DeWalt D28066 TYPE 1 Owner’s Manual

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INSTRUCTION MANUAL GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA DE GARANT[A. ADVERTENOIA: LEASE ESTE INSTRUCTIVO ANTES DE

USAR EL PRODUCTO.

D28065, D28065N, D28066N, D28115, D28115N

Angle Grinders

Meuleuses & renvoi d'angle Esmeriladoras de &ngulo

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. i_WARNING: Indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury. i_,CAUTION: Indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury. NOTICE: Indicates a practice not related to personal injury

which, if not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR

ANY DEWALT TOOL, CALL US TOLL FREE AT: 1-800-4-DEWALT

(1-800-433-9258}.

_ ARNING: To reduce the risk of injury, read the instruction

manual.

General Power Tool Safety Warnings

_ 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) If operating a powertool in a damp location isunavoidable,

use a ground fault circuit interrupter (GFCI) protected

supply. Use of a GFC/ 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 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 energizing 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 jewelry.

Keep your hair, clothing and gloves away from moving

parts. Loose clothes, jewelry 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.

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.

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.

SAFETY INSTRUCTIONS FOR

ALL OPERATIONS

Safety Warnings Common for Grinding, Sanding, Wire Brushing, Polishing or

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 a//instructions

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

b) 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.

c) 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.

d) The outside diameter and the thickness ofyour accessory

must be within the capacity rating of your power tool Incorrectly sized accessories cannot be adequately guarded or controlled.

e) The arbor size of wheels, flanges, backing pads or

any other accessory must properly fit the spindle of the power tool Accessories with arbor holes that do not match the mounting hardware of the power too/wi//run out of balance, vibrate excessively and may cause loss of control

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.

g) 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.

h) 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.

i) 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 parts of the power tool "live" and shock the operator.

j) Position the cord clear of the spinning accessory./f you

lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.

k) 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

I) 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.

m) 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.

n) Do not operate the power tool near flammable materials.

Sparks could ignite these materials.

o) Do not use accessories that require liquid coolants.

Using water or other liquid coolants may result in electrocution or shock.

p) When starting the tool with a new or replacement wheel,

or a new or replacement wire brush installed, hold the tool in a well protected area and let it run for one minute.

If the wheel has an undetected crack or flaw, it should burst in less than one minute. If the wire brush has loose wires, they will be detected. Never start the tool with a person in line with the wheel This includes the operator.

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 reaction or kickback forces, if

proper precautions are taken.

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. Comers,

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, accidental contact with wheel, and sparks that could ignite clothing.

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 'yam" 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 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 Polishing

Operations

a) Do not allow any loose portion of the polishing bonnet

or its attachment strings to spin freely. Tuck away or trim

any loose attachment strings. Loose and spinning attachment strings can entangle your fingers or snag on the workpiece.

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 centritugal tomes.

c) Safety goggles or safety glasses with side shields and a full

face shield compliant with ANSI Z87.1 MUST be worn by the operator and others that are within 50' (15.2 m) of the use of

this product.

Additional Safety Rules for Grinders

_ WARNING: The grinding wheel or accessory may loosen during coast-down of the tool when shut off./f grinding wheel

or accessory loosens, it may dismount from the machine and may cause serious personal injury.

• Use of accessories not specified in this manual is not

recommended and may be hazardous. Use of power boosters that would cause the tool to be driven at speeds greater than its rated speed constitutes misuse.

• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand

or against your body leaves it unstable and may lead to loss of control

• Avoidbouncing the wheel orgiving it rough treatment. If this occurs, stop the tool and inspect the wheel for cracks or flaws.

• Always handle and store wheels in a careful manner.

• Never cut into area that may contain electrical wiring or

piping. Serious injury may result.

• Do not operate this tool for long periods of time. Vibration caused by the operating action of this tool may cause permanent

injury to fingers, hands, and arms. Use gloves to provide extra

cushion, take frequent rest periods, and limit daily time of use.

• Do not use Type 11 (flaring cup) wheels on this tool. Using

inappropriate accessories can result in injury.

• Always use side handle. Tighten the handle securely. The

side handle should always be used to maintain control of the tool at all times.

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.

• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge

number of the wire, the greater the capacity of the cable, that is

16 gauge has more capacity than 18 gauge. An undersized cord

will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the

minimum wire size. The following table shows the correct size to

use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. Thesmaller the gauge number, the heavier the cord.

Minimum Gauge for Cord Sets

Volts

Ampere Rating

More Not More Than Than

0 6 18 16 16 14

6 10 18 16 14 12 10 12 16 16 14 12 12 16 14 12 NotRecommended

120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7) 240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)

Total Length of Cord

in Feet (meters)

AWG

_, WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is

dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),

• ANSI $12.6 ($3.19) hearing protection,

• NIOSH/OSHA/MSHA respiratory protection.

WARNING: Some dust created by power sanding, sawing,

grinding, drilling, and other construction activities contains chemicals

known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals:

work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to

filter out microscopic particles.

• Avoid prolonged contact with dust from power sanding,

sawing, grinding, drilling, and other construction activities.

Wear protective clothing and wash exposed areas with

soap and water. Allowing dust to get into your mouth, eyes, or

lay on the skin may promote absorption of harmful chemicals. A WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury.

Always use NIOSH/OSHA approved respiratory protection appropriate

for the dust exposure. Direct particles away from face and body. i_ WARNING: Always wear proper personal hearing protection

that conforms to ANSI $12.6 ($3.19) during use. Under some conditions and duration of use, noise from this product may

contribute to hearing loss.

• The label on your tool may include the following symbols. The

symbols and their definitions are as follows:

V................... volts A...................... amperes

Hz................. hertz W ..................... watts

min ............... minutes "_ or AC .......... alternating

- -- or DC... direct current current

(_)................. Class I Construction _, or AC/DC...altemating or

(grounded) direct current

[] ................. Class II Construction no .................... no load

(double insulated) speed

.../min .......... per minute n ...................... rated speed

BPM ............. beats per minute _ ..................... earthing

IPM ............... impacts per minute terminal

RPM ............. revolutions per _ ..................... safety alert

minute symbol

sfpm ............. surface feet per minute

SAVE THESE INSTRUCTIONS FOR

FUTURE USE

COMPONENTS (Fig. 1)

_ WARNING: Never modify the power

or personal injury could result.

A. Trigger Switch G2. B. Lock On Button

(D28065, D28115 only) C. Spindle Lock Button D. Type 27 Guard H.

E. Dust Ejection SystemTM I.

(DES)

F.Yellow Rubber Ring J'

G1.1-11/16" (43 mm) diameter

quick-change backing flange

INTENDED USE

The D28066, D26066N, D28066N, D28116, D28116N heavy-duty angle grinders have been designed for professional grinding at various work sites (i.e., construction sites). DO NOT use under wet conditions or in presence of flammable liquids or gases.

These heavy-duty angle grinders are professional power tools. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

ASSEMBLY AND ADJUSTMENTS

_,WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off. An accidental start-

up can cause injury.

tool or any part of it. Damage

3" (76 mm) diameter stamped steel backing flange (D28065, D28066N, D28065N only)

Threaded Clamp Nut Anti-Vibration Side Handle

(not shown)

Lock Off Button

(D28066N, only)

FIG. 1

D E

F_ G2

4-1/2" (114.3 mm) and 5" (127 mm)

Grinding Wheels

6" (152 mm) Grinding Wheels

Type 27 guard

1-11/16" (43 mm)

diameter quick-change

backing flange

Type 27 guard

Type 27 hubbed wheel

Type27 depressed

center wheel

Attaching Side Handle (Fig. 2)

The side handle (I)can be fitted to either side of the gear case in the threaded holes, as shown. Before using the tool, check that the handle is tightened securely. Use a wrench to firmly tighten the side

handle.

FIG. 2

Type27 guard

3" (76 mm) diameter

stamped steel

backing flange

Type 27 depressed

center wheel

threaded clamp nut

Type 27 guard

Type27 hubbed wheel

4-1/2" (114.3 mm) and

5" (127 mm) Cutting Wheels

6" (152 mm) Cutting Wheels

Type 1 guard

1-11/16" (43 mm)

diameter quick-change

backing flange

Type 1 abrasive

cutting wheel

threaded clamp nut

Wire Wheels

Type27 guard

3" (76,2 mm)

wire cup brush

Type 1 guard

1-11/16" (43 mm)

diameter quick-change

backing flange

diamond cutting wheel

threaded clamp nut

Type27 guard

4" (101.6 mm)

wire wheel

Type 1 guard

1-11/16" (43 mm)

diameter quick-change

backing flange

Type 1 abrasive

cutting wheel

threaded clamp nut

Type 1 guard

1-11/16" (43 mm)

diameter quick-change

backing flange

Diamond

cutting wheel

threaded clamp nut

Sanding Discs

rubber backing pad

sanding disc

threaded clamp nut

Type27 guard

3" (76 mm)

diameter stamped

steel backing flange

Type27 depressed

center wheel

threaded clamp nut

(114.3 mm) and 5" (127 mm)

Sanding Flap Discs

Type 27 guard

hubbed sanding

flap disc

Rotating the Gear Case

1. Remove guard and flanges from tool.

2. Remove the four corner screws attaching the gear case to motor housing.

3. Separating the gear case from motor housing not more than 1/4" (6.35 mm), rotate the gear case head to desired position.

Type 27 guard

1-11/16" (43 mm)

diameter quick-change

backing flange

non-hubbed sanding

flap disc

threaded clamp nut

NOTE: If the gear case and motor housing become separated by more than 1/4" (6.35 mm), the tool must be serviced and re-assembled by a DEWALTservice center. Failureto have the tool

serviced may cause brush, motor and bearing failure.

4. Re-install screws to attach the gear case to the motor housing. Tighten screws to 18 in./Ibs. (2.03 Nm) torque. Overtightening

could cause screws to strip.

5. Re-install guard and correct flanges for the appropriate accessories.

Accessories

Itis important to choose the correct guards, backing pads and flanges to use with grinder accessories. See pages 9-11 for information on

choosing the correct accessories. _ WARNING: Accessories must be rated for at least the speed

recommended on the toolwaming label Wheels and other accessories running over rated accessory speed may burst and cause injury. Threaded accessories must have a 5/8 "-11 hub. Every unthreaded accessory must have a 7/8" (22.2 mm) arbor hole. If it does not, it may have been designed for a circular saw and should not be used. Use only the accessories shown on pages 9-11 of this manual

Accessory ratings must be above listed minimum wheel speed as

shown on tool nameplate.

Mounting Guard

MOUNTING AND REMOVING GUARD (FIG. 3, 4}

_, CAUTION: Guards must be used with all grinding wheels, sanding flap discs, wire brushes, and wire wheels. The tool may

be used without a guard only when sanding with conventional sanding discs. Type 27 guards are provided for use with Type 27 depressed center wheels and Type 27 hubbed grinding wheels. These guards are designed for for use with sanding flap discs (Type 27 and 29) and wire brushes. Grinding and cutting with wheels other

thanType27and29requiredifferentaccessoryguardsnotincluded withtoolMountinginstructionsfortheseaccessoryguardsare includedintheaccessorypackage.

1. Opentheguardlatch(M).Alignthelugs(K)on FIG.3 the guard with the slots (L) on the gear K.

case.

2. Push the guard down until the guard lugs engage and rotate freely in the groove on the gear case hub.

3. With the guard latch open, rotate the guard (D) into the desired working position. The M guard body should be positioned between the spindle and the operator to provide maximum operator protection.

4. Close the guard latch to secure the guard on the gear case. You should not be able to rotate the guard by hand when the latch D is closed. Do not operate the grinder with a loose guard or the clamp lever in open position.

5. To remove the guard, open the guard latch, rotate the guard so that the arrows are aligned and pull up on the guard.

NOTE: The guard is pre-adjusted to the FIG.4 diameter of the gear case hub at the factory. If, after a period of time, the guard becomes loose, tighten the adjusting screw (N) with clamp lever in the closed position.

A CAUTION: Do not tighten the adjusting screw with the clamp lever

in open position. Undetectable damage to the guard or the mounting hub may result.

i_ CAUTION: If guard cannot be tightened by adjusting clamp, do not use tool and take the tool and guard to a service center to repair or replace the guard.

OPERATION

WARNING: To reduce the risk of injury, turn unit off and

disconnect ff from power source before installing and removing accessories, before adjusting or when making repairs. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off. An accidental start-up can cause

injury.

Guards and Flanges

It isimportant to choose the correct guards and flanges to use with the grinder accessories. See pages 9-11 for the correct accessories.

NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose.

_ WARNING: Accessories must be rated for at least the speed

recommended on the toolwaming label Wheels and other accessories running over rated accessory speed may burst and cause injury. Every unthreaded accessory must have a 7/8" (22.2 mm) arbor hole. Ifit does not, it may have been designed for a circular saw and should not be used. Use only the accessories shown on pages 9-11.

Accessory ratings must be above listed minimum wheel speed as

shown on tool nameplate.

Trigger Switch (Fig. 1, 5, 6)

A CAUTION: Hold the side handle and body of the tool firmly to maintain control of the tool at start up and during use and until the wheel or accessory stops rotating. Make sure the wheel has come to a complete stop before laying the tool down.

NOTE: To reduce unexpected tool movement, do not switch the tool on or off while under load conditions. Allow the grinder to run up to full speed before touching the work surface. Lift the tool from the surface before turning the tool off. Allow the tool to stop rotating before putting it down.

i_ CAUTION: Before connecting the tool to a power source depress and release the trigger switch (A) once without depressing the lock-on

button (B) to ensure that the switch is off. Depress and release the trigger switch as described above after any interruption in power

supply to the tool, such as the activation of a ground fault interrupter, throwing of a circuit breaker, accidental unplugging, or power failure.

TRIGGER SWITCH OPERATION (FIG. 5}

To turn the tool on, depress the trigger switch (A). The tool will run while the switch is depressed. Turn the tool off by releasing the

trigger switch.

LOCK-ON BUTTON (D28065, D28115) (FIG. 5}

The lock-on button (B) offers increased comfort FIG.5 in extended use applications. To lock the tool

on, depress the trigger switch (A), then push the lock-on button (B).The tool will continue to

run after the trigger switch is released. To unlock the tool, depress and releasethe trigger

switch. This will cause the tool to stop. B A

i_ CAUTION: Allow the tool to reach full speed before touching tool to the work surface. Lift the tool from the

work surface before turning the tool off.

LOCK-OFF Bu'rI'ON (FIG. 1, 6) D28066N FIG.6 J

1. To turn the tool on, depress lock-off button (J) and then depress the trigger switch (A).

2. Turn the tool off by releasing the trigger switch.

SPINDLE LOCK (FIG. 7)

The spindle lock (C) is provided to prevent the spindle from rotating when installing or removing

wheels. Operate the spindle lock only when the tool is turned off, unplugged from the power

supply, and has come to a complete stop. Do not engage the spindle lock while the tool is

operating because damage to the tool will result. To engage the lock, depress the spindle

lock button and rotate the spindle until you are unable to rotate the spindle further.

FIG. 7

Mounting and Using Depressed Center Grinding Wheels and Sanding Flap Discs

MOUNTING AND REMOVING HUBBED WHEELS

Hubbed wheels install directly on the 5/8"-11 threaded spindle. Thread of accessory must match thread of spindle.

1. Backing flange is retained to the grinder by an O-ring on the spindle. Remove backing flange by pulling and twisting flange

away form the machine.

2. Thread the wheel on the spindle by hand.

3. Depress the spindle lock button and use a wrench to tighten the hub of the wheel.

4. Reverse the above procedure to remove the wheel.

CAUTION: Failure to properly seat the wheel before turning the

tool on may result in damage to the tool or the wheel

MOUNTING NON-HUBBED WHEELS (FIG. 8, 9)

Depressed center Type 27 grinding wheels must be used with included flanges.

NOTE: The 3" (76 mm) diameter stamped FIG.8 steel backing flange (G2) is ONLY for use with G1,G2 6" (152 mm) Type 27 grinding wheels. Refer to pages 9-11 for more information.

1. Install the 3" (76 mm) diameter stamped O steel backing flange (G2) for 6" (152 mm)

Type 27 wheels or the 1-11/16" (43 mm) diameter quick-change backing flange (G1) for all other non-hubbed wheels on

spindle (O) with the raised section (pilot) against the wheel. Be sure the backing

flange recess is seated onto the flats of the H spindle by pushing and twisting the flange before placing wheel.

2. Place wheel against the backing flange, centering the wheel on the raised section (pilot) of the backing flange.

3. While depressing the spindle lock button, thread the clamp nut (H) on spindle. If the wheel you are installing is more than 1/8" (3.17 mm) thick, place the threaded clamp nut

on the spindle so that the raised section (pilot) fits into the center of the wheel. If the wheel you are installing is 1/8"

(3.17 mm) thick or less, place the threaded clamp nut on the spindle so that the raised section (pilot) is not against the wheel.

4. While depressing the spindle lock button, tighten the clamp nut with a wrench.

5. To remove the wheel, depress the spindle lock button and loosen the threaded clamp nut with a wrench.

NOTE: If the wheel spins after the clamp nut is tightened, check the orientation of the threaded clamp nut. If a thin wheel is installed with the pilot on the clamp nut against the wheel, it will spin because the height of the pilot prevents the clamp nut from holding the wheel.

FIG. 9

Wheels thicker than

1/8" (3.17 mm)

threaded clamp nut

Quick-Change Quick-Change backing flange backing flange

Wheels 1/8" (3.17 mm)

and thinner

threaded clamp nut

SURFACE GRINDING WITH GRINDING WHEELS (FIG. 10)

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply minimum pressure to the work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool

operates at high speed.

3. Maintain a 20° to 30° angle between the FIG.10 tool and work surface.

4. Continuously move the tool in a forward and back motion to avoid creating gouges

20°_30°

in the work surface.

5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

EDGE GRINDING WITH GRINDING WHEELS (FIG. 11)

J_CAUTION: Wheels used for cutting and edge grinding may break if

they bend or twist while the tool is being used to do cut-off work or deep grinding. Toreduce the risk of serious injury, limit the use of these wheels with a standard Type 2 7guard to shallow cutting and notching

[less than 1/2" (12.7 mm) in depth]. The open side of the guard must

be positioned away from the operator. For deeper cutting with a

Type 1 cut-off wheel, use a closed, Type 1 guard. See the chart on

page 10 for more information. Type 1guards are available at extra cost

from your local dealer or authorized service center.

1. Allow the tool to reach full speed before FIG.11 touching the tool to the work surface.

2. Apply minimum pressure to the work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool operates at high speed.

3. Position yourself so that the open- underside of the wheel is facing away

from you.

4. Once a cut is begun and a notch is established in the workpiece, do not

change the angle of the cut. Changing the angle will cause the wheel to bend

and may cause wheel breakage. Edge grinding wheels are not designed to withstand side pressures caused by bending.

5. Remove the tool from the work surface before turning the tool off. Allow the tool to stop rotating before laying it down.

WARNING: Do not use edge grinding/cutting wheels for surface grinding applications because these wheels are not designed for side pressures encountered with surface grinding. Wheel breakage and

injury may result.

SURFACE FINISHING WITH SANDING FLAP DISCS (FIG. 12)

3. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Sanding rate is greatest when the tool operates at high speed.

3. Maintain a 5° to 10° angle between FIG.12 the tool and work surface.

4. Continuously move the tool in a

forward and backward motion to ....6°--10°

avoid creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

MOUNTING SANDING BACKING PADS (FIG. 13)

A CAUTION: Proper guard must be reinstalled for grinding wheel, sanding flap disc, wire brush or wire wheel applications after

sanding applications are complete.

1. Place or appropriately thread backing pad (Q) on the spindle.

2. Place the sanding disc (P)on the backing pad.

3. While depressing spindle lock, thread FIG.13 clamp nut (H) on spindle, piloting the H_ P

raised hub on the clamp nut into the center of sanding disc and backing pad.

4. Tighten the clamp nut by hand. Then

depress the spindle lock button while .........

turning the sanding disc until the sanding disc and clamp nut are snug.

5. To remove the wheel, grasp and turn ,Q the backing pad and sanding pad while

depressing the spindle lock button.

USING SANDING BACKING PADS (FIG. 14}

Choose the proper grit sandpaper for your application. Sandpaper is available in various grits. Coarse grits yield faster material removal rates and a rougher finish. Finer grits yield slower material removal

and a smoother finish.

Beginwithcoarsegritdiscsforfast,roughmaterialremoval.Move toamediumgritpaperandfinishwithafinegritdiscforoptimal

finish.

Coarse 16-30grit

Medium 36-80grit FineFinishing 100- 120grit

VeryFineFinishing 150- 180grit

1.Allowthetooltoreachfullspeedbeforetouchingtooltothework surface.

2.Applyminimumpressuretoworksurface,allowingthetoolto operateathighspeed.Sandingrateisgreatestwhenthetool operatesathighspeed.

3.Maintaina5°to15°anglebetweenthetoolandworksurface. Thesandingdiscshouldcontactapproximatelyoneinchofwork

surface.

4.Movethetoolconstantlyinastraightline FIG.14 topreventburningandswirlingofwork surface.Allowingthetooltorestonthe worksurfacewithoutmoving,ormoving

thetoolin a circularmotioncauses burningandswirlingmarksonthework

surface.

5.Removethetoolfromworksurfacebeforeturningtooloff.Allow thetooltostoprotatingbeforelayingitdown.

Mounting and Using Wire Brushes

and Wire Wheels

Wire cup brushes or wire wheels screw directly on the grinder spindle without the use of flanges. Use only wire brushes or wheels

provided with a 5/8"-11 threaded hub. A Type 27 guard is required when using wire brushes and wheels.

i_ CAUTION: Wear work gloves when handling wire brushes and

wheels. They can become sharp. i_,CAUTION: Wheel or brush must not touch guard when mounted

or while in use. Undetectable damage could occur to the accessory, causing wires to fragment from accessory wheel or cup.

MOUNTING WIRE BRUSHES AND WIRE WHEELS

1. Thread the wheel on the spindle by hand.

2. Depress spindle lock button and use a wrench on the hub of the wire wheel or brush to tighten the wheel.

3. To remove the wheel, reverse the above procedure.

i_ CAUTION: Failure to properly seat the wheel hub before turning

the tool on may result in damage to tool or wheel

USING WIRE CUP BRUSHES AND WIRE WHEELS (FIG. 15, 16)

Wire wheels and brushes can be used for removing rust, scale and paint, and for smoothing irregular surfaces.

1. Allow the tool to reach full speed before FIG.15 touching the tool to the work surface.

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Material removal rate is

greatest when the tool operates at high speed.

3. Maintain a 5°to 10° angle between the tool and work surface for wire cup brushes.

4. Maintain contact between the edge of the wheel and the work surface with wire wheels.

5.Continuouslymovethetoolinaforwardand FIG.16 backwardmotiontoavoidcreatinggougesin

theworksurface.Allowingthetooltoreston theworksurfacewithoutmoving,ormovingthe toolina circularmotioncausesburningand swirlingmarksontheworksurface.

6.Removethetoolfromtheworksurfacebefore turningthetooloff.Allowthetoolto stop

rotatingbeforesettingitdown.

i_CAUTION: Use extra care when working over an edge,

sudden sharp movement of grinder may be experienced.

Mounting and Using Cutting (Type 1) Wheels (Fig. 1)

Cutting wheels include diamond wheels and abrasive discs. Abrasive cutting wheels for metal and concrete use are available. Diamond blades tor concrete cutting can also be used.

NOTE: All grinders that use Type 1 wheels use the 1-11/16" (43 mm) diameter quick-change backing flange (G1).

A WARNING: A closed, 2-sided cutting wheel guard is not included

with this tool and is required when using cutting wheels. Failureto use

proper flange and guard can result in injury resulting from wheel

breakage and wheel contact. See page 10 for more information.

MOUNTING CLOSED (TYPE 1) GUARD (FIG. 17, 18)

1. Open the guard latch (M). Align the lugs (K)on the guard with the slots (L) on the gear case.

as a

Push the guard down until the guard FIG. 17 lug engages and rotates freely in the L M

groove on the gear case hub.

Rotate guard (D) into desired working position. The guard body should be positioned between the spindle and K the operator to provide maximum operator protection.

Close the guard latch to secure the guard on the gear case cover. You should be unable to rotate the guard by hand when the latch is in closed position. If rotation is possible, D tighten the adjusting screw (N) with clamp lever in the closed position. Do not operate grinder with a loose guard or clamp lever in open position.

To remove the guard, open the guard latch, rotate the guard so that the arrows are aligned and pull up on the guard.

NOTE: If, after a period of time, the guard becomes loose, tighten the adjusting screw (N) with the clamp lever in the closed position.

ACAUTION: Do not tighten adjusting screw

with clamp leverin open position. Undetectable damage to guard or mounting hub may result.

MOUNTING CUTTING WHEELS (FIG. 9)

_ CAUTION: The quick-change backing flange and threaded clamp nut (included with tool) must be the same diameter when used with cutting wheels.

FIG. 18

1.Placetheunthreaded1-11/16"(43mm)diameterquick-change backingflangeonspindlewiththeraisedsection(pilot)facingup. Theraisedsection(pilot)onthebackingflangewillbeagainstthe

wheelwhenthewheelisinstalled.

2.Placethewheelonthe1-11/16"(43mm)diameterquick-change backingflange,centeringthewheelontheraisedsection(pilot).

3.Installthethreadedclampnutwiththeraisedsection(pilot)facing awayfromthewheel.

4.Depressthespindlelockbuttonandtightenclampnutwitha wrench.

5.Toremovethewheel,graspandturnwhiledepressingthespindle lockbutton.

USING CUTTING WHEELS (FIG. 19)

WARNING: Do not use edge grinding/cutting wheels for surface grinding applications because these wheels are not designed for side pressures encountered with surface grinding. Wheel breakage and

injury may result.

1. Allow tool to reach full speed before touching FIG.19 tool to work surface.

2. Apply minimum pressure to work surface, allowing tool to operate at high speed. Cutting rate is greatest when the tool operates at high speed.

3. Once a cut is begun and a notch is established in the workpiece, do not change the angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel breakage. I I

4. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating

before setting it down.

MAINTENANCE

WARNING: To reduce the risk of injury, turn unit off and

disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off. An accidental start-up can cause

injury.

Cleaning

i_,WARNING: Blow dirt and dust out of all air vents with clean, dry airat least once a week. To minimize the risk of eye injury,always wear

ANSI Z87.1 approved eye protection when performing this.

WARNING: Never use solvents or other harsh chemicals for

cleaning the non-metallic parts of the tool These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool,"never immerse any part of the tool into a liquid.

Accessories

WARNING: Since accessories, other than those offered by

DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of

injury, only DEWALT recommended accessories should be used with this product.

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-DEWALT (1-800-433-9258) or visit our website: www.

dewalt.com.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use identical replacement parts.

Thank you for your purchase. Register your product now for:

• WARRANTY SERVICE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.

• CONFIRMATION OF OWNERSHIP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will

serve as your proof of purchase.

• FOR YOUR SAFETY: Registering your product will allow us to contact you in the unlikely event a safety notification is required

under the Federal Consumer Safety Act.

Three Year Limited Warranty

DEWALTwill repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800- 433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, DEWALT tools are covered by our:

1 YEAR FREE SERVICE

DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your DfiiiWALTPower Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund - no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT (1-800-433-

9258) for a free replacement.

Dx xx

SES,

TOREDUCETSERiSI(OFII_'JtlRy.USESMUSTSEAD

USEONLYACCESSORIESSATEDATLEASTEOt_ALTOTHEMAXIMUMSt'EL;)M_I_E;)ON TSETOOLALWAYSUSEPROI'E;_GUARDSWHENGRINOI_G.ALWAYSUSEP_OPER

RESPIRATORYI'SOTECTIOr_.

_. FORSERWSEIt_FOSr,_ATION.CALLI-aOO4-_)_WALT www.DEWALT.com . j

SIISTRtI_T]ON MANUALALWAYSWEAREYEPSOTEC'_JOI_.

D_WALTINDUSTRIALTOOLCO..BALTIMORE.MOZ12SSUSA

D_finitions : lignes directrices

en mati_re de s_curit_

Les definitions ci-dessous decrivent le niveau de danger pour chaque mot-indicateur employe. Lire

le mode d'emploi et porter une attention particuliere

a.ces symboles. i_,DANGER : indique une situation dangereuse

imminente qui, si elle n'est pas evitee, entraTnera la mort ou des blessures graves. _AVERTISSEMENT : indique une situation

potentiellement dangereuse qui, si elle n'est pas evitee, pourrait entra_ner la mort ou des blessures graves.

_ATTENTION : indique une situation potentiellement dangereuse qui, si elle n'est pas evitee, pourrait entra_ner des blessures I_g_res

ou modifies. AVIS : indique une pratique ne posant aucun

risque de dommages corporels mais qui par contre, si rien n'est fairpour/'eviter, pourraff poser des risques de dommages materiels.

POUR TOUTE QUESTION OU REMARQUE AU SUJET DE CET OUTIL OU DE TOUT AUTRE OUTIL DEWALT, COMPOSE LE

NUMFt:ROSANS FRAIS : 1-800-4-DEWALT (1-800-433-9258}.

_ VERTISSEMENT : afin de reduire le risque de blessures, life

le mode d'emploi de I'outil.

Avertissements de s_curit_ g_n_raux pour les outils _lectriques

s_curit_ et toutes les directives. Le non-respect des

_ AVERTISSEMENT! life tous les avertissements de

avertissements et des directives pourrait se solder par un choc dectrique, un incendie et/ou une blessure grave.

CONSERVER TOUSLES AVERTISSEMENTS

ET TOUTES LES DIRECTIVES POUR UN

USAGE ULTERIEUR

Le terme _ outil dectrique _ cite dans les avertissements se rapporte

votre outil electrique a alimentation sur secteur (avec ill) ou par piles

(sansfi/).

1) S#CURIT# DU LIEU DE TRAVAIL a) Tenir I'aire de travail propre et bien _clair_e. /es Iieux

encombres ou sombres sont propices aux accidents.

b) Ne pas faire fonctionner d'outils _lectriques clans un

milieu d_flagrant, tel qu'en presence de liquides, de gaz ou de poussi_res inflammables. Les outi/s e/ectriques

produisent des etincelles qui pourraient enflammer la poussiere

ou les vapeurs.

c) Eloigner les enfants et les personnes a proximit_ pendant

I'utilisation d'un outil _lectrique. Une distraction pourrait en faire perdre la ma_trisea I'utilisateur.

2) S#CURIT# EN MATIERE D'#LECTRICIT#

a) Les fiches des outils _lectriques doivent correspondre

la prise. Ne jamais modifier la fiche d'aucune faqon.

Ne jamais utiliser de fiche d'adaptation avec un outil

_lectrique mis a la terre. Le risque de choc dectrique sera reduit par I'utilisation de fiches non modifiees correspondant

la prise.

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