Owner’s Manual

SERPENTINE SAW 54-8233-0

TOLL-FREE HELPLINE: 1-800-689-9928

CAUTION: Before using this serpentine saw or any of its accessories, read this manual and follow all Safety Rules and Operating Instructions.

General Safety Rules Specific Safety Rules

and Symbols Functional Description Assembly Instructions Operating Instructions Maintenance Accessories

Imported by Mastercraft Canada Toronto, Canada M4S 2B8 Rev 1.11 10/06/2009

Patent Pending

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SECTION PAGE SECTION PAGE Warranty ….………………………. 2 Know your serpentine saw ….. 9 Product specifications …………... 2 Accessories …………………… 10 Power tool safety ………………… 3–5 Contents……..……….………… 10–11 Specific safety rules …………….. 6–7 Assembly and operating

instructions …………………….

12–28 Extension cord safety …………… 7 Maintenance …….…………….. 29 Symbols ………………………….. 8 Parts & service ………………... 30–32

TABLE OF CONTENTS

WARRANTY

PRODUCT SPECIFICATIONS

Rating ……………………………….. 120 V AC, 60 Hz Amperage …………………………... 6.0 A Motor speed ………………………... 15,000–30,000 RPM (no load) Motor start control …………………. Soft start with memory Motor speed control ……………….. Digital in 1,000 RPM increments Collet sizes …………………………. 1/4" (6.4 mm), 5/32" (4 mm) and

1/8" (3.2 mm) Weight ………………………………. 5 lb (2.3 kg)

WARRANTY *Limited 5-year Replacement Warranty This Mastercraft Maximum product carries a five (5) year replacement

warranty against defects in workmanship and materials. Mastercraft Canada agrees to replace the defective product free of charge with the same model or one of equal value or specification, within the stated warranty period, when returned by the original purchaser with proof of purchase. The blow-moulded case carries a two (2) year

replacement warranty against defects in workmanship and materials. This product is not guaranteed against wear or breakage due to misuse and/or abuse. This product is not guaranteed if used for industrial or commercial purposes.

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POWER TOOL SAFETY

WARNING: To avoid electrical hazards, fire hazards or damage to the serpentine saw, use proper circuit protection. The serpentine saw is wired at the factory for 110–120 V operation. It must be connected to a 110–120 V, 15 A circuit that is protected by a time-delayed fuse or circuit breaker. To avoid shock or fire, replace power cord immediately if it is worn, cut or damaged in any way.

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ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA REQUIREMENTS or ANSI SAFETY STANDARD Z87.1

FLYING DEBRIS can cause permanent eye damage. Prescription

eyeglasses ARE NOT a replacement for proper eye protection.

WARNING: Non-compliant eyewear can cause serious injury if broken during operation of a power tool.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities 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, cement and other masonry products

Arsenic and chromium from chemically-treated lumber Your level of risk from exposure to these chemicals varies, depending on how often you do this type of work. To reduce your exposure to these chemicals, work in a well-ventilated area and work with approved safety equipment such as

dust masks that are specially designed to filter out microscopic particles.

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WARNING: Use hearing protection, particularly during extended

periods of operation of the tool, or if the operation is noisy. !

SAVE THESE INSTRUCTIONS FOR REFERENCE

WARNING: Always wear a dust mask designed to protect you from dust created by your power tool.

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4

POWER TOOL SAFETY GENERAL SAFETY RULES

WARNING: Read and understand all instructions. Failure to follow all

instructions listed below may result in electric shock, fire and/or serious personal injury. WORK AREA Keep your work area clean and well lit.

Cluttered benches and dark areas invite accidents. Do not operate power tools in potentially explosive environments,

such as in the presence of flammable liquids, gas or dust. Power tools create sparks, which may ignite dust or fumes. Keep bystanders, children and visitors away while operating the tool.

Distractions can cause you to lose control. ELECTRICAL SAFETY

Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will fit in a polarized plug only one way. If the plug does not fit into the outlet properly, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not alter the plug in any way. Double insulation eliminates the

need for the three-pronged grounded power cord and grounded power supply system. Avoid body contact with grounded surfaces such as pipes, radiators, ranges

and refrigerators. There is an increased risk of electric shock if your body is grounded.

Do not expose power tools to rain or wet conditions. Water entering the power

tool will increase the risk of electric shock. Do not abuse the cord. Never use the

cord to carry the tool or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges and moving parts. Replace a damaged cord immediately. A damaged cord increases the risk of electric shock.

When operating a power tool outdoors, use an outdoor extension cord marked “W-A” or “W”. These cords are rated for

outdoor use, and reduce the risk of electric shock.

PERSONAL SAFETY

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use the tool while

tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating a power tool may result in serious personal injury.

Dress properly. Do not wear loose

clothing or jewellery.

Contain long hair. Keep your hair,

clothing and gloves away from moving parts. Loose clothing, jewellery or long hair can get caught in moving parts.

Avoid accidental starting. Be sure the

switch is OFF before plugging in the

tool. Carrying tools with your finger on the

switch or plugging in tools that have the

switch ON invites accidents.

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5

POWER TOOL SAFETY Remove adjusting keys or wrenches before turning the tool ON. A wrench or

key that is left attached to a rotating part of the tool may result in personal injury. Do not overreach. Keep proper footing

and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. Use safety equipment. Always wear eye

protection. A dust mask, non-skid safety shoes, a hard hat, gloves and hearing protection

must be used for appropriate conditions. TOOL USE AND CARE

Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand

or against your body is unstable, and may lead to loss of control. Do not force the tool. Use the correct tool

for your application. The correct tool will do the job better and safer when used at the rate that it was designed to work at. Do not use the tool if the power switch does not turn it ON or OFF. Any tool that

cannot be controlled with the switch is dangerous, and must be repaired. Disconnect the plug from the power source before making any adjustments, changing accessories or storing the tool. Such preventive safety measures

reduce the risk of starting the tool accidentally. Store idle tools out of reach of children

and other untrained persons. Tools are dangerous in the hands of untrained users.

Maintain tools with care. Keep cutting

tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind, and are easier to control. Check for misalignment or binding of moving parts, broken parts and any other

condition that may affect the tool’s operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools. Use only accessories that are recommended by the manufacturer for

your model. Accessories that may be suitable for one tool may become hazardous when used with another tool. SERVICE

Service must be performed by qualified personnel. Service or maintenance

performed by unqualified personnel could result in risk of injury. When servicing a tool, use only identical replacement parts. Follow

instructions in the Maintenance section of this manual. The use of unauthorized parts or failure to follow Maintenance instructions may create a risk of electric shock or injury.

6

SPECIFIC SAFETY RULES Hold tool by insulated gripping surfaces

when performing any operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live”, and will shock the operator. Always make sure the work surface is free of nails and other foreign objects.

Cutting into a nail can cause the bit and the tool to jump, and can damage the bit. Always use a safe method to secure the workpiece, and use both hands to guide

the tool. Never place hands near or below the cutting surface. Never operate the serpentine saw while covering the air vents with your hands.

The motor will overheat. Never lay workpiece on hard surfaces

like concrete, stone, etc. The protruding cutting bit may cause the tool to jump. Always wear safety goggles, hearing protection and a dust mask. Use only in

a well-ventilated area. Using personal safety devices and working in a safe environment reduces the risk of injury. After changing the bits or making adjustments, make sure the collet nut and any other adjustment devices are securely tightened. Loose adjustment

devices and bits will be violently thrown. Never use dull or damaged bits. Sharp

bits must be handled with care. Damaged bits can snap during use. Dull bits require more force to push the tool, possibly causing the bit to break. Never touch the bit during or immediately after use. After use the bit is

too hot to be touched by bare hands.

WARNING: Before tightening the collet on the cutting bit, make sure the flutes (spiral portion) of the bit are completely visible outside the collet. Clamping the collet on the flutes of the bit will result in broken bits, and possible injury. Never use large router bits. Large bits

are hard to control, and may cause injury to the operator if used with this tool.

DANGER: Always make sure the shank of a 1/4" (6.4 mm), 5/32" (4 mm) or 1/8" (3.2 mm) cutting bit is properly inserted into the collet ensuring that the collet nut is properly tightened. The bit

may become loose and cause serious injury to the operator if not properly tightened.

DANGER: Never install or use a router bit in the tool with the bevel cutting sole plate installed on the tool. You MUST install the fixed sole plate before installing or using a router bit.

DANGER: Always make sure the 1/4" (6.4 mm) shank of the router bit is properly inserted into the collet; never allowing the top of the bit cutting edge to extend beyond the bottom of the sole plate.

WARNING: Always use self-guided router bits with a bearing at the end. The diameter of the router bit must not exceed 1 3/8" (34.9 mm). Router bits

without the bearing are unstable, and will be extremely difficult to control if used in the serpentine saw.

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7

EXTENSION CORD SAFETY

SPECIFIC SAFETY RULES

EXTENSION CORD

SAFETY

BIT USE

Application Acceptable bits

Freehand with base only

1/8" to 1/4" cutting bits or self-guided router bits with ball bearing (maximum 1

3/8" dia.)

Edge guide attached

1/8" to 1/4" cutting bits or self-guided router bits with ball bearing (maximum 1

3/8" dia.)

Circle cutter attached

1/8" to 1/4" cutting bits

WARNING: Never use a router bit with the circle cutter attachment. The bit

could come loose, and may cause serious injury. 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. Make sure any extension cord used with this tool is in good condition. When

using an extension cord, be sure to use one of heavy enough gauge to carry the current the tool will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The table at right shows the correct size to use according to cord length and nameplate amperage rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

Be sure your extension cord is properly wired and in good condition. Always

replace a damaged extension cord or have it repaired by a qualified electrician before using it. Protect your extension cord from sharp objects, excessive heat and damp or wet areas. Use a separate electrical circuit for your power tools. This circuit must not be less

than 14 gauge wire and should be protected with either a 15 A time-delayed fuse or circuit breaker. Before connecting the power tool to the power source, make sure the switch is in the OFF position and the power source is the same as indicated on the nameplate. Running at lower voltage will damage the motor.

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MINIMUM GAUGE (AWG) EXTENSION CORDS (120 V use only)

Amperage rating

Total length

More than

Not more than

25' (7.5 m)

50' (15 m)

100' (30 m)

150' (45 m)

0 6 18 16 16 14

6 10 18 16 14 12

10 12 16 16 14 12

12 16 14 12 Not Applicable

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SYMBOLS

V Volts

A Amperes

Hz Hertz

W Watts

kW Kilowatts

Microfarads

L Litres

kg Kilograms

H Hours

N/cm2 Newtons per square centimetre

Pa Pascals

Min Minutes

S Seconds

Alternating current

Three-phase alternating current

Three-phase alternating current with neutral

Direct current

No load speed

Alternating or direct current

Class II construction

Splash proof construction

Watertight construction

Protective grounding at grounding terminal, Class I tools

Revolutions or reciprocations per minute

Diameter

Off position

Arrow

Warning symbol

WARNING: Some of the symbols below may be used on your tool. Please study them and learn their meaning. Proper interpretation of

these symbols will allow you to operate the tool better and safer.

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3042597

LISTED

This symbol designates that this tool is

listed with Canadian requirements by

ETL Testing Laboratories, Inc.

Conforms to UL Std. 745-1, 745-2-17.

Certified to CAN/CSA Std. C22.2 No.

745-1, 745-2-17.

JD3353U

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KNOW YOUR SERPENTINE SAW

LED light

Handle

Edge guide locking knobs

LCD speed display

Air vents

Bevel locking lever

Sole plate

LED light

Light switch

Speed “+” button

Spindle locking button

Trigger switch

Trigger switch

Lock-on button

Speed “–” button

Dust blower switch

Vacuum port

LCD speed display

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ACCESSORIES AND CONTENTS AVAILABLE ACCESSORIES

WARNING: Use only accessories recommended for use with this serpentine saw. Follow instructions that accompany the accessories. Improper use of accessories may cause injury to the operator or damage to the tool.

Do not use any accessory unless you have completely read the instructions or Owner’s Manual for that accessory.

1/8" (3.2 mm) cutting bits

5/32" (4 mm) cutting bits

1/4" (6.4 mm) cutting bits

1/4" (6.4 mm) self-guided router edging bits

WARNING: If any part is missing or damaged, do not plug the serpentine saw into the power source until the missing or damaged part is replaced.

CONTENTS

Carefully unpack the serpentine saw. Compare the contents against the “SERPENTINE SAW COMPONENTS” chart at right. NOTE: See illustration of serpentine saw

and components on Page 11.

WARNING: To avoid fire or toxic reaction, never use gasoline, naphtha, acetone, lacquer thinner or similar highly volatile solvents to clean the tool.

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SERPENTINE SAW COMPONENTS

KEY DESCRIPTION QTY

A Serpentine saw 1

B Vacuum adaptor 1

C Cutting bit kit (see listing below)

1

D Edge guide 1

E Collet wrench 1

F Circle cutting guide 1

G Blow-moulded case 1

H Fixed sole plate 1

1/8" (3.2 mm) collet 1

5/32" (4 mm) collet 1

1/4" (6.4 mm) collet 1

Owner’s manual 1

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CUTTING BIT KIT COMPONENTS

KEY DESCRIPTION QTY

I J

K

L

Cutting bits

1/4" (6.4 mm) for wood, fiberglass, and laminates

1/4" (6.4 mm) for windows and doors

1/8" (3.2 mm) for wood, fiberglass, and laminates

1/8" (3.2 mm) for ceramic wall tile

1

1

2

1

M

N

O

P

Q

Router edging bits – 1/4" (6.4 mm) shank with bearing

1 1/4" (31.8 mm) round over

1 1/8" (28.6 mm) Roman ogee

45° chamfer

1" (25.4 mm) cove

3/4" (19.1 mm) beading

1

1

1

1

1

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CONTENTS

12

ASSEMBLY AND OPERATING INSTRUCTIONS

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.

ON/OFF SWITCH

This serpentine saw is equipped with a convenient ON/OFF trigger switch (1) (Fig. 1). To turn the switch ON, squeeze the trigger switch. To turn the tool OFF, release the trigger switch. NOTE: This tool is equipped with a “soft

start” feature to eliminate the kickback effect caused by the excessive torque of “hard starts”. When the trigger switch is turned ON, the tool will start slowly and increase to its running speed within approximately 2 seconds. LOCK-ON BUTTON

Your serpentine saw is equipped with a lock-on feature, which is convenient when continuous cutting is required for extended periods of time.

1. To lock the switch ON, depress the

trigger switch (1), push in and hold the lock-on button (2) located at the left side of the handle, and then release the trigger (Fig. 2). The serpentine saw will continue to run.

2. To turn the switch OFF, press and release the trigger switch. The lock-on button will release, and the trigger will return to its OFF position, causing the tool to turn OFF.

DIGITAL SPEED CONTROL

With the tool turned ON, bit speed can be set in increments of 1,000 RPM between 15,000 and 30,000 (30) RPM. 1. To increase the bit speed, press the

“+” button (1) below the LCD window (2) (Fig. 3). NOTE: Each time the button is

pressed, the speed of the bit will increase by 1,000 RPM, until the maximum speed of 30,000 RPM is reached. To increase the speed more quickly, you can press and hold the “+” button, and release it when the desired speed is indicated in the LCD display.

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Fig. 1

Fig. 2

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ASSEMBLY AND OPERATING DIGITAL SPEED CONTROL – cont’d

2. To decrease the bit speed, press the

“–” button (3) below the LCD window. NOTE: Each time the button is

pressed, the speed of the bit will decrease by 1,000 RPM, until the minimum speed of 15,000 RPM is reached. To decrease the speed quicker, press and hold the “–” button, and release it when the desired speed is indicated in the LCD display.

LIGHT SWITCH

This tool is equipped with two LED lights (1) for improved visibility of the bit cutting area (Fig. 4). To turn the lights ON, press the light switch (2) once. To turn the lights OFF, press the light switch a second time.

DUST BLOWER SWITCH

The dust blower switch (1) is designed to deflect the air from the blower, either to the workpiece cutting line or to the vacuum adaptor (Fig. 5). 1. Slide the dust blower switch backward

to deflect the air forward. This position should be used to provide a constant flow of air to the bit cutting area in order to provide better visibility at the cutting line.

2. Slide the dust blower switch forward to deflect the air toward the vacuum adaptor. This position will cause the air to move the bit cuttings toward the vacuum adaptor, which can be attached to the dust port at the rear of the tool.

INSTALLING THE VACUUM ADAPTER

To reduce the amount of loose sawdust produced while cutting a workshop vacuum can be attached to the serpentine saw by using the vacuum adaptor supplied with the tool.

Fig. 3

Fig. 5

Fig. 4

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ASSEMBLY AND OPERATING INSTALLING THE VACUUM ADAPTOR – cont’d

To install the vacuum adaptor (1), align the two locking tabs (2) with the matching slots (3) in the rear of the serpentine saw housing (Fig. 6). Firmly push the adaptor into the dust port (4). Lock the adaptor in place by turning it clockwise. INSTALLING CUTTING BITS

WARNING: Cutting bit and router bit cutting surfaces are extremely sharp. Handle with caution.

DANGER: Never use the bevel cutting sole plate with router bits. See Pages 27 & 28 for installing the fixed sole plate and using router bits.

1. Use the collet wrench to loosen and tighten the collet nut (1) (Fig. 7). NOTE: The collet wrench is attached

to the power cord just above the plug. 2. To loosen the collet nut, press the

shaft locking button (2), and rotate the collet locking nut with the other hand until the locking button drops into place, preventing the shaft from turning.

3. Continue to hold the shaft locking button IN, and use the collet wrench to turn the collet nut counter-clockwise. Loosen the collet nut two or three turns.

4. If a bit is already installed in the tool,

remove it. 5. Insert the new cutting bit (3) into the

collet. NOTE: The bit should fit snugly into

the collet. If it does not, refer to “CHANGING THE COLLET” (Fig. 8) and install the proper sized collet.

NOTES:

a) DANGER: Always make sure the shank of a 1/4" (6.4 mm), 5/32" (4 mm) or 1/8" (3.2 mm) cutting bit is properly inserted into the collet ensuring that the collet nut is properly tightened. The bit may

become loose and cause serious injury to the operator.

b) Insert the bit all the way into the collet and then pull it back between 1/16" (1.6 mm) and 1/8" (3.2 mm). This creates an air space between the motor shaft and the bit to help protect the bit from overheating.

c) Carefully slide the cutting bit in or out of the collet to adjust the cutting depth so the bit will protrude 1/8" (3.2 mm) beyond the thickness of the material to be cut. Some depth adjustment is possible, but be sure to maintain the criteria noted in NOTES a) and b) above.

WARNING: Before tightening the collet on the bit, make sure the top of the flutes (spiral portion) of the cutting bit are level with the bottom of the sole plate. Clamping the collet on the bit flutes will result in broken bits and possible injury.

6. When the bit is properly inserted in the

collet, depress the shaft locking button and turn the collet nut clockwise as far as possible by hand.

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Fig. 6

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15

ASSEMBLY & OPERATING INSTALLING CUTTING BITS - cont’d 7. Securely tighten the collet nut using

the collet wrench. CHANGING THE COLLET

The cutting bits for this tool are locked into place with a collet nut (1) and collet (2) (Fig. 8). The 1/8" (3.2 mm) and 5/32" (4 mm) collets are used for holding spiral cutting and hobby tool accessory bits. The 1/4" (6.4 mm) collet is used for holding 1/4" (6.4 mm) spiral cutting and router edging bits (see Pages 17 & 27). To change from one collet size to another: 1. To loosen the collet nut, press the

shaft locking button (3) and rotate the collet locking nut with the other hand until the locking button drops into place, preventing the shaft from turning. NOTE: Use the collet wrench to

loosen the collet nut.

2. Remove bit (4) from the tool.

3. Turn the collet nut counter-clockwise

until it can be removed from the motor shaft (5).

4. Pull the collet out of the motor shaft

and insert the appropriate collet. NOTE: Each collet is the same on

both ends, so either end can be inserted into the motor shaft.

5. Re-install the collet nut, and tighten it

slightly by hand. NOTES:

a) Tightening the collet nut without a bit in the collet will cause the collet hole to become smaller, and will make installing bits difficult. b) Install the new bit, as described in “INSTALLING CUTTING BITS” (Fig. 7). c) When storing the tool with no bit installed, leave the collet nut loose.

Fig. 7

Fig. 8

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ASSEMBLY & OPERATION ASSEMBLY AND OPERATING SELECTING THE PROPER MOTOR SPEED

Selecting the proper motor speed for your application will ensure smoother, more efficient cutting action. Choose LOWER speeds for cutting plastics. Choose HIGHER speeds for cutting wood, metal and drywall, and to reduce “chatter” that may develop when cutting some materials at LOW speed. NOTE: See Pages 12 and 13 “DIGITAL

SPEED CONTROL” (Fig. 3) for instructions on how to change the motor speed. ADJUSTING THE SOLE PLATE FOR BEVEL CUTTING

The sole plate can be adjusted to make “angle” or bevel cuts. For most applications, the sole plate should be set at 90°, which will produce cuts at a right angle to the cutting surface of the workpiece. 1. Pull the sole plate locking lever (1)

downward from the sole plate (2) (Fig. 9).

2. Rotate the opened locking lever counter-clockwise until the sole plate becomes loose.

3. Slide the sole plate forward approximately 1/8" (3.2 mm), until the notch (3) in the sole plate disengages from the locating pin in the sole plate mount.

4. Tilt the sole plate left or right to the desired bevel angle (4). NOTE: There are notches in the sole

plate at 90° and 45°. To positively lock the sole plate at these locations, slide the sole plate back so that the corresponding notch engages the locating pin.

5. Turn the locking lever clockwise until it

begins to tighten on the sole plate, and then push the locking lever upward into the sole plate to fully lock it into position.

WARNING: Have you read “POWER TOOL SAFETY”,

“SPECIFIC SAFETY RULES”,

EXTENSION CORD SAFETY” and

“SYMBOLS” on pages 3, 4, 5, 6, 7

and 8 of this Manual? If not, please

read them now before you operate

this serpentine saw. Your safety

depends on it!

Every time you use the serpentine

saw, you should verify the

following: 1. The bit is sharp and in good

condition 2. The bit is securely fastened in

the collet 3. The workpiece is properly

secured

4. Safety glasses are being worn.

Failure to adhere to these safety

rules can greatly increase the

chances of injury.

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Fig. 9

17

ASSEMBLY AND OPERATING MAKING PRACTICE CUTS

Soft wood* refers to spruce, pine and fir (SPF) NOTE: Refer to the above chart for materials, material thickness, speed of the tool and

recommended cut feet per minute to be used with the various cutting bits. The speeds referenced chart are intended as a guide only and must be adjusted according to hardness, density and characteristics of the material being cut. Material thickness must never exceed the length of the cutting flutes. Making practice cuts on a scrap workpiece that is the same material as the good workpiece will assist you in selecting the speeds that will produce the smoothest cut.

Cutting Bit Type

Material and Thickness

Tool Speed (RPM)

Recommended Cut Feet / Minute

1/4" (soft wood*, fibreglass and laminate)

Fibreglass and laminate up to 1/4" and soft wood* up to 1"

15-30,000 1 ft./min

1/4" (windows and doors)

Drywall, gypsum board up to 5/8"

15-30,000 1.5 ft./min

1/8" (soft wood*, fibreglass and laminate)

Fibreglass and laminate up to 1/8", soft wood* up to 1"

15-30,000 1 ft./min.

5/32" Metal Air duct plenum up to 1/32" 15-30,000 0.5 ft./min.

1/8" Ceramic tile “Porous” ceramic wall tiles up to 3/8"

15-30,000 0.5 ft./min.

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ASSEMBLY AND OPERATING MAKING PRACTICE CUTS – cont’d

Refer to the above chart for materials, material thickness, speed of tool and recommended cut feet per minute to be used with the various cutting bits. Before attempting to work on an actual project, take the time to make a few practice cuts with your serpentine saw. Use some scraps of material that are the same material as the workpiece that will be used for your project. 1. Draw a pattern similar to your first

project on a piece of scrap material.

2. Install the appropriate cutting bit in the collet as shown in (Fig. 7).

3. Adjust sole the plate bevel angle, as shown in Fig. 9.

4. Turn the switch ON, and set the speed control to the proper speed. NOTE: Turn the switch OFF before

proceeding to the next step.

5. Rest the edge of the sole plate on the workpiece with the bit at an angle of approximately 30° to 45° (Fig. 10). NOTE: DO NOT allow the bit to come

into contact with the workpiece until the power switch is turned ON and the tool is up to the set speed.

WARNING: Before turning the switch ON, make sure you are holding the tool firmly with one hand.

6. Turn the switch ON.

7. When the motor is fully up to the set

speed, slowly tip the tool down, allowing the bit to cut into the workpiece. Once the sole plate is flat against the workpiece, and the bit has cut through the workpiece, slowly move the tool in a clockwise

direction, using slow steady pressure to make the cut (Fig. 11). NOTE: Except for cutting around

outlet boxes in drywall, always cut in a clockwise direction.

8. When the cut is complete, turn the tool OFF, wait until it comes to a complete stop, and remove it from the workpiece.

Fig. 10

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ASSEMBLY AND OPERATING MAKING PRACTICE CUTS – cont’d

DANGER: Do not attempt cutting around outlet boxes in drywall until: 1. All electricity in the vicinity of

electric wires has been disconnected by either turning the breaker OFF or removing the fuses.

2. You have read the instructions on the following page entitled “CUTTING OUTLET OPENINGS IN DRYWALL”.

CUTTING TIPS

Freehand cutting with the serpentine saw is similar to using a jigsaw, with one very important exception. With the serpentine saw, there is no limit to the radius of the curves you can cut. Simply guide the tool in any direction (forward, backward or sideways) to cut the desired pattern. The rotating cutting action of the bit will cause a slight pull to the left when cutting. Natural variations in the structure of wood will cause the bit to “wander”. This tendency will be magnified when applying too much pressure to the bit.

Slower movement of the tool while cutting gives you better control. Excessive pressure or fast cutting will increase 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 that the cut-out part will not drop onto the rotating bit. Always turn

the tool OFF before removing it from the workpiece. CUTTING OUTLET OPENINGS IN DRYWALL

DANGER: Do not attempt to use this tool to make cut-outs around any fixture or opening that has live electrical wires, or on any wall that may have electrical wiring behind it. If a live wire is contacted, the bit could conduct the electric current to the tool, creating an electrocution hazard for the operator. Turn OFF breakers or remove fuses to disconnect the electric circuit in the cutting area. Always hold the tool by its insulated handle when working in areas where there is a possibility of contacting electric wires. Always wear eye protection when operating this tool.

1. Before installing drywall, push the

electrical wires as far to the back of the outlet box as possible so that they will not be cut by the bit when cutting the opening.

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!

Fig. 11

20

ASSEMBLY AND OPERATING ASSEMBLY AND OPERATING CUTTING OUTLET OPENINGS IN DRYWALL – cont’d

2. Before fastening the drywall sheet

over the electrical box, mark the sheet as close as possible to the centre of the box opening. The mark should be on the side of the drywall facing you.

3. When fastening the drywall in place, do not place nails or screws within 12" (305 mm) of the box. This will prevent the drywall from becoming deformed under pressure.

4. Install the cutting bit and collet, as outlined in Fig. 7 and 8. Adjust cutting depth of cut so the bit will protrude 1/8" (3.2 mm) beyond the thickness of the drywall.

5. Hold the tool firmly with both hands

and turn it ON. Plunge the bit through the drywall at the mark indicating the centre of the box. See Fig. 12 for cutting pattern.

6. Move the bit slowly to the right until

you feel and hear the bit contacting the inside of the box.

7. Pull the bit out far enough to slip it

over the edge of the box. Once the bit is outside the box, push it back to its full depth beside the outside edge of the box.

8. Move the tool upward while applying

slight pressure toward the centre of

the box. When you feel the bit reach the top right corner of the box, move the tool to the left while applying slight downward pressure toward the centre of the box. NOTE: Always move the tool in a counter-clockwise direction when

cutting around electrical outlet boxes.

9. Continue moving the tool around the

box in a counter-clockwise direction while maintaining slight pressure toward the centre of the box. When the box cut-out is complete, turn the tool OFF and remove it from the cut-out.

10. The completed electrical box cut-out will be accurately and neatly cut (Fig. 13).

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.

Fig. 12

21

ASSEMBLY AND OPERATING CUTTING OUTLET OPENINGS IN DRYWALL – cont’d

CUTTING A STRAIGHT LINE WITH A STRAIGHT EDGE TEMPLATE

To cut a straight line, you can use a straight edge template to guide the serpentine saw. 1. Draw a line (1) on the workpiece

where you wish to make the cut (Fig. 14).

2. Draw a parallel second line (2)

approximately 137

/64" (40 mm) plus ½ the diameter of the cutting bit back into the workpiece (away from the cutting line). NOTE: Be sure to ADD ½ the

diameter of the cutting bit to the 137

/64" (40 mm) measurement. If the cutting bit diameter is

1/8" (3.2 mm), the

distance between the lines should be 1

41/64" (41.7 mm).

3. Clamp the straight edge (3) onto the

larger portion of the workpiece that is to be clamped while cutting.

4. Place the flat side of the sole plate

against the straight edge with the bit near the start of the cutting line. NOTE: Check bit location to ensure

cut will be made in the correct location.

5. Turn the switch ON while firmly holding the tool.

6. Slide the sole plate against the straight edge while making the cut.

Fig. 13

Fig. 14

22

ASSEMBLY AND OPERATING CUTTING A CURVED LINE WITH A TEMPLATE

To cut a curved line, you can use a curved template to guide the rounded front of the sole plate. 1. Make a template from hardboard or

other similar material in the required shape (Fig. 15). NOTE: The radius of the curve must

be greater than 1 5/8” (41.3 mm) in order for the sole plate to properly follow the curved template.

2. Mark the location of the cut to be made.

3. Mark the workpiece approximately 2 7/16” (61.9 mm) back into the workpiece (away from the cutting line).

4. Clamp the template onto the larger portion of the workpiece that is to be clamped while cutting.

5. Place the curved portion of the sole plate against the template with the bit near the start of the cutting line. NOTE: Check bit location to ensure

cut will be made in the correct location.

6. Turn the switch ON while firmly holding the tool.

7. Slide the front curved portion of the sole plate against the template while making the cut. NOTE: Make sure the front curved

portion of the sole plate is in contact with the template at all times while cutting.

INSTALLING AND USING THE EDGE GUIDE

The edge guide is used for “ripping” or for cutting a narrow strip off a workpiece. 1. Loosen the two edge guide knobs (1)

on the front of the sole plate (2) (Fig. 16).

2. Insert the edge guide (3) through the two edge guide mounting slots (4). NOTE: The edge guide can be

inserted from either the left-hand or right-hand side of the sole plate.

3. Slide the edge guide into the sole plate until the distance between the outside of the cutting bit and the edge guide foot equals the amount to be cut off the workpiece.

4. Tighten the edge guide mounting screws in order to hold the edge guide in position.

Fig. 15

23

ASSEMBLY AND OPERATING INSTALLING AND USING THE EDGE GUIDE – cont’d

NOTES:

a) Do not over-tighten the edge guide mounting screws. b) Always make a test cut on a scrap workpiece to ensure the edge guide is set correctly. 5. Turn the switch ON, and begin cutting

in the normal manner, making sure the edge guide foot is making contact with the workpiece at all times (Fig. 17). NOTE: If the edge guide foot is

allowed to lose contact with the workpiece, the strip being cut off will not be a consistent width.

INSTALLING CIRCLE CUTTING GUIDE

The circle cutting guide is ideal for cutting precise circles. The circle cutting guide is completely assembled and ready to be installed on the serpentine saw. Remove the sole plate

1. Pull the sole plate locking lever (1) away from the sole plate (2) (Fig. 18).

2. Rotate the opened locking lever counter-clockwise until the sole plate becomes loose.

3. Continue turning the locking lever counter-clockwise until it is removed from the sole plate.

4. Remove the sole plate from the base of the serpentine saw.

Fig. 18

Fig. 17

Fig. 16

24

ASSEMBLY AND OPERATING Installing the circle cutting guide – cont’d

5. Place the circle cutting guide mounting bracket (6) onto the base of the serpentine saw (Fig. 19).

6. Insert the sole plate locking lever screw (4) through the curved insert (5) and the circle cutting guide mounting bracket (6) and into the matching threaded hole in the base of the saw. NOTE: Make sure the notch in the

mounting bracket engages the locating pin in the base of the saw.

7. Turn the locking lever (7) clockwise until it begins to tighten on the circle cutting guide mounting bracket, and then push the locking lever upward into the mounting bracket to fully lock it into position.

WARNING: Never use a router bit with the circle cutter attachment. The bit

could come loose and may cause serious injury.

WARNING: Never use metal cutting bits or ceramic cutting bits with the circle cutter attachment.

USING THE CIRCLE CUTTING GUIDE

WARNING: Unplug the tool from the power source before changing accessories, changing bits and making adjustments. Before turning the tool ON, check to make sure bit and all accessory fasteners are securely tightened.

1. Mark the centre of the circle you wish

to cut on the workpiece.

2. Adjust cutting bit depth to 1/8" (3.2 mm) longer than the thickness of the material being cut (Fig. 7).

3. Remove the protective cover from the pivot point (2).

4. Adjust the circle cutting guide radius by loosening the pivot point knob (1), sliding it to the correct circle radius, and re-tightening in the desired location (Fig. 20). NOTE: Check circle cutting guide

radius setting by measuring from the pivot point to the outside of the spiral bit for cutting holes and to the inside

of the bit for cutting discs.

5. Rest the edge of the freehand cutting guide and the rear of the sole plate on the workpiece. Press the circle cutting guide pivot point into the mark at the centre of the circle. NOTE: DO NOT let the bit touch the

workpiece before switch is turned ON and the tool is up to the set speed.

6. Turn the switch ON.

!

!

Fig. 19

7 5 4 6

!

25

ASSEMBLY AND OPERATING USING THE CIRCLE CUTTING GUIDE – cont’d

7. Once the motor is up to the set speed,

slowly tip the tool and circle cutting guide assembly to an upright position, allowing the bit to cut into the workpiece. Be careful to keep the pivot point located at the centre of the circle to be cut. 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 (Fig. 21). Continue to cut the circle, keeping the tool rotating around the circle cutting guide pivot point.

8. When the cut is complete, turn the tool OFF, wait until it comes to a complete stop, and remove it from the workpiece.

Fig. 20

Fig. 21

26

ASSEMBLY AND OPERATING INSTALLING FIXED SOLE PLATE

Removing the beveling sole plate

1. Pull the sole plate locking lever (1) away from the sole plate (2) (Fig. 22).

2. Rotate the opened locking lever counter-clockwise until the sole plate becomes loose.

3. Continue turning the locking lever counter-clockwise until it is removed from the sole plate.

4. Remove the sole plate from the base of the serpentine saw.

Installing the fixed sole plate

1. Insert the threaded locking lever bolt (1) through the hole in the rear of the curved base retaining block (2) (Fig. 23).

2. Insert the threaded locking lever bolt through the hole in the fixed base (3).

3. Thread the locking lever bolt into the

base of the tool by turning it clockwise. NOTES:

a) Make sure the notch (4) in the front of the fixed sole plate mounting point is placed over the matching indexing key (5) in the base of the tool. b) Do not fully tighten the locking lever screw.

4. When the fixed sole plate is properly nested in the base of the tool and the locking lever screw is nearly hand-tight, pull the locking lever (6) toward the rear of the fixed sole plate to lock the sole plate into position on the base of the tool. NOTE: Be sure to press the locking

lever fully into the fixed sole plate so it does not protrude below the base of the fixed sole plate (7).

Fig. 22

Fig. 23

27

ASSEMBLY AND OPERATING EDGING BOARDS USING SELF-GUIDED ROUTER BITS

DANGER: Never use the bevel cutting sole plate with router bits. See instructions on Page 26 for installing the fixed sole plate.

WARNING: Always use self-guided router bits with a bearing at the end. The diameter of the router bit must not exceed 1 3/8" (34.9 mm). Router bits

without the bearing are unstable, and will be extremely difficult to control if used in the serpentine saw. The use of piloted router bits with a 1/4” (6.4 mm) shank will provide a decorative edge to the workpiece. 1. Remove the existing collet and install

a 1/4" (6.4 mm) collet (Fig. 8).

2. Install the desired router bit (Fig. 7).

DANGER: Always make sure the 1/4" (6.4 mm) shank of the router bit is properly inserted into the collet; never allowing the top of the bit cutting edge to extend beyond the bottom of the sole plate.

3. Place the rear half of the sole plate (1)

on a scrap workpiece (2) (Fig. 24). NOTES:

a) Make sure the workpiece is securely clamped to a workbench or other secure location. b) Make sure the router bit does NOT contact the workpiece.

4. Turn the switch ON and adjust the motor speed according to the recommendations in the chart below.

!

! !

ROUTER BIT SPEED REFERENCE CHART

Material Router Bit Diameter Speed (RPM)

Hardwood

1/2" 15,000 to 25,000

1/2 to 1-1/8" 15,000 to 21,000

1-1/8 to 1-3/8" 15,000 to 16,000

Softwood

1/2" 15,000 to 25,000

1/2 to 1-1/8" 15,000 to 25,000

1-1/8 to 1-3/8" 15,000 to 16,000

Chipboard/ laminates

1/2" 15,000 to 25,000

1/2 to 1-1/8" 15,000 to 25,000

1-1/8 to 1-3/8" 15,000 to 16,000

Solid plastics

1/2" 15,000 to 25,000

1/2 to 1-1/8" 15,000 to 25,000

1-1/8 to 1-3/8" 15,000 to 16,000

NOTE: The above router bit speed reference chart is intended as a guide only.

Routing speeds must be adjusted according to wood hardness, density and moisture content. Making practice cuts on a scrap workpiece that is the same material as the good workpiece will assist you in selecting the speed that will produce the smoothest cut.

DANGER: Never operate a router ABOVE the maximum recommended speed. The blades could break off and cause serious personal injury.

!

28

ASSEMBLY AND OPERATING EDGING BOARDS USING GUIDED ROUTER BITS – cont’d

5. When the motor reaches its set

speed, slowly move the router bit into the workpiece until the router bit begins to cut and the bearing on the bottom of the router bit contacts the edge of the workpiece.

6. Slowly move the tool forward while maintaining contact between the router bit bearing and the workpiece. NOTES:

a) Always work with the rear portion of the sole plate on the workpiece, because this will provide greater stability and make the tool easier to control. b) For easier control and cleaner cuts, always move the tool so that the bit cuts against the direction of rotation (Fig. 24).

7. Turn the switch OFF, and allow the tool to come to a complete stop before removing it from the workpiece. NOTE: To protect the router bit,

always place the tool on its side when the bit is installed.

WARNING: Never touch the router bit immediately after it has been used. It will be extremely hot, and will cause severe burns.

8. Check the edge of the workpiece to

see if the bit is cutting in the correct location. To raise the cutting position, raise the bit by loosening the collet nut and sliding the shank of the bit further into the collet. NOTE: Be sure to retighten the collet

nut securely after any adjustments.

DANGER: Always make sure the 1/4" (6.4 mm) shank of the router bit is properly inserted into the collet; never allowing the top of the bit cutting edge to extend beyond the bottom of the sole plate.

9. Once you have verified that the router

bit is set correctly, proceed with edging the workpiece.

!

!

Fig. 24

29

MAINTENANCE WARNING: When servicing, use only

identical replacement parts. The use of any other part may create a hazard or cause product damage. DO NOT abuse power tools. Abusive practices can damage the tool and the workpiece.

WARNING: DO NOT attempt to modify tools or create accessories. Any such alteration or modification is misuse, and could result in a hazardous condition, leading to possible serious injury. It will also void the warranty. CLEANING

Keep air vents clean and unobstructed in order to allow maximum airflow through the serpentine saw. DO NOT use 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 a clean cloth dampened with a mild detergent to remove dirt, dust, oil, grease, etc.

WARNING: Do not allow brake fluids, gasoline, petroleum-based products, penetrating oils, etc. to come into contact with plastic parts. They contain chemicals that can damage, weaken or destroy plastic. LUBRICATION

All of the bearings in this serpentine saw are lubricated with a sufficient amount of high-grade lubricant for the life of the unit under normal conditions. Therefore, no further lubrication is required.

!

!

!

30

PARTS DIAGRAM – MODEL 54-8233-0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

38

39

40

41

42

43

44

46

47

48

49

52

53

54

55

56

57

60

61

62

63

64

65

66

67

68

69

70

71

58

59

50

51

72

73

74

75

76

77

78

84

83

82

81

80

79

45

37

31

PARTS LIST – MODEL 54-8233-0

WARNING: When servicing, use only Mastercraft® replacement parts. Use of any other parts may create a safety hazard or cause damage to the tool. Any attempt to repair or replace electrical parts on this power tool may create a safety hazard unless repair is performed by a qualified technician.

Always order by PART NUMBER, not by key number.

Key # Part # Part Name Quantity

1 315822 Vacuum adaptor 1

2 322006 Cord guard 1

3 315000 Cord clamp 1

4 321000 Buffer cap 2

5 315959 Bearing sleeve 1

6 520012 Roller bearing 2

7 162400 Carbon brush 2

8 222800 Brush holder 2

9 314500 Brush holder support 2

10 110119 Stator 1

11 100119 Rotor 1

12 513004 Woodruff key 2

13 314055 Fan 1

14 224506 Bearing hold down 1

15 520017 Roller bearing 1

16 312982 Speed increasing button 1

17 312983 Speed reducing button 1

18 312186 LCD cover 1

19 162884 Speed control PCB 1

20 500409 Tapping screw 3

20 500802 Screw 1

21 504003 Spring washer 14

22 503001 Flat washer 14

23 500010 Tapping screw 4

24 312958 Dust baffle 1

25 300122 Housing 1 pair

26 312957 Dust button 1

27 236050 Magnesium cover 1 set

28 163738 Switch 1

29 161911 LED light 2

30 224528 Fence 1

31 153506 LED switch button 1

32 163616 LED switch 1

33 235505 Gear box 1set

34 500810 Screw 6

35 312213 Lower sensing disk 1

36 312212 Upper sensing disk 1

37 511007 Snap ring 1

38 214917 Driven bevel gear 1

!

32

PARTS LIST – MODEL 54-8233-0

Key # Part # Part Name Quantity

39 520027 Roller bearing 1

40 213031 Main spindle 1

41 215075 Chuck nut 1

42 146529 Fence locking knob 2

43 241618 Spring 2

44 311725 Angle indicator plate 1

45 242585 Leaf spring 2

46 203080 Shoe-fixing block 1

47 237503 Shoe-fixing screw 1

48 318018 Bottom plate 1

49 500828 Countersink screw 6

50 215045 Pin 1

51 226500 Quick-adjustment lever for shoe 1

52 235012 Aluminum shoe 1

53 312188 Storage flap 2

54 215042 Square nut 1

55 514060 Pin 1

56 216509 1/4” Collet 1

57 138010 Magnetic block 1 pair

58 511006 Snap ring 2

59 214916 Driving bevel gear 1

60 500847 Screw 4

61 511011 "E" ring 1

62 500816 Screw 1

63 500862 Screw 2

64 146532 Spindle lock button 1

65 241599 Spring 1

66 500200 Tapping screw 9

67 500201 Tapping screw 2

68 311638 Spanner holder A 1

69 224529 Spanner 1

70 160205 Cord & plug 1

71 311639 Spanner holder B 1

72 312211 Handle cover 1

73 237504 Fixing screw 1

74 312550 Handle 1

75 503009 Flat washer 1

76 152546 Locating knob 1

77 235510 Circle-cutting support 1

78 311594 Fixing bolt 1

79 315846 Disk nut 1

80 224507 Gauge 1

81 203034 Square nut 1

82 322308 Protective sleeve 1

83 502008 Hex. lock nut 1

84 311734 Lining plate 1