DeWalt D28065-XE, D28065N-XE, D28115N-XE, D28115-XE Instruction Manual

D28065-XE, D28065N-XE, D28115-XE, D28115N-XE

HEAVY-DUTY ANGLE GRINDERS

INSTRUCTION MANUAL

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IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US AT: 1800 654 155 (Aust) or 09 259 1111 (NZ).

SAFETY INSTRUCTIONS FOR POWER TOOLS

When using power tools, always observe the safety regulations applicable in your
country to reduce the risk of fire, electric shock and personal injury. Read the following
safety instructions before attempting to operate this product. Keep these instructions in
a safe place.

General Safety Rules

WARNING! Read all instructions. Failure to follow all instructions listed below
may result in electric shock, fire and/or serious injury. The term “power tool” in all
of the warnings listed below refers to your mains operated (corded) power tool or
battery operated (cordless) power tool.

SAVE THESE INSTRUCTIONS

1. WORK AREA

a. Keep work area clean and well lit. Cluttered and 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.

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 safety equipment. Always wear eye protection. Safety equipment such

as dust mask, non-skid safety shoes, hard hat, or hearing protection used for
appropriate conditions will reduce personal injuries.

c. Avoid accidental starting. Ensure the switch is in the off position before

plugging in. Carrying power tools with your finger on the switch or plugging

in 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.

Definitions: Safety Guidelines

The definitions below describe the level of severity for each
signal word. Please read the manual and pay attention to
these symbols.

DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

injury.
CAUTION: Used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, may
result in property damage.

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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 these

devices 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 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 tools
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 and in the manner intended for the particular type of
power tool, 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.

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.

Electrical Safety

The electric motor has been designed for one voltage only. Always check that the
power supply corresponds to the voltage on the rating plate. 240 V AC means your
tool will operate on alternating current. As little as 10% lower voltage can cause loss
of power and can result in overheating. All DEWALT tools are factory tested; if this
tool does not operate, check the power supply. Your DEWALT tool is double insulated,
therefore no earth wire is required.

• Young children and the infirm. This appliance is not intended for use by
young children or infirm persons without supervision. Young children should be
supervised to ensure that they do not play with this appliance.

• Replacement of the supply cord. If the supply cord is damaged, it must be
replaced by the manufacturer or an authorised DEWALT Service Centre in order
to avoid a hazard.

Extension Cords

CAUTION: Use only extension cords that are approved by the country’s Electrical
Authority. Before using extension cords, inspect them for loose or exposed wires,
damaged insulation and defective fittings. Replace the cord if necessary.

MINIMUM GAGE FOR CORD SETS
For Cable length (m): 7.5 15 25 30 45 60
Use Cable with minimum rating (Amperes)
Tool Amperes

0 - 3.4 7.5 7.5 7.5 7.5 7.5 7.5

3.5 - 5.0 7.5 7.5 7.5 7.5 10 15

5.1 - 7.0 10 10 10 10 15 15

7.1 - 12.0 15 15 15 15 20 20

12.1 - 20.0 20 20 20 20 25 –

Safety Warnings Common for Grinding, Sanding, Wire Brushing,
and Abrasive Cutting-Off Operations:

a) This power tool is intended to function as a grinder, sander, wire brush,

polisher or cut-off tool. Read all safety warnings, instructions, illustrations
and specifications provided with this power tool. Failure to follow all

instructions listed below may result in electric shock, fire and/or serious injury.

b) Operations such as polishing are not recommended to be performed with this

power tool. Operations for which the power tool was not designed may create a

hazard and cause personal injury.

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c) Do not use accessories which are not specifically designed and

recommended by the tool manufacturer. Just because the accessory can be

attached to your power tool, it does not assure safe operation.

d) The rated speed of the accessory must be at least equal to the maximum

speed marked on the power tool. Accessories running faster than their rated

speed can break and fly apart.

e) The outside diameter and the thickness of your accessory must be within

the capacity rating of your power tool. Incorrectly sized accessories cannot be

adequately guarded or controlled.

f) The arbour size of wheels, flanges, backing pads or any other accessory

must properly fit the spindle of the power tool. Accessories with arbour holes

that do not match the mounting hardware of the power tool will run out of
balance, vibrate excessively and may cause loss of control.

g) Do not use a damaged accessory. Before each use inspect the accessory

such as abrasive wheels for chips and cracks, backing pad for cracks,
tear or excess wear, wire brush for loose or cracked wires. If power tool
or accessory is dropped, inspect for damage or install an undamaged
accessory. After inspecting and installing an accessory, position yourself and
bystanders away from the plane of the rotating accessory and run the power
tool at maximum no-load speed for one minute. Damaged accessories will

normally break apart during this test time.

h) Wear personal protective equipment. Depending on application, use face

shield, safety goggles or safety glasses. As appropriate, wear dust mask,
hearing protectors, gloves and workshop apron capable of stopping small
abrasive or workpiece fragments. The eye protection must be capable of

stopping flying debris generated by various operations . The dust mask or
respirator must be capable of filtrating particles generated by your operation.
Prolonged exposure to high intensity noise may cause hearing loss.

i) Keep bystanders a safe distance away from work area. Anyone entering the

work area must wear personal protective equipment. Fragments of workpiece

or of a broken accessory may fly away and cause injury beyond immediate area
of operation.

j) Hold power tool by insulated gripping surfaces only, when performing an

operation where the cutting accessory may contact hidden wiring or its own
cord. Cutting accessory contacting a “live” wire may make exposed metal par ts

of the power tool “live” and shock the operator.

k) Position the cord clear of the spinning accessory. If you lose control, the cord

may be cut or snagged and your hand or arm may be pulled into the spinning
accessory.

l) Never lay the power tool down until the accessory has come to a complete

stop. The spinning accessory may grab the surface and pull the power tool out

of your control.

m) Do not run the power tool while carrying it at your side. Accidental contact

with the spinning accessory could snag your clothing, pulling the accessory into
your body.

n) Regularly clean the power tool’s air vents. The motor’s fan will draw the dust

inside the housing and excessive accumulation of powdered metal may cause
electrical hazards.

o) Do not operate the power tool near flammable materials. Sparks could ignite

these materials.

p) Do not use accessories that require liquid coolants. Using water or other

liquid coolants may result in electrocution or shock.

Kickback and Related Warnings

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing
pad, brush or any other accessory. Pinching or snagging causes rapid stalling
of the rotating accessory which in turn causes the uncontrolled power tool to
be forced in the direction opposite of the accessory’s rotation at the point of the
binding.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the
edge of the wheel that is entering into the pinch point can dig into the surface
of the material causing the wheel to climb out or kick out. The wheel may either
jump toward or away from the operator, depending on direction of the wheel’s
movement at the point of pinching. Abrasive wheels may also break under these
conditions.

Kickback is the result of power tool misuse and/or incorrect operating procedures
or conditions and can be avoided by taking proper precautions as given below.

a) Maintain a firm grip on the power tool and position your body and arm to

allow you to resist kickback forces. Always use auxiliary handle, if provided,
for maximum control over kickback or torque reaction during start-up. The

operator can control torque reactions or kickback forces, if proper precautions
are taken.

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b) Never place your hand near the rotating accessory. Accessory may kickback

over your hand.

c) Do not position your body in the area where power tool will move if kickback

occurs. Kickback will propel the tool in direction opposite to the wheel’s

movement at the point of snagging.

d) Use special care when working corners, sharp edges etc. Avoid bouncing

and snagging the accessory. Corners, sharp edges or bouncing have a

tendency to snag the rotating accessory and cause loss of control or kickback.

e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such

blades create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and Abrasive
Cutting-Off Operations:

a) Use only wheel types that are recommended for your power tool and the

specific guard designed for the selected wheel. Wheels for which the power

tool was not designed cannot be adequately guarded and are unsafe.

b) The guard must be securely attached to the power tool and positioned for

maximum safety, so the least amount of wheel is exposed towards the
operator. The guard helps to protect operator from broken wheel fragments and

accidental contact with wheel.

c) Wheels must be used only for recommended applications. For example: do

not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended

for peripheral grinding, side forces applied to these wheels may cause them to
shatter.

d) Always use undamaged wheel flanges that are of correct size and shape for

your selected wheel. Proper wheel flanges support the wheel thus reducing the

possibility of wheel breakage. Flanges for cut-off wheels may be different from
grinding wheel flanges.

e) Do not use worn down wheels from larger power tools. Wheel intended for

larger power tool is not suitable for the higher speed of a smaller tool and may
burst.

Additional Safety Warnings Specific for Abrasive
Cutting-Off Operations:

a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt

to make an excessive depth of cut. Overstressing the wheel increases the

loading and susceptibility to twisting or binding of the wheel in the cut and the
possibility of kickback or wheel breakage.

b) Do not position your body in line with and behind the rotating wheel. When

the wheel, at the point of operation, is moving away from your body, the
possible kickback may propel the spinning wheel and the power tool directly at
you.

c) When wheel is binding or when interrupting a cut for any reason, switch off

the power tool and hold the power tool motionless until the wheel comes to a
complete stop. Never attempt to remove the cut-off wheel from the cut while
the wheel is in motion otherwise kickback may occur. Investigate and take

corrective action to eliminate the cause of wheel binding.

d) Do not restart the cutting operation in the workpiece. Let the wheel reach full

speed and carefully reenter the cut. The wheel may bind, walk up or kickback

if the power tool is restarted in the workpiece.

e) Support panels or any oversized workpiece to minimize the risk of wheel

pinching and kickback. Large workpieces tend to sag under their own weight.

Supports must be placed under the workpiece near the line of cut and near the
edge of the workpiece on both sides of the wheel.

f) Use extra caution when making a “pocket cut” into existing walls or other blind

areas. The protruding wheel may cut gas or water pipes, electrical wiring or
objects that can cause kickback.

Safety Warnings Specific for Sanding Operations:

a) Do not use excessively oversized sanding disc paper. Follow manufacturers

recommendations, when selecting sanding paper. Larger sanding paper

extending beyond the sanding pad presents a laceration hazard and may cause
snagging, tearing of the disc or kickback.

Safety Warnings Specific for Wire Brushing Operations:

a) Be aware that wire bristles are thrown by the brush even during ordinary

operation. Do not overstress the wires by applying excessive load to the
brush. The wire bristles can easily penetrate light clothing and/or skin.

b) If the use of a guard is recommended for wire brushing, do not allow any

interference of the wire wheel or brush with the guard. Wire wheel or brush

may expand in diameter due to work load and centrifugal forces.

Additional Safety Instructions

• Check that the grinding wheel backing flange has a yellow rubber ring (F)

installed, see Figure 1. Replace rubber ring if missing, damaged or worn. See
page 5 for details regarding proper accessory installation.