5.8 AMP. CUT-OUT SAW 241-0968 Owner’s Manual Rating: Amperes: Speed: Weight: PRODUCT SPECIFICATIONS 120 V, 60 Hz AC 5.8 Amp. 10,000 – 30,000 RPM (no load) 3 lb 3 oz (1.
TABLE OF CONTENTS Product specifications ………….……………………………………………………. Table of contents ……………………………………………………………………... General safety warnings …………………………………………………………….. Eye, ear & lung protection …………………………………………………………… Electrical safety ………………………………………………………………………. Power tool safety ……………………………………………………………………... General safety rules ………………………………………………………………….. Work area ………………………………………………………………….………….. Electrical safety ………………………………………………………………………. Personal safety ………………………………………………………………………..
GENERAL SAFETY WARNINGS ! WARNING: Before using this tool or any of its accessories, read this manual and follow all Safety Rules and Operating Instructions. The important precautions, safeguards and instructions appearing in this manual are not meant to cover all possible situations. It must be understood that common sense and caution are factors which cannot be built into the product.
GENERAL SAFETY WARNINGS WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT. ! WARNING: Dust that is created by power sanding, sawing, grinding, drilling, and other construction activities may contain chemicals that are known to cause cancer, birth defects, or other genetic abnormalities.
POWER TOOL SAFETY ! WARNING: Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. Save all warnings and instructions for future reference.
POWER TOOL SAFETY PERSONAL SAFETY – cont’d Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. Dress properly. Do not wear loose clothing or jewelry.
SPECIFIC SAFETY RULES ! WARNING: Know your cut-out saw. Read the Owner’s Manual carefully. Learn the tool’s 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 make sure the work surface is free from nails and other foreign objects. Cutting into a nail can cause the bit and the tool to jump and damage the bit.
EXTENSION CORD SAFETY ! WARNING: Keep the extension cord clear of the working area. Position the cord so it will not get caught on the workpiece, tools or any other obstructions while you are working with the power tool. MINIMUM GAUGE (AWG) EXTENSION CORDS (120V use only) Amperage rating Not More more than than 0 6 6 10 10 12 12 16 Make sure any extension cord used with this tool is in good condition.
SYMBOLS ! WARNING: Some of the following symbols may appear on the cut-out saw. Study these symbols and learn their meaning. Proper interpretation of these symbols will allow for more efficient and safer operation of this tool. V A Hz W kW L kg H N/cm2 Pa OPM Min S or a.c.
KNOW YOUR CUT-OUT SAW ON/OFF switch Speed control wheel Hanging loop Circle cutting knob Side assist handle Spindle locking button Freehand cutting guide collar Pivot point Locking knob Collet nut Locking lever Freehand guide foot Circle cutting guide Pivot point Mounting disc Mounting insert ACCESSORIES AVAILABLE ACCESSORIES Before using any accessory, carefully read the instructions or the owner’s manual for the accessory.
CONTENTS CONTENTS CUT-OUT SAW COMPONENTS KEY DESCRIPTION QTY A Cut-out saw 1 B Side assist handle 1 C Freehand cutting guide 1 Circle cutting guide D with installation 1 adapter 1/4" general purpose E 1 cutting bit 1/8" general purpose F 2 cutting bit G 1/4" collet 1 H 5/32" collet 1 I 1/8" collet 1 J Collet wrench 1 Tote case 1 (Not illustrated) Owner’s Manual 1 Carefully unpack the cut-out saw. Compare the contents against the “CUTOUT SAW COMPONENTS” chart at right.
ASSEMBLY AND OPERATING ! WARNING: Remove the plug from the power source before assembly, changing accessories or cutters and making adjustments. This will prevent accidental starting of the tool which could result in serious injury. INSTALLING THE ASSIST HANDLE The removable assist handle is designed for use when precision control over the tool movement is desired. Use the assist handle when operating the tool with either the freehand cutting guide or the circle cutting guide. 1.
ASSEMBLY AND OPERATING INSTALLING THE FREEHAND CUTTING GUIDE The freehand cutting guide is designed for basic freehand cutting with the cutting bit. It is ideally suited for cutting electrical outlet holes in drywall. 1. Open the freehand cutting guide mounting collar (1) by pulling the quick release lever (2) outward (Fig. 2). 2. Slide the mounting collar onto the bottom of the motor housing (3). NOTES: a) The mounting collar must be pushed onto the motor housing as far as it will go.
ASSEMBLY AND OPERATING INSTALLING CUTTING BITS – cont’d 1. Depress the shaft locking button (1) and rotate the collet lock nut (2) with the other hand until the locking button drops into place, preventing the shaft from turning (Fig. 3). 2. While continuing to hold the shaft locking button IN, use the collet wrench (3) to turn the collet nut counter-clockwise. Loosen the collet nut two or three turns. 3. Remove the bit if one is already installed in the tool. 4.
ASSEMBLY AND OPERATING CHANGING THE COLLET The cutting bits for this tool are locked into place with a collet nut (1) and collet (2) (Fig. 4). 1/8" and 5/32" collets are used for holding 1/8" and 5/32" cutting bits and hobby tool accessory bits. The 1/4" collet is supplied for holding 1/4" drywall bits. To change from one collet size to the other: 1. Remove bit from the tool. 2. Turn the collet nut counter clockwise until it can be removed from the motor shaft (3) (Fig. 4). 3.
ASSEMBLY AND OPERATING ON/OFF SWITCH This cut-out saw is equipped with a convenient ON/OFF switch (1) located on the top of the tool handle (Fig. 5). To turn the switch ON, slide the switch outward. To turn the switch OFF, slide the switch inward. SPEED CONTROL SWITCH The cut-out saw is equipped with a variable speed control located below the ON/OFF switch. To run the tool at its slowest speed, rotate the speed control wheel (2) to number “1” (Fig. 6).
ASSEMBLY AND OPERATING ADJUSTING THE FREEHAND CUTTING GUIDE – cont’d Before starting to cut, double check the bit depth. Make sure the cutting guide is at a right angle to the bit and securely tightened. Double check the collet to make sure the bit is securely fastened. ! WARNING For safety reasons, the operator must read the sections of this Owner’s Manual entitled “GENERAL SAFETY WARNINGS”, “POWER TOOL SAFETY”, “SPECIFIC SAFETY RULES”, “EXTENSION CORD SAFETY” and “SYMBOLS” before using this cut-out saw.
ASSEMBLY AND OPERATING CUTTING BIT APPLICATIONS Cutting Bit Type 1/4" (soft wood*, fiberglass and laminate) 1/4" (windows and doors) 1/8" (soft wood*, fiberglass and laminate) 5/32" All purpose (not included) 1/8" Ceramic tile (not included) Material and Thickness Fiberglass and laminate up to 1/4" and soft wood* up to 1" Drywall, gypsum board up to 5/8" Fiberglass and laminate up to 1/8", soft wood* up to 1" All materials and thicknesses listed in this chart plus sheet metal up to 1/32" thick “Porous” ce
ASSEMBLY AND OPERATING PRACTICE CUTS USING THE FREEHAND CUTTING GUIDE Before attempting to work on an actual project, take the time to make a few practice cuts with your cut-out saw. Use some scraps of material that are the same material as will be used in your actual project. 1. Draw a pattern similar to your first project on a scrap piece of material. 2. Install the assist handle and the freehand cutting guide as shown in Fig. 1 & 2. 3. Install cutting bit in the collet as shown in Fig. 3. 4.
ASSEMBLY AND OPERATING PRACTICE CUTS USING THE FREEHAND CUTTING GUIDE – cont’d 8. When the motor is up to full speed, slowly tip the tool to an upright position, letting the bit cut into the workpiece (Fig. 9). Once the tool has reached the upright position and the bit has cut through the workpiece, slowly move the tool in a clockwise direction using slow steady pressure to make the cut. NOTE: Except for cutting around outlet boxes in drywall, always cut in a clockwise direction. 9.
ASSEMBLY AND OPERATING CUTTING TIPS – cont’d Slower cutting gives you better control. Excessive pressure or fast cutting will increase the bit temperature and shorten the life of the bit. When cutting a hole in a vertical surface, avoid ending the cut at the bottom of the hole. Always start and end the cut at the “top” so the cut out part will not drop onto the rotating bit. Always turn the tool OFF before removing it from the workpiece.
ASSEMBLY AND OPERATING CUTTING OUTLET OPENINGS IN DRYWALL – cont’d 3. When fastening the drywall in place, do not place nails or screws closer than 12" from the box. This will prevent the drywall from becoming deformed under pressure. 4. Install the assist handle, freehand cutting guide and cutting bit, as outlined in Fig. 1, 2 & 3. Adjust depth of cut so the bit will protrude 1/8" beyond the thickness of the drywall (Fig. 7). 5. Hold the tool firmly with both hands and turn it ON.
ASSEMBLY AND OPERATING CUTTING OUTLET OPENINGS IN DRYWALL – cont’d 10. The completed electrical box cut out will be accurately and neatly cut (Fig. 11). NOTE: Always move the cutting bit in a counter- clockwise direction around the outlet box. The natural tendency of the cutting bit to move to the left will make it easier to cut close to the box. INSTALLING THE CIRCLE CUTTING GUIDE The circle cutting guide accessory is ideal for precision cutting of circles.
ASSEMBLY AND OPERATING INSTALLING THE CIRCLE CUTTING GUIDE – cont’d 4. Screw the internally threaded circle cutting guide mounting disc (6) onto the externally threaded circle cutting guide mounting insert and hand tighten. NOTES: a) Make sure the boss (7) on the cutting guide mounting disc goes through the hole in the circle guide. b) Do not over tighten the circle cutting guide mounting plastic parts. Hand tighten only. 5. Fig.
ASSEMBLY AND OPERATING CIRCLE CUTTING GUIDE OPERATION – cont’d 3. Adjust the circle cutting guide radius by loosening the pivot point knob, sliding it to the correct circle radius and re-tightening in the desired location. NOTE: Check the circle cutting guide radius setting by measuring from the pivot point to the outside of the spiral bit. 4. Rest the edge of the freehand cutting guide on the workpiece with the bit at an angle of about 45° (Fig. 13).
MAINTENANCE Remove accumulated dust and debris regularly using a soft DRY brush. GENERAL ! WARNING: When servicing, use only identical replacement parts. The use of any other part may create a hazard or cause product damage. It has been found that electric tools are subjected to accelerated wear and possible premature failure when they are used on fiberglass boats and sports cars, wallboard, spackling compounds or plaster.
EXPLODED VIEW 27
PARTS LIST ! WARNING: When servicing, use only original equipment replacement parts. The use of any other parts may create a safety hazard or cause damage to the cut-out saw. Any attempt to repair or replace electrical parts on this cut-out saw may create a safety hazard unless repairs are performed by a qualified technician. For more information, call the Toll-free Helpline, at 1-866-349-8665 Monday – Friday from 9am to 5pm Eastern Standard Time. Always order by PART NUMBER, not by key number.
PARTS LIST Key # 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Part # 2040140007 2030030014 3150100001 1160030002 4060020001 3140080001 2050080075 3120110009 1061150001 3150020005 3140010014 1190030006 3120020015 2050060023 410050002 2030070016 1230010016 4100020013 3150010013 4010010058 3190010005 2040150006 1140060002 2040190003 2030030024 3160020001 2040140004 3120070003 4040010021 4060090001 3150130013 Part Name Bakelite ball Ruler Round nut Positioning k
PERFORMAX® 5.8 AMP. CUT-OUT SAW WARRANTY 30-DAY MONEY BACK GUARANTEE: This PERFORMAX® brand power tool carries our 30-Day Money Back Guarantee. If you are not completely satisfied with your PERFORMAX® brand power tool for any reason within thirty (30) days from the date of purchase, return the tool with your original receipt to any MENARDS™ retail store, and we will provide you a refund – no questions asked.
