Dongcheng DJX03-255 User manual

Edition 2 Feb., 2017
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
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17.Do not force the power tool. Use the correct power tool for your
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
Rated Power Input
1650 W
No-Load Speed
6000 r/min
Blade Diameter
Ø255mm
Hole Diameter of Blade
Ø25.4 mm
Max. Cutting
Capacity
(H×W)
Miter Angle
Bevel Angle
0°
45°
(Left and Right)
0°
60mm×130mm
60mm×93mm
45° (Left)
45mm×130mm
45mm×93mm
Net Weight
12.0 Kg
※Due to the continuing program of research and development, the specifications
herein are subject to change without prior notice.
ADDITIONAL SAFETY RULES
1. Always wear eye protection to avoid injuries to eyes cased by the flying out
sawdust.
2. Do not operate this tool without guards in place. Check blade guard for proper
closing before each use. Do not operate miter saw if blade guard does not move
freely and close instantly. Never clamp or tie the blade guard at the open position.
3. Do not use the tool in the presence of flammable liquids or gases.
4. Check the blade carefully for cracks or damage before operation. Replace cracked
or damaged blade immediately. Gum and wood pitch hardened on blades slows
saw and increases potential for kickback. Keep blade clean by first removing it
from tool, and then cleaning it with gum and pitch remover, hot water or kerosene.
Never use gasoline to clean blade.
5. Use only flanges specified for this tool.
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6. Be careful not to damage the spindle, flanges (especially the installing
surface) or bolt. Damage to these parts could result in blade breakage.
7. Make sure that the turn base is properly secured so it will not move during
operation. Use the holes in the base to fasten the tool to a stable work
platform or bench. NEVER use tool where operator positioning would be
awkward.
8. Remove the chips, small pieces, etc. from the table top before operation for
your safety. Meanwhile, the chips, small pieces, etc. may cause damages to
the surface of the workpiece.
9. Do not perform any operation freehand. The workpiece must be secured
firmly against the turn base and guide fence with a vise during all operations.
Never use your hand to secure the workpiece.
10. Avoid cutting nails. Inspect for and remove all nails from the workpiece before
operation.
11. Make sure the shaft lock is released before the switch is turned on.
12. Be sure that the blade does not contact the turn base in the lowest position.
13. Make sure the blade is not contacting the workpiece before the switch is
turned on.
14. Before using the tool on an actual workpiece, let it run for a while. Watch for
vibration or wobbling that could indicate poor installation or a poorly balanced
blade.
15. Wait until the blade attains full speed before cutting.
16. Hold the handle firmly during operation. Be aware that the saw moves up or
down slightly during start-up and stopping.
17. Stop operation immediately if anything abnormal be noted.
18. Do not attempt to lock the switch trigger in the ON position.
19. Be alert at all times, especially during repetitive, monotonous operations. Do
not be lulled into a false sense of security. Blades are extremely unforgiving.
20. Turn off tool and wait for saw blade to stop before moving workpiece or
changing settings.
21. Unplug tool before changing blade or servicing.
22. Keep hands out of path of saw blade. Avoid contact with any coasting blade. It can
still cause severe injury.
23. Always secure all moving portions before carrying the tool.
24. Do not abuse cord. Never yank cord to disconnect it from the receptacle. Keep
cord away from heat, oil, water and sharp objects.
25. Always attach the dust bag to the tool in operation.
26. NEVER stack workpieces on the table top to speed cutting operations. Cut only
one piece at a time.
27. Do not use this tool to cut materials excluding aluminum, wood or other similar
materials.
28. Some material contains chemicals which may be toxic. Take caution to prevent
dust inhalation and skin contact. Follow material supplier safety data.
SAVE THESE INSTRUCTIONS.
WARNING!
MISUSE or failure to follow the safety rules stated in this
instruction manual may cause serious personal injury.
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INSTRUCTIONS FOR OPERATION
Carrying Tool
CAUTION:
Make sure that the tool is unplugged.
Stopper pin is for carrying and storage purposes only and not for any cutting
operations.
Lower the handle fully and lock it in
the lowered position by pushing in the
stopper pin. Secure the turn base by
tightening the grip clockwise, then the
tool can be carried by carrying grip as
shown in Fig. 1.
Bench Mounting
The tool should be bolted with four
bolts to a level and stable surface
using the bolt holes provided in the
tool’s base. This will help prevent
tipping and possible injury. (Fig. 2)
Installing or Removing Saw Blade
CAUTION:
Always be sure that the tool is switched off and unplugged before installing or
removing the blade.
Use only the provided socket wrench to install or remove the blade. Failure to do so
may result in overtightening or insufficient tightening of the hex bolt. This could cause
an injury.
After installing a new blade, always be sure that the blade does not contact any part
of the lower base when the handle is lowered completely. Always do this with the tool
unplugged.
To remove the saw blade, turn lower
safety guard to exceed the position of the
screw firstly and loosen the screw holding
the lower safety guard. (Fig. 3)
Free the handle from the lowered position,
raise the blade guard and center cover.
Press the shaft lock to prevent the spindle
from revolving and use the socket wrench
to loosen the hex bolt. Then remove the
hex bolt, outer flange and the blade. (Fig.
4)
To install the saw blade, mount it carefully
onto the spindle, making sure that the
direction of the arrow on the surface of the
blade matches the direction of the arrow
on the blade case. Install the outer flange
and hex bolt, and then use the socket
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wrench to tighten the hex bolt securely counterclockwise while pressing the shaft
lock. (Fig. 5)
To remove the saw blade, raise the
blade guard and fixed plate, and use
the socket wrench to loosen the hex
bolt, and then remove the hex bolt,
outer flange and the blade. (Fig. 6)
Blade Guard
CAUTION:
Never use the tool in case the blade guard or spring be damaged, faulty or
removed.
Do not use solvents or any petroleum-based cleaners on the plastic guard.
The blade guard will rise automatically when lowering the handle, and will return
to its original position when the cut is
completed and the handle is raised as
it is spring loaded. (Fig. 7)
For your personal safety, always
maintain the blade guard in good
condition. Any irregular operation of
the blade guard should be corrected
immediately.
When the blade guard becomes dirty,
or sawdust adheres to it in such a way that the blade is no longer easily visible,
unplug the saw and clean the guard carefully with a damp cloth.
Dust Bag
The use of the dust bag makes cutting
operations clean and dust collection easy.
To attach the dust bag, fit it onto the dust
nozzle. (Fig. 8)
Switch Action
CAUTION:
Before plugging in the tool, always
check to see that the switch trigger
actuates properly and returns to the
“OFF”position when released.
This tool is equipped with a lock-off button
to prevent the tool from unintended
starting. To start the tool, firstly push the
shifter to the left, press in the lock-off
button and pull the switch trigger. Release
the switch trigger to stop. (Fig. 9)
Maintaining Maximum Cutting Capacity
CAUTION:
Always be sure that the tool is switched off and unplugged before making any
adjustment on the tool.
This tool is factory adjusted to provide the maximum cutting capacity for a 255 mm saw
blade. When the saw blade has worn down, turn the adjusting bolt by the socket
wrench to maintain a maximum cutting capacity. Turn the adjusting bolt clockwise to
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raise the blade and counterclockwise
to lower it. (Fig. 10)
Refer to the following procedures for
the adjustment:
Unplug the tool and lower the handle
completely, use the socket wrench to
turn the adjusting bolt until the
distance between the front face of the
guide fence and the front point where
the blade crossing with the top
surface of the turn base meets 130
mm (5-1/9”). (Fig. 11)
With the tool unplugged, rotate the
blade by hand while holding the
handle all the way down to be sure
that the blade does not contact any
part of the lower base. Re-adjust
slightly, if necessary.
Adjusting the Miter Angle
CAUTION:
Be sure to raise the handle fully
while turning the turn base.
Loosen the grip by turning it
counterclockwise. Turn the turn base
while pressing down the lock lever.
When the grip has been moved to the
position where the pointer points to the desired angle on the miter scale, securely
tighten the grip clockwise. (Fig. 12)
Adjusting the Bevel Angle
CAUTION:
Be sure to raise the handle fully while tilting the saw blade.
The saw blade can be tilted at 45° to the left only when the sub-fence locates at the
left position (refer to the instructions of “Sub-fence”).
After changing the bevel angle, always secure the arm by tightening the lever
clockwise.
To adjust the bevel angle, loosen the lever
at the rear of the tool counterclockwise. (Fig.
13)
Push the handle to the left to tilt the saw
blade until the pointer points to the desired
angle on the bevel scale. Then tighten the
lever clockwise firmly to secure the arm.
(Fig. 14)
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Securing Workpiece
CAUTION:
Always be sure to secure the workpiece properly and tightly with the vise.
Failure to do so can cause the tool to be damaged and/or the workpiece to be
destroyed. PERSONAL INJURY MAY ALSO RESULT.
DO NOT raise the blade until the blade has come to a complete stop after each
cutting operation.
Shifting Dam
This tool is equipped with the shifting
dam. It should be positioned as shown
in Fig. 15.
Be sure to flip the dam over to the left
position when performing left bevel
cuts. (Fig. 16)
Vertical Vise
CAUTION:
Always secure the workpiece firmly against the turn base and guide fence with
the vise during all operations.
When cutting long workpieces, use supports that are as high as the top surface
level of the turn base. Do not rely solely on the vertical vise to secure the
workpiece. (Fig. 17)
Thin material tends to sag. Support
workpiece over its entire length to avoid
blade pinch and possible KICKBACK.
The vertical vise can be installed in two
positions on either the left or right side of
the guide fence or the holder assembly
(optional accessory). Insert the vise rod
into the hole in the guide fence or the
holder assembly and tighten the screw to secure the vise rod.
Position the vise arm according to the thickness and shape of the workpiece and
secure the vise arm by tightening the screw. If the screw to secure the vise arm
contacts the guide fence, install the screw on the opposite side of vise arm. Make sure
that no part of the tool contacts the vise
when lowering the handle all the way. If
some part contacts the vise, re-position the
vise.
Press the workpiece flat against the guide
fence and the turn base. Position the
workpiece at the desired cutting position
and secure it firmly by tightening the vise
knob. (Fig. 18)
Holder Assembly
CAUTION:
Always support long workpieces level
with the top surface of the turn base for
accurate cuts and to prevent dangerous
loss of control of the tool.
Use the holder assembly when cutting long
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workpieces. Insert the rods of the holder assembly into the holes in the base and
tighten the screws to secure the holder assembly. (Fig. 19)
Cutting Operation
CAUTION:
Be sure to release the handle from the lowered position by pulling the stopper
pin before use.
Make sure the blade is not contacting the workpiece, etc. before turning on the
switch.
Do not apply excessive pressure on the handle when cutting. Too much force
may result in overload of the motor and/or decreased cutting efficiency.
Gently press down the handle to perform the cut. If the handle is pressed down
with force or if lateral force is applied, the blade will vibrate and leave a mark
(saw mark) in the workpiece and the precision of the cut will be impaired.
Press Cutting
CAUTION:
Part of the workpiece, the
thickness of which equal to the
thickness of the blade, will be cut off
when making cutting operations with
this tool. So position the cutting line
on the left or right side of the kerf
groove for precise cutting. (Fig. 20)
Secure the workpiece with the vise.
Switch on the tool without the blade
making any contact and wait until the blade attains full speed before lowering.
Then lower the handle slowly. When the blade contacts the workpiece, gently
lower the handle to begin the cutting operation.
When the cut is completed, switch off the tool and wait until the blade has come to a
complete stop before returning the blade to its fully elevated position.
Miter Cutting
Refer to the instructions of “Adjusting the Miter Angle”.
Bevel Cutting
CAUTION:
Always set the sub-fence to the left position when performing left bevel cuts.
Always be sure that the blade will move down to bevel direction during a bevel cut.
Keep hands out of path of saw blade.
During a bevel cut, it may create a condition whereby the piece cut off will come to
rest against the side of the blade. If the blade is raised while the blade is still rotating,
this piece may be caught by the blade, causing fragments to be scattered which is
dangerous. The blade should be raised only after the blade has come to a complete
stop.
Apply pressure parallel to the blade when pressing the handle down. If the pressure is
not parallel to the blade during a cut, the angle of the blade might be shifted and the
precision of the cut will be impaired.
Refer to the instructions of “Adjusting the
Bevel Angle”to set the bevel angle.
Secure the workpiece with the vise. Switch
on the tool without the blade making any
contact and wait until the blade attains full
speed before lowering. Then lower the
handle slowly. When the blade contacts the
workpiece, gently lower the handle to begin
the cutting operation. (Fig. 21)
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Compound Cutting
Compound cutting is the process in which a bevel angle is made at the same time
in which a miter angle is being cut on a workpiece. Compound cutting can be
performed at angle shown in the following table.
Bevel Angle
Miter Angle
45°
Left and Right 0-45°
When performing compound cutting, refer to the instructions of “Miter Cutting”
and “Bevel Cutting”.
Cutting Aluminum Extrusion
CAUTION:
Never attempt to cut thick or round aluminum extrusions. Thick aluminum
extrusions may come loose during operation and round aluminum extrusions
cannot be secured firmly with this tool.
Use a cutting lubricant when cutting
the aluminum extrusion to prevent
build-up of the aluminum material on
the blade.
Use spacer blocks or pieces of scrap
to prevent deformation of the
aluminum when securing aluminum
extrusions. (Fig. 22)
MAINTENANCE AND INSPECTION
CAUTION:
Always be sure that the tool is switched off and unplugged before attempting to
perform inspection or maintenance.
Always keep the blade sharp and clean for the best and safest performance.
Adjust the Cutting Angle
This tool is carefully adjusted and aligned before leaving the factory, but rough
handling may have affected the alignment. If the tool is not aligned properly, perform
the following to readjust:
Miter Angle
Loosen the grip which secures the turn
base. Turn the turn base so that the pointer
points to the 0° on the miter scale. Tighten
the grip and loosen the hex bolts securing
the guide fence with the socket wrench.
(Fig. 23)
Lower the handle fully and lock it in the
lowered position by pushing in the stopper
pin. Square the side of the blade with the
face of the guide fence using a triangular
rule, try square, etc. Then securely tighten
the hex bolts on the guide fence in the
order from the right side. (Fig. 24)
Bevel Angle
a) 0° Bevel Angle
Lower the handle fully and lock it in the
lowered position by pushing in the
stopper pin. Loosen the lever at the
rear of the tool.
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Loosen the hex nut and turn the adjusting bolt (A) on the right side of the turn
base 2-3 turns clockwise to tilt the blade to the right. (Fig. 25)
Carefully square the side of the
blade with the top surface of the
turn base using the triangular rule,
try square, etc. by turning the
adjusting bolt (A)
counterclockwise. Then tighten
the hex nut to secure the adjusting
bolt (A) and tighten the lever
securely. (Fig. 26)
Make sure that the pointer on the turn base point to 0° on the bevel scale on
the arm. If it does not point to 0°, loosen the screw which secures the pointer
and adjust the pointer so that it will point to 0°.
b) 45° Bevel Angle
Adjust the 45° bevel angle only after performing 0° bevel angle adjustment.
To adjust left 45° bevel angle, loosen
the lever and tilt the blade to the left
fully. Make sure that the pointer on the
arm points to 45° on the bevel scale
on the arm. If the pointer does not
point to 45° turn the adjusting bolt (B)
on the left side of the arm until the
pointer points to 45°. (Fig. 27)
After Use
After use, wipe off chips and dust adhering to the tool with a cloth or the like. Keep the
blade guard clean according to the directions in the previously covered section titled
“Blade Guard”.
Lubricate the sliding portions with machine oil to prevent rust.
Inspecting and Replacing Carbon Brushes
Remove and check the carbon brushes
regularly. Replace when they wear down
to the limit mark (Fig. 28).
Keep the carbon brushes clean and free to
slip in the holders. Both carbon brushes
should be replaced at the same time and
use only identical carbon brushes.
Use a screwdriver to remove the brush
holder caps. Take out the worn carbon
brushes, insert new ones and secure the
brush holder caps. (Fig. 29)
※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.
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-21- -22-

EXPLANATION OF GENERAL VIEW
1
Pan Head Screw (with Spring and
Flat Washers)
32
Flat Washer
2
Wrench
33
Spring Washer
3
Locking Screw
34
Hex. Socket Head Screw
4
FlatWasher
35
Dust Exit
5
Wire
36
Arresting Pin
6
Pan Head Tapping Screw
37
O Ring
7
Guide Rule
38
Pan Head Screw (with Spring
Washers)
8
Wing Bolt
39
Connecting Bracket
9
Fixed Dam
40
Compression Spring
10
Shifting Dam
41
Spindle Sleeve
11
Dam Label
42
Lock Pin
12
Cross Recessed Countersunk
Head Screw
43
Stator Assembly
13
Kerf Board
44
Ball Bearing
14
Connecting Rod Bracket
45
Pan Head Tapping Screw
15
Base
46
Armature Assembly
16
Cup Head Rivet
47
Ball Bearing
17
Hex. Bolt
48
Colloidal Particle
18
Guide Rule
49
Nameplate
19
Label 1
50
Pan Head Screw (with Flat and
Spring Washers)
20
Grip
51
Motor Housing
21
Pan Head Screw (with Flat and
Spring Washers)
52
Carbon Brush
22
Knock Spring
53
Brush Holder
23
Label 6
54
Brush Holder Cap
24
Shim
55
Screw
25
Turntable
56
Connecting Rod
26
Pointer
57
Latch Segment
27
Pan Head Screw (with Spring
Washers)
58
Sleeve
28
Flat Washer
59
Cross Recessed Countersunk
Head Screw
29
Hex Nut
60
Safety Guard
30
Nut
61
Lower Safety Guard
EXPLANATION OF GENERAL VIEW
62
Screw
92
Compression Spring
63
Torsion Spring
93
Locking Pin
64
Rubber Sleeve
94
Bracket
65
Pan Head Screw (with Flat and
Spring Washers)
95
Cover
66
Pan Head Screw with Flat
Point
96
Pan Head Screw
67
Fixed plate
97
Hex Lock Nut
68
Lock Screw
98
Handle Base
69
Flange
99
Strain Relief
70
Sub Plate
100
Warning Label
71
Hex Socket Head Screw
101
Cord Guard
72
Label 5
102
Cord
73
Upper Safety Guard
103
Pan Head Tapping Screw
74
Strain Relief
104
Pan Head Tapping Screw
75
Pan Head Screw
105
Handle Cover
76
Hex Socket Head Screw
106
Trigger Switch
77
Hex Socket Head Screw
107
Pan Head Tapping Screw
78
Drive Spindle
108
Pan Head Screw
79
Circlip for Hole
861
Vertical Vise (Incl. Vise Plate,
Vise Screw, Vise Arm, Vise
Knob, Wing Bolt, Vise Rod)
80
Ball Bearing
862
Dust Bag
81
Locking Piece
863
Socket Wrench
82
Ball Bearing
864
Triangle Ruler
83
Driven Wheel
84
Flat Key
85
Washer
86
Pan Head Screw (with Spring
Washers)
87
Pan Head Screw
88
Belt Cover
89
Belt
90
Pan Head Screw (with Spring
Washers)
91
Split Washer
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