DS 460
Manual
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TranslationoftheOriginalOperating
Instructions
Contents:
1 ScrollSawDS460: ……………………………………………12
2 GeneralSafetyInformation……………………………………12
3 Legend(Fig.1) …………………………………………………13
4 DescriptionoftheMachine(seealsofig.1aand1b) ………13
5 TechnicalData:…………………………………………………13
6 InstallationandCommissioningoftheSaw …………………14
6.1 Unpacking(Fig.2aand2b): …………………………………14
6.2 InstallingtheSaw ………………………………………………14
6.3 AdjustingtheAngleDisplay(Fig.3):…………………………14
6.4 AssemblingtheAirNozzle(Fig.4): …………………………14
6.5 ConnectingtheVacuumCleaner(Fig.5):……………………14
6.6 SawBlades……………………………………………………14
6.6.1 ClampingandChangingtheSawBlade ……………………14
6.6.1.1 PushingtheSawTableBackorintothe
WorkingPosition(Fig.6)………………………………………14
6.6.1.2 SawBladeswithFlatEnds
(HandandFretSawBlades)(Fig.7aand7b): ……………15
6.6.2 SwaBladeswithPinEnds(Fig.8): …………………………15
6.6.3 FineSettingoftheCorrectSawTension(Fig.9): …………15
7 WorkingwiththeSaw:…………………………………………15
7.1 GeneralInformationforWorkingwiththeScrollSaw………15
7.1.1 ChoiceofSawBlade …………………………………………15
7.1.2 SelectingtheSpeed:…………………………………………16
7.1.3 PossibleCausesofBrokenSawBlades: ……………………16
7.2 Sawing(Fig.10) ………………………………………………16
7.2.1 InsideCuts(Fig.11)……………………………………………16
7.2.2 MitreCuts(Fig.2b) ……………………………………………16
7.2.2.1 SettingtheMitreAngle…………………………………………16
7.2.2.2 FineSetting(Fig.2b) …………………………………………16
7.2.2.3 Settingthesawbladestroke(fig.12aand12b) …………16
8 MaintenanceandRepairs ……………………………………17
9 CleaningandCare: ……………………………………………17
10 Disposal …………………………………………………………17
11 CEDeclaration:…………………………………………………17
12 SparePartsList…………………………………………………78
13 ExplodedDrawing………………………………………………79
1ScrollSawDS460:
Dearcustomer!
Theuseoftheseinstructions
•makesiteasiertobecomeacquaintedwiththedevice,
•preventsmalfunctionsduetoimproperhandling,and
•increasestheservicelifeofyourdevice.
Alwayskeeptheseinstructionsclosetohand.
Onlyoperatethisdevicewithexactknowledgeofitandcomplywiththe
instructions.
PROXXONwillnotbeliableforthesafefunctionofthedevicefor:
•handlingthatdoesnotcomplywiththeusualintendeduse,
•otherapplicationusesthatarenotstatedintheinstructions,
•disregardofthesafetyregulations,
Youwillnothaveanywarrantyclaimsfor:
•operatingerrors,
•lackofmaintenance.
Foryoursafety,pleasecomplywiththesafetyregulationswithoutfail.
OnlyuseoriginalPROXXONspareparts.
Allrightsreservedforfurtherdevelopmentsinthecourseoftechnical
progress.Wewishyoumuchsuccesswiththedevice.
2GeneralSafetyInformation
CAUTION!Whenusingelectricpowertools,thefollowingsafety
measuresmustbeobservedforprotectionfromelectricshock,
riskofinjury,andfirehazards.
Readandtakenoteofalltheseinstructionsbeforeyoustartup
theproduct.Keepthesesafetyinstructionsinasafeplace.
Safeworking
Alwayskeepyourworkingareatidy.
1.Disorderintheworkingareacanleadtoaccidents.
Takeaccountofsurroundinginfluences.
1. Do not expose tools to the rain.
2. Do not use tools in damp or wet surroundings.
3. Ensure that the lighting is good.
4. Do not use tools in the vicinity of combustible liquids or gases.
Protectyourselffromelectricshocks.
1. Avoid body parts from coming into contact with earthed parts.
Keepotherpeopleaway.
1. Do not let other people, especially children, touch the tool or the
cable.Keepthemwellawayfromtheworkingarea.
Keepunusedtoolsinasafeplace.
1. Unused equipment should be kept in a dry, closed location out of
thereachofchildren.
Donotoverloadyourtool.
1. You will be able to work better and safer within the given power
range.
Alwaysusethecorrecttool.
1. Do not use low power machines for heavy work.
2. Do not use tools for purposes for which they were not designed. For
exampledonotusemanually-operatedcircularsawsforcutting
branchesorfirewood.
Wearsuitableworkingclothing.
1. Do not wear loose clothing or jewellery, they can get caught up by
movingparts.
2. When working in the open air we recommend the use of non-slip
footwear.
3. Wear a hair net if you have long hair.
Usetheprotectiveequipment.
1.Wearsafetyglasses.
2.Wearabreathingmaskwhencarryingoutdust-generatingwork.
Connecttothedustextractionequipment.
1. If connections are available to dust extraction and collection equip-
ment,makesurethattheyareproperlyconnectedandused.
Donotusethecableforpurposesforwhichitwasnotdesigned.
1. Do not use the cable to pull the plug out of its socket. Protect the
cablefromheat,oilandsharpedges.
Securethetool.
1. Use the clamping fixture or a vice to hold the tool tightly. It is thus
heldmoresafelythanwithyourhand.
Avoidabnormalpostures.
1.Ensurethatyouarestandingsafelyandalwaysmaintainyourbal-
ance.
Takegreatcareofyourtools.
1. Keep the tools sharp and clean so as to be able to work better and
safer.
2. Follow the maintenance instructions and the advice about tool
changing.
12
GB
3. Regularly check the tool cable and have it replaced by an author-
izedspecialistifitisdamaged.
4. Regularly check the extension cables and replace them if they are
damaged.
5. Keep handles dry and free from oil and grease.
Pulltheplugoutofthesocket:
1. When the tool is not in use, before maintenance and when chang-
ingtoolssuchasthesawblade,drillormillingcutters,alwaystake
theplugoutofthesocket.
Donotleaveanytoolspannersorsettingkeysinplace.
1. Before switching on always check that spanners, keys and setting
toolshavebeenremoved.
Avoidunintentionalstarting.
1. Always make sure that the switch is in the OFF position when you
plugthetoolintothesocket.
Extensioncablesintheopenair.
1. In the open air always use extension cables which are authorized
forthepurposeandwhicharecorrespondinglymarked.
Alwaysbeattentive.
1. Be aware of what you are doing. Carry out your work sensibly. Do
notusethetoolifyouaretired.
Checkthetoolfordamage.
1. Before further use of the tool, examine protective devices or
slightly-damagedpartstoensurethatthefunctionisperfectand
meetstherequirements.
2. Check that the moving parts function perfectly and do not stick and
thatpartsarenotdamaged.Allpartsmustbecorrectlymounted
andalltheconditionsfulfilledtoensuretrouble-freetooloperation.
3. Damaged protective equipment and parts must be properly repaired
orexchangedbyanauthorizedspecialistworkshopifnootherinfor-
mationisgivenintheinstructionsforuse.
4. Arrange for damaged switches to be exchanged by a customer
servicesworkshop.
5. Never use tools on which the switch cannot be switched on and off.
WARNING!
1.Theuseofothertoolinsertsandaccessoriescanpresentariskof
injury.
Arrangeforyourtooltoberepairedbyaspecialistelectrician
1.Thistoolmeetstherelevantsafetyregulations.Repairsmayonlybe
carriedoutbyelectricalspecialistsandoriginalsparepartsmustbe
used.Otherwiseaccidentscanhappentotheuser.
3Legend(Fig.1)
1. Adjustingknobforsawbladetension
2. Sawbladeholder,top
3. Sawblade
4. ON-OFFswitch
5. Adjustingknobfornumberofstrokes
6. Screwforfinesettingoftheworktable’sangleofrotation
7. Die-caststeelpedestal
8. Airnozzle
9. Die-caststeelmachinebody
10. Rotatable saw table
11. Saw blade holder, bottom
12. Holes for fastening screws
13. Slide blocks for clamping the saw blade
14. Rubber connecting piece for vacuum cleaner connection
15. Mains cable
16. Induction motor
17. Saw arm (top)
18. Saw arm (bottom)
19. Recesses for the slide blocks
20. Lock lever
21. Clamping screw for lock lever
22. T-handle key
23. Hose
24. Clamping screw for air nozzle alignment
25. Dust suction connection
26. Arm for saw blade guard
27. Clamping screw for saw blade guard
28. Saw blade guard
4DescriptionoftheMachine
(seealsofig.1aand1b)
ThePROXXONscrollsawisaverysturdy,ruggedlydesignedbutnev-
erthelessmechanicallyverysophisticatedandcarefullyproduced
device.Theheavydie-castpedestalandtherigiddie-castmachine
bodyformasolidbaseforthecomplexmachinemechanicsandaper-
fectplatformfortheprecisionmountingofthesawarmswhichare
madeofultra-lightbutstrongmagnesiuminordertoreducethemoved
weights.Theyaredrivenbyaquiet,powerfulinductionmotorwhich
canbeadaptedtotherequiredmaterialpropertieswithtwospeeds
(900/1400rpm)foroptimumsmoothrunningandlowvibration.
YourDS460hasmanyareasofapplicationandisparticularlysuitable
formouldconstruction,finemechanics,modelbuildingandtoymanu-
facture.Itisthereforejusttherighttoolforambitiousmodelbuilders,
designers,architects(modelbuilding)orcarpenters.
Thelargetiltablesawtableformitrecutsof-5to50°ismadeofdie-
castaluminiumformaximumaccuracyandstabilityandprecision
groundforoptimumglidingcharacteristics.Itsspecialdesignalsosim-
plifieschangingofthesawblade.
Thesawtablecanbeunlockedandpushedbacktoimprovetheacces-
sibilityofthelowersawbladeattachment.Thisenablesquickandeasy
changingofthesawblades.
Sawbladeswithbothpinendsandflatendscanbeused.Theuseof
slidingblocksallowspreciseguidingofthesawbladewithoutinterfer-
encefrombendingforces.
Youwillfindtheappropriatesawbladesfortherespectivejobinthe
Proxxonrangeofaccessories.WerecommendyoutouseProxxon
sawbladesexclusively!
TheDS460sawssoftwooduptoathicknessof50mm,plasticupto
30mmandnon-ferrousmetalsupto10mm.
Thesawcanalsobeusedtoeasilycutplexiglass,GRP,foam,rubber,
leatherandcork.
Andthereisanautomaticallydrivenbellowswithanadjustableairnoz-
zletoensurethatdustdoesnotobstructtheviewofthecuttingline
duringwork.
Avacuumcleanercanbeconnectedadditionally.Thisguarantees
cleanworking.
5TechnicalData:
Numberofstrokes:900or1,400/min
Liftingheight: 18mm
Max.cuttingdepth: 60mm
(inwood)at45°: 35mm
Sawbladelength: 127mm(withpinend)
125-130mm(withoutpinend)
Noisedevelopment: <70dB(A)
Vibration <2.5m/s
Weight: approx.20kg
Dimensions:
LxWxH 580x320x300(inmm,approx.data)
Table: 400x250mm
Throat: 460mm
Motor:
Voltage: 220/240V,50/60Hz
Powerinput: 145/205W
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6InstallationandCommissioningoftheSaw
Caution:
Makesureyourmainsplughasaprotectiveearthingconductorandis
suitabletooperatethedevice!
6.1 Unpacking(Fig.2aand2b):
1. Take the device carefullyoutofthebox.Pleaseholdthescrollsaw
bythedie-casthousingasshowninfig.2a.Thiswillavoiddamage.
2. The saw table 1isfoldedupatanangleofabout45°fortransport
reasons.Pleaseloosentheclampingscrew2(fig.2b),pulldown
thelockleveroftheangleadjustment,movethetableintothehori-
zontalpositionandsnapthelockleverbackintothegear4.
6.2 InstallingtheSaw
N.B.:
Safeandaccurateworkisonlypossiblewithcarefulfastening!
1. Fix the saw to astrongworkbenchwithtwoscrews(Ø8mm,not
included).Usetheholes(12,fig.1)ontherightandleftinthe
pedestal.
6.3 AdjustingtheAngleDisplay(Fig. 3):
Caution:
Makesurethatthemainsplugisremovedbeforedoinganysetting
work,otherwisethereisadangerofinjuryincaseofaccidentalstarting
ofthemachine!
Theangledisplay1issetexactlyatthefactoryanddoesnotnormally
needtobereadjusted.Ifithasbecomemisadjusted,thisisquiteeasy
tocorrect:
1. Clamp the saw blade2.Seetherelevantsectionofthismanual.
2. Set the saw tabletothe“0°”position.Seethesection“MitreCuts”.
Thistellsyouhowtosettheangleofthesawtable.
3. Check using a square3whetherthesawbladeactuallyisataright
angletothesawtableinthisposition.Ifnot,readjustthesawtable
settingattheknurledscrew4.
4. Check the positionintheangledisplay1.Thismustnowbealigned
exactlytothe0°positiononthescale.
5. If the angle displayneedstobeadjusted,loosentheAllenscrew5,
movetheangledisplaytothe0°positionandretightentheAllen
screw.
6. Test by sawing apieceofwoodandchecktheangleonthework-
pieceagain.
6.4 AssemblingtheAirNozzle(Fig. 4):
Sawdustalongthecuttinglineisremovedimmediatelybyablowerdur-
ingwork.Idealforafreeview.Theblowerstartsautomaticallyassoon
asthesawisswitchedon.
1. Remove the air nozzlepipe1andhose2fromtheenclosedbag.
2. Loosen the knurledscrew3andinserttheairnozzlepipe1intothe
appropriaterecessintheopenclampingpieces4.
3. Align the air nozzlepipeandtightentheknurledscrew3.
4. Push the air hose2ontotherearendoftheairnozzlepipe1and
thenipple5onthebellowsonthetopsawarm.
Toaligntheairnozzle,simplyloosentheknurledscrew3andposition
theairnozzlepipebyturningandmovingittowardstheworkpiece.
6.5 ConnectingtheVacuumCleaner(Fig. 5):
Caution:
Sawdustfromcertainmaterialscanbehazardoustoyourhealthif
inhaledorifittouchesyourskin.Forthatreason,alwayswearappro-
priateprotectiveclothing(e.g.respirator)andalwaysworkwiththesuc-
tiondevice.
Danger:Dustincertainconcentrationscangenerateanexplosive
mixtureintheair!
1. Push the rubber connector1ontotheconnectingpiece2.
2. Push the vacuum cleanerhose3ontotherubberconnector1.
3. Switch on the vacuumcleanerbeforesawingsothatthesawdustis
suckedoffandthesuctiondeviceisnotblocked.
Anothersmalltip:
WhenusingtheProxxonCW-maticvacuumcleaner,manualswitching
onandoffisnolongernecessary. TheCW-maticisequippedwithan
automaticcontrolthatswitchesonandoffautomaticallywheneverthe
electricaltoolisactivatedordeactivated.Youhavethesameeffect
withcommerciallyavailablevacuumcleanerswhenusingourAS/E
vacuumcleanercontroller.
6.6 SawBlades
Caution:
Alwayspulloutthemainsplugforalltheactivitiesdescribedhere.
Onlyusesuitablesawblades.Makesurethatthesawbladesaresuit-
ableforusewiththeDS460.Youmustcomplywiththedimensions
specifiedinthetechnicaldata.
Pleasemakesurethatthesawbladeisinperfectconditionand
changedamagedorwornsawbladesimmediately!Deformedordam-
agedsawbladesaredangeroustoworkwithandmaynotbeused!
Theyalsoproducepoorworkresults:Fullsawingperformanceand
precisioncanonlybeachievedwithperfectsawblades.
WerecommendtheuseoforiginalPROXXONsawblades!
Choosethesuitablesawbladescarefullyandfortherespectiveappli-
cationandmaterialtobesawn.
Proxxonsuppliesdifferentfineteeth,flatandroundbladesandblades
withandwithoutpinends.Youwillfindourrangeofbladesinthe
MicromotcatalogueorontheInternetunderwww.proxxon.com.
6.6.1ClampingandChangingthe SawBlade
Bothconventionalsawbladeswithpinendsandhand(fret)sawblades
withoutpinendscanbeused.Thesawtablecanbepushedbackfor
optimumaccessibilityofthesawbladeholdersothatchangingthesaw
bladesischild’splay.
Caution:
Pleasenotethatthesawbladeguardcanbefoldedawaytochange
thesawblades.
6.6.1.1PushingtheSawTable Backorinto theWorking
Position(Fig.6)
Caution:
Pleasenotethatthesawtablecanonlybepushedbackwhenthesaw
tableisinthe0°position,i.e.horizontal.
1. Release clampingscrew1(fig.6)ofthelocklever2.
2. Move down the lockleverandpushthesawtable3back.
3. Pull the saw table3forwardafterattachingthesawblade.Thelock
leverisactuatedautomaticallyinthefrontendpositionandlocks
thesawtable.
6.6.1.2SawBladeswithFlat Ends(Handand FretSaw
Blades)(Fig.7aand7b):
TheconceptoftheDS460isnotdesignedlikeconventionalscroll
sawstosimplyclampthebladesinthesawbladeholdersattheends
ofthesawarms.Thisconventionalclampingmethodinevitablyleadsto
fluctuatingbendingforcesinthesawbladewhenthesawarmsmove
upanddownbecausethependulummovementcannotbecompen-
sated.Thesecauseheavywear,thesawbladecanbreaksooner.
Frequentbladechangingisnottoeveryone’slikingeither.Wehave
designedtheclampingmethodwithslidingblocksforallthosewhodo
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notwanttodowithoutthemoreaccurateguidingofthebladeswithflat
ends(unlikethosewithpinends)butdonotwanttheirdisadvantages.
Thereisnolateraltwistingintheattachmentyetthebladescanstillfol-
lowtheupanddownmovementsofthesawarmsfreelywithoutbeing
exposedtobendingforces.
1. Place the sliding blocks 1 (fig. 7a) in the openings provided in the
sawtable2.Therightclampinglengthisdefinedimmediately.Cau-
tion:Theclampingnuts3mustbeloosenedandfacingupwards!
Theslidingblocksmustbeinsertedsothatthepointedendsare
facingeachother,i.e.inwards.
2. Insert the saw blade in the centre of the clamping slit and tighten
theclampingnutswiththeAllenkey5provided.Caution:Thesaw
blademustbeinsertedthesamedistanceintotheclampingsliton
bothslidingblocks.
3. Push back the saw table 2 as described above and fold away the
sawbladeguard6ifnecessary.
4. Turn the knob 7 to the left to loosen the tension on the saw blade.
5. Remove the saw blade if necessary and insert a new saw blade 4
withtheslidingblocksintothesawbladeholdersasshowninfig.
7b.Slightpressurecanbeappliedtothetoparmasrequiredorthe
bladetensioncanbeloosenedfurtherontheknob7ifnecessary.
Caution:Theteethoftheblademustfacedownwards!
6. Pull the table forward again as described above.
7. Regulate the saw blade tension as described in the section “Fine
SettingoftheCorrectSawTension”.
6.6.2SwaBladeswithPinEnds (Fig.8):
Sawbladeswithpinendsareverysuitableforworkingwithmany
closedinsidecuts.Here,thesawbladecanbetakenquicklyandcon-
venientlyoutofthetopholder,loopedthroughtheworkpieceandreat-
tached.Detailscanbefoundinthe“InsideCuts”section.Butbe
carefully:Theprecisionoftheguidingwithpinendbladesisinferiorto
thatofsawbladeswithflatendsandslidingblocks.Absoluteprecision
intheguidingofthecutcanonlybeachievedwiththese.
1. Push back the saw table 1 as described above and fold away the
sawbladeguard2ifnecessary.
2. Turn the knob 3 to the left to loosen the tension on the saw blade.
3. Remove a saw blade already in the holder and fit the saw blade 4
withtheteethfacingdownwardsintothebottomholder5.
4. Press the top arm 6 lightly if necessary and attach a new saw blade
tothetopholder7.Loosenthesawbladetensionfurtherwiththe
knob3ifnecessary.
5. Release the arm after attaching the blade and set the blade tension
withtheknob3.
6. Regulate the saw blade tension as described in the section “Fine
SettingoftheCorrectSawTension”.
6.6.3FineSetting oftheCorrectSawTension(Fig. 9):
Therightsawtensionisdecisiveforagoodworkresult.Itmustthere-
forebesetcarefully.Thesawbladecanalsobreakifitistootightor
tooslack.
Pleaseturntheknob1(fig.9)tosetthetension.Thesawbladeis
tightenedbyturningtheknobtotheright(clockwise)andloosenedby
turningittotheleft(anticlockwise).
Acorrectlytensionedbladeemitsahightonewhen“plucked”.
7WorkingwiththeSaw:
7.1 GeneralInformationforWorkingwith theScrollSaw
Thescrollsawisprimarilyamachineforsawingcurvesandprecise
cut-outs.Atypicalapplicationisshowninfig.10.Theoperatormust
movetheworkpiececarefullyforthis.N.B.:Scrollsawsareusually
operatedwithoutalongitudinalstopbecausethesawblade“wanders”
whenitisguided“byforce”againstastop,especiallyinthegrainof
wood.
Pleasenotethatthesawbladeonlysawsinthedownwardmovement
inthedirectioninwhichtheteetharefacing.
Forgoodresults,pleasenotethefollowingpoints:
•Presstheworkpieceagainsttheworktopwhensawing;guidegently
withlittleforce;morepressureontheworktop,lesspressureonthe
sawblade.
•Makesurethattheworkpieceislyingfirmlyonthesawtable(noburr
orchips).
•Adaptthemovementtotherequirementsofthesawblade,speed
andmaterialoftheworkpiece.
•Movetheworkpieceintothesawbladeslowlyespeciallyiftheblade
isverythinandtheteethveryfineortheworkpieceisverythick.
N.B.:Theteethonlysawinthedownwardmovement!
•Onlyuseperfectsawblades!
•Donotleavethedeviceunattended!
•Draw/marktheguidelinecarefully.
•Providegoodlightingconditions!
•Alwaysworkwithconnecteddustexhaustandaligntheairnozzle
carefully(seealso“AssemblingtheAirNozzle”).
•Thebestresultsareachievedwithawoodthicknessoflessthan25
mm.
•Forwoodthicknessesgreaterthan25mm,youhavetoguidethe
workpieceverycarefullytoavoidjamming,bending,twistingand
snappingofthesawblade.
•Forexactcutsinwoodpleasebearinmindthatthesawbladewill
alwaystrytofollowthegrain(appliesespeciallyforthinsawblades).
•Whensawingroundmaterials,pleasebearinmindthatthesecould
turnwiththemovementofthesawbandandthereforemustbeheld
particularlytightly!Pleaseuseasuitableholdingdeviceforthework-
pieceifnecessary!
7.1.1ChoiceofSawBlade
Asalreadymentioned,therightchoiceofbladeforthematerialhasa
greatinfluenceonthequalityoftheresult.Thetablebelowservesfor
orientation.Ofcourse,awideexperiencewithmanydifferenttypesof
materialsandsawbladesisalwayshelpful,too.Itisworthexperiment-
ingalittle!
Atip:Thesawbladesareusuallyonlyheavilywornintheplacewhere
theteetharemoststressedandthereforegetbluntquickly.To“useup”
theteethwhicharenotwornandthusprolongthelifeofthesaw
blades,thecontactsurfacefortheworkpiececanbe“raised”slightly
artificially.
Simplyfixasmoothunderlayoftheappropriatethicknessandsame
sizeofthetabletothesawtablewithdouble-sidedadhesivetapefor
example.Thepartsofthesawbladewhicharenotwornnowsawinto
theworkpiece.
Thisisparticularlyusefulwhensawingveryhardandthereforevery
wearingmaterialsfrequentlywithfineblades.
Thefiguresforcharacterisingthe“fineness”oftheteethrefertothe
numberofteethperinchofthesawbladelength:
Roundsawblades(withflatends)areidealforusewithplastic,hard
andsoftwood.Theycutonallsidessothereisnoneedtoturnthe
workpiecewhensawing.
OurfullrangeofsuitablesawbladesforyourDS460canbefoundin
ourMicromotcatalogueorontheInternetunderwww.proxxon.com.
Teeth/inch Material:
approx.10-14 softandhardwood(approx.6-50mm),
plastics,softermaterials,thickerwork-
pieces
approx.17-18 finersawingwork,wood(uptoapprox.
6mm),plastics,softermaterials,thinner
workpieces
approx.25-28 plastic,GRP,non-ferrousmetal,plexiglass,
iron,FR-2withrestrictions
approx.41 iron,FR-2
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7.1.2Selectingthe Speed:
Thisdescriptioncanofcourseonlygiveaguidelinefortheoptiontobe
taken.Asintheprevioussection,youhavetodoalittle“experiment-
ing”tofindtheoptimumresult.Therightspeedalsodependsonthe
bladeused,theworkpiecematerial,feedetc.ofcourse.
7.1.3PossibleCausesofBrokenSaw Blades:
Thesawbladecanbreakforthefollowingreasons:
•bladetensiontoohighortoolow
•mechanicaloverloadingofthebladebymovingtooquickly
•bendingortwistingofthebladewhenturningtheworkpiecetoo
quicklytocutcurves
•whenthewearlimitofthesawbladeisreached
•whenthescrewsaretightenedwithsawbladeswithpinends
7.2 Sawing(Fig.10)
Pleaseholdtheworkpieceonthesawtableasshowninfig.10.Adapt
thefeedingtothematerial,thesawbladeandthethicknessofthe
workpiece!Hardmaterials,finesawbladesandthickerworkpiecesdo
not“stand”asmustthrustassoftermaterials,coarsersawbladesand
thinworkpieces.
Tryoutresultsatdifferentspeeds.
N.B.:
Safeandaccurateworkisonlypossiblewithcarefulfastening!
Thescrollsawisprimarilyamachineforsawingcurves.Forgood
results,pleasenotethefollowingpoints:
Foryourownsafetyplease:
•Onlyuseperfectsawblades!
•Alwayspulloutthemainsplugformaintenanceandcleaning.
•Donotleavethedeviceunattended.
•Alwaysmakesurethatthesawbladeguardisintheoperatingposi-
tionasshowninfig.10!
1. Press the workpiece against the worktop when sawing; guide gently
withlittleforce;morepressureontheworktop,lesspressureonthe
sawblade.Caution:Thesawdoesnotcuttheworkpieceonitsown.
Youhavetomovetheworkpieceintothesawblade.
2. Move the workpiece into the saw blade slowly especially if the blade
isverythinandtheteethveryfineortheworkpieceisverythick.
Thebestresultsareachievedwithawoodthicknessoflessthan25
mm.
7.2.1InsideCuts(Fig.11)
Caution:
Alwayspulloutthemainsplugbeforelooseningthesawblade!
Ifyouwanttomakeinsidecutswhenworkingwithyourscrollsaw,
therearedifferentwaystothreadthesawbladethroughtheopeningin
theworkpiece.
Iftheinsidecutsarebigenough,thesawbladecanbeinsertedwith
theslidingblock,i.e.intheassembledstate.However,finerinsidecuts
arealsopossible:Todothis,theslidingblockisclampedinthetop
holder,thesawbladeloosened,insertedintotheworkpieceand
reclamped.Whenusingsawbladeswithpinends,thesemustbesim-
plyattachedanddetachedafterlooseningthesawbladetension.
1. Drill a hole in the part of the workpiece to be cut out 1.
2. Loosen the saw blade tension by turning the knob 2.
3. Detach the saw blade with the sliding block or the pin end from the
topsawbladeholder3or
4. clamp the sliding block with the knurled screw 4, loosen the nut 5
andremovethesawblade.
5. Push the saw blade through the hole in the workpiece and reattach
theslidingblockorpinendorinsertthesawbladeinthesliding
blockandreclampwiththenut5.Loosenknurledscrew4!
Caution:
Pleasenotethattheknurledscrew4mustalswaysbeloosenedin
operation!Theslidingblockmaynotbeclampedduringoperationbut
mustswingfreely!
6. Set the saw blade tension correctly with the knob 2.
7. Cut out the opening and remove the workpiece after detaching the
sawbladeagain.
Atip:
Ifyoudrilltheholesothatitdoesnottouchthelaterinsidecontour,
youcanhavethesawingline“runin”tothecontourtobesawnouttan-
gentially.Thisgivesaniceevensawingedge.
Ifnecessary,theloweroftherecessesinthesawingtable(fig.1,item
19)canbeusedforfixingtheslidingblockifitisnecessarytoloosen
thenutoftheslidingblocktoremovetheblade.
7.2.2MitreCuts(Fig.2b)
7.2.2.1SettingtheMitreAngle
Formitrecuts,thetableissimplytiltedbythedesiredangle.Thiscan
bedonequicklyandeasilywiththeangleadjustmentofyourDS460.
1. Loosen the clamping screw 2.
2. Move the lock lever 3 down and tilt the saw table 1 to the desired
angle.
3. Snap the lock lever into the appropriate recess of the angle scale 4
onthesawtable.
4. Retighten the clamping screw 2.
Caution!
Pleasepresstheworkpieceveryfirmlyagainstthetabletosawamitre
cut.
7.2.2.2FineSetting (Fig.2b)
Pleasenote:
Therecessesintheanglescalearedesignedsothatthemostcom-
monmitrecutscanbeselectedquickly.Anyintermediatesettingcan
alsobemadeofcourse.Todothis,simplyturntheknurledscrew5
whentheleverisinadetentposition.Pleasenote:Theclampingscrew
2canbelefttighttomakethesetting!
7.2.2.3Settingthesawbladestroke (fig.12a and12b)
Thefactory-setsawbladestrokeof18mmrepresentstheoptimumfor
mostapplicationsandusuallydoesnotneedtobechanged.Inrare
cases,certainworkingconditionsdonotpermitsatisfactoryworking
results,forexample,ifthesawbladespeedistoohighevenatalow
numberofstrokes(e.g.,ifsawingplasticandthematerialmeltsand
weldsbacktogether).Inthiscase,theDS460makesitpossibleto
minimisethestrokewhichreducesthecuttingspeed.
1.Unscrewbothscrewsfromsuctionconnection8andremovethe
suctionconnection
2.Unscrewbothscrews1anddetachcoverplate4
3.Use the included Allen screw to unscrew screw 6 from the eccentric
7.
4.Screwinscrew6tothesecondthreadintheeccentric.
5.Screwplate4togetherwithscrew3
6.Screwplate2togetherwithbothscrews1
7.Refastenthesuctionconnection
Speed Material
900strokes/min Steel,brass,non-ferrousmetals,GRP,
plastics
1,400strokes/min aluminium,wood,polystyrene,rubber,
leather,cork
16
8MaintenanceandRepairs
Caution:
Alwayspulloutthemainsplugbeforemaintenance,cleaningand
repairs.
Thedeviceismaintenance-freeexceptforthenecessityforregular
cleaning(seebelow).
Repairsmayonlybecarriedoutbyqualifiedtechnicalpersonnelorbet-
terstillbythePROXXONCentralService!Neverrepairelectricalparts
butalwaysreplacethemwithoriginalPROXXONspareparts!
9CleaningandCare:
Caution:
Alwayspulloutthemainsplugbeforemaintenance,cleaningand
repairs.
Toensurealongservicelife,themachineshouldbecleanedwitha
softcloth,handbrushorpaintbrushaftereachtimeitisused.Avacuum
cleanerisalsorecommendedhere.
Asalreadymentioned,youshouldalwaysworkwithadustsuction
devicetopreventahighaccumulationofdustinthefirstplace.
Theoutsideofthehousingcanbecleanedwithasoft,possiblydamp
cloth.Inthisprocess,mildsoaporanothersuitablecleaningagentcan
beused.Solventsorcleaningagentscontainingalcohol(e.g.petrol,
cleaningalcoholsetc.)shouldbeavoided,sincethesecanattackthe
plasticparts.
Itisbesttoapplyadropofmachineoiltomovingpartsoccasionally.
Thearmbearingsandthesliding/rotatingaxisofthesawtableshould
beoiledatregularintervals.
10 Disposal
Pleasedonotdisposeofthismachineinhouseholdrefuse!The
machinecontainsmaterialsthatcanberecycled.Ifyouhaveanyques-
tionsaboutthis,pleasecontactyourlocalrecyclingcompanyorother
relevantcommunalinstitutions.
11 ECDeclarationofConformity
Nameandaddress:
PROXXONS.A.
6-10,Härebierg
L-6868Wecker
Productdesignation: DS460
ArticleNo.: 27094
Insoleresponsibility,wedeclarethatthisproductconformstothe
followingdirectivesandnormativedocuments:
EUEMCDirective 2004/108/EC
Appliedstandards:DINEN55014-1/05.2012
DINEN55014-2/06.2009
DINEN61000-3-2/03.2010
DINEN61000-3-3/07.2012
EUMachineryDirective 2006/42/EC
Appliedstandards: DINEN61029-1/01.2010
Date: 08.03.2013
Dipl.-Ing.JörgWagner
PROXXONS.A.
MachineSafetyDepartment
TheCEdocumentauthorizedagentisidenticalwiththesignatory.
17
78
Spare Parts List
PROXXON DS 460
ET- Nr.: Description ET- Nr.: Description
63
39
40
28
30
38
29
32
33
46
25
26
27
44
24
48
47
45
51
49
42
41
43
4
69
76
78
79
80
83
81
84
5
8
7
64
65
50
52
1
93
6
88
86
20
12
13
91
9
87
82
31
75
73
71
72
21
85
56
17
16
18
16
10
70
66
90
89
62
68
67
92
34
35
37
36
54
15
19
11
14
74
77
2
94
95
99
101
102
22
23
106
107
108
110
111
112
109
GB Service note
All PROXXON products are thoroughly inspected after production. Should a defect
occur nevertheless, please contact the dealer from whom you purchased the
product. Only the dealer is responsible for handling all legal warranty claims
which refer exclusively to material and manufacturer error.
Improper use, such as capacity overload, damage due to outside influences
and normal wear are excluded from the warranty.
You will find further notes for each country regarding "Service and Spare Parts
Management" at www.proxxon.com.
Art.-Nr.27094-99 Rev. 03/2013
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