Craftsman 286.17589 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 operatingapowertooloutside,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 a key that isleft attached 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 NOT use 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 startingthetool accidentally.
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"wirewill make 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 apinched, 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 aresult 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 may walk up or 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 full speed 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
IZ_ 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 II construction
,../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.
Rememberthatacarelessfraction 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 of the 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
ojwax
_,_,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 Depthof Cut
6Amps
,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 no other 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 cutwithadull,gummed up, or
improperlyset blades,
3. Not providingpropersupportfor workpiece,
ALWAYS providepropersupportas shown
in Fig.3.
4. Forcingacut.
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 acut. 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 abalanced
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 weightof this 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 is important.
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 adamaged 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.
IZ_ 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 amaximum 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 ofan 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 a clamping
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 atar 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
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.To keepthe lossat a
minimum and to preventoverheating,use an extensioncordthat isheavy enoughto
carrythe currentthat the toolwilldraw.
Awire 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