Dongcheng DJG04-355B User manual

Edition 3 Jan., 2017
Read through carefully and understand these instructions
before use.

GENERAL POWER TOOL SAFETY WARNINGS
(For All Power Tools)
WARNING! Read and understand all instructions. Failure
to follow all instructions listed below may result in electric shock, fire
and/or serious personal injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power
tool or battery-operated (cordless) power tool.
Work Area Safety
1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Power tools create sparks
which may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
Electrical Safety
4. Power tool plugs must match the outlet. Never modify the plug in anyway.
Do not use any adapter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
5. Avoid body contact with earthed or grounded surfaces, such as pipes,
radiators, ranges and refrigerators. There is an increased risk o electric shock
if your body is earthed or grounded.
6. Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
7. Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords increase the risk of electric shock.
8. When operating a power tool outdoors, use an extension cord suitable for
outdooruse. Use of a cord suitablefor outdoor use reduces the risk of electric shock.
9. If operating a power in a damp location is unavoidable, use a residual current
device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
NOTE: The term “residual current device (RCD)” may be replaced by the term
“ground fault circuit interrupter (GFCI)” or “earth leakage circuit breaker (ELCB)”.
Personal Safety
10.Stay alert, watch what you are doing and use common sense when operating a
power tool. Do not use a power tool while you are tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
11.Use personal protective equipment. Always wear eye protection. Protective
equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection
used for appropriate conditions will reduce personal injuries.
12.Prevent unintentional starting. Ensure the switch is in the off-position before
connecting to power source and /or battery pack, picking up or carrying the
tool. Carrying power tools with your finger on the switch or energising power tools
that have the switch on invites accidents.
13.Remove any adjusting key or wrench before turning the tool on. A wrench or a
key left attached to a rotating part of the power tool may result in personal injury.
14.Do not overreach. Keep proper footing and balance at all times. This enables
better control of the power tool in unexpected situations.
15.Dress properly. Do not wear loose clothing or jewellery. Keep your hair,
clothing, and gloves away from moving parts. Loose clothes, jewellery or long hair
can be caught in moving parts.
16.If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of dust collection
can reduce dust-related hazards.
Power Tool Use and Care
17.Do not force the power tool. Use the correct power tool for your application.
The correct power tool will do the job better and safer at the rate for which it was
designed.
-1- -2-

18. Do not use tool if switch does not turn it on or off. Any power tool that
cannot be controlled with the switch is dangerous and must be repaired.
19. Disconnect the plug from the power source and/or the battery pack from
the power tool before making any adjustments, changing accessories, or
storing power tools. Such preventive safety measures reduce the risk of
starting the power tool accidentally.
20. Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate
the power tool. Power tools are dangerous in the hands of untrained users.
21. Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
22. Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
23. Use the power tool, accessories and tool bits etc. in accordance with
these instructions, taking into account the working conditions and the
work to be performed. Use of the power tool for operations different from
those intended could result in a hazardous situation.
Service
24. Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
VOLTAGE WARNING:
Before connecting the machine to a power source (receptacle, outlet, etc.), be sure
the voltage supplied is the same as that specified on the nameplate of the machine.
A power source with voltage greater than that specified for the machine can result in
SERIOUS INJURY to the user, as well as damage to the machine. If in doubt, DO
NOT PLUG IN THE MACHINE. Using a power source with voltage less than
nameplate rating is harmful to the motor.
SPECIFICATIONS
※Due to the continuing program of research and development, the specifications
herein are subject to change without prior notice.
ADDITIONAL SAFETY RULES
1. This cut-off machine should only be placed on the ground for operation, never try to
mount it on a table.
2. Wear hearing protection during extended periods of operation, also wear safety
glasses.
3. Use only wheels with maximum operating speed at least as high as “No-Load Speed”
indicated on the machine nameplate. Be sure to use only fiberglass-reinforced
wheels.
4. Check the wheel carefully for cracks or damage before operation. Replace cracked or
damaged wheel immediately. Run the tool (with guard) at no load for about a minute,
keeping tool away from others. If wheel is flawed, it will likely separate during this test.
5. Secure the wheel carefully.
Rated Power Input
2000 W
No-Load Speed
3800 r/min
Max. Cutting Angle
45°
Max. Diameter for Cutting Discs
240 mm
Wheel Size
External Diameter
355 mm
Thickness
3 mm
Internal Diameter
25.4 mm
Max. Cutting Capacity
Pipe
100 mm
Profiled Bar
95 mm×120 mm
Net Weight
17KG
-3- -4-

6. Use only flanges specified for this tool.
7. Be careful not to damage the spindle, flanges (especially the installing surface)
or bolt. Damage to these parts could result in wheel breakage.
8. Never operate this cut-off machine without guards in place.
9. Make sure that the workpiece is securely clamped before cutting, and control the
feed speed according to the size, material or diameter of the workpiece. Use a
non-flammable block to support the end of the workpiece when it is too long.
10. Counterforce will be produced when switching on the machine. Hold the
machine firmly by your right hand and switch on the machine by another one.
11. Make sure the wheel is not contacting the workpiece before the switch is turned
on.
12. Before using this machine on an actual workpiece, let it run for a while. Watch
for vibration or wobbling that could indicate poor installation or a poorly
balanced wheel.
13. Watch out for flying sparks when operating. They can cause injury or ignite
combustible materials.
14. Remove material or debris from the area that might be ignited by sparks. Be
sure that others are not in the path of the sparks. Keep a proper, charged fire
extinguisher closely available.
15. Hold the handle firmly. Keep hands away from rotating parts.
16. Use the cutting edge of the wheel only. Never use side surface.
17. Do not attempt to keep the trigger in the ON position.
18. When cutting with a new wheel, do not press the handle down to the bottom.
That will cause the wheel cut into the ground. Do not press the handle down
more once the workpiece is cut off.
19. This cut-off machine is designed only for dry cutting; do not use any cooling fluid
in cutting operation. Wet or damp may weaken the intensity of the wheel and
invite dangerous.
20. Avoid overload operation. Stop operation immediately if you notice anything
abnormal.
21. If the wheel stops during operation, makes an odd noise or begins to vibrate,
switch off the tool immediately.
22. Always switch off and wait for the wheel to come to a complete stop before moving
workpiece or changing settings.
23. Do not touch the workpiece immediately after operation; it may be extremely hot and
could burn your skin.
24. This machine should be properly earthed when in use. Be sure to use an earth-leakage
circuit breaker, with actuating current not more than 30mA and actuating time not more
than 0.1s, if wok area is too hot and wet or poisoned by electric dust.
25. Store wheels in a dry location only.
SAVE THESE INSTRUCTIONS.
WARNING! MISUSE or failure to follow the safety rules stated in this instruction
manual may cause serious personal injury.
-5- -6-

INSTRUCTIONS FOR OPERATION
Stop Screw
Stop screw is used to prevent cut-off wheel
from contacting with worktable or ground.
When installing the cut-off wheel, set the
stop screw at a higher position. When the
wheel is worn to less than 330 mm in
diameter, set the stopper at lower position
so that the servicing life of the machine can
be prolonged.(Fig. 1)
Installing or Removing the
Wheel
Caution:
Always be sure that the machine is
switched OFF and unplugged before
installing or removing the cut-off
wheel.
Be sure to tighten the hex bolt
securely.
Always pull out the lock pin after
installing or removing the wheel or
before switching on the machine.
To remove the wheel, uplift the connecting
rod first (Fig. 2) and lift the adjustable guard
up to the end. (Fig. 3) Loosen the wing bolt
and pull the wheel guard cover backwards.
(Fig. 4)
Press the lock pin to prevent the wheel from
rotating. Loosen the hex bolt with wrench
and remove the hex bolt, outer flange and the wheel. (Fig. 5) Do not remove the O ring,
piston ring and the inner flange. (Fig. 6)
To install the wheel, follow the removing procedures in reverse.
Interval between Vise Plate and Guide Plate
The original spacing or interval between the vise plate and the guide plate is 0-170mm.
If your work requires wider spacing or
interval, proceed as follows to change the
spacing or interval.
Remove the two hex bolts which secure the
guide plate. Move the guide plate as the
direction of arrow shown in the right figure
and secure it by tightening the two hex bolts.
Then the space or interval can be set
between 35 to 205 mm or between 70 to 240
mm. But under such circumstance, fixity of
the workpiece turns bad relatively. (Fig. 7)
Setting for Desired Cutting
Angle
Caution:
When the space or interval is set between
35 to 205 mm or between 70 to 240 mm, the
-7- -8-

machine cannot be used to bevel cutting.
To change the cutting angle, loosen the two hex bolts which secure the guide plate.
Move the guide plate to the desired angle (0° - 45°) and tighten the hex bolts
securely. (Fig. 8)
Securing Workpiece
CAUTION:
Always set the vise nut to right fully
when securing the workpiece. Failure to
do so may result in insufficient securing
of the workpiece. This could cause the
workpiece to be ejected or cause a
dangerous breakage of the wheel.
By setting the vise nut to left, the thread
shaft can be moved rapidly in and out.
To grip workpieces, set the vise nut to
left and push the thread shaft until the vise plate contacts the workpiece. Set the vise
nut to right and then turn the vise handle clockwise to securely retain the workpiece.
(Fig. 9)
Spacer Blocks
When the cut-off wheel has worn down
considerably, use a spacer block of sturdy,
non-flammable material behind the
workpiece. (Fig. 10)
You can more efficiently utilize the worn
wheel by using the midpoint on the
periphery of the wheel to cut the
workpiece.
Cutting at an Angle
When cutting workpiece over 65mm wide at an angle, attach a straight piece of
wood (spacer) over 190mm long and 45mm wide to the guide plate. (Fig. 11)
Attach this spacer with screws through the holes in the guide plate.
If you use a spacer block which is slightly narrower than the workpiece. (Fig. 12) You
can also utilize the wheel economically.
Cutting Long Workpieces
Long workpiece must be supported by blocks of
non-flammable material on either end so that it will
be level with the base top. (Fig. 13)
Switch Action
CAUTION:
Before plugging in the tool, always check to see that
the switch trigger actuates properly and returns to
the “OFF” position when released.
To start the machine, simply press the switch trigger.
Release the switch trigger to stop. For continuous
operation, pull the switch trigger and then push in
the lock button. To stop the machine from the locked
position, press the switch trigger fully and then release it. (Fig. 14)
-9- -10-

Operation
CAUTION:
Proper handle pressure during cutting and maximum cutting efficiency can be
determined by the amount of sparks that is produced while cutting. Your pressure on
the handle should be adjusted to produce the maximum amount of sparks. Do not
force the cut by applying excessive pressure on the handle.
Hold the handle firmly. Switch on the machine and wait until the wheel attains full
speed before lowering gently into the cut. When the wheel contacts the workpiece,
gradually bear down on the handle to perform the cut. When the cut is completed,
switch off the machine and wait until the wheel has come to a complete stop before
returning the handle to the fully elevated position.
Cutting Capacity
The maximum cutting capacity of the machine depends on cutting angle and the
shape of the workpiece.
45°
100mm
95mm
95mm×105mm
100mm
90°
100mm
100mm
95mm×120mm
125mm
Carrying Machine
To move or carry the machine
conveniently, depress the handle and
hang the chain into the hook. (Fig. 15)
MAINTENANCE AND INSPECTION
CAUTION:
Always be sure that the machine is switched off and unplugged before attempting to
perform inspection or maintenance.
After Use
Brush off accumulation of dust on the base. Accumulation of dust in the motor or on the
base may cause a malfunction of the machine.
Inspecting the Mounting Screws
Regularly inspect all mounting screws and ensure that they are properly tightened.
Should any of the screws be loose, retighten them immediately. Failure to do so could
result serious hazard.
Changing Cut-off Wheel
When the cut-off wheel has worn down considerably and results in reduced efficiency,
replace with a new one immediately.
Storing after Operation
Disconnect the machine after operation and store it out of reach of children.
Lubrication
To prolong the service life of this machine, lubricate the machine’s active parts such as
those of shaft threads, vise plate and holder etc. every month.
Replacing Carbon Brushes
Remove and check the carbon brushes regularly. Replace when they wear down to the
limit mark (Fig. 16), in which time the motor will stop running automatically. Keep the
carbon brushes clean and free to slip in the holders. Both carbon brushes should be
Cutting
Angle
Shape of
Workpiece
-11- -12-

replaced at the same time. Use only
identical carbon brushes.
Use a screwdriver to remove the brush
holder caps. Take out the worn carbon
brushes insert new ones and secure the
brush holder caps. (Fig. 17)
※Damaged cord must be replaced by a special cord purchased from authorized
service center.
※To maintain product SAFETY and RELIABILITY, repairs, any other maintenance or
adjustment should be performed by authorized centers, always using original
replacement parts.
-13- -14-

EXPLANATION OF GENERAL VIEW
1
Ball Bearing
25
Safety Guard Screw
2
Gear(Large)
26
Gear Housing
3
Ball Bearing
27
Compression Spring
4
Drive Spindle
28
Lock Pin
5
Stator Wire（long）
29
Sleeve
6
Stator Wire（short）
30
Ball Bearing
7
Hex Flange Head Bolt
31
Washer
8
Paper Washer
32
Armature
9
Bearing Retainer
33
Insulation Washer
10
Circlip for Shaft
34
Ball Bearing
11
Connecting Rod
35
Baffle Plate
12
Open-end Blind Rivet
36
Pan Head Tapping Screw
13
Washer
37
Stator
14
Label
38
Motor Housing
15
Guard Assembly
39
Carbon Brush
16
Pan Head Screw (with Spring
and Flat Washer)
40
Brush Holder
17
Adjustable Guard Assembly
41
Brush Holder Cap
18
Inner/Outer Flange
42
Nameplate
19
O Ring
43
Pan Head Screw (with Spring and
Flat Washer)
20
Washer
44
Right Handle
21
Spring Washer
45
Switch
22
Hex. Head Bolt
46
Trigger Buckle
23
Safety Guard
47
Switch Trigger
24
Wing Bolt
48
Lock Lever
EXPLANATION OF GENERAL VIEW
49
Spring
74
Round Pin
50
Chain Hook
75
Small Shaft
51
Pin
76
Flat Washer
52
Left Handle
77
Dead Plate
53
Screw
78
Washer
54
Hex Lock Nut M6
79
Spring Washer
55
Lock-off Button
80
Hex. Nut
56
Pan Head Tapping Screw
81
Hex Flange Head Bolt (with
Spring Washer)
57
Pan Head Tapping Screw (with
Spring and Flat Washer)
82
Dead Baffle
58
Pan Head Tapping Screw
83
Compression Spring
59
Strain Relief
84
Spring Base
60
Block Hook
85
Hex Bolt
61
Cord Guard
86
Hex Lock Nut
62
Cord
87
Washer
63
Handle
88
Sleeve
64
Jack Screw
89
Hex. Nut
65
Round Pin
90
Spring Washer
66
Hex Bolt with Spring Washer
91
Hex Socket Head Screw
67
Wing Bolt
92
Connecting Rod Bracket
68
Saw Chain
93
Pan Head Tapping Screw (with
Spring and Flat Washer)
69
Vise Nut
94
Spark Baffle
70
Hex Flange Head Bolt (with
Spring Washer)
95
Backing Ring
71
Jaw Set
96
Tightening Screw
72
Weld Assembly
861
Wrench
73
Plastic Base
-15- -16-