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Exakt A0528 Use and Care Manual

1. Diagram A b When cutting wood the depth of cut should be set to slightly greater than the thickness of the material for best results c When cutting plastics the depth of cut should be set to slightly greater than the thickness of the material If melting occurs a greater depth setting will improve results d When cutting metals the depth of cut should be set to approximately 1 32 greater than the material thickness for best results If it is desirable not to mark the surface beneath the workpiece the depth can be set to the same as the material thickness when cutting wood or plastics but this may result in a rough edge NOTE If the depth control knob becomes difficult to turn unscrew it until the rubber seal can be seen Clean the surrounding area with a soft brush and then apply a very small quantity of synthetic grease to the seal Blade Changing NOTE Incorrect positioning of the blade can permanently damage the tool a Ensure the tool is unplugged from the power supply b Unscrew the depth adjuster until the number 7 is visible a Without removing the guard insert the U key into the blade shaft to lock it Diagram B Slide off the removable EXAKT PT Ltd 2010 cover insert the torx key into the blade retaining screw and unscrew clockwise Diagram C b Depress the guard to remove the blade c Place the new blade onto the blade shaft ensuring the hole locates correctly and the teeth point fo
2. more than one rear vent c To operate ensure that any part of the thumb between the tip and middle joint is over the serrated area of the switch Whichever part is most comfortable Squeeze the switch in towards the handle and then pull backwards Left handed operator Diagram G a Grasp the handle firmly with the left hand so that it feels comfortable The forefinger should be towards the rear of the power switch b Do not cover any of the front vents and no more than one rear vent c To operate ensure that any part of the forefinger between the tip and middle joint is over the serrated area of the switch Whichever part is most comfortable Squeeze the switch in towards the handle and then pull backwards Guard Lock a Place the tool at the start of the cut b Switch on the tool in accordance with the instruction manual Next release the guard lock Diagram H Then plunge the saw blade to start the cut The guard lock is released by pushing in the direction of the arrow in the diagram Either the hand holding the tool or work piece can be used whichever is easier c After the cut has been finished and the tool switched off ensure the guard lock has fully returned to its resting position If not clean thoroughly with a soft brush Cutting The EXAKT PS 160 is unique because it clamps the material to be cut between its base plate and the work surface using a plunge action to ease the blade into the cut
3. EXAKT PS 160 Instructions for Use Distributed by JML USA Inc Patents Apply 3PL Worldwide 500 Bic Drive Registered Design Ground Floor Building 4 Made in PRC Milford CT 06461 APS 160 Safety Warnings Instructions for Putting Into Use A Setting up the Saw for Use After unpacking check that there are no parts missing or damaged If there are contact supplier and do not operate Before using a blade needs to be fitted as described in the operating instructions See Blade Changing Section A cardboard packing disk may be fitted in place of the blade which will need to be removed Information on Power Supply This equipment should be connected to a normal domestic socket outlet with a voltage rating of 120 V Illustrated Description of Functions 1 Baseplate 2 Guard lock not shown 3 Depth adjuster knob 4 Switch 5 Handle List of contents e 1xPS 160 Saw e Blades dependant on kit e 1x Instruction manual 6 and 7 Air vents 8 Dust extract nozzle 9 Cutting width marks 10 Guard removal screw 11 Saw blade 2 1 8 1x Torx key amp 1x U key 1x Spare safety washer 1x Dust extraction hose 1x Storage case A PS 160 Safety Warnings Operating Instructions This tool should always be used with the dust hose connected and attached to a suitable vacuum cleaner dust extractor Setting the Cutting Depth a The depth of cut can be set by turning the depth control knob
4. Setting the Cutting Depth Section for example to 7 c Identify this number e g 72 both on the front and rear of the guard d Align the indication mark below the rearmost number on the guard with the start line on the material to be cut e Proceed with the cut until the indication mark below the forward number aligns with the finish line on the material being cut Cut outs NOTE Plunge cutting may not be possible in some hard materials a Set the depth of cut See Setting the Cutting Depth Section plug in the power supply and then place the metal base plate onto the work surface Ensure that the rear width indication mark on the guard aligns with the start line See Measuring the Cutting Width Section To ensure accurate cut outs the guard can be held with the free hand but ensure it does not come into contact with the blade b Switch on the tool and wait for one second for the blade to run up to speed Next plunge the blade into the material slowly and gently but firmly Then push the tool forwards along the line to be cut Never draw the tool backwards c Once the finish line has been reached lift the tool from the work surface before switching off If a lot of 4 EXAKT PT Ltd 2010 dust has been created keep switched on for a few seconds extra to allow the dust to clear from within the tool d Cutting out tips e f the cut is to be covered for example by a vent cover the corners can be overlap
5. This results in a faster easier and cleaner cut NOTE Always cut in a forward direction Never draw the tool backwards If you are a novice user practice by cutting thin wood until proficient a Check the specifications to ensure the suitability of the material to be cut b Fit the correct blade ensuring it is sharp and not damaged c Set the depth of cut See Setting Cutting Depth Section d Place the material to be cut onto a flat surface such as a workbench table or floor Use a piece of scrap material underneath if e You do not wish to mark the work surface e The work surface is likely to damage the blade E g a concrete floor e Plug into power supply f Grasp the tool firmly See Holding amp Switching on Section and rest its metal base plate onto the surface to be cut Ensure that the rear half of the base plate overhangs the work surface Do not plunge the blade into the material g Switch on the tool and wait for one second for the blade to run up to speed Next depress the guard lock lever and plunge the blade into the material slowly and gently but firmly Then push the tool 3 EXAKT PT Ltd 2010 forwards along the line to be cut Never motion the tool backwards h Very little force should be used to feed the tool along the cut Excess force will cause operator fatigue and excessive wear to the blade and tool Excess force is also likely to cause the temperature cut out to trip resulting in d
6. Wear suitable b Clean thoroughly with a small soft brush like a paint Read brush instructions before use eye protection Safety Blade Retaining Washer Wear suitable ear protection ta X A Risk of electric The blade is clamped in place using a special safety shock washer that is designed to slip if the blade jams The result is that the motor slows down sounds like it is Risk of injury K Discard at labouring and the tool will stop cutting If this happens when recognised the operator should immediately reduce the feed instructions are collection point pressure until the motor sounds healthy or remove the not followed tool from the work piece to prevent permanent damage The washer is a consumable item which should be replaced if damaged or deformed Specifications PS 160 Usage DIY NOTE Never replace this washer with anything Motor power 120V 350W other than an EXAKT replacement part See List Depth of cut 0 9 16 of user replacable parts Approx no load blade speed 4000 rpm Maximum duty cycle 3 min 5 min Blades Gearbox reduction ratio 8 8 1 Approximate weight 1 2 kg 2 6 Lbs e NOTE Always use a sharp blade _ Maximum blade diameter 2 118 e f the tool does not cut as well as expected or if it Maximum Minimum blade 0 08 0 03 overheats temperature cut out may trip the most width common cause is a blunt blade igre Hand arm vibration value lt 2 5 m s oe ber n Si i
7. airs by an unauthorized facility or products purchased used serviced or damaged outside of the United States Distributed by JML USA Inc 3PL Worldwide 500 Bic Drive Ground Floor Building 4 Milford CT 06461 Contact customer services on 877 660 9784 www JMLDirectUSA com EXAKT PT Ltd 2009
8. elays Ensure that the base plate is always held flat on the material being cut This is particularly important at the start or finish of a cut or if thin strips are being cut where the base plate is not fully supported Once the cut has been finished lift the tool from the work surface before switching off If a lot of dust has been created keep switched on for a few seconds extra to allow the dust to clear from within the tool ces Line Following a Pointers at the front and rear of the guard allow a line to be followed when cutting Diagram I b For more accurate and neater cutting a metal ruler held with the free hand can be followed To position the ruler draw a second line 3 8 to the left of the cutting line Or 1 5 16 to the right of the cutting line for left handed operators Diagram J Measuring the Cutting Width When making cut outs it is desirable to know exactly where the cut will start and stop to prevent unsightly over cutting Indication numbers which correspond to the depth setting are marked on both sides of the guard to show where the blade starts and stops Diagram K a Mark the area to be cut out on the material to be cut If the area is not a square or rectangle separate start and finish lines may have to be drawn These are drawn from the start and finish point at right angles to the line of cut b To use the width indication system first set the cutting depth See
9. f the blade is blunt If in Sound pressure level No load 3dBA e Blades are consumable items _ Sound power level Lwa No Load 94dBA _ _ _ e Always use Exakt blades E e Beware when changing blades as they can become Cutting Specs _ _ _ _ _ _____ hot during use Allow the blade time to cool before _ Wood All types up to 9 16 replacing Metals Up to 1 8 in Aluminium amp lead e The blade diameter for the PS 160 saw is 2 1 8 Composites MDF ply amp chipboard to 7 Plastics Tufnol perspex fibreglass etc Servicing and replacable Parts Minerals Wall amp Floor tiles slates etc For replacement blades serving and repairs Where there is access to cut from the back surface of contact JML USA Inc the material over cutting by the allowance shown will ensure perfect corners on the front surface JML USA Inc 3PL Worldwide 500 Bic Drive Approximate over cutting allowances Ground Floor Building 4 Milford CT 06461 8 1614 16 8 Call customer service on 877 660 9784 8 6 2 16 8 Assumes the depth has been set to 1 64 greater than the material to be cut 6 EXAKT PT Ltd 2010 JML Guarantee This product is unconditionally guaranteed for one year against all defects of workmanship and materials This guarantee does not affect your statutory rights This warranty does not cover damage from negligence misuse abuse accident failure to follow operating instructions commercial use rental rep
10. nised mild steel e Every 2 minutes of metal cutting should be followed by a rest of at least 3 minutes gt 2 Ceramic tiles slates etc Only use a blade specifically designed for the purpose Always use with a suitable vacuum cleaner or dust extractor connected as the dust can be hazardous to the operator and prevent the guard operating correctly Applying masking or PVC tape to the base plate of the tool or alternatively to the work piece can make cutting easier and avoid scratching the tile Plasterboard oo e The PS 160 is only recommended for making occasional cut outs in plasterboard and always with a Suitable vacuum cleaner or dust extractor connected The dust can prevent the guard operating correctly Conventional tools such as keyhole saws or knives generally give excellent results though the PS 160 can be used if a particularly neat dust free cut is required or if there is a danger of cutting pipes or cables Dust Extraction The PS 160 is a powerful tool capable of producing a large amount of dust As the tool has a fully enclosed blade forced dust extraction is particularly efficient Forced dust extraction should be used for all but small trimming jobs a An industrial vacuum dust extractor or domestic vacuum cleaner can be connected to the dust outlet nozzle of the tool using the dust hose supplied with your saw kit from EXAKT b Before using ensure that the metal retaining clip is flush
11. ped to ensure that the waste material is completely detached If the cut out is to be seen do not overlap the corners In this circumstance as the cutting blade is circular the waste material will not be fully detached The corners will therefore require finishing with a knife If the material is thin and the back surface unimportant the waste material can just be pushed out Where there is access to the back surface of the material to be cut the cut out can be marked out with an over cutting allowance The cut is then made from the back surface to ensure perfect corners on the front surface A table of over cutting allowances is shown in the specifications section Cutting particularly Tough or Abrasive Materials NOTE Learn to use the tool by cutting wood before attempting to cut anything tougher When cutting tougher material such as metals and some plastics more force is required to hold the work piece Clamping may be required Never cut materials that produce toxic dust or fumes such as PTFE or asbestos Sheet metal Always set the depth adjustment to at least 1 32 greater than the material thickness to avoid the blade riding up over the surface Scrap material is required underneath the work surface e Remove burrs and rust as these impede the feed e Thick beeswax furniture polish applied to the base plate of the tool makes metal cutting easier Only suitable for cutting brass copper lead aluminum or galva
12. rwards in the direction of the curved arrow Diagram C d Replace the safety retaining washer and tighten the screw Diagram D e Remove both keys before plugging in Guard Removal NOTE Do not use without the Guard a Ensure the tool is unplugged from the power supply b Unscrew the guard release screw Slide off the guard Diagram E NOTE When replacing the guard the blade can protrude through the slot in the base plate To avoid injury ensure that the hand is kept well clear Ensure the guard is replaced the correct way round Clamping It is not normally necessary to clamp the material being cut as long as it is fully supported on a work surface and held with one hand Clamping should be used where e The operator is inexperienced in the use of power saws or weak handed e Small parts or tough material is to be cut Cutting Limitations There is no limitation on the size of material that can be cut as long as it is fully supported The saw will cut up to 2 deep Material up to twice as thick can be cut if cutting is performed on both sides Holding and Switching On Holding the tool correctly will result in easier and safer operation with less fatigue Right handed operator Diagram F 2 EXAKT PT Ltd 2010 a Grasp the handle firmly with the right hand so that it feels comfortable The thumb should be towards the rear of the power switch b Do not cover any of the front vents and no
13. with the end of the hose c To attach the hose disconnect the tool from the power supply Press the hose end with the metal clip onto the dust nozzle only as far as the raised ridges on the tool body Ensure the guard moves up and down freely Press the adaptor into the vacuum hose Tape can be used to assist if required d Ensure that the vacuum cleaner to be used is recommended for use with a power tool Generally most domestic wet and dry vacuum cleaners are suitable e Forced dust extraction is particularly recommended when a lot of cutting is being carried out as far fewer stoppages are required for cleaning the tool and surrounding area f Forced dust extraction should always be used when cutting hazardous materials such as hard woods MDF or ceramics g Forced dust extraction is recommended when it is desirable to keep the working area clean h Forced dust extraction is essential if the material being cut is slightly damp A PS 160 Safety Warnings Maintenance and Servicing Cleaning Regular cleaning is required for the safe operation of the tool as an excessive build up of dust will prevent the tool operating correctly 5 EXAKT PT Ltd 2010 The dust extract nozzle may block and require Explanation of Symbols cleaning occasionally especially if damp wood is being cut Double Wear suitable insulated NS face mask a Unplug from mains supply and remove guard See appliance Guard Removal Section

Exakt A0528 Use and Care Manual

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