Dongcheng DSM05-180 User manual

Edition 3 Oct., 2016
Read through carefully and understand these instructions
before use.

GENERAL POWER TOOL SAFETY WARNINGS
(For All Power Tools)
WARNING! Read and understand all instructions.
Failure to follow all instructions listed below may result in electric
shock, fire and/or serious personal injury.
Save all warnings and instructions for future reference.
The term “power tool”in the warnings refers to your mains-operated (corded)
power tool or battery-operated (cordless) power tool.
Work Area Safety
1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Power tools create sparks
which may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
Electrical Safety
4. Power tool plugs must match the outlet. Never modify the plug in
anyway. Do not use any adapter plugs with earthed (grounded) power
tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
5. Avoid body contact with earthed or grounded surfaces, such as pipes,
radiators, ranges and refrigerators. There is an increased risk o electric
shock if your body is earthed or grounded.
6. Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
7. Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords increase the risk of electric
shock.
8. 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.
9. If operating a power in a damp location is unavoidable, use a residual current
device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
NOTE: The term “residual current device (RCD)” may be replaced by the term
“ground fault circuit interrupter (GFCI)” or “earth leakage circuit breaker (ELCB)”.
Personal Safety
10.Stay alert, watch what you are doing and use common sense when operating
a power tool. Do not use a power tool while you are tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal injury.
11.Use personal protective equipment. Always wear eye protection. Protective
equipment such as dust mask, non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will reduce personal injuries.
12.Prevent unintentional starting. Ensure the switch is in the off-position before
connecting to power source and /or battery pack, picking up or carrying the
tool. Carrying power tools with your finger on the switch or energising power tools
that have the switch on invites accidents.
13.Remove any adjusting key or wrench before turning the tool on. A wrench or a
key left attached to a rotating part of the power tool may result in personal injury.
14.Do not overreach. Keep proper footing and balance at all times. This enables
better control of the power tool in unexpected situations.
15.Dress properly. Do not wear loose clothing or jewellery. Keep your hair,
clothing, and gloves away from moving parts. Loose clothes, jewellery or long
hair can be caught in moving parts.
16.If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of dust
collection can reduce dust-related hazards.
Power Tool Use and Care
17.Do not force the power tool. Use the correct power tool for your
-1- -2-

application. The correct power tool will do the job better and safer at the rate
for which it was designed.
18. Do not use tool if switch does not turn it on or off. Any power tool that
cannot be controlled with the switch is dangerous and must be repaired.
19. Disconnect the plug from the power source and/or the battery pack
from the power tool before making any adjustments, changing
accessories, or storing power tools. Such preventive safety measures
reduce the risk of starting the power tool accidentally.
20. Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate
the power tool. Power tools are dangerous in the hands of untrained users.
21. 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.
22. Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
23. Use the power tool, accessories and tool bits etc. in accordance with
these instructions, taking into account the working conditions and the
work to be performed. Use of the power tool for operations different from
those intended could result in a hazardous situation.
Service
24. Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power
tool is maintained.
VOLTAGE WARNING:
Before connecting the machine to a power source (receptacle, outlet, etc.), be
sure the voltage supplied is the same as that specified on the nameplate of the
machine. A power source with voltage greater than that specified for the machine
can result in SERIOUS INJURY to the user, as well as damage to the machine. If
in doubt, DO NOT PLUG IN THE MACHINE. Using a power source with voltage
less than nameplate rating is harmful to the motor.
SPECIFICATIONS
Model
S1M-FF05-180
S1M-FF05-230
Rated Power Input
2800W
2800W
Rated Speed
8300 r/min
6600 r/min
Wheel Size
φ180X6Xφ22
φ230X6Xφ22
Type of Wheel
Type 27
Type 27
Net Weight
5.0 Kg
5.0 Kg
※Due to the continuing program of research and development, the specifications
herein are subject to change without prior notice.
Safety instructions for all operations
General Safety Warnings for Grinding
a) This power tool is intended to function as a grinder. Read all safety warnings,
instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire
and/or serious injury.
b) Operations such as sanding, wire brushing, polishing and cutting-off are not
recommended to be performed with this power tool. Operations for which the
power tool was not designed may create a hazard and cause personal injury.
c) Do not use accessories which are not specifically designed and
recommended by the tool manufacturer. Just because the accessory can be
attached to your power tool, it does not assure safe operation.
d) The rated speed of the accessory must be at least equal to the maximum
speed marked on the power tool. Accessories running faster than their rated
speed can break and fly apart.
e) The outside diameter and the thickness of your accessory must be within the
-3- -4-

capacity rating of your power tool. Incorrectly sized accessories cannot be
adequately guarded or controlled.
f) Threaded mounting of accessories must match the grinder spindle thread. For
accessories mounted by flanges, the arbour hole of the accessory must fit the
locating diameter of the flange. Accessories that do not match the mounting
hardware of the power tool will run out of balance, vibrate excessively and may
cause loss of control.
g) Do not use a damaged accessory. Before each use, inspect the accessory
such as abrasive wheels for chips and cracks, backing pad for cracks, tear or
excess wear, wire brush for loose or cracked wires. If power tool or accessory
is dropped, inspect for damage or install an undamaged accessory. After
inspecting and installing an accessory, position yourself and bystanders away
from the plane of the rotating accessory and run the power tool at maximum
no-load speed for one minute. Damaged accessories will normally break apart
during this test time.
h) Wear personal protective equipment. Depending on application, use a face
shield, safety goggles or safety glasses. As appropriate, wear dust mask,
hearing protectors, gloves and workshop apron capable of stopping small
abrasive or work piece fragments. The eye protection must be capable of
stopping flying debris generated by various operations. The dust mask or
respirator must be capable of filtrating particles generated by your operation.
Prolonged exposure to high intensity noise may cause hearing loss.
i) Keep bystanders a safe distance away from work area. Anyone entering the
work area must wear personal protective equipment. Fragments of workpiece
or of a broken accessory may fly away and cause injury beyond immediate
area of operation.
j) Hold the power tool by insulated gripping surfaces only, when performing an
operation where the cutting accessory may contact hidden wiring or its own
cord. Cutting accessory contacting a "live" wire may make exposed metal parts
of the power tool "live" and could give the operator an electric shock.
k) Position the cord clear of the spinning accessory. If you lose control, the cord
may be cut or snagged and your hand or arm may be pulled into the spinning
accessory.
l) Never lay the power tool down until the accessory has come to a complete
stop. The spinning accessory may grab the surface and pull the power tool out
of your control.
m) Do not run the power tool while carrying it at your side. Accidental contact
with the spinning accessory could snag your clothing, pulling the accessory
into your body.
n) Regularly clean the power tool’s air vents. The motor’s fan will draw the dust
inside the housing and excessive accumulation of powdered metal may
cause electrical hazards.
o) Do not operate the power tool near flammable materials. Sparks could ignite
these materials.
p) Do not use accessories that require liquid coolants. Using water or other
liquid coolants may result in electrocution or shock.
Further safety instructions for all operations
Kickback and Related Warnings
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing
pad, brush or any other accessory. Pinching or snagging causes rapid stalling of
the rotating accessory which in turn causes the uncontrolled power tool to be
forced in the direction opposite of the accessory’s rotation at the point of the
binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the
edge of the wheel that is entering into the pinch point can dig into the surface of
the material causing the wheel to climb out or kick out. The wheel may either jump
toward or away from the operator, depending on direction of the wheel’s
movement at the point of pinching. Abrasive wheels may also break under these
conditions.
Kickback is the result of power tool misuse and/or incorrect operating procedures
or conditions and can be avoided by taking proper precautions as given below.
a) Maintain a firm grip on the power tool and position your body and arm to allow
you to resist kickback forces. Always use auxiliary handle, if provided, for
-5- -6-

maximum control over kickback or torque reaction during start-up. The
operator can control torque reactions or kickback forces, if proper
precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may kickback
over your hand.
c) Do not position your body in the area where power tool will move if kickback
occurs. Kickback will propel the tool in direction opposite to the wheel’s
movement at the point of snagging.
d) Use special care when working corners, sharp edges etc. Avoid bouncing
and snagging the accessory. Corners, sharp edges or bouncing have a
tendency to snag the rotating accessory and cause loss of control or
kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such
blades create frequent kickback and loss of control.
Additional Safety Warnings for Grinding Operation
a) Use only wheel types that are recommended for your power tool and the
specific guard designed for the selected wheel. Wheels for which the power
tool was not designed cannot be adequately guarded and are unsafe.
b) The grinding surface of centre depressed wheels must be mounted below the
plane of the guard lip. An improperly mounted wheel that projects through the
plane of the guard lip cannot be adequately protected.
c) The guard must be securely attached to the power tool and positioned for
maximum safety, so the least amount of wheel is exposed towards the
operator. The guard helps to protect operator from broken wheel fragments
and accidental contact with wheel and sparks that could ignite clothing.
d) Wheels must be used only for recommended applications. For example: do
not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended
for peripheral grinding, side forces applied to these wheels may cause them
to shatter.
e) Always use undamaged wheel flanges that are of correct size and shape for
your selected wheel. Proper wheel flanges support the wheel thus reducing
the possibility of wheel breakage. Flanges for cut-off wheels may be different
from grinding wheel flanges.
f) Do not use worn down wheels from larger power tools. Wheel intended for larger
power tool is not suitable for the higher speed of a smaller tool and may burst.
SAVE THESE INSTRUCTIONS.
WARNING!
MISUSE or failure to follow the safety rules stated in this instruction manual
may cause serious personal injury.
INSTRUCTIONS FOR OPERATION
Installing or Adjusting Wheel Guard
CAUTION:
Always be sure that the tool is switched OFF and unplugged before installing or
removing the wheel guard.
Wheel guard is a device to protect operator
from injuries if the wheel breaks during
operation. Before operation, make sure the
wheel guard is tightly installed. By slightly
loosening the setting screw, the wheel
guard can be turned and set at any desired
angle for maximum operational
effectiveness. Ensure that the setting
screw is thoroughly tightened after adjusting the wheel guard. (Fig. 1)
-7- -8-

Installing or Removing the Wheel
CAUTION:
Always be sure that the tool is
switched OFF and unplugged before
installing or removing the wheel.
Screw the inner flange onto the spindle.
Press the spindle lock firmly so that
the spindle cannot revolve, then use
the lock nut wrench to secure the inner
flange. Fit the wheel on over the inner
flange and screw the outer flange onto
the spindle. (Fig.2)
Auxiliary Handle
CAUTION:
Always be sure that the auxiliary
handle is installed securely before
operation.
Use auxiliary handle offered during
operation. Screw the auxiliary handle
securely into the hole on the side of
gear housing or on the top of it. (Fig.
3)
Spindle Lock
CAUTION:
Never actuate the spindle when the
spindle is moving. The tool may be
damaged.
Press the spindle lock to prevent spindle rotation when installing or removing
accessories (e.g. depressed center wheel). (Fig. 4)
Switch Operation
CAUTION:
Before plugging in the tool, always check to see that the switch trigger actuates
properly.
To start the tool, simply pull the switch
trigger. Release the switch trigger to stop.
For continuous operation, pull the switch
trigger and then push in the lock button. To
stop the tool from the locked position, pull
the switch trigger fully, and then release it.
(Fig. 5)
Operation
CAUTION:
Do not force too much on the tool, or it may damage the wheel and cause
personal injuries.
Stop use the tool when the diameter of
the wheel is worn to 150mm for
S1M-FF05-180, 180mm for
S1M-FF05-230. Exchange with a new
one, or it may cause danger.
In general, keep the edge of the wheel at an
angle of about 15-30 degrees to the
workpiece surface. (Fig. 6)
During the break-in period with a new wheel,
-9- -10-

do not work the grinder in the A direction or it will cut into the workpiece. Once the
edge of the wheel has been rounded off by use, the wheel may be worked in both
A and B direction.
MAINTENANCE AND INSPECTION
CAUTION:
Always be sure that the tool is switched off and unplugged before attempting to
perform inspection or maintenance.
1. Cleaning Air Vents
The tool and its air vents have to be
kept clean. Regularly clean the tool’s
air vents or whenever the vents start
to become obstructed. (Fig. 7)
2. Inspecting and Replacing
Carbon Brushes
Remove and check the carbon
brushes regularly. Replace when
they wear down to the limit mark.
(Fig. 8)
Keep the carbon brushes clean and
free to slip in the holders. Both
carbon brushes should be replaced
at the same time. Use only identical
carbon brushes.
Use a screwdriver to remove the
motor housing covers. Take out the
worn carbon brushes, insert the new ones and secure the brush holder caps.
(Fig. 9)
※Damaged cord must be replaced by a special cord purchased from authorized
service center.
※To maintain product SAFETY and RELIABILITY, repairs, any other maintenance or
adjustment should be performed by authorized centers, always using original
replacement parts.
-11- -12-

EXPLAINATION OF GENERAL VIEW
1
Outer Flange
30
Pan Head Screw (with Spring
Washer)
2
Inner Flange
31
Armature
3
Wheel Guard
32
Insulation Washer
4
Slotted Cheese Head Screw
33
Deep Groove Ball Bearing
5
Key
34
Bearing Cover
6
Drive Spindle
35
Baffle Plate
7
Dust Cap
36
Pan Head Tapping Screw
8
Hex Socket Head Screw
37
Stator
9
Gear Housing Cover
38
Nameplate
10
Felt
40
Motor Housing
11
Felt Washer
41
Right-half Brush Holder Cap
12
Deep Groove Ball Bearing
42
Carbon Brush Holder
13
Bearing Retainer
43
Pan Head Tapping Screw
14
Pan Head Screw (with Spring
Washer)
44
Carbon Brush
15
Driven Spiral Bevel Gear
45
Left-half Brush Holder Cap
16
Deep Groove Ball Bearing
46
Pan Head Tapping Screw
17
Auxiliary Handle
47
Pan Head Tapping Screw
18
Pan Head Tapping Screw
48
Right-half Handle
19
Lock Pin
49
Switch
20
Auto-lock Spring
50
Left-half Handle
21
Lock Nut
51
Cord
22
Gear Housing
52
Cord Guard
23
Hex. Nut
53
Pan Head Tapping Screw
24
Driving Spiral Bevel Gear
860
Wrench
25
Washer
26
Deep Groove Ball Bearing
27
Washer
28
Felt
29
Guide Plate
-13- -14-