REXON DC3550A Instruction Manual

2 Power Tool Safety ..................................................................................... 3 Metal Cutter Safety .................................................................................... 5 Electrical Requirements and Safety ........................................................... 9 Tools Needed for Assembly ....................................................................... 10 Carton Contents ........................................................................................ 10 Know Your Metal Cutter............................................................................. 11 Assembly and Adjustments ....................................................................... 12 Operation ................................................................................................... 16 Maintenance .............................................................................................. 18 Troubleshooting Guide .............................................................................. 19 Parts List .................................................................................................... 20 MOTOR Type ....................................................................................... Universal Amps ..................................................................................... 10.5 Voltage .................................................................................. 220 Hz .......................................................................................... 60 RPM (no load) ........................................................................ 1300 Saw blade arbor size ............................................................. 25.4 mm Saw blade size ....................................................................... 355 mm CUTTING CAPACITY Cross cut 0° Round .................................................................................... φ130mm Square ................................................................................... 120 × 120 mm Rectangular ........................................................................... 100 × 195 mm Angle beam ............................................................................ 165 × 84 mm 133.4 × 133.4 mm Miter cut 45° Round .................................................................................... φ120 mm Square ................................................................................... 95 × 95 mm Rectangular ........................................................................... 90 × 120 mm Angle beam ............................................................................ 90 × 90 mm Vise clamp angle .................................................................... 0° ~ 45 ° TABLE OF CONTENTS PRODUCT SPECIFICATIONS

GENERAL SAFETY INSTRUCTIONS BEFORE USING THIS POWER TOOL Safety is a combination of common sense, staying alert and knowing how to use your power tool. CAUTION To avoid mistakes that could cause serious injury, do not plug the tool in until you have read and understood the following. 1. READ and become familiar with this entire Instruction Manual. LEARN the tool’s applications, limitations and possible hazards. 2. NEVER OPERATE THIS MACHINE WITHOUT THE SAFETY GUARD IN PLACE FOR ALL THROUGH–SAWING OPERATIONS. 3. DO NOT USE IN A DANGEROUS ENVIRONMENT such as damp or wet locations or in the rain. Keep work area well lighted. 4. DO NOT use power tools in the presence of flammable liquids or gases. 5. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. 6. KEEP CHILDREN AWAY. All visitors should be kept at a safe distance from the work area. 7. DO NOT FORCE THE TOOL. It will do the job better and safer if used at the rate for which it was designed. 8. USE THE RIGHT TOOL. Don’t force the tool or attachment to do a job for which it is not designed. 9. WEAR PROPER APPAREL. DO NOT wear loose clothing, gloves, neckties, rings, bracelets or other jewelry that may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. 10. WEAR A FACE MASK OR DUST MASK. Sawing, cutting and sanding operations produce dust. 11. DISCONNECT TOOLS before servicing and when changing accessories, such as blades, cutters, etc. 12. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure the switch is in the OFF position before plugging tool into the power supply. 13. USE ONLY RECOMMENDED ACCESSORIES. Consult the Instruction Manual for recommended accessories. The use of improper accessories may cause injury to you or damage to the tool. 14. REMOVE ADJUSTING KEYS AND WRENCHES. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning ON. 15. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN THE POWER OFF. Do not leave the tool before the blade comes to a complete stop.

Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted. 17. DO NOT OVERREACH. Keep proper footing and balance at all times. 18. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for most efficient and safest performance. Follow instructions for lubricating and changing accessories. 19. CHECK FOR DAMAGED OR LOOSE PARTS. Check for alignment of moving parts, binding of moving parts, loose mounting and any other conditions that may affect its safe operation. A guard or other part that is loose or damaged should be properly adjusted, repaired or replaced. 20. MAKE WORKSHOP CHILDPROOF with padlocks, master switches or by removing starter keys. 21. DO NOT operate the tool if you are under the influence of any drugs, alcohol or medication that could impair your ability to use the tool safely. 22. USE A DUST COLLECTION SYSTEM whenever possible. Dust generated from certain materials can be hazardous to your health and, in some cases, a fire hazard. Always operate the power tool in a well-ventilated area with adequate dust removal. 23. ALWAYS WEAR EYE PROTECTION. Any power tool can throw debris into your eyes that could cause permanent eye damage. ALWAYS wear safety goggles (not glasses) that comply with ANSI safety standard Z87.1. Everyday glasses have only impact resistant lenses. They ARE NOT safety glasses. NOTE: Glasses or goggles not in compliance with ANSI Z87.1 could cause serious injury when they break. 24. DIRECTION OF FEED. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only.

SPECIFIC SAFETY INSTRUCTIONS FOR THIS METAL CUTTER To avoid mistakes that could cause serious or permanent injury, do not plug in the metal cutter until the following instructions have been read and understood. 1. Learn the function of the ON/OFF switch, cutting handle and blade guard. 2. Review and understand all safety instructions and operating procedures in this INSTRUCTION MANUAL. 3. Review the maintenance methods for this metal cutter. 4. Find and read all the warning labels on the metal cutter: ● Read manual before using the metal cutter. ● Wear safety goggles. ● Never perform cutting operations with blade guard removed. ● Turn power OFF, wait for blade to stop and remove power cord from power source before adjusting or servicing. 5. The arbor bolt and all clamps have to be tightened before cutting. 6. Make sure the workpiece and the blade are not in contact prior to operating the saw. WHEN INSTALLING OR MOVING YOUR METAL CUTTER: 1. Avoid a dangerous environment: ● Use the metal cutter in a dry, indoor location protected from rain and moisture. ● Keep work area well lit. 2. To avoid injury from unexpected metal cutter movement: ● Bolt or clamp the metal cutter to a firm level surface where there is plenty of room to move the workpiece through the entire cut. ● Position the Metal Cutter so the feet are level and the metal cutter does not rock. ● Position the metal cutter where operators and bystanders stand a safe distance away from the saw and are not in direct line with the saw blade. ● To avoid injury from electrical shock, make sure your fingers do not touch the plug’s metal prongs when plugging in or unplugging the metal cutter. ● Turn OFF and unplug the metal cutter before moving it to a new area. To avoid back injury, get help when transporting. ● Bolt the metal cutter to the floor if it tends to move when cutting long, heavy workpieces. ● DO NOT STAND ON the metal cutter. Do not store materials above or near it. Standing on the tool could result in serious injury. BEFORE EACH USE 1. INSPECT YOUR METAL CUTTER: ● If any part is missing, bent or broken in any way, or any electrical part does not work properly, turn the metal cutter OFF and unplug the tool. ● Replace damaged or missing parts before using the metal cutter. 2. AVOID INJURY FROM JAMS, SLIPS OR THROWN PIECES (KICKBACKS): ● Use this metal cutter to cut ferrous material only. ● Avoid injury from thrown pieces. Make sure the saw blade is properly installed and the arbor bolt is tight. WARNING !

the tool to do a job it is not intended to do. 3. INSPECT YOUR WORK AREA: ● Keep the work area clean. ● Cluttered areas and benches invite accidents. The floor must not be slippery from wax, sawdust or shavings, etc. ● Avoid burns or other fire damage. Do not use the metal cutter near flammable liquids, vapors or gases. ● Before using the metal cutter, clear the table of all objects not needed to feed the workpiece. ● Avoid injury. Do not perform layout, assembly or setup on the metal cutter. ● Never hold a workpiece. Workpiece will become very hot while being cut. 4. PLAN YOUR WORK: ● Before trying a new or not often used operation, carefully plan your hand placement. Make sure you have proper fixtures, stops and other items ready to use. Avoid injury form unsafe accessories. Use only recommended accessories. 5. DRESS FOR SAFETY: ● Plan ahead to protect your eyes, hands, face and ears. ● Do not wear loose clothing, gloves, neckties or jewelry (rings, wrist watches). They can get caught and draw you into moving parts. ● Wear non-slip footwear. ● Tie back long hair. ● Roll long sleeves above the elbow. ● Noise levels vary widely. To avoid possible hearing damage, wear ear plugs or muffs when using the metal cutter. ● The metal cutter can throw debris into your eyes which can result in permanent eye damage. Wear safety goggles (not glasses) that comply with ANSI Standards. Regular eyeglasses have only impact-resistant lenses. They are not safety glasses. ● Wear a dust mask along with safety goggles during each operation. 6. INSPECT YOUR WORKPIECE: ● Make sure there are no bolts or foreign objects in the part of the workpiece to be cut. 7. PLAN YOUR CUT: ● Do not cut freehand. Guide your workpiece solidly against the fence and table top. Make sure there is no debris between the workpiece and its supports. ● Use extra caution with large, small or awkward workpieces. ● Use extra support (tables, sawhorses, blocks) if your workpiece is hard to hold down to the table. Do not use another person as additional support or to help feed, support or pull the workpiece. ● Do not cut more than one workpiece at a time. ● Do not turn your metal cutter ON before clearing everything except the workpiece and related support devices off the table. 8. AVOID ACCIDENTAL STARTING: Make sure the switch is off before plugging the metal cutter into a power source. WHEN THE METAL CUTTER IS RUNNING Do not allow familiarity gained from frequent use of your metal cutter to cause a careless mistake. remember that a careless fraction of a second is enough to cause a severe injury. WARNING !

● Make sure all bystanders are clear of the power tool before and during use. ● Before using the power tool, test the saw by turning it on and letting it run for a few seconds. If it makes an unfamiliar noise or vibrates, stop immediately. Turn the metal cutter off and unplug. Do not restart the tool until the problem has been corrected. 2. DO NOT FORCE THE TOOL: ● Only cut one piece per cutting operation. 3. BEFORE FREEING JAMMED MATERIAL: ● Release the trigger switch. ● Wait for all moving parts to stop. ● Unplug the metal cutter. 4. BEFORE LEAVING THE METAL CUTTER: ● Release the trigger switch. ● Unplug the metal cutter. ● Make the workshop childproof. Lock the shop. Disconnect master switches. ● A 355 mm saw blade is the maximum blade capacity of your metal cutter. Never use a blade that is too thick to allow outer flange to engage with the flats on the spindle. Larger blade will come in contact with the blade guards, while thicker blades will prevent the bolt from securing the blade on the spindle. Either of these situations could result in a serious accident causing personal injury. ● Do not attempt to cut wood or masonry with this metal cutter. Never cut magnesium or magnesium alloy with this machine. Failure to comply could result in serious personal injury. WARNING ! ● To prevent metal cutter movement or tipping during cutting procedure, secure the metal cutter to a workbench or work surface that is also secure. ● Always use the vise on the metal cutter to prevent accidents that could result in serious personal injury. ● Never stand or have any part of your body in line with the path of the blade. Doing so may cause an accident resulting in serious personal injury. Large, circular or irregularly shaped workpieces may require additional clamping in order to be properly secured for cutting. Use “C” clamps that can be mounted along the left and front side of the machine base. Also use blocks to hold material securely. Failure to comply could result in serious personal injury. To avoid accidental start-up of your metal cutter, always make sure switch is off and “lock-on” feature is disengaged before connecting to power source. Failure to heed this warning could result in serious personal injury. ● USE ONLY CORRECT BLADES. Do not use blades with incorrect size holes. Never use blade washers or blade screws that are defective or incorrect. The maximum blade capacity of your metal cutter is 355 mm. ● DO NOT REMOVE THE METAL CUTTER’S BLADE GUARDS. Never operate the metal cutter with any guard or cover removed. Make sure all guards are operating properly before each use. WARNING ! WARNING !

CUTTING AREA. Keep hands away from blade. Do not reach underneath work or around or under the blade while the blade is rotating. Do not attempt to remove cut material while blade is moving. ● NEVER USE IN AN EXPLOSIVE ATMOSPHERE. Normal sparking of the motor or sparking from cutting metal could ignite fumes. ● DO NOT USE TOOL IF SWITCH DOES NOT TURN IT ON AND OFF. Have defective switch replaced by an authorized service center. ● KEEP TOOL DRY, CLEAN AND FREE FROM OIL AND GREASE. Always use a clean cloth when cleaning. Never use brake fluids, gasoline, petroleum-based products or any solvents to clean tool. ● ALWAYS SUPPORT LONG WORKPIECES. To minimize risk of tipping the saw, always support long workpieces. ● BEFORE MAKING A CUT, BE SURE ALL ADJUSTMENTS ARE SECURE. ALWAYS USE THE VISE CLAMP to secure the workpiece. ● NEVER TOUCH BLADE or other moving parts during use. ● NEVER START THE METAL CUTTER WHEN THE BLADE IS IN CONTACT WITH THE WORKPIECE. ● NEVER cut more than one workpiece at a time. ● DO NOT STACK more than one workpiece on the machine base at a time. ● NEVER PERFORM ANY OPERATION FREE-HAND. Always secure the workpiece to be cut in the vise. ● NEVER hand hold a workpiece. Workpiece will become very hot while being cut. ● NEVER reach behind, under or within 7.6 cm of the blade and its cutting path with your hands and fingers for any reason. ● NEVER reach to pick up a workpiece, a piece of scrap or anything else that is in or near the cutting path of the blade. ● MAKE SURE THE BLADE IS SECURELY MOUNTED as described in the operating instructions before connecting the tool to a power supply. Do not tighten blade excessively, since this can cause cracks. ● CHECK THE BLADE FOR FISSURES AND CRACKS, and test for normal operation prior to use. ● ALWAYS EASE THE SAW BLADE AGAINST THE WORKPIECE when starting to cut. A harsh impact can break the blade. ● ONLY USE A METAL CUTTER BLADE RATED FOR 1300 RPM OR GREATER and manufactured in compliance with ANSI B 7.1. Always store blades in a dry place with little temperature variation. ● BEFORE CUTTING, press the trigger switch and allow the blade to reach full speed. ● This metal cutter has been designed for cutting metals, using reinforced abrasive metal cutter blades only. Do not remove the blade, install a steel blade and attempt to cut other types of materials such as wood, masonry, etc. Attempting to cut these other types of materials could cause an accident resulting in serious personal injury. ● Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to serious personal injury.

POWER SUPPLY AND MOTOR SPECIFICATIONS To avoid electrical hazards, fire hazards, or damage to the tool, use proper circuit protection. Use a separate electrical circuit for your tool. Your saw is wired at the factory for 220 V operation. Connect to a 220 V, 10.5 Amp circuit and use a 10.5 Amp time delay fuse or circuit breaker. To avoid shock or fire, if power cord is worn, cut, or damaged in any way, have it replaced immediately. DOUBLE INSULATED The power tool is double insulated to provide a double thickness of insulation between you and tool’s electrical system. All exposed metal parts are isolated from the internal metal motor components with protecting insulation. CONNECTING TO THE POWER SUPPLY Check that the power supply and plug used is in accordance with your metal cutter. Have a look at the rating plate of the motor or the rating on the metal cutter. Any changes should always be carried out by a qualified electrician. Avoid contact with the terminals on the plug when installing (removing) the plug to (from) the power supply outlet. Contact will cause a severe electrical shock. USING AN EXTENSION LEAD The use of any extension lead will cause some loss of power. To keep this to a minimum and to prevent overheating and motor burn-out, ask advice from a qualified electrician to determine the minimum wire size of the extension lead. The extension lead should be equipped with an earthed type plug that fits the power supply outlet at one end, and with an earthed type socket that fits the plug of this machine at the other end. WARNING ! WARNING ! WARNING !

Saw blade wrench Phillips screwdriver Adjustable wrench or 11 mm, 13 mm, 17 mm wrenches 8 mm hex wrench CARTON CONTENTS UNPACKING AND CHECKING CONTENTS Separate all parts from packing materials. Check each part with the illustration on the right column to make certain all items are accounted for, before discarding any packing material. To avoid the risk of personal injury: If any part is missing or damaged, do not attempt to assemble the metal cutter, plug in the power cord, or turn the switch ON until the missing or damaged part is obtained and is installed correctly. NOTE: To make assembly easier, keep contents of box together. UNPACKING YOUR METAL CUTTER WARNING ! Metal cutter assembly Saw blade wrench Extension tube hardware bag Extension tube Instruction manual

Carrying Handle Motor Depth Stop Adjustment Bolt Lock Nut Locking Chain Locking Hook Hex Wrench Quick-release Lever Spindle Lock Trigger Lock-on Button Vise Clamp Stop Block Switch Handle Trigger Switch Base Vise Adjustable Fence Vise Handle Upper Cutting Blade Guard Lower Cutting Blade Guard Extension Wing Eye Shield

WARNING  ! Never connect the plug to the power source outlet until all installations and adjustments are completed and you have read and understood the safety and operational instructions. Failure to unplug your saw could result in accidental starting causing possible serious personal injury. RAISING AND LOCKING THE CUTTING HEAD (FIG. A) 1. For shipping purposes, the cutting head is locked in the down position. 2. Push down on the upper arm assembly and remove the locking chain (1) from the hook (2). 3. After releasing the locking chain, move the cutting head to the upward position. Do not remove the chain, as you will need it for locking the arm down for storage. Fig. A STORING Blade wrench (Fig. B) When you are not using the saw blade wrench (1) provided, a storage holder (2) is located on the rear of the saw base to store the wrench. WARNING  ! Hex wrench (Fig. B) 1. For convenient storage and prevention of loss, there is a hole (3) in the rear of the base (4) for storing the hex wrench (5) when not in use. Fig. B INSTALLING AND CHANGING THE SAW BLADE (FIG. C, D, E) NOTE: Use only recommended reinforced saw blade (not included with unit). 1. Raise the cutting handle to the upward position. 2. Loosen the screw (1). (Fig. C) Fig. C 3. Lift up slightly the lower blade guard (2), and then move the lower blade guard (2) downward to expose the arbor bolt (4). (Fig. D) 4. Push the spindle lock (3) and loosen the arbor bolt (4) counterclockwise in the centre of saw blade with the wrench provided. (Fig. D) 1 2 1 2 3 4 5 1

blade flange (5) and the saw blade (6). (Fig. D) 6. Install the new saw blade followed by the outside blade flange (5) and then the arbor bolt (4). (Fig. D) 7. Press on the spindle lock (3). Fig. D 8. Turn the arbor bolt (4-Fig. D) clockwise until snug and tighten with the blade wrench (7) provided. (Fig. E) 9. Make sure the saw blade is secured. 10.Turn the lower blade guard (2) back and tighten the screw (1). (Fig. C) Fig. E 2 3 4 6 5 7 ADJUSTING THE CUTTING DEPTH STOP BOLT (FIG. F) NOTE: The cutting depth was adjusted properly at the factory. If adjustments are needed, be careful not to adjust the depth stop bolt too deep, as the saw blade may contact the base. 1. Loosen the locknut (1) with a 13 mm wrench. 2. Turn the depth stop bolt (2) with a 13 mm wrench counterclockwise to decrease the cutting depth or clockwise to increase the cutting depth. 3. Lower the cutting head to check if the blade contacts the base. 4. Repeat until adjusted properly and tighten the locknut (1). NOTE: ● To maintain this adjustment, the locknut (1) on the depth stop bolt (2) must be tightened securely. ● The depth stop is factory set providing maximum cutting capacity for the 355 mm saw blade provided with your metal cutter. When the diameter of the blade has reduced in size due to normal wear, the depth stop bolt may require adjustment to provide maximum cutting capacity. When a replacement blade is installed onto the unit, it is necessary to check the clearance of the saw blade to the machine base, before operating. Fig. F 2 1 4 5 6

NOTE: The vise of your saw is used to secure the workpiece during cutting operations. 1. Rotate the handle (1) counterclockwise to allow enough room for the workpiece to fit between the vise clamp (2) and the adjustable fence (3). 2. Position the workpiece between the vise clamp (2) and the adjustable fence (3). Turn the handle (1) clockwise to clamp the workpiece securely. 3. The vise incorporates a quick release locking lever (4). To use the quick release feature, lift up on the quick release locking lever (4) and slide the vise clamp in or out to the desired position. 4. When vise clamp (2) is in desired location, flip the quick release locking lever (4) down to engage the threads with the threads of the vise. Begin to turn the handle (1) clockwise to secure the workpiece within the vise. Fig. G 3 2 4 1 ADJUSTING FOR ANGLE CUTTING (FIG. H) 1. Loosen the vise handle and back the vise clamp (2) away from the adjustable fence (3). 2. Loosen the two bolts (1) of the adjustable fence with a 17 mm wrench. 3. Move the adjustable fence (3) to the desired angle between 0 and 45 degrees. 4. Tighten the two bolts (1). 5. The vise clamp (2) will align itself automatically with the angle of the workpiece when clamping a workpiece in position. Fig. H INSTALLING AND ADJUSTING THE EXTENSION WING AND STOP BLOCK (FIG. I, J) 1. Attach the stop block (1) into the extension tube (2). (Fig. I) 2. Loosen the locking screw (3) with the Phillips screwdriver. 3. Insert the extension tube (2) into the mounting holes (4) located on the right side of the metal cutter base. (Fig. J) 4. Thread the stop screw (5) and into the end of the extension tube (2). 5. Adjust the extension tube (2) to the desired position. 6. Tighten the locking screw (3). 0 15 30 45 1 3 2

repetitive cutting by loosening the wing nut (6), sliding the stop block to the desired position and locking in place. Fig. I Fig. J CARRYING YOUR METAL CUTTER (FIG. K) The metal cutter can be transported to any workplace conveniently by: 1. Lower the cutting arm to its lowest position and secure in place by attaching the locking chain (1) to the hook (2). 2. Transport the saw by the carrying handle (3) located above the motor. 1 2 3 4 6 5 1 2 1 2 3 Fig. K

source outlet until all installations and adjustments are completed and you have read and understood the safety and operational instructions. ON/OFF SWITCH (FIG. L) The ON/OFF trigger switch (1) is located on the handle position of the cutting arm. 1. Turn the metal cutter ON by depressing the trigger switch (1). 2. To turn off, release the trigger switch (1). NOTE: Make the ON/OFF switch childproof. Insert a padlock or chain with padlock through the hole (3) in the trigger switch. Locking the tool’s switch, preventing children and other unauthorized users from turning the machine on. LOCK-ON BUTTON (FIG. L) 1. To engage the lock-on feature, depress the trigger switch (1), and simultaneously push in the lock-on button (2) located on the side of the handle. Release the trigger switch and the tool will run continuously. 2. To disengage the lock-on feature, depress the trigger switch and release. ● If you have the lock-on feature engaged during use and the power is disconnected to the saw, disengage the lock-on feature immediately. ● To avoid accidental start-up of your metal cutter, always make sure the switch is OFF and the lock-on feature is disengaged WARNING  ! before connecting to power source. Failure to heed this warning could result in serious personal injury. Fig. L REPETITIVE CUTTING USING THE STOP BLOCK (FIG. I) NOTE: When cutting long workpieces, support the right side end of the material with extension wing (1). 1. Loosen the screw (2) and then slide the extension wing (1) to desired position and tighten the screw. 2. The stop block (3) is designed for use during repetitive cutting. 3. Loosen the wing knob (4), raise the stop block (3), and retighten the wing knob (4). Fig. I WARNING  ! 1 2 3 1 2 3 4 5

machine base. 2. Firmly secure the material to be cut using the machine’s vise clamp assembly (5-Fig. I). 3. When cutting long workpieces, support the opposite end of the material with a roller stand or with a work surface level with the machine. (See WORKPIECE SUPPORT) 4. Before turning the machine on, perform a dry run of the cutting operation to verify no problems will occur when the cut is made. 5. Turn on the machine by depressing the trigger switch. Allow a few seconds for the blade to build up to full speed before letting it come into contact with the workpiece. 6. Once the motor has reached full speed, slowly lower the handle of the cutting arm until the saw blade contacts the workpiece. Continue to use steady, even pressure to obtain a uniform cut through the workpiece. Do not force the blade into the workpiece. 7. When the cut is complete, release the trigger switch and allow the blade to stop rotating BEFORE raising the cutting arm out of the workpiece. Do not attempt to cut wood or masonry with this metal cutter. Never cut magnesium or magnesium alloy with this machine. Failure to comply could result in serious personal injury. WARNING  ! WORKPIECE SUPPORT (FIG. J) NOTE: When cutting long workpieces, the opposite end of the material need extra support. The support should be placed under the workpiece. Keep your hand holding the workpiece positioned 3 inches or more away from the blade. The support must let the workpiece lay flat on the work table during the cutting operation. When mounted on a flat surface, the metal cutter table is 60 mm high. Fig. J CUTTING A WORKPIECE Failure to heed the safety rules could result in serious personal injury: ● Never perform any cutting operation freehand (without placing workpiece in the vise). ● Material will get hot during cutting operations. Keep hands off the metal being cut to avoid serious personal injury. ● Do not touch the cut material until it cools or you can be burned. ● Keep your hands at least 3 inches from the saw blade. ● Inspect the abrasive saw blade before every operation. Check for cracks, chipping and correct speed ratings on the saw blade. WARNING  ! 60 mm

blade while it is spinning. To avoid fire or toxic reaction, never use gasoline, naphtha acetone, lacquer thinner or similar highly volatile solvents to clean the metal cutter. To avoid injury from unexpected starting or electrical shock, unplug the power cord before working on the tool. To avoid electrical shock, fire or injury, only use the parts identical with the parts list. Reassemble exactly as the original assembly to avoid electrical shock. REPLACING CARBON BRUSHES (FIG. K) NOTE: Before replacing carbon brushes, make sure the machine has be disconnected from the power source. The carbon brushes furnished will last approximately 50 hours of running time, or 10,000 ON/OFF cycles. Replace both carbon brushes when either has less than 6.4 mm length of carbon remaining, or if the spring or wire is damaged or burned. 1. To inspect or replace brushes, first unplug the tool, remove the black plastic cap (1) on the side of the motor (2). NOTE: The brush assembly has a spring, so the cap may pop out when loosened. 2. Pull out the brush assembly and replace with the new one, if needed. The ears on the metal end of the WARNING  ! assembly go into the same slots where the carbon into. Tighten the cap snugly, but do not overtighten. Repeat for the other side. NOTE: To reinstall the same brushes, first make sure the brushes go back in the way they came out. This will avoid a break-in period that reduces motor performance and increases wear. Fig. K LUBRICATION ● Motor and cutterhead bearings are sealed and need no lubrication. ● Gears and elevation screws should be cleaned of debris and grease. CLEANING THE METAL CUTTER Keep your metal cutter clean. Continually remove metal chips, dust, dirt and debris a turn. 1 2

remove the plug from the power source before making any adjustments. SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Metal cutter blade hits base or work surface. 1. The cutting depth adjustment bolt is set too deep. 1. See “Adjusting the Cutting Depth Stop Bolt” section. Saw blade does not cut through workpiece. 1. Depth stop bolt setting is incorrect. 1. See “Adjusting the Cutting Depth Stop Bolt” section. Cut is not square. 1. Defective blade. 2. Workpiece is not positioned properly. 3. Excessive blade pressure. 1. Replace immediately. 2. Check adjustable fence for squareness to cut blade. 3. Lessen blade pressure during cutting operation. Metal cutter blade binds, jams, burns workpiece. Rough cuts. 1. Improper operation. 2. Dull metal cutter blade. 3. Improper metal cutter blade. 1. See “Operation” section. 2. Replace blade. 3. Replace with 355 mm saw blade. Tool vibrates or shakes. 1. Blade not round. 2. Blade damaged. 3. Blade loose. 4. Machine is not secured. 5. Other. 1. Replace blade. 2. Replace blade. 3. Tighten arbor bolt. 4. Mount tool to worksurface. 5. Call customer service. Power head won’t fully rise. 1. Pivot spring not replaced properly after service. 2. Part failure. 1. Call customer service. 2. Call customer service. Cutting head hard to pull/push down. 1. Lubrication needed. 1. See “Maintenance” section.

When servicing use only REXON replacement parts. Use of any other parts many create a HAZARD or cause product damage. Any attempt to repair or replace electrical parts on this Metal Cutter may create a HAZARD unless repair is done by a qualified service technician. Repair service is available at your nearest Service Center. PARTS LIST FOR SAW SCHEMATIC WARNING ! I.D. Description Size Q’ty I.D. Description Size Q’ty 0F5U VISE CLAMP 1 22A4 LOCKING CABLE TIE 4 0F5Z QUICK RELEASE LEVER 1 28S4 RIVET 1 0F60 PLUNGER HOUSING 1 2DFB BLIND RIVET 1 0F67 CHAIN 1 2ECV FENCE 1 0F6A WRENCH HEX. 1 2ED3 WRENCH SET 1 0F7L HEX. HD. SCREW AND WASHER 1 2EYQ SLIDER 1 0FA0 LOCKING CHAIN HOOK 1 2G8Y FOOT 3 0FA1 CLAMP-CORD 1 2JZG PLATE 1 0FLJ PLUNGER 2 2YBE FLAT WASHER φ16.5*40-3 1 0HFW BOLT CLAMP 1 2ZSU TRIGGER SWITCH 1 0J3T HEX. WRENCH 1 3401 CLAMP HANDLE 1 0J4E FLAT WASHER φ6*13-1 1 3750 COLLAR 1 0J4J FLAT WASHER φ10*20-2 1 3824 WARNING LABEL 1 0J4L FLAT WASHER φ12*21-2.5 1 3825 WARNING LABEL 1 0J5W FLAT WASHER φ18.1*26-0.3 1 30XZ HEX. SOC. HD. CAP BOLT M6*1.0-16 1 0J70 FLAT WASHER 1/4*3/4-7/64 1 325G FLOOR PLATE 1 0J7K FLAT WASHER 3/8*29/32-5/64 2 325H MOVABLE COVER ASS’Y 1 0J93 SPRING WASHER φ10 2 325J TORSION SPRING 1 0J9T SPRING WASHER φ5/16 2 325K EXTENSION BRACKET 1 0JB0 WAVE WASHER WW-8 1 325L CLEAR PLATE 1 0JB5 WAVE WASHER WW-18 1 32CQ CUTTER SHAFT GUARD 1 0JCV SPRING PIN 1 32CT SPRING GUARD 1 0JE7 C-RING 1 32CX LEVER 1 0JEF C-RING 2 32CY SUPPORT 1 0JPC HEX. HD. BOLT M6*1.0-12 1 32CZ ARBOR COLLAR 2 0JPU HEX. HD. BOLT M8*1.25-20 2 32D0 COVER 1 0JQ7 HEX. HD. BOLT M8*1.25-25 2 32D1 BUSH 2 0JUK HEX. SOC. HD. CAP BOLT M6*1.0-16 2 32D2 BUSH 1 0JUX HEX. SOC. HD. CAP BOLT M8*1.25-30 4 32D5 SCREW BAR 1 0JV5 HEX. SOC. HD. CAP BOLT M10*1.5-35 2 32EZ STEEL COVER ASS’Y 1 0JXA HEX. SOC. SET SCREW M6*1.0-12 1 32K5 BASE 1 0K35 CR. RE. PAN HD. SCREW & WASHER M5*0.8-25 1 32K9 BOLT 1 0K37 CR. RE. PAN HD. SCREW & WASHER M5*0.8-16 2 32KA WRENCH SET 1 0K3V CR. RE. PAN HD. SCREW & WASHER M6*1.0-12 1 32P6 SUPPORT 1 0K3W CR. RE. PAN HD. SCREW & WASHER M6*1.0-16 1 32SJ HANDLE COVER 1 0K44 CR. RE. PAN HD. SCREW & WASHER M5*0.8-12 4 32SL DUST BOX 1 0K71 CR. RE. TRUSS HD. SCREW M5*0.8-8 2 32SQ SPECIAL BOLT 1 0K9E CR. RE. TRUSS HD. TAPPING SCREW M4*16-12 2 33YJ CR. RE. TRUSS HD. ROUND NECK SCREW M6*1.0-12 1 0K9L CR. RE. TRUSS HD. TAPPING SCREW M4*16-10 2 33YL CR. RE. TRUSS HD. ROUND NECK SCREW M6*1.0-18 1 0KDG CR. RE. PAN HD. SCREW M5*0.8-6 1 344H CAPACITOR 1 0KDN CR. RE. PAN HD. SCREW M5*0.8-25 9 34FS RIVET φ6-20 2 0KDU CR. RE. PAN HD. SCREW M6*1.0-12 5 34HU TRADE-MARK LABEL 1 0KMR HEX. NUT M5*0.8 T=4 10 35R7 BASE 1 0KMT HEX. NUT M8*1.25 T=5 3 36GE MOTOR HANDLE (R) 1 0KQX NUT M6*1.0 T=6 1 36GF MOTOR HANDLE (L) 1 0KR0 NUT M12*1.75 T=12 1 36K6 POWER CABLE 1 0KR1 LOCK NUT M16*2.0 T=16 1 3A2B BUSH 1 0LVP FERRITE CORE 1 3A49 MOTOR ASS’Y 1 0QQ1 CORD GUARD 1 3AA2 LABEL 1

PARTS LIST FOR MOTOR I.D. Description Size Q’ty 0HX9 NEEDLE BEARING 1 0JX3 HEX. SOC. SET SCREW M5*0.8-8 2 0K26 HEX. SOC. HD. CAP SCREW M5*0.8-25 3 0KAA CR. RE. PAN HD. TAPPING SCREW M5*12-16 2 0KD7 CR. RE. PAN HD. SCREW M4*0.7-10 2 0KDR CR. RE. PAN HD. SCREW M5*0.8-10 1 0QQU CARBON BRUSH ASS’Y 2 0QR0 BRUSH COVER 2 0R1S BEARING BUSHING 1 2FG0 KNOB-HANDLE 1 2LV6 CR. RE. PAN HEAD TAPPING & WASHER SCREW M5*12-85 2 2ZP1 COMPRESSION SPRING 1 2ZPM MOTOR COVER 1 2ZPN MOTOR REAR COVER 1 2ZPP FLOW GUIDE 1 2ZPS PLATE COVER 1 2ZS3 BRUSH HOLDER ASS’Y 2 32F8 CR. RE. PAN HD. SCREW & WASHER M5*0.8-45 4 32SX FIELD ASS’Y 1 32SY ARMATURE ASS’Y 1 32T0 ARBOR SHAFT ASS’Y 1 344K INSULATING SLEEVE 1 344T ARM 1 345J CABLE SHIELD 1 36GJ CLEVIS PIN 1