909 LS1200 Instruction Manual - User Manual

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INSTRUCTION MANUAL

LS1200 / TCAT235

2000W

235MM (9 1/4”)
MAGNESIUM BASE
CIRCULAR SAW /

1200W

165MM (6 1/2”)

LASER GUIDED
CIRCULAR SAW

CONTENTS

Warranty Power Tools

For full details please visit us at www.909.com

Warranty

Introduction

Environmental protection

Description of symbols

Specifications

General safety rules

Additional safety rules for laser lights

Additional safety rules for circular saws

Accessories

Unpacking

Assembly

Know your product

Overview

Adjusting the cutting depth

Adjusting the bevel angle

Switching on and off

Making a cut

Making a pocket cut

Using the parallel fence

Using the laser system

Changing the blade

Maintenance

Cleaning

General inspection

Power cord maintenance

Troubleshooting

Description of symbols

The rating plate on your tool may show symbols.

These represent important information about the

product or instructions on its use.

Wear hearing protection.

Wear eye protection.

Wear breathing protection.

For safe operation read instruction manual.

Double insulated for additional protection.

Conforms to relevant standards

for electromagnetic compatibility.

Specifications

LS1200

TCAT235

Voltage:

230 – 240V ~ 50 Hz

Power rating:

1200W

2000W

No load speed:

5000 min

-1

4700 min

-1

Blade diameter:

165mm (6 1/2")

235mm (9 1/4")

Blade teeth:

40 TCT

Blade arbour:

16mm (5/8")

25.4mm (1”)

Blade kerf:

2.2mm

2.4mm

Bevel capacity:

0° to 55°

Depth of cut at 90°:

55mm (2 5/32")

82mm (3 1/4")

Depth of cut at 45°:

38mm (1 1/2")

58mm (2 9/32")

Laser:

Class 2

N/A

Electrical insulation:

Double insulated

Weight:

4.1kg (9.3lbs)

5.4kg (11.8lbs)

This tool is double insulated. There are two independent

barriers of insulation to protect you from the possibility of

electric shock.
The sound intensity level for the operator may exceed

85dB(A) and sound protection measures are necessary.

WARNINGS.

1. Do not attempt to change the position of the laser under

any circumstances, it has been set at the factory and is

accurately focused on the centre of the saw blade.

2. It may be more difficult to see the laser line in conditions

of bright sunshine and on certain surfaces.

Introduction

Your new 909 power tool will more than satisfy

your expectations. It has been manufactured under

stringent 909 Quality Standards to meet superior

performance criteria.
You will find your new tool easy and safe to operate,

and, with proper care, it will give you many years

of dependable service.

CAUTION.

Carefully read through this entire Instruction

Manual before using your new 909 Power Tool. Take

special care to heed the Cautions and Warnings.
Your 909 power tool has many features that will make

your job faster and easier. Safety, performance, and

dependability have been given top priority in the

development of this tool, making it easy to maintain

and operate.

Environmental protection

Recycle unwanted materials instead

of disposing of them as waste. All tools,

hoses and packaging should be sorted,

taken to the local recycling centre and

disposed of in an environmentally safe way.

General safety rules

WARNING.

Read all safety warnings and all instructions.

Failure to follow the warnings and instructions may result in

electric shock, fire and/or serious 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.

1) Work area safety
a) Keep work area clean and well lit.

Cluttered or dark

areas invite accidents.

b) 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.

c) Keep children and bystanders away while operating a

power tool.

Distractions can cause you to lose control.

2) Electrical safety
a) Power tool plugs must match the outlet. Never modify

the plug in any way.

Do not use any adapter plugs with

earthed (grounded) power tools. Unmodified plugs and

matching outlets will reduce risk of electric shock.

b) Avoid body contact with earthed or grounded

surfaces, such as pipes, radiators, ranges and

refrigerators.

There is an increased risk of electric

shock if your body is earthed or grounded.

c) Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of

electric shock.

d) 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.

e) 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.

f) To reduce the risk of electric shock, the manufacturer

recommends the use of a residual current device

with a rated residual current of 30mA or less at

all times.

3) Personal safety
a) 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.

b) 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.

c) 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.

d) Remove any adjusting key or wrench before

turning the power tool on.

A wrench or a key left

attached to a rotating part of the power tool may result

in personal injury.

e) Do not overreach. Keep proper footing and balance

at all times.

This enables better control of the power tool

in unexpected situations.

f ) 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.

g) 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.

4) Power tool use and care
a) 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.

b) Do not use the power tool if the switch does not turn

it on and off.

Any power tool that cannot be controlled

with the switch is dangerous and must be repaired.

c) 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.

d) 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.

e) 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.

f ) Keep cutting tools sharp and clean.

Properly

maintained cutting tools with sharp cutting edges are

less likely to bind and are easier to control.

g) 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.

h) This appliance is not intended for use by persons

(including children) with reduced physical, sensory

or mental capabilities, or lack of experience and

knowledge,

unless they have been given supervision or

instruction concerning use of the appliance by a person

responsible for their safety.

i) Children should be supervised to ensure that they do

not play with the appliance.

5) Service
a) 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.

Additional safety rules for laser lights

The laser light used in the system is Class 2 with maximum

1mW and 650nm wavelengths. These lasers do not

normally present an optical hazard, although staring at the

beam may cause flash blindness.

WARNING.

Do not stare directly at the laser beam.

A hazard may exist if you deliberately stare into the beam.

Please observe all safety rules as follows:

•

The laser shall be used and maintained in accordance

with the manufacturer’s instructions.

•

Never aim the beam at any person or an object other

than the work piece.

•

The laser beam shall not be deliberately aimed at

personnel and shall be prevented from being directed

towards the eye of a person for longer than 0.25s.

•

Always ensure the laser beam is aimed at a sturdy work

piece without reflective surfaces, i.e. wood or rough

coated surfaces are acceptable. Bright shiny reflective

sheet steel or the like is not suitable for laser use as

the reflective surface could direct the beam back at the

operator.

•

Do not change the laser light assembly with a different

type. Repairs must only be carried out by the laser

manufacturer or an authorised agent.

CAUTION.

Use of controls or adjustments or performance

of procedures other than those specified herein may result

in hazardous radiation exposure.

Additional safety rules for circular saws

WARNING!

The warnings, precautions, and instructions

discussed in this manual cannot cover all possible

conditions and situations that may occur. The operator must

understand that common sense and caution are factors

which cannot be built into this product, but must be supplied

by the operator.

DANGER

Keep hands away from cutting area and the blade.

Keep your second hand on auxiliary handle, or motor

housing. If both hands are holding the saw, they cannot

be cut by the blade.

Do not reach underneath the workpiece.

The guard

cannot protect you from the blade below the workpiece.

Adjust the cutting depth to the thickness of the

workpiece.

Less than a full tooth of the blade teeth

should be visible below the workpiece.

Never hold piece being cut in your hands or across

your leg.

Secure the workpiece to a stable platform. It is

important to support the work properly to minimize body

exposure, blade binding, or loss of control.

Hold power tool by insulated gripping surfaces when

performing an operation where the cutting tool may

contact hidden wiring or its own cord.

Contact with

a “live” wire will also make exposed metal parts of the

power tool “live” and shock the operator.

When ripping always use a rip fence or straight edge

guide.

This improves the accuracy of cut and reduces

the chance of blade binding.

Always use blades with correct size and shape

(diamond versus round) of arbour holes.

Blades that

do not match the mounting hardware of the saw will run

eccentrically, causing loss of control.

Never use damaged or incorrect blade washers or

bolt.

The blade washers and bolt were specially designed

for your saw, for optimum performance and safety of

operation.

Causes and operator prevention of kickback:

•

Kickback is a sudden reaction to a pinched, bound or

misaligned saw blade, causing an uncontrolled saw to lift

up and out of the workpiece toward the operator;

•

When the blade is pinched or bound tightly by the kerf

closing down, the blade stalls and the motor reaction

drives the unit rapidly back toward the operator;

•

If the blade becomes twisted or misaligned in the cut, the

teeth at the back edge of the blade can dig into the top

surface of the wood causing the blade to climb out of the

kerf and jump back toward the operator.

Kickback is the result of saw misuse and/or incorrect

operating procedures or conditions and can be avoided by

taking proper precautions as given below.

Maintain a firm grip with both hands on the saw and

position your arms to resist kickback forces.

Position

your body to either side of the blade, but not in line

with the blade. Kickback could cause the saw to jump

backwards, but kickback forces can be controlled by the

operator, if proper precautions are taken.

When blade is binding, or when interrupting a cut

for any reason, release the trigger and hold the saw

motionless in the material until the blade comes to

a complete stop.

Never attempt to remove the saw

from the work or pull the saw backward while the blade

is in motion or kickback may occur. Investigate and take

corrective actions to eliminate the cause of blade binding.

When restarting a saw in the workpiece, centre the

saw blade in the kerf and check that saw teeth are

not engaged into the material.

If saw blade is binding, it

may walk up or kickback from the workpiece as the saw

is restarted.

Support large panels to minimise the risk of blade

pinching and kickback.

Large panels tend to sag under

their own weight. Supports must be placed under the

panel on both sides, near the line of cut and near the

edge of the panel.

Do not use dull or damaged blades.

Unsharpened

or improperly set blades produce narrow kerf causing

excessive friction, blade binding and kickback.

Blade depth and bevel adjusting locking levers

must be tight and secure before making cut.

If blade

adjustment shifts while cutting, it may cause binding and

kickback.

Use extra caution when making a “plunge cut” into

existing walls or other blind areas.

The protruding

blade may cut objects that can cause kickback.

The protruding blade may cut objects that can

cause kickback.
a.

Check lower guard for proper closing before each

use.

Do not operate the saw if lower guard does not

move freely and close instantly. Never clamp or tie the

lower guard into the open position. If saw is accidentally

dropped, lower guard may be bent. Raise the lower guard

with the retracting handle and make sure it moves freely

and does not touch the blade or any other part, in all

angles and depths of cut.

Check the operation of the lower guard spring.

If the

guard and the spring are not operating properly, they

must be serviced before use. Lower guard may operate

sluggishly due to damaged parts, gummy deposits, or a

build-up of debris.

Lower guard should be retracted manually only for

special cuts such as “plunge cuts” and “compound

cuts.”

Raise lower guard by retracting handle and as

soon as blade enters the material, the lower guard must

be released. For all other sawing, the lower guard should

operate automatically.

Always observe that the lower guard is covering the

blade before placing saw down on bench or floor.

An unprotected, coasting blade will cause the saw to

walk backwards, cutting whatever is in its path. Be aware

of the time it takes for the blade to stop after switch is

released.

e. Do not use abrasive wheels
WARNING.

We recommend the use of a residual current

device with a residual current rating of 30mA or less.

Wear goggles
Wear earmuffs
Wear a breathing mask

Accessories

The 909 TIMBERCAT TCAT235 Circular saw is supplied

with the following accessories as standard:
1. 235 mm (9 1/4”) TCT Blade (not fitted)
2. Blade Wrench
3. Parallel Fence

The 909 TIMBERCAT LS1200 Circular saw is supplied

with the following accessories:
1. 165 mm (6 1/2”) TCT Blade (fitted)
2. Allen Key
3. Parallel Fence

Unpacking

Due to modern mass production techniques, it is unlikely

that your 909 Power Tool is faulty or that a part is missing.

If you find anything wrong, do not operate the tool until the

parts have been replaced or the fault has been rectified.

Failure to do so could result in serious personal injury.

Assembly

The 909 circular saw is packed fully assembled, except for

the blade and the Parallel Fence which will need to

be attached.

Know your product
TCAT235

1. On/Off Trigger switch
2. Lock-off button
3. Motor housing
4. Main handle
5. Front handle
6. Bevel adjustment lever
7. Bevel scale
8. Parallel fence

locking knob

9. Parallel fence
10. Blade guard lever
11. Lower blade guard
12. Base plate
13. Upper blade guard
14. Dust extraction port
15. Depth locking lever
16. Depth of cut indicator
17. Spindle lock button
18. Blade
19. Blade wrench
20. Blade guide notch
21. Parallel fence slots
22. Disc rotation indicator

7
8

Know your product
LS1200

1. Laser light assembly
2. Laser light on/off button
3. Laser light aperture
4. On/Off Trigger switch
5. Lock-off button
6. Motor housing
7. Main handle
8. Front handle
9. Bevel adjustment knob
10. Bevel scale
11. Parallel fence locking knob
12. Parallel fence
13. Blade guard lever
14. Lower blade guard
15. Base plate
16. Upper blade guard
17. Dust extraction port
18. Depth locking lever
19. Depth of cut indicator
20. Spindle lock button
21. Blade
22. Allen key
23. Blade guide notch
24. Parallel fence slots
25. Disc rotation indicator

Overview

You have purchased a 1200W or 2000W Circular Saw.
Please refer to the safety instructions given earlier in this

manual for important instructions.
The saw is capable of ripping and cross cutting hardwoods,

softwoods and man made boards quickly, accurately and safely.
By loosening the bevel adjustment knob/lever, the body and

the blade of the saw can be tilted to any angle up to 55° for

making angle cuts. Please note that the maximum depth of

cut is reduced when cutting at an angle.
The fixed upper blade guard encloses the upper part of the

blade. As the saw advances through the work piece,

the pivoting lower blade guard is pushed back by the edge

of the wood to expose only that part of the blade which is

needed. When the blade clears the work, the spring loaded

lower blade guard snaps back to completely enclose the

blade.

Adjusting the cutting depth

CAUTION.

Always ensure that the saw is switched off

and unplugged from the power supply before making

any adjustments.
1. Ensure that the saw is facing away from you.
2. Loosen the depth locking lever (Fig. A).
3. Hold the base plate flat against the edge of the work

piece and lift the body of the saw until the blade is at

the right depth (Fig. B). Use the depth of cut indicator to

determine the cutting depth.

4. Tighten the depth locking lever.

Note.

Always use the correct blade depth setting.

The correct blade depth setting for all cuts should not be

more than

(6.35mm) 1/4” below the material being cut.

Allowing more depth will increase the chance of kickback

and result in a rough cut.

Adjusting the bevel angle

CAUTION.

Always ensure that the saw is switched off

and unplugged from the power supply before making

any adjustments.
1. The saw can be adjusted to cut at any angle between

0° and 55°. When making 45° bevel cuts, there is a

notch in the saw base to help you line up the blade with

the line of cut. Align your line of cut with the inner blade

guide notch on the base of the saw when making 45°

bevel cuts.

2. Loosen the bevel adjustment knob/lever located at the

front of the base plate (Fig. C).

3. Tilt the body of the

saw until the required angle

is reached (Fig. D) using the

bevel scale as a guide.

4. Tighten the bevel adjustment

knob/lever to secure the base

plate (Fig. E).

Note.

Always make a trial cut in a scrap piece of material

along a guideline to determine how much you should offset

the blade from the guideline to make an accurate cut.

Switching on and off

1. Connect the plug to the power supply.
2. Depress the lock-off button (Fig. F) and squeeze the On/

Off trigger switch (Fig. G).

3. The blade will take approximately 2 seconds to reach

full speed.

4. When you release the On/Off trigger switch, the machine

turns off and the lock-off button re-engages to prevent

accidental operation.

CAUTION.

Allow the blade to come to a complete standstill

before setting the saw down.

Making a cut

1. Mark the line of cut on the work piece.
2. Adjust the depth of cut and bevel angle as required.
3. When making 90° cross or rip

cuts, align your line of cut with

the outer blade guide notch on

the base of the saw (Fig. H).

4. When making 45° bevel cuts,

align your line of cut with the

inner blade guide notch on the

base of the saw.

5. Rest the front edge of the

base on the work piece (Fig. I).

6. Start the motor by depressing

the lock-off button and

squeezing theOn/Off trigger

switch.

Note.

Always let the blade reach

full speed (approximately

2 seconds) before you begin

to cut into the work piece.

7. Slowly push the saw forward

using both hands (Fig. J).

8. When making a cut always

use steady, even pressure.

Forcing the saw causes rough

cuts and could shorten the life

of the saw or cause kickback.

Allow the blade and the saw to

do the work.

9. After completing your cut, release the trigger switch

and allow the blade to come to a complete stop.

Do not remove the saw from the work piece while the

blade is moving.

Note.

Since blade thickness varies, always make a trial

cut in scrap material along the guideline to determine how

much, if any, the guideline must be offset to get an

accurate cut.

Making a pocket cut

1. Adjust the depth of cut as

required.

2. Adjust the bevel setting to 0°.
3. Raise the lower blade guard

lever to expose the saw blade

and firmly rest the front of

the base flat against the work

piece with the rear handle

raised so the blade does not

touch the work piece (Fig. K).

Blade guide notch

4. With the blade just clearing the work piece, start the

motor by depressing the lock-off button and squeezing

the trigger switch.

5. Always let the blade reach full speed (approximately 2

seconds) before you begin to cut into the work piece.

6. Slowly lower the saw into the work piece, using the front

of the base resting on the work piece as a hinge point.

WARNING.

As soon as the blade starts cutting the material,

release the lower blade guard lever.
7. Once the base plate is flat against the work piece,

proceed cutting in a forward direction to the end of

the cut.

8. After completing your cut, release the trigger switch

and allow the blade to come to a complete stop.

Do not remove the saw from the work piece while the

blade is moving.

Note.

If the corners of your pocket cut are not completely

cut through, use a jigsaw or hand saw to finish the corners.

Using the parallel fence

The parallel fence allows you to make parallel cuts

in a sheet of wood, all at the same width.

CAUTION.

Always ensure that the saw is switched off

and unplugged from the power supply before making

any adjustments.

1. Loosen the parallel fence locking knob (Fig. L).
2. Slide the parallel fence through the parallel fence slots in

the base plate (Fig. M).

3. Adjust the parallel fence to the

required width and secure it in

position with the parallel fence

locking knob.

4. Ensure that the parallel

fence rests against the

wood along its entire length

to give a consistent parallel

cut (Fig. N).

Using the Laser system (Applicable only on

the LS1200 Circular Saw)

WARNING.

Before proceeding to use the laser line system,

ensure that the

Additional safety rules for laser lights

section is read and fully understood.
Always ensure the laser beam is aimed at a sturdy work

piece without reflective surfaces. i.e. wood or rough coated

surfaces are acceptable. Bright shiny reflective sheet steel

or the like is not suitable for laser use as the reflective

surface could direct the beam back at the operator.
Only turn laser beam on when tool is on the work piece.
1. Mark the line of the cut on the work piece.
2. Adjust the depth of cut and bevel angle as required.
3. Rest the front edge of the base on the work piece.
4. Switch on the laser beam using the laser light on/off

button (Fig. O).

5. Align the beam with the line on the work piece (Fig. P).

6. Start the motor by depressing the lock-off button (5) and

squeezing the On/Off trigger switch.

7. Always let the blade reach full speed (approximately

2 seconds) before you begin to cut into the work piece.

8. Slowly push the saw forward using both hands, keeping

the red laser light beam on the line of cut.

9. After completing your cut, release the trigger switch

and allow the blade to come to a complete stop.

Do not remove the saw from the work piece while the

blade is moving.

10. Switch off the laser beam on completion of the cut.

Note.

The laser generated line is preset to align with the left

side of the blade (closest to the motor).

Changing the blade

CAUTION.

Always ensure that the saw is switched off

and unplugged from the power supply before making any

adjustments.
1. Place saw on its side on a flat surface.
2. Rotate the saw blade by hand whilst depressing the

spindle lock button until the blade locks (Fig. Q).

3. Whilst depressing the spindle lock button, turn the blade

bolt anti-clockwise using the blade wrench or allen key

provided (Fig. R).

4. Remove the outer blade flange and the blade bolt.
5. Raise the lower blade guard using the blade

guard lever.

6. Remove the saw blade

from the inner flange

and pull it out (Fig. S)

7. Clean the saw blade

flanges thoroughly

before mounting the new

saw blade. Wipe a drop

of oil onto the inner and

outer flange where they

will touch the blade.

8. Mount the new saw blade onto

the spindle and against the

inner flange.

9. Replace the outer flange and

tighten the blade bolt (Fig. T).

WARNING.

The direction in

which the blade rotates has

to be the same as the direction of the arrow marked on

the housing.
10. Ensure that the spindle lock button is released.
11. Before using the saw again, check that the safety

devices are in good working order.

IMPORTANT.

After replacing the saw blade, make sure that

the saw blade runs freely by turning the blade by hand.
12. Plug the machine into a power socket and run the saw

under no load to check that it runs smoothly before

using it to cut any material.

Maintenance

WARNING.

Always ensure that the tool is switched off and

the plug is removed from the power point before making any

adjustments or maintenance procedures.

Cleaning

1. Keep the tool’s air vents unclogged and clean at all times.
2. Remove dust and dirt regularly. Cleaning is best done

with a rag.

3. Re-lubricate all moving parts at regular intervals.
4. If the body of the saw needs cleaning, wipe it with a soft

damp cloth. A mild detergent can be used but nothing like

alcohol, petrol or other cleaning agent.

5. Never use caustic agents to clean plastic parts.

CAUTION.

Do not use cleaning agents to clean the plastic

parts of the tool. A mild detergent on a damp cloth is

recommended. Water must never come into contact

with the tool.

General inspection

Regularly check that all the fixing screws are tight. They

may vibrate loose over time.

Power cord maintenance

If the supply cord needs replacing, the task must be carried

out by the manufacturer, the manufacturer’s agent, or a

qualified electrical service repairer to avoid a safety hazard.

Troubleshooting

Trouble

Problem

Suggested remedy

Saw will not start

Power cord not plugged in

Ensure that the cord is connected to the power supply

Power fault, fuse or circuit breaker tripped Check the power supply
Cord damaged

Use authorised service centre to repair or replace

Burned out switch

Use authorised service centre to repair or replace

Faulty motor

Use authorised service centre to repair or replace the motor

Blade does not reach
full speed

Tool is overheating

Turn off the tool and let it cool down to room temperature.
Inspect and clean the ventilation slots

Poor cutting

Blunt blade

Replace or sharpen circular saw blade

Vibration or abnormal
noise

Loose parts

Check to see that all knobs and levers are securely
tightened including bevel adjustment knob, depth locking
lever and parallel fence locking knob

Blade vibrating

Ensure that the blade nut is securely tightened

Moving parts excessively worn

Use a qualified electrical service repairer to repair or replace

Ask a Question ?