Never attempt to operate saw with only one blade”. Kickback will occur and send
the saw towards you resulting in serious injury.”
CAUSES AND OPERATOR PREVENTION FROM KICKBACK
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.
When the blade is pinched or bound tightly by the kerf closing down, the blade stalls
and the motor reaction drives the unit rapidly out of the work piece.
If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the
blade can dig into the top surface of the workpiece causing the blade to climb out of
the kerf.
Kickback is the result of tool misuse and/or incorrect operating procedures or
conditions that 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 blade pinching & 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.
Depending upon use, the switch may not last the life of the saw. If the switch should
fail in the “OFF” position, the saw may not start. If it should fail while the saw is
running, the saw may not shut off. If either occurs, unplug the saw immediately and do
not use until repaired.
Use rip fence support large panels. Guard against kickback. Kickback occurs when
the saw stalls, rapidly and is driven back towards the operator. Release switch
immediately if blade binds or saw stalls. Do not force tool. Stay alert, exercise control.
4
CAUSES AND OPERATOR PREVENTION FROM KICKBACK
WARNING
DO NOT let familiarity with your saw make you careless. Remember that a
careless fraction of a second is sufficient to cause severe injury.
This Double-cut Saw uses specially designed blades and no other types of blades
should ever be used. Other types of blades will not operate safely in this saw &
could result in serious personal injury.
If the blades come in contact with the workpiece before they reach full speed, it
could cause the saw to kickback towards you resulting in serious injury.
Always make sure both blades enter into the workpiece at the same time.
Entering with only one blade will cause unexpected kickback, risking serious
injury. Therefore, in the case of cutting at an angle, do not approach from the side
with only one blade touching, but from the top with both blades entering
simultaneously.
The side of the blades cannot be used for cutting. Therefore, in horizontal cuts,
make sure saw is not resting on lower blade. Wedge the workpiece to prevent
unexpected kickback.
DO NOT abuse the cord. NEVER use the cord to carry the tool or to pull the plug
from the outlet. Keep cord away from heat, oil, sharp edges or moving parts.
Replace damaged cords immediately. Damaged cords increase the risk of
electric shock.
Following this rule will reduce the risk of electric shock or fire.
DO NOT use the tool while tired or under the influence of drugs, alcohol or any
medication Following this rule will reduce the risk of electric shock, fire or serious
personal injury.
ADDITIONAL RULES FOR SAFE OPERATION
WARNING : BE SURE to read and understand all instructions. Failure to follow
all instruction listed below may result in electric shock, fire and/or serious
personal injury.
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. Following this
rule will reduce the risk of electric shock, fire or serious injury.
ALWAYS wear safety glasses or eye shields when using this saw. Everyday
eyeglasses have only impact-resistant lenses; they are NOT safety glasses. Following
this rule will reduce the risk of serious personal injury.
ALWAYS protect your lungs. Wear a face mask or dust mask if the operation is dusty.
Following this rule will reduce the risk of serious personal injury.
ALWAYS protect your hearing. Wear protection during extended periods of operation.
Following this rule will reduce the risk of serious personal injury.
ALWAYS inspect the tool cords periodically and if damaged have them repaired at
your nearest Service Center or other Authorized Service Facility.
ALWAYS be aware of the cord location. Following this rule will reduce the risk of
electric shock or fire.
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 would operate
properly and perform its intended function. Check for misalignment 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 an Authorized Service Center. Following this rule will reduce the risk of
electric shock, fire or serious injury.
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SPECIFICATIONS
Rated Voltage: 120V~60Hz
Input Power: 7.5 Amp
Blade Diameter: 5"
No-load Speed: 5500 RPM
Max Depth Cut: 1-3/16"
Includes:
1pc Double-cut Saw
10pcs Wax Sticks
1pc Wrench
1pc Handle
Your DOUBLE-CUT Saw has many built-in convenience features for fast, efficient
cutting. These features include an innovative Two Saw Blade System where the blades
spin in opposite directions to provide smooth, clean cuts with less vibration and kickback.
It also includes a pre-installed blade lubricating system for cutting Aluminium, copper,
stainless steel and cast iron.
For your convenience, there is no special assembly required for your DOUBLE-CUT
Saw except assist handle.
WARNING : This Double Blade Cutter saw uses specially designed blades and no other
types of blades should ever be used. Other blades will not operate safely in this saw
and could result in serious personal injury.
FUNCTION DESCRIPTION
1 4
2
3
OPERATING INSTRUCTIONS
SAW BLADES:
Even the best saw blades would not cut efficiently if they are not kept clean, sharp &
properly set. Using a dull blade will place a heavy load on your saw and increases the
danger of kickback. Keep extra blades on hand, so sharp blades are always available.
Gum and wood pitch hardened on your blade will slow your saw down. Use gum and
pitch remover, hot water or kerosene to remove these accumulations. DO NOT use
gasoline.
When it becomes necessary to replace the blades, see the Assembly on page 19 of
this manual for the proper blades to use with this Double Cut Saw and Removing and
Replacing the Blades on Page 9 of this manual for the proper blade changing
procedures.
5
6
6
OPERATING INSTRUCTIONS
BLADE GUARD SYSTEM
The lower blade guard, attached to your saw, is there for your protection and safety. It
should NEVER be altered or removed for any reason. If it becomes damaged or begins
to return slowly or sluggishly, 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.
CAUTION: NEVER use the saw when the guard is not operating properly. The guard
should be checked for correct operation before each use. If you drop your saw, check
the lower blade guard and bumper for damage at all depth setting before using.
NOTE: The guard is operating properly when it moves freely and then readily returns
to the closed position. If, for any reason, your lower blade guard does not close freely,
take it to your nearest authorized Repair Center for service before using it.
WARNING: ALWAYS maintain control of the saw to make sawing safer and easier.
Loss of control of the saw could cause an accident resulting in possible serious
injury.
STARTING A CUT
DANGER: If the cord hangs up on the workpiece during a cut, release the trigger
switch immediately. Unplug the saw and move the cord to prevent it from hanging up
again.
DANGER: Using the saw with a damaged cord could result in serious injury or death.
If the cord has been damaged, have it replaced before using the saw again.
ALWAYS use your saw correctly.
ALWAYS support the workpiece near the cut.
WARNING: If the blades come in contact with the workpiece before they reach full
speed, it could cause the saw to kickback towards you, resulting in serious injury
ALWAYS support the workpiece so the cut will be on your side.
ALWAYS clamp the workpiece so it will not move during the cut. Before starting a cut,
draw a guideline along the desired line of cut. Then place the front edge of the saw
blades on that part of the workpiece that is solidly supported.
NEVER place the saw on the part of the workpiece that will fall off when the cut is
made.
ALWAYS keep the cord away from the cutting area. ALWAYS place the cord so it does
not hang up on the workpiece when making a cut.
Slide the on/off switch to start the saw. ALWAYS let the blades reach full speed before
you begin to cut into the workpiece.
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.
ALWAYS use the lubricating device (included) when cutting Aluminium, Copper,
Stainless Steel & Cast Iron materials, because they have a tendency to smear and
adhere to the blades.
ALWAYS Feeding must be parallel to the blade. Feeding at an angle can burn the
blade and damage the blade teeth.
FEED SPEED
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.
In the thin materials first feed the blades down with the teeth protruding only change to
standard, then move forward (or backward) for cutting. see picture at next page.
7
OPERATING INSTRUCTIONS
If the feed speed is too slow.
The blades will only press down the material rather than cutting it.
The blade edges glides and wears down the material.
This will cause a poor cut and will cause excessive wear on the blades.
If the feed speed is too fast..
There is a definite risk that the cut might split. The splinter will get bigger and
bigger and eventually break risking serious personal injury.
SELECTING THE CORRECT FEED IS IMPORTANT
If the feed speed is too low, the blades will only press down the material rather than
cutting it. The edge glides or wears down the material. The result is a poor cut and
rapid wear of the blades.
If the feed speed is too high there is a risk that the cut might split and the splinter
opening's volume will not be sufficient to divert all the shaving. The result is a poor cut
with significant discharge on the lower side of the material.
Feeding must be parallel to the blade. Feeding at an angle can burn the blade and
damage the teeth.
INSTRUCTION FOR CUTTING VARIOUS CROSS SECTIONAL MATERIALS
Inch
8
3/8 Inch
3/8 Inch
3/8
OPERATING INSTRUCTIONS
REMOVAL OF USED SAW BLADES
Unplug the saw and allow blades to cool
Lock one of the driver flange with a help of spindle lock pin on the gear housing. (Fig 5)
Unscrew Lock Nut by rotation in counter clock wise direction.(Fig 7)
Open the lower guard.
Lift up and remove Blade “B” (Fig 6).
Lift up and remove Blade “A”
FIXING REPLACEMENT SAW BLADES
Unplug the saw.
Lay the saw down with the lock nut pointing upwards.
Open the lower guard.(Fig.4)
Place blade “A” onto the flange with the “A” clearly visible.
Place the blade “B” with the “B” easily visible. (Fig.7)
Then thread lock nut onto shaft.
Tighten the lock nut (see Fig.8).
Carefully turn blades with your hand to be sure they easily turn in opposite directions.
Wax Stick
LUBRICANT INSTRUCTIONS:
The blades are equipped with “Dry Cut” teeth. As a rule these need not be lubricated.
However, in extreme cutting conditions, cutting paste can be applied. Insert a cutter
paste rod.
When cutting Aluminium /Copper/ Stainless steel and cast iron, the lubricating device
must always be used. We recommend that you buy cutter paste in rod form, available
from your nearest dealer.
Insert a cutter paste rod.
IMPORTANT! The lubricating paste is added by turning the feeder wheel. Dosage as
required.
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MAINTENANCE
All parts represent an important part of the double insulation system and should be
serviced only at our authorized service centers.
Avoid using solvents when cleaning plastic parts. Most plastics are susceptible to
damage from various types of commercial solvents and may be damaged by their use.
Use clean cloths to remove dirt, carbon dust etc.
It is a known fact that electric tools are subject to accelerated wear and possible
premature failure when they are used to work on fiber glass boats and sports cars,
wallboard, spackling compounds or plaster. The chips and grindings from these materials
are highly abrasive to electrical tool parts, such as bearings, brushes, commutators, etc.
Consequently clean the tool even more intensely after working these materials.
LUBRICATION
All of the bearings in this tool are lubricated with a sufficient amount of high-grade
lubricant for the life of the tool under normal operating conditions. Therefore, no
further lubrication is required.
DOUBLE INSULATION
Double insulation is a concept in safety in electric power tools, which eliminates the need
for the standard 3-wire ground power cord. All exposed metal parts are isolated from the
internal motor components with protecting insulation. Double insulated power tools do
not need to be grounded.
IMPORTANT
The servicing of a tool with double insulation requires extreme care and knowledge of
the system and should be performed only by a qualified service technician. For service,
we recommend that you return the tool to our authorized Service Centre for repair.
ALWAYS use original factory replacement parts when servicing.
EXTENSION CORDS
The use of any extension cord will cause some loss of power. To keep the loss at a
minimum and to prevent overheating, use an extension cord that is heavy enough to
carry the current that the tool will draw.
CLEANING AND STORAGE
Resin and other materials that easily become attached to the sides of the blade often
cause the blade to overheat. This means that it can buckle or even split. You must
therefore always keep the blade clean. Wash it with a solvent. Never try to scrape the
blade clean with a hard object.
When the blade is not in use, it should be stored in its original sheath, well cleaned
and coated with an antirust agent.
TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
An unusually 1. Damaged teeth 1. Replace blades
large amount 2. Feed speed is too slow 2. Increase feed speed
of sparks 3. Blunt teeth 3. Mount new set of cutter
A lot of wear 1. Feed speed is too fast 1. Reduce the feed speed
in sections 2. Damaged teeth 2. Replace blades
3. Blunt teeth 3. Replace blades
4. Not cutting parallel or 4 Hold saw parallel to
perpendicular to work surface
work surface
Blades are 1. Damaged teeth 1. Replace blades
breaking 2. Feed speed is too fast 2. Reduce feed speed
3. Blunt teeth 3. Replace blades
4. Blades have buckled 4. Replace blades
5. Blades have burned out 5. Replace blades
10
blades
PARTS LIST & SCHEMATIC DRAWING
WARNING Repairs should be made by an authorized repair center. Do not
open or disassemble
for questions regarding this power tool.
this power tool
.
Contact at
1-866-915-8626
!
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