LUMBERJACK TOOLS PRO Series User manual

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POBox730•ChippewaFalls,WI54729•7157204719•www.lumberjacktools.com
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MadeintheUSA
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USERMANUAL
PROSERIES(RadiusShoulderProfile)
DualBladeTenonCutters
MODELS:
LumberJackToolsInc.ProSeriesTTR0500
POBox730ProSeriesTTR0625
ChippewaFalls,WI54729ProSeriesTTR0750
www.lumberjacktools.comProSeriesTTR1000
Email:[e-mail]ProSeriesTTR1500
Phone:7157204719ProSeriesTTR2000
Rev:09/13

AboutYourProduct
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ThankyouforpurchasingourDualBladeProSeriesTenonCutter!
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LumberJackengineers,alongwithourcraftsmen,havedesignedthesafest,
mosteasytousetenoncuttersonthemarket.Bycombiningoldworld
skills,alongwithDFMAprinciplesandCNCtechnology,we’veeliminatedthe
issuesofoffcentertenonsandsideloadcuttingassociatedwithsingle
bladedesigns.
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We’veaddedvaluewiththedualbladetechnologywhichwillcutthetenon
inhalfthetime.Havingtwoblades,allowsthemtostaysharper,longer.The
bladesarestamped,heattreatedandprecisiongroundtoprovideyearsof
servicewhenproperlymaintained.
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Oursolidbilletofaircraftgradealuminumisdesignedtolastalifetime
undernormaloperatingconditions.ThealuminumbodyisCNCmachinedto
ensureprecisecuttingeachandeverytime.
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OuruniqueInSightmeasurementsystemallowsthecraftsmantocutthe
tenontotheirdesiredlengthwithouttheprocessofmeasuringbyhandto
ensureaccurateandconsistenttenonlengths.
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Warranty
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.Bladesharpnessisbasedonthetypeofwood(peeled
orunpeeled).Grit,dirt,etc.,willimpacthowlongyourbladesstaysharp,
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.
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1

AdditionalTips
Aswithanynewhobbyorproject,itwilltaketimetomasterusingourtools,
andbuildingfurniture.Youmustfirsthaveaplanorasketchofwhatyou
wanttobuild,alongwithatoolsandmaterialslistbeforeyoubegin.
Anotherimportantissueisreadingthenaturaltwist,stressorother
deformitiesinthelogsandusingtheseskillstoyouradvantage,allowing
yourpiecestobecomemoreuniqueasyourabilitiesgrow.Itisalso
importantistonotovercomplicateyourfirstfewpieces,soyoucanhavea
“positive”experience.
Beforestartingyourfirstproject,usesomescrapmaterialand“practice”
cuttingtenonsandusingtools.Makesureyouarecomfortableoperating
thedrillandcuttersbeforeyoubegintheproject.
Thankyouagainforpurchasingourtools!
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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followALLsafety
instructionsmaycausephysicalharmtoyourselforthosearoundyou.Ifyoufeel
uncomfortableusingourtenoncutteroranyothertools,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.
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•Neveroperatethistoolundertheinfluenceofalcohol,drugsor
medication
•Youmustwearsafetyglasses,adustmask,andanyotherpersonal
safetyaccessoriesyoudeemnecessary
•Beforeinstalling/removingthetool,thedrillmustcometoa
completestopandthepowermustbedisconnected
•Donotweargloves,looseclothingorotheritemsthatmayget
caughtinthemovingparts
•Neveroperatethistoolinadrillpress,latheoranyotherdevice
exceptfora½”drill.Doingsovoidsthewarranty
•WerecommendasinglespeeddrillwithRPMsof500orless.It
shouldbeageardrivendrillandnotavariablespeeddrill
•OverloadingorexceedingtheRPM’scanresultinannealingthe
bladeorshankfailure
•Thelogmustbesecuredinaviseorclamppriortostartingyour
drill.Failuretodosomayresultinbodilyharm
•Donotrunthetoolintoanailorforeignobject.Doingsomayruin
thebladesortool,andvoidsthewarranty
•Donotalterormisusethistoolinanyfashion
•Rememberthebladesaresharp.Usecautionwhenhandling
•Donotapplysideforceonthedrillwhileinoperationoritcould
resultinprematureshankfailureorbladedamage
•Thistoolmustbemaintainedbykeepingthebladessharpandclean
ofbuildup
•Whenexcessiveforceisrequiredtocut,resharpenorreplacethe
blades.Asharptoolisasafetool!
•Underseverworkingconditions,whilecuttingtough,dryorknotty
logs,sideloadingthetoolmaycausetheshanktofail,ormayresult
inbladedamage
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2

AssemblyPartsIncluded:
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BladeAssembly/Setting
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1. Inserttheallenwrench(included)intothecapscrewandtighten
thescrew
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2. Makesurethebladegapsettingisthesamedistanceapartforboth
blades(about1/8”1/4”)Seebelow
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3. Youcanslightlychangethetenondiameterbyslidingthebladeinor
out.Slidingitinwillreducethediameter,andslidingitbackwill
increasethediameter.DONOTslideitbeyond¼”fromthefaceof
thecutout.Doingsowillnotcutatenon,astheblademustbe
exposed
  
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4. Ifthebitistooaggressiveorstopsyourdrillwhilecutting,youcan
removeonebladefromthetoolandoperateitwithoneblade
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Securelytightenthecapscrew,buttakecautionnottostripit(donotover
tighten).Recheckbothscrewsbeforestarting
Troubleshooting
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TOOLSKIPSOFFTOONESIDEORBOUNCESAROUND
•Logislargerthanwhatthetoolwillaccept
•Notenoughbodypressureisbeingapplied
•Drillrunningpriortopositioningtothelog.Youmusthavethe
drillpositionedagainstthelog,applybodypressure,thenstart
thedrill
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NOTCUTTING
•Bladesareslidbacktoofar–notgrabbing
•Notapplyingenoughbodypressure
•Bladesaredull
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TAKESTOOMUCHOFA“BITE”
•Removeonebladeor“shim”upnomorethan.020”
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DRILLSTOPSORCUTSONSMALLDIAMETERLOGSBUTNOTLARGERONES
•Thisiscausedbyusingavariablespeeddrill
•ToohighofRPM
•ThismayalsobecausedbyusinganonMilwaukeebranddrill
oDeWalt,Makita,Rigid,etchavelesstorquethan
Milwaukee
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CROCKEDJOINT
•Thisisfromholdingthedrillcrockedtothelog
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SPIRALGROOVESONTHETENONJOINT
•Thisiscausedbywobblingthedrillsidetosidewhilecutting
OR
•Removingthecutterfromthelogwhilethedrillisstillspinning
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AllenWrench
CapScrews
Blades
RIGHT
RIGHT
WRONG
1/8”
1/4”
3

•Donotremovethetoolfromtheloguntilthedrillcomestoa
completestop.Failuretodosowillwafflecutthetenonorcause
harmtotheoperator.Donotplacehandsorbodypartsnearthe
toolorbladeswhileinoperation
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•Donotdroporallowthetooltofalltothefloorbyitselforwhilein
thedrill.Doingsomaybendtheshankordamagethetool.This
damageisnotcoveredbythewarranty
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Maintenance
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Itisbestifyoukeepthetenoncutterbodycleanofsapandbuildup.
Removethebladesfromthetoolfirst.Carefullycleanthetoolwiththe
solventorcleanerofyourchoice,anddrywhencompleted.
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Thebladesaremadefromhighqualitytoolsteel,andmayformoxidation.
Thisisanaturaloccurrenceandwillvarydependingonyourgeographic
location,climateandshopenvironment.Youshouldperiodicallycleanthe
bladesandapplyathinfilmofoil.
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Resharpeningtheblades:Wearsafetyglasses,andusecautionwhen
sharpeningtheblades.Everytimeyouresharpentheblades,youmust
applyathinfilmofoil.Useextremecautionsonottocutyourself.
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WerecommendourBladeBossJig0750(BB0750)forsharpeningtheblades.
(BB0750NotIncluded)
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Shank:Oneoftheuniquefeaturesaboutourtenoncuttersisthattheyoffer
areplaceableshank.Intherareinstancethatyourshankbreaks,weoffer
replacementshanksforsalesoyoudon’thavetoreplacetheentiretenon
cutter.Theshanksarethreaded,sotoloosenthem,turntheshanktothe
left
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UsingtheInSightMeasurementSystem
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QuickStopPins
Includedinthefollowingkits:PSK2,PSK3,PSK5
(Alsoavailableforindividualpurchase)
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OurQuickStopPinsfitintothe1”,1½”and2”ProSeriesTenonCutters.
Thesepinsstopthelogatthespecifiedtenonlengthtoavoidmeasurement
basedonsightalone.

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
2.5”fromthe
faceofthetenon
tooltothefirst
Radial
Measurement
Ring.(Models:
TTR0750
TTR2000)
Models:TTR0500
&TTR0625(2”)
Radial
Measurement
Ringsevery½”
4InSight
measurement
slotsevery90°for
easeofsight.
TheQuickStop
Pinsstopthelog
atthedesired
length.
Viewofthepin
insidethemouth
ofthetenon
4

GettingStarted
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WARNING:SecuringthelogisprobablythemostIMPORTANTsafety
factorthatwillarisewhilebuildinglogfurniture.

•Obtainthelogyouwanttotenon.Cutittolengthandmakesure
theendisflat.Iftheendisnoteven/flat,thetenonwillbecrooked

•Securetheloginavise,orclampittoatableinaVshapednotch

•Carefullyinstallthetenoncutterintoanunplugged½“drill,and
tightenitfirmly;aThandleisalsorecommended

•Anytimeyouadjusttheblades,orretightenthechuck,youmust
ALWAYSunplugthedrill




CuttingTenons

•Ifthelogdiameterisgreaterthanwhatthetoolwillaccept,usea
drawknifetotapertheendofthelog,asonewouldsharpena
pencil,togetthetoolstarted

•Withyourlogsecurelyclamped,positionthetenoncutterface
squarelyagainstthelogyou’regoingtotenon
  

•DoNOTdepressthetriggerorstartthedrillbeforepositioningit
againstthelog.Doingsocouldharmyourselforthetool

•Whileholdingthedrillsquarelyagainstthelog,applybodypressure
(straightinline)withthedrillanddepressthetrigger)
oNOTE:Applyquiteabitofforce.Leanintothedrillsothatit
doesnotjumparoundorskipoffthelog
•Youshouldnowbecuttingyourtenontothedesiredlength

•Oncethecuttinghasbegun,youmayeaseuponthepressure,and
thedualbladetechnologywillassistyouin“pulling”thetoolinto
thelog

•WARNING:Ifthelogcomeslooseorunclampedwhilemakingthe
tenon,DONOTdropthedrillortrytograbthelog.Hangontothe
drillandpointitinasafedirection(usuallytowardstotheground),
awayfromeveryoneuntilitcomestoacompletestop

Continuedonnextpage

RIGHT
WRONG
5

GettingStarted

WARNING:SecuringthelogisprobablythemostIMPORTANTsafety
factorthatwillarisewhilebuildinglogfurniture.

•Obtainthelogyouwanttotenon.Cutittolengthandmakesure
theendisflat.Iftheendisnoteven/flat,thetenonwillbecrooked

•Securetheloginavise,orclampittoatableinaVshapednotch

•Carefullyinstallthetenoncutterintoanunplugged½“drill,and
tightenitfirmly;aThandleisalsorecommended

•Anytimeyouadjusttheblades,orretightenthechuck,youmust
ALWAYSunplugthedrill




CuttingTenons

•Ifthelogdiameterisgreaterthanwhatthetoolwillaccept,usea
drawknifetotapertheendofthelog,asonewouldsharpena
pencil,togetthetoolstarted

•Withyourlogsecurelyclamped,positionthetenoncutterface
squarelyagainstthelogyou’regoingtotenon
  

•DoNOTdepressthetriggerorstartthedrillbeforepositioningit
againstthelog.Doingsocouldharmyourselforthetool

•Whileholdingthedrillsquarelyagainstthelog,applybodypressure
(straightinline)withthedrillanddepressthetrigger)
oNOTE:Applyquiteabitofforce.Leanintothedrillsothatit
doesnotjumparoundorskipoffthelog
•Youshouldnowbecuttingyourtenontothedesiredlength

•Oncethecuttinghasbegun,youmayeaseuponthepressure,and
thedualbladetechnologywillassistyouin“pulling”thetoolinto
thelog

•WARNING:Ifthelogcomeslooseorunclampedwhilemakingthe
tenon,DONOTdropthedrillortrytograbthelog.Hangontothe
drillandpointitinasafedirection(usuallytowardstotheground),
awayfromeveryoneuntilitcomestoacompletestop

Continuedonnextpage

RIGHT
WRONG
6

•Donotremovethetoolfromtheloguntilthedrillcomestoa
completestop.Failuretodosowillwafflecutthetenonorcause
harmtotheoperator.Donotplacehandsorbodypartsnearthe
toolorbladeswhileinoperation

•Donotdroporallowthetooltofalltothefloorbyitselforwhilein
thedrill.Doingsomaybendtheshankordamagethetool.This
damageisnotcoveredbythewarranty

Maintenance

Itisbestifyoukeepthetenoncutterbodycleanofsapandbuildup.
Removethebladesfromthetoolfirst.Carefullycleanthetoolwiththe
solventorcleanerofyourchoice,anddrywhencompleted.

Thebladesaremadefromhighqualitytoolsteel,andmayformoxidation.
Thisisanaturaloccurrenceandwillvarydependingonyourgeographic
location,climateandshopenvironment.Youshouldperiodicallycleanthe
bladesandapplyathinfilmofoil.

Resharpeningtheblades:Wearsafetyglasses,andusecautionwhen
sharpeningtheblades.Everytimeyouresharpentheblades,youmust
applyathinfilmofoil.Useextremecautionsonottocutyourself.

WerecommendourBladeBossJig0750(BB0750)forsharpeningtheblades.
(BB0750NotIncluded)

Shank:Oneoftheuniquefeaturesaboutourtenoncuttersisthattheyoffer
areplaceableshank.Intherareinstancethatyourshankbreaks,weoffer
replacementshanksforsalesoyoudon’thavetoreplacetheentiretenon
cutter.Theshanksarethreaded,sotoloosenthem,turntheshanktothe
left

UsingtheInSightMeasurementSystem


QuickStopPins
Includedinthefollowingkits:PSK2,PSK3,PSK5
(Alsoavailableforindividualpurchase)

OurQuickStopPinsfitintothe1”,1½”and2”ProSeriesTenonCutters.
Thesepinsstopthelogatthespecifiedtenonlengthtoavoidmeasurement
basedonsightalone.






2.5”fromthe
faceofthetenon
tooltothefirst
Radial
Measurement
Ring.(Models:
TTR0750
TTR2000)
Models:TTR0500
&TTR0625(2”)
Radial
Measurement
Ringsevery½”
4InSight
measurement
slotsevery90°for
easeofsight.
TheQuickStop
Pinsstopthelog
atthedesired
length.
Viewofthepin
insidethemouth
ofthetenon
7

AssemblyPartsIncluded:





BladeAssembly/Setting

1. Inserttheallenwrench(included)intothecapscrewandtighten
thescrew


2. Makesurethebladegapsettingisthesamedistanceapartforboth
blades(about1/8”1/4”)Seebelow

3. Youcanslightlychangethetenondiameterbyslidingthebladeinor
out.Slidingitinwillreducethediameter,andslidingitbackwill
increasethediameter.DONOTslideitbeyond¼”fromthefaceof
thecutout.Doingsowillnotcutatenon,astheblademustbe
exposed
  

4. Ifthebitistooaggressiveorstopsyourdrillwhilecutting,youcan
removeonebladefromthetoolandoperateitwithoneblade

Securelytightenthecapscrew,buttakecautionnottostripit(donotover
tighten).Recheckbothscrewsbeforestarting
Troubleshooting

TOOLSKIPSOFFTOONESIDEORBOUNCESAROUND
•Logislargerthanwhatthetoolwillaccept
•Notenoughbodypressureisbeingapplied
•Drillrunningpriortopositioningtothelog.Youmusthavethe
drillpositionedagainstthelog,applybodypressure,thenstart
thedrill

NOTCUTTING
•Bladesareslidbacktoofar–notgrabbing
•Notapplyingenoughbodypressure
•Bladesaredull

TAKESTOOMUCHOFA“BITE”
•Removeonebladeor“shim”upnomorethan.020”

DRILLSTOPSORCUTSONSMALLDIAMETERLOGSBUTNOTLARGERONES
•Thisiscausedbyusingavariablespeeddrill
•ToohighofRPM
•ThismayalsobecausedbyusinganonMilwaukeebranddrill
oDeWalt,Makita,Rigid,etchavelesstorquethan
Milwaukee

CROCKEDJOINT
•Thisisfromholdingthedrillcrockedtothelog

SPIRALGROOVESONTHETENONJOINT
•Thisiscausedbywobblingthedrillsidetosidewhilecutting
OR
•Removingthecutterfromthelogwhilethedrillisstillspinning




AllenWrench
CapScrews
Blades
RIGHT
RIGHT
WRONG
1/8”
1/4”
8

AdditionalTips
Aswithanynewhobbyorproject,itwilltaketimetomasterusingourtools,
andbuildingfurniture.Youmustfirsthaveaplanorasketchofwhatyou
wanttobuild,alongwithatoolsandmaterialslistbeforeyoubegin.
Anotherimportantissueisreadingthenaturaltwist,stressorother
deformitiesinthelogsandusingtheseskillstoyouradvantage,allowing
yourpiecestobecomemoreuniqueasyourabilitiesgrow.Itisalso
importantistonotovercomplicateyourfirstfewpieces,soyoucanhavea
“positive”experience.
Beforestartingyourfirstproject,usesomescrapmaterialand“practice”
cuttingtenonsandusingtools.Makesureyouarecomfortableoperating
thedrillandcuttersbeforeyoubegintheproject.
Thankyouagainforpurchasingourtools!













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followALLsafety
instructionsmaycausephysicalharmtoyourselforthosearoundyou.Ifyoufeel
uncomfortableusingourtenoncutteroranyothertools,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thistoolundertheinfluenceofalcohol,drugsor
medication
•Youmustwearsafetyglasses,adustmask,andanyotherpersonal
safetyaccessoriesyoudeemnecessary
•Beforeinstalling/removingthetool,thedrillmustcometoa
completestopandthepowermustbedisconnected
•Donotweargloves,looseclothingorotheritemsthatmayget
caughtinthemovingparts
•Neveroperatethistoolinadrillpress,latheoranyotherdevice
exceptfora½”drill.Doingsovoidsthewarranty
•WerecommendasinglespeeddrillwithRPMsof500orless.It
shouldbeageardrivendrillandnotavariablespeeddrill
•OverloadingorexceedingtheRPM’scanresultinannealingthe
bladeorshankfailure
•Thelogmustbesecuredinaviseorclamppriortostartingyour
drill.Failuretodosomayresultinbodilyharm
•Donotrunthetoolintoanailorforeignobject.Doingsomayruin
thebladesortool,andvoidsthewarranty
•Donotalterormisusethistoolinanyfashion
•Rememberthebladesaresharp.Usecautionwhenhandling
•Donotapplysideforceonthedrillwhileinoperationoritcould
resultinprematureshankfailureorbladedamage
•Thistoolmustbemaintainedbykeepingthebladessharpandclean
ofbuildup
•Whenexcessiveforceisrequiredtocut,resharpenorreplacethe
blades.Asharptoolisasafetool!
•Underseverworkingconditions,whilecuttingtough,dryorknotty
logs,sideloadingthetoolmaycausetheshanktofail,ormayresult
inbladedamage
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