DeWalt D28106, D28113, D28132, D28135 Instruction Manual
D28106, D28113, D28132, D28135, D28402, D28402N
Heavy-Duty Small 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 09 526 2556 (NZ).
General Safety Rules – For All 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 THESE INSTRUCTIONS
WORK AREA
• Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the pres-
ence of flammable liquids, gases, or dust. Power tools create sparks which
may ignite the dust or fumes.
• Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control.
ELECTRICAL SAFETY
• Grounded tools must be plugged into an outlet properly installed and
grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in any way. Do not use any adaptor
plugs. Check with a qualified electrician if you are in doubt as to whether
the outlet is properly grounded. If the tools should electrically malfunction or
break down, grounding provides a low resistance path to carry electricity away
from the user. Applicable only to Class I (grounded) tools.
• Double insulated tools are fitted with a plug that will fit into the outlet only
one way. If the plug does not fit fully in the outlet contact a qualified electrician to install a new outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord.
Applicable only to Class II (double insulated) tools.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
• Don’t expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
• Do not abuse the cord. Never use the cord to carry the tools or pull the plug
from an outlet. Keep cord away from heat, oil, sharp edges or moving parts.
Replace damaged cords immediately. Damaged cords increase the risk of elec-
tric shock.
• When operating a power tool outside, use an outdoor extension cord marked
“W-A” or “W.” These cords are rated for outdoor use and reduce the risk of
electric shock. When using an extension cord, be sure to use one heavy enough
to carry the current your product will draw. An undersized cord will cause a
drop in line voltage resulting in loss of power and overheating. The following
table shows the correct size to use depending on cord length and nameplate
ampere rating. If in doubt, use the next heavier gage. The smaller the gage
number, the heavier the cord.
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 –
PERSONAL SAFETY
• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs,
alcohol, or medication. A moment of inattention while operating power tools may
result in serious personal injury.
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from moving parts. Loose clothing, jewelry,
or long hair can be caught in moving parts. Air vents often cover moving parts and
should also be avoided.
• Avoid accidental starting. Be sure switch is off before plugging in. Carrying
tools with your finger on the switch or plugging in tools that have the switch on
invites accidents.
• Remove adjusting keys or wrenches before turning the tool on. A wrench or
a key that is left attached to a rotating part of the tool may result in personal
injury.
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• Do not overreach. Keep proper footing and balance at all times. Proper foot-
ing and balance enables better control of the tool in unexpected situations.
• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
• 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 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 Black & Decker Service Centre in
order to avoid a hazard.
TOOL USE AND CARE
• Use clamps or other practical way to secure and support the workpiece to a
stable platform. Holding the work by hand or against your body is unstable and
may lead to loss of control.
• Do not force tool. Use the correct tool for your application. The correct tool
will do the job better and safer at the rate for which it is designed.
• Do not use tool if switch does not turn it on or off. Any tool that cannot be
controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source before making any adjustments,
changing accessories, or storing the tool. Such preventative safety measures
reduce the risk of starting the tool accidentally.
• Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly main-
tained tools, with sharp cutting edges are less likely to bind and are easier to
control.
• Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the tool’s operation. If damaged, have
the tool serviced before using. Many accidents are caused by poorly main-
tained tools.
• Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool, may become hazardous
when used on another tool.
SERVICE
• Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result in a risk of
injury.
• When servicing a tool, use only identical replacement parts. Follow instruc-
tions in the Maintenance section of this manual. Use of unauthorized parts or
failure to follow maintenance instructions may create a risk of electric shock or
injury.
Additional Specific Safety Instructions for Grinders
• Check that the grinding wheel backing flange has a yellow rubber ring (S)
installed, see Figure 1. Replace rubber ring if missing, damaged or worn. See
page 9 for details regarding proper accessory installation.
WARNING: The grinding wheel or accessory may loosen during coast-down of the
tool when shut off if rubber ring is missing or damaged. If grinding wheel or accesso-
ry loosens, it may dismount from the machine and may cause serious personal injury.
• Always use proper guard with grinding wheel. A guard protects operator from
broken wheel fragments and wheel contact.
• Accessories must be rated for at least the speed recommended on the tool
warning label. Wheels and other accessories running over rated speed can fly
apart and cause injury. Accessory ratings must be above listed minimum wheel
speed as shown on tool nameplate.
• Hold 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 make exposed metal parts of the tool “live” and shock the
operator.
• Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate
accessories can result in injury.
• ALWAYS WEAR EYE PROTECTION WHEN USING THIS TOOL.
• 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 driv-
en at speeds greater than its rated speed constitutes misuse.
• Do not use circular saw blades or any other toothed blades with this tool.
Serious injury may result.
• When starting the tool with a new or replacement wheel, or a new or replace-
ment 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.
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• Avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the
tool and inspect the wheel for cracks or flaws.
• Direct sparks away from operator, bystanders or flammable materials.
Sparks may be produced while cutting and/or grinding. Sparks may cause
burns or start fires.
• Always use side handle. Tighten the handle securely. The side handle should
always be used to maintain control of the tool at all times.
• Never cut into area that may contain electrical wiring or piping. Serious
injury may result.
• Clean out your tool often, especially after heavy use. Dust and grit containing
metal particles often accumulate on interior surfaces and could create an electric shock hazard.
• 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.
• Direct the Dust Ejection System (DES) away from operator and coworkers.
Serious injury may result (Fig. 1, K).
• 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 ............alternating current
....direct current
n
o ..............no load speed
........Class II Construction ..............safety alert symbol
........earthing terminal …/min ........revolutions per minute
Causes and Operator Prevention of Kickback
• Kickback is a sudden reaction to a pinched, bound or misaligned wheel, wire
brush or flap disc causing an uncontrolled cut-off tool to lift up and out of the
workpiece toward the operator.
• When the wheel is pinched or bound tightly by the workpiece, the wheel stalls and
the motor reaction drives the unit rapidly back toward or away from the operator.
• Kickback is the result of tool 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 unit and position your
body and arm to allow you to resist kickback forces. Kickback forces
can be controlled by the operator, if proper precautions are taken.
• When wheel is binding, or when interrupting a cut for any reason,
release the trigger and hold the unit motionless in the material until
the wheel comes to a complete stop. Never attempt to remove the
unit from the work or pull the unit backward while the wheel is in
motion or kickback may occur. Investigate and take corrective actions
to eliminate the cause of wheel binding.
• When restarting a cut-off tool in the workpiece, check that the wheel
is not engaged into the material. If wheel is binding, it may walk up or
kickback from the workpiece as the tool is restarted.
• Support large panels to minimize the risk of wheel pinching and kick-
back. Large panels tend to sag under their own weight. Support must be
placed under the panel on both sides, near the line of cut and near the
edge of the panel.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known 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 (CCA).
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, a
nd 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.
WARNING: Use of this tool can generate and/or disburse 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.
CAUTION: Use extra care when working into a corner because a sudden, sharp
movement of the grinder may be experienced when the wheel or other accessory con-
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tacts a secondary surface or a sur face edge.
CAUTION: Wear appropriate personal hearing protection during use. Under some
conditions and duration of use, noise from this product may contribute to hearing loss.
COMPONENTS (Fig. 1)
A. Paddle Switch H. Threaded Clamp Nut
(D28402, D28402N) I. Guard
B. Lock-Off Lever J. Lock On Button
C. Spindle Lock Button K. Dust Ejection System
D. Spindle (not shown) (DES)
E. Side Handle L. Slider Switch
F. Grinding Wheel
G. Anti-Lockup Backing Flange
NOTE: Type 1 Guard and Accessories available as option accessories.
ASSEMBLY AND ADJUSTMENTS
ATTACHING SIDE HANDLE
The side handle (E) 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.
Rotating the Gear Case
CAUTION: Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Before reconnecting the tool,
depress and release the paddle switch to ensure that
the tool is off.
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 6 mm (1/4"), rotate the gear case
head to desired position.
90˚
90˚
E
H
G
A
B
C
F
I
FIG. 1
D28402
D28106
D28113
D28135
L
K
K
K
S
J
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