Dongcheng DMY02-235 User manual

Edition 1 April, 2015
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
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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
2000W
No-Load Speed
4100 r/min
Max. Cutting Depth
90°
85mm
45°
60mm
Max. Cutting Angle
50°
Max. Dia. Of Blade
235 mm
Net Weight
6.5 kg
※Due to the continuing program of research and development, the specifications
herein are subject to change without prior notice.
ADDITIONAL SAFETY RULES
DANGER:
1. Keep hands away from cutting area and blade. Keep your second hand on auxiliary
handle, or motor housing. If both hands are holding the saw, they cannot be cut by
the blade.
2. Keep your body positioned to either side of the saw blade, but not in line with the
saw blade. KICKBACK could cause the saw to jump backwards.
3. Do not reach underneath the work. The guard can not protect you from the blade
below the work. Do not attempt to remove cut material when blade is moving.
CAUTION: Blades coast after turn off. Wait until blade stops before grasping cut
material.
4. Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of
the blade teeth should be visible below the workpiece.
5. NEVER hold piece being cut in your hands or across your leg. It is important to
support the work properly to minimize body exposure, blade binding, or loss of
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control.
6. Hold tool by insulated gripping surfaces when performing an operation where
the cutting tool may contact hidden wiring or its own cord. Contact with a “live”
wire will also make exposed metal parts of the tool “live”and shock the
operator.
7. Check lower guard for proper closing before each use. Do not operate saw if
lower guard does not move freely and close instantly. Never clamp or tie the
lower guard into the open position. If saw is accidentally dropped, lower guard
may be bent. Raise the lower guard with the Retracting Lever and make sure it
moves freely and does not touch the blade or any other part, in all angles and
depths of cut.
To check lower guard, open lower guard by hand, then release and watch
guard closure. Also check to see that Retracting Lever does not touch tool
housing. Leaving blade exposed is VERY DANGEROUS and can lead to
serious personal injury.
8. Check the operation and condition of the lower guard spring. If the guard and
the spring are not operating properly, they must be serviced before use. Lower
guard may operate sluggishly due to damaged parts, gummy deposits, or a
buildup of debris.
9. Lower guard should be retracted manually only for special cuts such as
“Plunge Cuts”and “Compound Cuts”. Raise lower guard by Retracting Lever.
As soon as blade enters the material, lower guard must be released. For all
other sawing, the lower guard should operate automatically.
10.Always observe that the lower guard is covering the blade before placing saw
down on bench or floor. An unprotected, coasting blade will cause the saw to
walk backwards, cutting whatever is in its path. Be aware of the time it takes
for the blade to stop after switch is released.
11.When ripping always use a rip fence or straight edge guide. This improves the
accuracy of cut and reduces the chance for blade binding.
12.Always use blades with correct size and shape (diamond versus round) arbor
holes. Blades that do not match the mounting hardware of the saw will run
eccentrically, causing loss of control.
13.Never use saw blades made of high-speed steel.
14.Never use damaged or incorrect blade washers or bolts. The blade washers and
bolt were specially designed for your saw, for optimum performance and safety of
operation.
15.Causes and Operator Prevention of Kickback:
—Kickback is a sudden reaction to a pinched, bound or misaligned saw blade,
causing an uncontrolled saw to lift up and out of the workpiece toward the
operator;
—When the blade is pinched or bound tightly by the kerf closing down, the blade
stalls and the motor reaction drives the unit rapidly back toward the operator;
—If the blade becomes twisted or misaligned in the cut, the teeth at the back edge
of the blade can dig into the top surface of the wood causing the blade to climb
out of the kerf and jump back toward operator.
Kickback is the result of tool misuse and/or incorrect operating procedures or
conditions and can be avoided by taking proper precautions as given below:
Maintain a firm grip with both hands on the saw and position your body and arm
to allow you to resist KICKBACK forces. KICKBACK forces can be controlled by
the operator, if proper precautions are taken.
When blade is binding, or when interrupting a cut for any reason, release the
trigger and hold the saw motionless in the material until the blade comes to a
complete stop. Never attempt to remove the saw from the work or pull the saw
backward while the blade is in motion or KICKBACK may occur. Investigate and
take corrective actions to eliminate the cause of blade binding.
When restarting a saw in the workpiece, center the saw blade in the kerf and
check that saw teeth are not engaged into the material. If saw blade is binding, it
may walk up or KICKBACK from the workpiece as the saw is restarted.
Support large panels to minimize the risk of
blade pinching and KICKBACK. Large
panels tend to sag under their own weight.
Supports must be placed under the panel
on both sides, near the line of cut and near
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the edge of the panel. (Fig. 1)
To minimize the risk of blade pinching
and kickback, when cutting operation
requires the resting of the saw on the
workpiece, the saw should be rested
on the larger portion and the smaller
piece cut off. (Fig. 1&2)
Do not use dull, deformed, cracked or
damaged blade. Unsharpened or improperly set blades produce narrow
kerf causing excessive friction, blade binding and KICKBACK. Keep blade
sharp and clean. 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.
Blade depth and bevel adjusting locking levers must be tight and secure
before making cut. If blade adjustment shifts while cutting, it may cause
binding and KICKBACK.
Use extra caution when making a “Plunge Cut”into existing walls or other
blind areas. The protruding blade may cut objects that can cause
KICKBACK. For plunge cuts, retract lower guard using Retracting Lever.
ALWAYS hold the tool firmly with both
hands. NEVER place your hand or
fingers behind the saw. If kickback
occurs, the saw could easily jump
backwards over your hand, leading to
serious personal injury. (Fig. 3)
Never force the saw. Forcing the saw
can cause uneven cuts, loss of accuracy, and possible kickback. Push the
saw forward at a speed so that the blade cuts without slowing.
16.Use the appropriate riving knife for the blade being used. For the riving knife to
work, it must be thicker than the body of the blade but thinner than the tooth
set of the blade.
17.Adjust the riving knife as described in this instruction manual. Incorrect spacing,
positioning and alignment can make the riving knife ineffective in preventing
kickback.
18.Always use the riving knife except when plunge cutting. Riving knife must be
replaced after plunge cutting. Riving knife causes interference during plunge
cutting and can create kickback.
19.For the riving knife to work, it must be engaged in the workpiece. The riving knife is
ineffective in preventing kickback during short cuts.
20.Do not operate the saw if riving knife is bent. Even a light interference can slow the
closing rate of a guard.
21.Use extra caution when cutting damp wood, pressure treated lumber or wood
containing knots. Adjust speed of cut to maintain smooth advancement of tool
without decrease in blade speed.
22.Adjustments. Before cutting be sure depth and bevel adjustments are tight.
23.Avoid Cutting Nails. Inspect for and remove all nails from lumber before cutting.
24.When operating the saw, keep the cord away from the cutting area and position it
so that it will not be caught on the workpiece during the cutting operation. The tool
is provided with a front grip and rear handle for two hand operation. Operate with
proper hand support, proper workpiece support, and supply cord routing away from
the work area.
WARNING: It is important to support the
workpiece properly and to hold the saw firmly
to prevent loss of control which could cause
personal injury. Fig. 4 illustrates typical hand
support of the saw.
25.Place the wider portion of the saw base on
that part of the workpiece which is solidly
supported, not on the section that will fall off
when the cut is made.
As examples, Fig. 5 illustrates the RIGHT way
to cut off the end of a board, and Fig. 6 the
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WRONG way.
If the workpiece is short or small, clamp it down. DO NOT TRY TO HOLD
SHORT PIECES BY HAND!
26.Never attempt to saw with the circular saw held upside down in a vise. This is
extremely dangerous and can lead to serious accidents. (Fig. 7)
27.WARNING: Blade coasts to stop after switch is released. Contact with
coasting blade can cause serious injury. Before setting the tool down after
completing a cut, be sure that the lower (telescoping) guard has closed and
the blade has come to a complete stop.
28.Do not stop the blades by lateral pressure on the saw blade.
29.Always use blades recommended in this manual. Do not use any abrasive or
grinding wheels.
30.Wear a dust mask and hearing protection when use the tool.
31.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.
INSTRUCTIONS FOR OPERATION
Auxiliary Handle
Always be sure that the auxiliary handle is
installed securely before operation. (Fig. 8)
Adjusting Depth of Cut
CAUTION:
Use a shallow depth of cut when cutting thin
workpiece for cleaner, safer cuts.
After adjusting the depth of cut, always
tighten the lever securely.
Hold the handle with one hand and loosen the
lever on the depth guide with the other. Move
the base up or down. At a desired depth of
cut, secure the base by tightening the lever.
(Fig. 9)
Bevel Cutting
Loosen the wing nut on the bevel gauge in
front, and tilt the tool to the desired angle for
bevel cut (0-45°). Secure the wing nut on the
bevel gauge tightly after making the
adjustment. (Fig. 10)
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Sighting
For straight cuts, align the right notch on the
front of the base with the cutting line on the
workpiece. For 45° bevel cuts, align the left
notch with it. (Fig. 11)
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.
To start the tool, simply pull the switch trigger.
Release the switch trigger to stop. (Fig. 12)
Removing or Installing Saw Blade
CAUTION:
Always be sure that the tool is switched off and unplugged before installing or
removing the saw blade.
Do not use saw blades which do not comply with the characteristics specified in
these instructions.
Do not use saw blades the disc of which is thicker or the set of which is smaller than
the thickness of the riving knife.
Be sure the blade is installed with teeth pointing forward in the same direction as the
tool rotation (the arrow on the blade should point in the same direction as the arrow
on the tool).
Never depress the spindle lock while the saw is running.
Use only original wrench to remove or install the blade.
The following blade can be used with this tool:
Max. Dia.
Min. Dia.
235 mm
230 mm
The thickness of the riving knife is 1.6 mm.
To remove the blade, press the spindle lock so
that the blade cannot revolve and use the hex
wrench to loosen the hex socket head bolt
counterclockwise. (Fig. 13)
Then remove the hex socket head bolt, outer
flange, raise the lower safety guard as much as
possible, and remove the saw blade. (Fig. 14)
To install the saw blade, follow the removal
procedures in reverse. Install the inner flange,
saw blade, outer flange and hex socket head bolt,
in that order. (Fig. 15)
Be sure to secure the hex socket head bolt
clockwise tightly with the spindle lock fully depressed.
When changing blade, make sure to also clean upper and lower blade guards of
accumulated sawdust. Such efforts do not, however, replace the need to check
lower guard operation before each use.
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Cutting Operation
CAUTION:
Be sure to move the tool forward in a straight line gently. Forcing or twisting the
tool will result in overheating the motor and dangerous kickback, possibly
causing severe injury.
The riving knife should always be used except when plunging in the middle of
the workpiece.
Do not stop the saw blade by lateral pressure on the disc.
Hold the tool firmly. The tool is provided with both a front grip and rear handle. Use
both to best grasp the tool. If both hands are holding saw, they cannot be cut by
the blade.
Set the base on the workpiece to be cut
without the blade making any contact. Then
turn the tool on and wait until the blade
attains full speed. Now simply move the tool
forward over the workpiece surface, keeping
it flat and advancing smoothly until the
sawing is completed. (Fig. 16)
To get clean cuts, keep your sawing line straight and your speed of advance
uniform. If the cut fails to properly follow your intended cut line, do not attempt to
turn or force the tool back to the cut line. Doing so may bind the blade and lead to
dangerous kickback and possible serious injury. Release switch, wait for blade to
stop and then withdraw tool. Realign tool on new cut line, and start cut again.
Attempt to avoid positioning which exposes operator to chips and wood dust being
ejected from saw. Use eye protection to help avoid injury.
Rip Fence (Guide Rule)
The handy rip fence allows you to do
extra-accurate straight cuts. Simply slide the rip
fence up snugly against the side of the workpiece
and secure it in position with the wing bolt on the
front of the base. It also makes repeated cuts of
uniform width possible. (Fig. 17)
MAINTENANCE AND INSPECTION
CAUTION:
Always be sure that the tool is switched off and unplugged before attempting to
perform inspection or maintenance.
Maintenance of the Motor
The motor unit winding is the very “heart”of the power tool. Exercise due care to
ensure the winding does not become damaged and /or wet with oil or water.
Inspecting the Carbon Brushes
Remove and check the carbon brushes regularly. Replace when they wear down
to the limit mark. 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 brush holder caps. Take out the worn carbon
brushes, insert the new ones and secure the brush holder caps.
※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 service centers,
always using original replacement parts.
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EXPLANATION OF GENERAL VIEW
1
Hex Socket Head Bolt
21
Flat Washer 8
2
Outer Flange
22
Fixed Safety Guard
3
Inner Flange
23
Flat Head Bolt with Square
Neck M8
4
Circlip 40
24
Baffle Plate
5
Pan Head Screw with Flat
Washer M4X10
25
Cross Recessed Countersunk
Head Screw M6X28
6
Adjusting Lever
26
Rubber Sleeve
7
Adjustable Safety Guard
27
Backward Spring
8
Torsion Spring
28
Rubber Pin
9
Bearing Retainer
29
Lock Lever
10
Cross Recessed Countersunk
Head Screw M6X22
30
Ball Bearing 6002VV
11
Ball Bearing 6202VV
31
2# Washer
12
Bearing Holder
32
Armature Assembly
13
Drive Spindle
33
Insulation Washer
14
2# Gear
34
Ball Bearing 6200VV
15
Ball Bearing 6000VV
35
Baffle Ring
16
Roller Plate
36
Stator Assembly
17
Support Plate
37
Pan Head Tapping Screw
ST5X59
18
Pan Head Screw M5X10
38
Auxiliary Handle
19
Adjusting Lever Assembly
39
Pan Head Tapping Screw
ST4.2X17
20
Hex Nut
40
Nameplate
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EXPLANATION OF GENERAL VIEW
41
Pan Head Screw (with Flat
Washer and Spring Washer)
M5X50
55
Wing Nut
42
Carbon Brush Holder Assembly
56
Spring Washer
43
Carbon Brush
57
1# Washer
44
Brush Holder Cap
58
Flat Head Bolt with Square Neck
M6
45
Switch
59
Base Assembly
46
Lock-off Button
60
Flat Head Bolt with Square Neck
M6
47
Spring
61
Slotted Cheese Head Shoulder
Screw
48
Trigger Switch
62
Wing Bolt M6
49
Trigger
63
Hex Lock Nut M6
50
Capacitor
861
Rip Fence (Guide Rule)
51
Cord
862
Wrench
52
Cord Guard
53
Strain Relieve
54
Handle Cover
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