LUMBERJACK TOOLS PRO Series User manual

MODELS:
Pro Series - TTR0500
Pro Series - TTR0750
Pro Series - TTR1000
Pro Series - TTR1500
Pro Series - TTR2000
Home Series - TRH1000
Home Series - TRH1500
Home Series - TRH2000
Due to continuing improvements, actual product may differ slightly from the product described herein.
USER MANUAL
&
Dual Blade Tenon Cutters
All Rights Reserved.
© 2022 Lumberjack Group, LLC
DBA Lumberjack Tools
www.lumberjacktools.com
Email: [email protected]
Phone: [phone]

2
Our lifetime guarantee covers the tool body and shank. The blades are
covered for 90 days from the date of purchase for breakage under normal
working conditions. Blades will dull faster cutting hardwoods vs
softwoods (peeled or unpeeled). Soil and other abrasive substances will
reduce blade life and is not covered under this warranty. When making a
claim, you must show proof of purchase from an authorized distributor.
This is valid only to the original buyer, and not for tools sold secondhand,
used, or sold “as is” to a second party.
WhatVoidsWarranty
In order to keep our lifetime and 90 day warranty you must AVOID the
following actions:
●Operating the tool in a drill press or lathe (or any system other than
a hand-held drill)
●Running the tool into a nail or foreign object
●Altering or modifying the tool
AboutYourProduct
Thank you for purchasing our Dual Blade - Radius Shoulder Tenon Cutter!
Lumberjack engineers, along with our craftsmen, have designed the
safest, easiest-to-use tenon cutters on the market. By combining old
world skills with 3D CAD modeling and CNC manufacturing, we have
created the ideal tenon cutter: straight tenons, smooth finish, precision
operation, and long tool life.
Dual-bladed tenon tools will cut a tenon in half the time of a single-bladed
tool. Wear is reduced by putting force of cutting across two blades
instead of one. The blades are stamped, heat treated and precision
ground to provide years of service if properly maintained. The Pro Series
tools are machined from a solid aluminum billet and the Home Series
tools are made of die-cast aluminum.

3
SAFETY
Before beginning any project, carefully read and follow ALL safety and
operational instructions for any tools or devices you will be using. Failure to do
so may cause physical harm to yourself or those around you. If you feel
uncomfortable using our tenon cutters or any other tool, STOP immediately.
Lumberjack Tools assumes no responsibility for injury caused to the operator,
bystander, or tools used in conjunction with the use or misuse of our tenon
cutters.
NEVER OPERATE POWER TOOLS UNDER THE INFLUENCE OF
DRUGS, ALCOHOL, OR ANY MEDICATIONS
ALWAYS WEAR SAFETY GLASSES, DUST MASK, AND ANY OTHER
PERSONAL PROTECTION ITEMS AS NEEDED
NEVER WEAR LOOSE ITEMS THAT COULD BE CAUGHT IN MOVING
PARTS. SECURE LOOSE OR LONG HAIR AWAY FROM AREA
WE STRONGLY RECOMMEND A SINGLE-SPEED, GEAR DRIVEN DRILL
WITH RPMS OF 500 OR LESS. EXCEEDING THESE RPMS MAY
RESULT IN DAMAGE TO THE TOOL
ALWAYS DISCONNECT POWER AND ALLOW DRILL TO COME TO A
COMPLETE STOP BEFORE INSTALLING, REMOVING, OR ADJUSTING
THE TOOL
NEVER APPLY BENDING FORCE (SIDE LOADING) TO THE TOOL. SIDE
LOADING COULD CAUSE THE SHANK TO FAIL, OR MAY RESULT IN
BLADE DAMAGE
ALWAYS SECURE THE LOG IN A VISE OR CLAMP PRIOR TO
STARTING YOUR DRILL. FAILURE TO DO SO MAY RESULT IN INJURY
ALWAYS HANDLE THE BLADES WITH EXTREME CARE! FAILURE TO
DO SO MAY RESULT IN SERIOUS INJURY
WHEN EXCESSIVE FORCE IS REQUIRED TO CUT, RE-SHARPEN OR
REPLACE THE BLADES. A SHARP TOOL IS A SAFE TOOL!
NEVER PUT HANDS OR ANY BODY PART INSIDE THE TOOL WHILE THE
BLADES ARE ATTACHED! DOING SO MAY CAUSE SERIOUS INJURY

4
ProSeriesONLY
QuickStopInstallation
●Install the quick stop pin through
the tool body
●Secure with the supplied acorn nut
●The length of the tenon is
determined by measuring from
the face of the tool to the bottom
of the Quick Stop Pin and
subtracting 3/4”
●In the image to the left, dimension
“X” - 3/4” = approximate length of
the tenon
1
2
X
The Quick Stop Pins are not included
with individual tools
NOTE:
NOTE:
For sale separately or
included with kits
NOTE:
For sale separately or
included with kits

5
3/16”
SettingtheBlades
●Install and secure
the blades with the
Button Head Cap
Screws
●Take your time and
make sure blade
offset/spacing is
equal (see below)
Cardboard
Spacer
BladeOffset (Spacing)
MaxLog
Capacity
Series MaxDia.
TTR0500
2.00”
TTR0750
2.25”
TTR1000
2.50”
TTR1500
3.00”
TTR2000
3.50”
TRH1000
2.50”
TRH1500
3.00”
TRH2000
3.50”
●The cardboard box that the tool
comes in is about 3/16”
●Remove a piece of thebox to use
as a quick spacer for blade
setting
Tip
It is critical that both blades have the same “offset”. Blade offset refers to
the gap size between the blade cutting edge and the side of the pocket.
3/16” is the standard gap size to use.
●The tool will not cut with 5/16” or greater spacing
●The tool will not cut with 1/16” or less spacing
Correct (Blade too far)
WRONG
(Blade too close)
WRONG

6
Determine tenon length before cutting
●The key is to have a gap
between the end of the
tenon and bottom of the
mortise hole
●This can be done by making
the tenon 1/8” to 1/4”
shorter than the mortise
hole is deep
Hole Depth
1/8” to 1/4”
Gap
Tenon Length
Calculated Tenon Length
Simple Tenon Length
●Tenon length can be controlled without
having the Industrial Series or Quick
Stop Pins
●Cut off a piece of tenon to use as a plug
to stop cutting at a set length
Cut Mark = desired tenon length + 3/4”
Gather the following
information and use the
calculation provided
below:
●Desired tenon
length
Cut Mark
3/4" Desired Tenon Length
Series TenonLength
TRH1000
2½”–PlugLength
TRH1500
3½”–PlugLength
TRH2000
4½”–PlugLength
Plug Length
Tenon Length

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CuttingTenons
●Secure the stock in a vise, clamp,
or fixture with a “V” shaped
notch
●The Log Lock (LL1545) is a safe,
easy, economical way to clamp
material, and is available on our
website
WARNING: If the stock comes loose or unclamped while cutting, DO NOT
drop the drill or try to grab the stock! Stop cutting and remove the tool
from the end of the stock. Re-secure the stock, and resume cutting
●Obtain the stock you want to cut
●Check that the diameter fits the tool capacity
●Cut stock to length and make sure the ends
are flat. If the ends are not even/flat, the
tenon will be crooked
●If the diameter is larger
than the tool can accept,
taper the end with a
hatchet or draw knife
1
2
3

8
CuttingTenons(cont.)
ALWAYS unplug the drill before adjusting the blades or
adjusting the chuck
4.5
CORRECT
Drill in-line with log
WRONG
Drill not in-line with log (crooked)
●Make sure the tool is square against the end of the stock
before cutting
●If the tool is held at an angle the tenon will be cut angled
Maintain
constant
pressure
Pull tool back once
drill has stopped
4
●Carefully install the tenon cutter into an unplugged 1/2” drill, and
tighten it firmly by using the chuck key
●With the tool installed, square up to the stock so that the cutting face is
flush with the end of the stock
●Apply body pressure by leaning against the back of the drill
●Pull drill trigger to cut a tenon. Continue applying body pressure as the
tool cuts
●Wait until the drill comes to a complete stop before removing the tool
from the stock

9
Tip
Measure and mark the locations of all holes before drilling
DrillingHoles(Mortise)
1
2
●Drill mortise between
1/3 and 1/2 of the log
diameter
●Do not drill more than
1/2 of the log diameter
unless a specific project
calls for a deeper mortise
1/2 Diameter
1/3 Diameter
●Place the center of the bit on the
desired hole location
●Hold the drill perpendicular to the log
(unless angled holes are desired)
●Maintain constant pressure while
drilling down
●Pull drill bit out in a controlled manner
We recommend using a forstner bit or self-feeding bit to drill the hole.
Spade/paddle bits will work but cut rough

10
Maintenance
●Body
- Cleaning
○ Keep the tenon cutter body clear of sap and other build-up
○ Always remove the blades before cleaning
○ Clean the tool with a solvent (such as mineral spirits)
●Blades
- Care
○ Always wipe blades with a thin film of oil at the end of the day
to help prevent oxidation
- Cleaning
○ Clean the blades with a solvent (such as mineral spirits) and
immediately apply a thin film of oil to prevent oxidation
- Sharpening
○ Use a sharpening stone, file or the Blade Boss (BB2575) to re-
sharpen the blades, then clean the blades and apply a thin film
of oil
●Shank
- Replacement
○ If your shank breaks, we offer replacement shanks (see first
page for contact information)
○ Turn the shank counter-clockwise to remove
○ Turn the shank clockwise to install
WARNING: ALWAYS HANDLE THE BLADES WITH EXTREME CARE!
FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY
TASK EACH USE MONTHLY
Clean blade pockets X
Clean cutter bore X
Clean blades X
Inspect blades X
Oil blades X
Oil shank & screws X
Visit our website or call
for more information
about our Blade Boss

11
Thank you again for purchasing our tools!
PROBLEM CAUSE SOLUTION
• Tool Skips off
to one side or
bounces around
• Log is larger than tool will
accept
• Taper down the end of the
log with a draw knife
• Not enough pressure is being
applied • Lean into drill with body
• Not cutting log
• Log is larger than tool will
accept
• Taper down the end of the
log with a draw knife
• Blade offset too great • See page 5
• Blades are dull
• Not applying enough
pressure
• Sharpen blades
• Purchase new blades
• Lean into drill with body
• Takes too
much of a "bite"
• Aggressive cutting from dual
blades
• Remove one blade or
"shim" blade up to .020”
• Crooked Joint • Holding drill crooked while
cutting
• Position the drill square
against the log before cutting
• Drill stops or
cuts on small
diameter logs
but not larger
ones
• Using a variable speed drill or
drill not powerful enough
• We strongly recommend
using a single-speed drill with
low RPM and high torque
• Spiral grooves
on the tenon
joint
• Lateral wobbling of the drill • Hold the drill steady while
cutting
• Removing the cutter while
drill is still spinning
• DO NOT remove the cutter
until the drill has come to a
complete stop
Troubleshooting
Engineers and Quality Control staff at Lumberjack Tools have provided
you with one of the easiest to use and safest tenon cutters on the market.
However, there is always the unexpected chance of failure.
●Please contact our customer support for a replacement if a failure
ever occurs to the tool body, shank or blades
UnexpectedOccurrences

3210 Hogarth Street, Eau Claire, WI 54703 • 715-514-0319
[email protected] • www.lumberjacktools.com
REV. 7-2022