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

-1- -2-

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.

-3- -4-

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.

-5- -6-

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.

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

-7- -8-

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

-9- -10-

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)

-11- -12-

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

-13- -14-

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)

-15- -16-

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.

-17- -18-

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