Sealey CP4002 User manual

1.1 GENERAL SAFETY.
 Disconnect the battery from the saw unit before changing
accessories, servicing or performing any maintenance.
 Maintain the saw and battery in good condition. Check moving
parts alignment on a regular basis.
Replace or repair damaged parts. Use an authorised service
agent and recommended parts only. Unauthorised parts may
be dangerous and will invalidate the warranty.
 Ensure the saw is switched off before installing the battery.
Keep the saw, battery and charger clean for best and safest
performance.
Remove ill fitting clothing. Remove ties, watches, rings and
other loose jewellery and contain long hair.
 Evaluate your working area before using the saw e.g. ceiling,
floors and enclosures may contain electrical items or water piping.
 Ensure battery is correctly inserted into the saw handle
and latched in place before attempting to switch on saw.
 Secure loose workpieces with a clamp, vice or other adequate
holding device.
 Avoid unintentional starting.
 Wear approved safety eye protection (standard spectacles are
not adequate).
 Maintain correct balance and footing. Ensure the floor is not
slippery and wear non-skid shoes.
 Be aware that this saw does not need to be plugged into the
mains power..
Keep children and unauthorised persons away from the
working area.
 DO NOT use the saw where there are flammable liquids, solids
or gases, such as paint solvents, etc.
 DO NOT allow children to operate the saw.
 DO NOT operate the saw if any parts are missing as this may
cause failure or possible personal injury.
 DO NOT hold unsecured workpiece in your hand.
 DO NOT carry the saw with your finger on the power switch.
Keep trigger release button in the locked position.
 DO NOT use the saw for a task it is not designed to perform.
 DO NOT operate the saw when you are tired or under the
influence of alcohol, drugs or intoxicating medication.
 DO NOT get the saw, battery or charger wet or use in damp or
wet locations.
Keep saw, battery and charger in a safe, dry, childproof area
where the temperature will not exceed 104°F (40°C).
1.2 ELECTRICAL SAFETY.
REGARDING DIRECT MAINS POWER USE WITH THE
CHARGING BASE AND PLUG ONLY.
WARNING! It is the owner’s responsibility to read, understand
and comply with the following electrical instructions:
You must ensure the risk of electric shock is minimised by the
installation of appropriate safety devices. An RCCB (Residual
Current Circuit Breaker) should be incorporated in the main
distribution board. We also recommend that an RCD (Residual
Current Device) is used with all electrical products, particularly
portable equipment which is plugged into an electrical supply
not protected by an RCCB.You must also read and understand
the following instructions concerning electrical safety.
The Electricity At Work Act 1989 requires all portable•
electrical appliances, if used on business premises, to be
tested by a qualified electrician, using a Portable
Appliance Tester (PAT), at least once a year.
The• Health & Safety at Work Act 1974 makes owners of
electrical appliances responsible for the safe condition of the
appliance, and the safety of the appliance operator. If in any
doubt about electrical safety, contact a qualified electrician
Battery Charger Safety Instructions•
 WARNING! DO NOT use the charging base to charge any
battery other than that required for the tool. Other types of
batteries may explode!
Inspect the plug, cable and the charging base for wear
and damage to ensure items are safe before connecting to the
mains power supply. If worn or damaged DO NOT use,
immediately replace, or contact a qualified electrician.
Check cables are always protected against short circuit and
overload.
Uncoil the power cable between the plug and the charging base
before use.
 DO NOT pull or carry the charging base by the charger power
lead, or pull the plug from the mains socket by the power lead.
 DO NOT use any other type of transformer with the charging
base.
 DO NOT try to open or dis-assemble the plug or charging base.
 DO NOT use the plug to power any other electrical item.
Disconnect the plug from the charging base and the mains
power supply when not in use.
 DO NOT expose the charging base to damp or wet conditions
(for indoor use only).
 DO NOT pull or carry the charging base by the power lead.
 DO NOT operate the charging base if it has been dropped, or
has received a sharp knock, or is damaged. Contact an
authorised service agent.
 DO NOT dismantle the charging base as this may cause
damage or personal injury and will invalidate your warranty.
 DO NOT insert foreign objects or material into the hole
reserved for the battery.
 DO NOT immediately charge a second battery. Consecutive
charging will overheat the charging base. Allow the unit to cool
for 15 minutes before charging the next battery.
Ensure that the insulation on all cables and on the appliance is
safe before connecting it to the power supply.
Ensure that cables are always protected against short circuit
and overload.
DO NOT use worn or damaged
cables, plugs or connectors.
Immediately have any faulty
item repaired or replaced by a
qualified electrician. When a
BS1363/A UK 3 pin plug is
damaged, cut the cable just
above the plug and dispose of
the plug safely.
Fit a new plug according to the
following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the earth
terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that all
wires have been correctly connected, that the cable outer
insulation extends beyond the cable restraint and that the
restraint is tight.
1. SAFETY INSTRUCTIONS
INSTRUCTIONS FOR:
CORDLESS LITHIUM-ION
RECIPROCATING SAW 12V
MODEL No: CP4002
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and properly
maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS, AND
CAUTIONS. USE THIS PRODUCT CORRECTLY, AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY
CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY.
FUSE RATING
5 AMP
Blue
Neutral
Wire
Yellow & Green
Earth Wire
Cable
Restraint
Original Language Version CP4002 Issue: 2 - 01/03/10

2. INTRODUCTION & SPECIFICATIONS
Slim, compact and lightweight design featuring a quick-release clamp
for simple and fast blade changing. Safety trigger control prevents
accidental operation. Responsive variable speed trigger gives higher
control for intricate operations. Soft grip handles for added comfort
and control. Powered by lithium-ion battery (sold separately, order
Model No: CP40BP), which maintains a high energy density level
with a flat discharge curve - performing better and longer than a
conventional Ni-CD/Ni-MH battery. No memory effect allows the
battery to recover from a deep discharge with no tendency to reduce
overall capacity. Requires 1 hour mains charger (sold separately,
order Model No: CP40MC). Suitable for a wide variety of body shop
applications. Supplied with two blades, one fine and one coarse.
No Load Speed: ................................................................. 0-2100spm
Stroke Length: ............................................................................ 13mm
Weight: .........................................................................................0.7kg
Battery Model No (not included):.............................................CP40BP
Mains Charger Model No (not included): ............................... CP40MC
Replacement Blades: ...............SJS700B06 (6tpi), SJS700B10 (10tpi)
................................................................................ SJS700B24 (24tpi)
Noise Power: ...........................................................................86.6dBA
Noise Pressure:.......................................................................75.6dBA
Vibration: .................................................................................. 5.1m/s²
3. CHARGING
Double insulated products, which are always marked with this
symbol ,are fitted with live (brown) and neutral (blue) wires
only.
DO NOT connect either wire to the earth terminal.
1.3 BATTERY SAFETY INSTRUCTIONS.
 WARNING! Battery contains lithium-ion which is dangerous.
Handle with care to avoid damage, fire, corrosion or personal
injury.
Charge battery prior to its first use. The battery will have
been shipped in a low charge state.
 WARNING! To reduce the risk of burns or fire:
 DO NOT Attempt to open, disassemble, modify or service the
battery pack.
 DO NOT Crush, puncture, short external contacts or dispose of
in fire or water.
 DO NOT Expose to temperatures above 40°C (104°).
 Replace only with the battery pack designated for this product.
 Recycle or dispose of used battery as stipulated by local
regulation.
Use only the charging base provided to charge the saw battery.
 DO NOT attempt recharging the battery by means of an engine
generator or a DC power source.
 WARNING! Dispose of spent batteries correctly as they contain
Lithium-ion. DANGER! DO NOT attempt to disassemble the
battery. For safety and environmental reasons DO NOT discard
in domestic waste or by burning. ONLY discard or recycle
according to local authority regulations.
 WARNING! DO NOT allow a leaking battery to contact your
person. If you come into contact with battery liquid take the
following immediate action:
a) Skin contact: Wash immediately with soap and water,
then wash flesh in either lemon juice or vinegar.
 b) Eye contact: Wash with a strong solution of boric acid,
and seek immediate medical attention.
SAWING INSTRUCTIONS. (Ensure you have read,
understood and comply with all the safety instructions)
WARNING! Always wear approved safety glasses when sawing.
4.1 Blade Installation
To insert he blade pull back the blade clamp (fig.2) ensure
the blade is the correct way around and insert in to the
saw, release the blade clamp to secure in place.
Note: Coarse blades should be used to cut wood and composites
and fine blades used to cut metal.
4.2 Variable Speed Trigger and Starting the Saw
The speed of the saw is controlled by the variable speed trigger
(fig.3). Depress the trigger release button (fig.3) then squeeze
the trigger gently for a slow speed and progressively increase
the pressure on the switch to produce correspondingly higher
speeds (try before starting to saw).
4.3 General Cutting
After inserting the blade as in 4.1, if possible secure the work
piece. Rest the blade guide on the work piece and ensure the
blade is not touching it.
Start the saw as in 4.2, apply pressure in the direction of the
cut but also keep the blade guide firmly on the work piece.
Note: Any vibration or chattering may indicate the need for a finer
blade or faster cutting.
Note: If the blade overheats or be comes clogged this may indicate
the use of a coarser blade or a
slower speed is needed.
4.4 Replace the blade as soon as it
starts to hinder performance a
blunt blade will produce poor
results, will overheat and could
shorten the life of the saw.
4.5 When finished remove the battery
and clean the saw with a
dampened cloth.
fig.1
fig.2
4. OPERATION
CHARGING THE BATTERY (NOT INCLUDED, ORDER
MODEL NO: CP40BP)
Note:When new, the battery will have been shipped in a low charge
state. Fully charge the battery before using your tool
3.1 To remove the battery from the saw, depress the two side
clips on the battery. DO NOT touch the metal battery terminals.
3.2 Take the base charger (Not included, order model No:
CP40MB) and plug it into the mains.
3.3 The battery is designed to fit into the charger one way
only. This is to ensure that the positive (+) and negative (-)
polarities correspond. Insert the battery and press lightly to
seat the battery firmly into the charging base, as in fig.1.
 WARNING! DO NOT try to force battery into the base the
wrong way around.
3.4 When the battery is inserted into the charger the green LED
(fig.1) will begin to flash, this indicates the battery is charging.
3.5 When the green LED (fig.1) stops flashing and is solid the
battery is fully charged.
3.6 If the red LED (fig.1) illuminates the battery is too hot to charge
and will need to cool down before the charging cycle begins.
3.7 If the red LED (fig.1) flashes this means either the battery is
not seated in the charger correctly or the battery is defective
and should be replaced.
3.8 Remove the battery from the charger. Switch off and remove
the plug from the mains. Push the battery back into the saw.
Original Language Version CP4002 Issue: 2 - 01/03/10

fig.3
Environmental Protection
Recycle unwanted materials instead of disposing of
them as waste. All tools, accessories and packaging
should be sorted, taken to a recycle centre and
disposed of in a manner which is compatible with
the environment.
When the product is no longer required, it must be
disposed of in an environmentally protective way.
Battery Removal - Unclip the battery from the tool
and dispose of according to local authority
guidelines. Rechargeable battery contains
Lithium-ion (Li-ion). It is recyclable. Take to your
local recycling centre to be disposed of properly.
Li
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
email
Original Language Version CP4002 Issue: 2 - 01/03/10
Risk of Hand Arm Vibration Injury.
The CP4002 , Cordless Reciprocating Saw when operated in accordance with these instructions and tested in accordance with
BS EN 28662-1:1993, ISO 8662-1:1988 and BS EN ISO 8662-12:1997 in the following vibration emission declared in accordance
with BS EN12096:1996.
Measured vibration emission value: 5.1 m/s ² Uncertainty: 2.1 m/s ²
These values are suitable for comparison with emission levels of other tools that have been subject to the same test.
This tool may cause hand-arm vibration syndrome if its use is inadequately managed.
Recommended Measures to reduce risk of hand-arm vibration syndrome:
This tool should not be used by an individual regularly for more than 232 minutes in any 8 hour period.
This duration of use should be reduced if the individual is exposed to hand-arm vibration from other sources.