DeWalt D28144 TYPE 1, D28144N TYPE 1, D28140 TYPE 1, D28131 TYPE 2, D28131 TYPE 1 Owner’s Manual

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iNSTRUCTiON MANUAL GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y P©LIZA DE GARANT[A. ADVERTENClA: LEASE ESTE INSTRUCTIVO ANTES DE

USAR EL PRODUCTO.

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D28114, D28114N, D28131, D28140, D28144, D28144N Heavy-Duty Small Angle Grinders

Petites meuleuses _ renvoi d'angle de type industriel Esmeriladoras de _ngulo peque5o para trabajo pesado

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.

,i_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. 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 Warnmgs

Failure to follow the warnings and instructions may result in

_ WARMNG! Read all safety warnmgs and all mstructions.

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.

If operating apowertool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI 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. 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 misallgnment 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 too/is maintained.

SAFETY iNSTRUCTiONS FOR

ALL OPERATIONS

Safety Warnings Common for Grinding, Sandingj Wire Brushingj Polishing or

Abrasivej Cu_ing-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 of your 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 could give the operator

an electrical shock.

j) Positionthecord clear of the spinning accessory. /f you

lose control, the cord may be cut orsnagged 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.

Causes and Operator Prevention of Kickback

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 fomed 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 operatod 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. 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 Cu_ing-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)Wheelsmustbeused 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 fomes applied to these wheels may cause them to shatte_

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 too/is not suitable for the higher speed of a smaller tool and may burst.

Additional Safety Warnings Specific for Abrasive Cu_ing-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./nvestigate 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 ifthe power too/ 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 centrifugal fomes.

Additional Safety Rules for Grinders

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

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

o Use of accessories not specified in this manual is not

recommended and may be hazardous. Use of power boosters

that would cause the too/to be driven at speeds greater than its rated speed constitutes misuse.

• Use clamps or anotherpractical 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

Avoid bouncing the wheel or giving 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 manne_

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 too/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 too/ 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, u,_ethe next heavier gauge. Thesmaller the gauge numbe_ 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 (i5.2) 100 (30.5) 200 (61.0) 300 (91.4)

Total Length of Cord

in Feet (meters}

AWG

i_,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.

i_WARNING: Some dust created by power sanding, sawing,

grinding, drilling, and other construction activities contains chemicals

known to the State of Califomia to cause canced 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 lumbe_

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

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. _, 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

Hz................. hertz

min ............... minutes

- -- or DC... direct current

_) ................. Class I Construction

(grounded)

[] ................. 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

A...................... amperes

W..................... watts

* or AC ..........alternating

current

or AC/DC... alternating or

direct current

SAVE THESE INSTRUCTIONS FOR

FUTURE USE

FIG. 1

D28114

D28114N

D28144

D28144N

D28131 D28140

COMPONENTS (Fig. 1)

A WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

A. Paddle Switch: D28114, G2.

D28144, D28144N

B. Lock-Off Lever C. Spindle Lock Button

D. Yellow Rubber Ring H.

E.Anti-Vibration Side Handle I1.

(not shown) 12.

F.5" (127 mm) Grinding Wheel

(Type27): D28114, J. D28131, D28114N

F1.6" (152 mm) Grinding Wheel K.

(Type 1): D28140, L. D28144, D28144N

G1.Quick-Change Backing

Flange

INTENDED USE The D28114, D28114N, D28131

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.

Stamped Steel Quick-Change Backing Flange (depressed center wheels only):

D28140, D28144, D28144N Threaded Clamp Nut

Type 27 Guard Type 1 Guard (not shown): D28140, D28144, D28144N

Lock On Button: D28114, D28144 Dust Ejection SystemTM (DES)

Slider Switch: D28131, D28140

D28140, D28144, D28144N heavy-

FEATURES

E-SWITCH PROTECTION TM

The ON/OFF switch has a no-volt release function. In the event of a power outage or other unexpected shut down, the switch needs to be cycled (turned off and on) to restart tool.

CLUTCH (D28140, D28144, D28144N) The torque limiting clutch reduces the maximum reaction torque

transmitted to the operator in case of jamming a cutting disc. This feature also prevents the gearing and electric motor from stalling. The torque limiting clutch has been factory set and cannot be adjusted.

E-CLUTCH TM

This unit is equipped with an E-Clutch TM (Electronic Clutch), which in the event of a high-load or wheel pinch, the unit will shut off to reduce the reaction torque to the user. The switch needs to be cycled (turned

off and on) to restart the tool.

POWER-OFF TM OVERLOAD PROTECTION

The power supply to the motor will be reduced in case of motor overload. With continued motor overload, the tool will shut off. The

switch must be cycled (turned off and on) to restart tool. The power will return to normal once the tool has cooled down to a suitable

operating temperature. NOTE: Run the tool at no load to reduce the cool down time.

COMPLETE ELECTRONIC CONTROL TM The internal electronic speed control offers consistent wheel speed

while using the tool.

ASSEMBLY AND ADJUSTMENTS

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

disconnect # 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.

Attaching Side Handle (FIG. 2) r2_

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.

FIG.2

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.

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. Failure to 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.

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

Grinding Wheels

6" (152 turn) Grinding Wheels

Type 27 guard

Quick-Change backing flange

Type 27 depressed

center wheel

threaded clamp nut

Accessories

Itis important to choose the correct guards, backing pads and flanges to use with grinder accessories. See pages 10-12 for information on

choosing the correct accessories.

Type 27 guard

Type 27 hubbed wheel

Type 27 guard

stamped steel Quick-Change backing flange

Type 27 depressed

center wheel

threaded clamp nut

WARNING: Accessories must be rated for at least the speed recommended on the tool warning 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 10-12 of this manual Accessory ratings must be above listed minimum wheel speed as shown on tool nameplate.

Type 27 guard

Type 27 hubbed wheel

4-1/2" (114.3 turn) and 5"

(127 rnrn) Cutting Wheels

6" (152 rnrn) Cutting Wheels

Type 1 guard

Quick-Change backing flange

Type 1 abrasive

cutting wheel

threaded clamp nut

Wire Wheels

Type 27 guard

3" (76,2 mm)

wire cup brush

Type 1 guard

Quick-Change backing flange

diamond cutting wheel

threaded clamp nut

Type 27 guard

4" (101.6 mm)

wire wheel

Type 1 guard

Quick-Change

backing flange

Type 1abrasive

cutting wheel

threaded clamp nut

Type 1 guard

Quick-Change backing flange

Diamond

cutting wheel

threaded clamp nut

Sanding Discs

rubber backing pad

sanding disc

threaded clamp nut

Type 27 guard

stamped steel

Quick-Change backing flange

Type 27 depressed

center wheel

threaded clamp nut

(114.3 rnm) and 5" (127 ram)

Sanding Flap Discs

Type 27 guard

hubbed sanding

flap disc

Type 27 guard

Quick-Change backing flange

non-hubbed sanding

flap disc

threaded clamp nut

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 too/may be used without a guard only when sanding with conventional sanding discs. Some DEWALTmodels are provided with a guard intended for use with depressed center wheels (Type27) and hubbed grinding wheels

(Type27). The same guard is designed for use with sanding flap discs

(Type27 and 29) and wire brushes. Grinding and cutting with wheels

other than Type 27 and 29 require different accessory guards not included with tool Mounting instructions for these accessory guards are included in the accessory package.

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

FIG.3

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 (I) into the desired working position. The 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 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 diameter of the gear case hub at the factory. If, after a period of time, the guard becomes loose, tighten the adjusting screw (P) with clamp lever in the closed position.

FIG.4

i_,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.

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 itfrom 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 is important to choose the correct guards and flanges to use with the grinder accessories. See pages 10-12 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 thetool warning 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 10-12.

Accessory ratings must be above listed minimum wheel speed as

shown on tool nameplate.

Switches

_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.

SOFT START FEATURE The soft start feature allows a slow speed build-up to avoid an initial

jerk when starting. This feature is particularly useful when working in

confined areas. Current surge will also be reduced.

PADDLE SWITCH (FIG. 1, 5} D28114, D28114N, D28144, D28144N

_, CAUTION: Before connecting the tool to a power soume depress and release the paddle switch (A) once without depressing the lock- on button (Fig. 1, J) [D28114, D28144 only] to ensure that the switch is off. Depress and release the paddle switch as described above after any interruption in power supply to the tool, such as the activation of a ground fault interrupte_ throwing of a circuit breake_ accidental unplugging, or power failure.

To turn the tool on, push the lock-off FIG.5 lever (B) toward the back of the tool, then depress the paddle switch (A).

The tool will run while the switch is depressed. Turn the tool off by A

releasing the paddle switch. B

,_J,WARNING: Do not disable the lock-off level'.If the lock-off lever is

disabled, the tool may start unexpectedly when it is laid down.

SLIDER SWITCH (FIG. 6)

D28131, D28140

i_,CAUTION: Before connecting the tool to a power supply, be sure the switch is in the off position by pressing the rear part of the switch and releasing. Ensure the switch is in the off position as described above after any interruption in power supply to the tool, such as the activation of a ground fault interrupte_ throwing of a circuit breake_ accidental unplugging, or power failure.

Tostart the tool, slide the ON/OFF switch FIG.6 (L)toward the front of the tool. To stop the tool, release the ON/OFF switch.

For continuous operation, slide the switch toward the front of the tool and press the forward part of the switch inward. To stop L the tool while operating in continuous mode, press the rear part of the switch and release.

LOCK-ON BUTTON (FIG. 7) D28114, D28144

The lock-on button (J) offers increased FIG.7 comfort in extended use applications. To lock the tool on, push the lock-off

lever (B) toward the back of the tool then depress the paddle switch (A). With the tool running, depress the Iock-

on button (J).The tool will continue to A B run after the paddle switch is released.

To unlock the tool, depress and release the paddle switch. This will cause the tool to stop.

J_CAUTION: Allow the too/to reach full speed before touching too/ to the work surface. Lift the tool from the work surface before tuming

the tool off.

SPINDLE LOCK (FIG. 8} The spindle lock (C) is provided to prevent FIG.8

the spindle from rotating when installing or O 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.

Mounting and Using Depressed Center Grinding Wheels and Sanding Flap Discs

MOUNTING AND REMOVING HUBBED WHEELS

Hubbed wheels installdirectly 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. 9, 10} Depressed center Type 27 grinding wheels must be used with

included flanges. NOTE: The stamped steel quick-change backing flange (G2)is

for use with D28140, D28144 and D28144N for Type 27 grinding wheels only. Refer to page 10-12 for more information.

1. Install the stamped steel quick-change backing flange (G2) (D28140, D28144, D28144N only) for Type 27 6" (152 mm)

wheels or the quick-change backing flange (G1) for all other non-hubbed wheels on spindle (Q) with the raised

section (pilot) against the wheel. Be sure the backing flange recess is seated onto the flats of the spindle by pushing and twisting the

flange before placing wheel.

FIG.9 G1

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.

FIG. 10

1/4" WHEELS 1/8" WHEELS

(6.35 mm) (3.17 mm)

THREADED CLAMP THREADED CLAMP

NUT NUT

QUICK-CHANGE

BACKING FLANGE

QUICK-CHANGE

BACKING FLANGE

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.

SURFACE GRINDING WITH GRINDING WHEELS (FIG, 11}

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.11 tool and work surface.

4. Continuously move the tool in a forward and back motion to avoid creating 20°-30°

gouges inthe work surface.

5.Removethetoolfromworksurfacebeforeturningtooloff.Allow thetooltostoprotatingbeforelayingitdown.

EDGE GRINDING WITH GRINDING WHEELS (FIG. 12) _ 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. To reduce the risk of serious injury, limit the use of these wheels with a standard Type 27 guard 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 11 for more information. Type 1 guards are available at extra cost from your local dealer or authorized service center

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. 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, 13}

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

2. Apply minimum pressure to work FIG. 13 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 the tool and work surface.

4. Continuously move the tool in a forward and backward motion to 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, 14}

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 (R) on the spindle.

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

3.Whiledepressingspindlelock,threadFIG.14 clampnut(H)onspindle,pilotingthe H_ S raisedhubontheclampnutintothe centerofsandingdiscandbackingpad. /.

4. Tighten the clamp nut by hand. Then L ',_J 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 the backing pad and sanding pad while depressing the spindle lock button.

USING SANDING BACKING PADS (FIG. 15} 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. Begin with coarse grit discs for fast, rough material removal. Move

to a medium grit paper and finish with a fine grit disc for optimal finish.

Coarse 16 - 30 grit

Medium 36 - 80 grit Fine Finishing 100 - 120 grit

Very Fine Finishing 150 - 180 grit

1. Allow the tool to reach full speed before touching 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 15° angle between the tool and work surface. The sanding disc should contact approximately one inch of work

surface.

4. Move the tool constantly in a straight line FIG.15 to prevent burning and swirling of work surface. Allowing the tool to rest on the

work surface without moving, or moving ........

the tool in a circular motion causes burning and swirling marks on 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 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. _, 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.

A 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. 16, 17)

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 touching the tool to the work surface.

2. Apply minimum pressure to work FIG.16 surface, allowing the tool to operate at high speed. Material removal rate

is greatest when the tool operates at high speed. 0o

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. Continuously move the tool in a forward and FIG.17 backward motion to avoid creating gouges in the work surface. Allowing the tool to rest on the work surface without moving, or moving the tool in a circular motion causes

burning and swirling marks on the work surface.

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

_ CAUTION: Use extra care when working over an edge, as a

sudden sharp movement of grinder may be experienced.

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

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

NOTE: All grinders that use Type 1 wheels use the quick-change backing flange (G1).

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

with this tool (D28140, D28144, D28144N ONLY) and is required when using cutting wheels. Failure to 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. 18, 19}

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

FIG. 18 O

M I

2. Push the guard down until the guard lug engages and rotates freely in the groove on the gear case hub.

3.Rotateguard(I)intodesiredworkingposition.Theguardbody shouldbepositionedbetweenthespindleandtheoperatorto providemaximumoperatorprotection.

4.Closetheguardlatchtosecuretheguardonthegearcasecover. Youshouldbeunabletorotatetheguardbyhandwhenthelatch isinclosedposition.Ifrotationispossible,tightentheadjusting screw(P)withclampleverintheclosedposition.Donotoperate grinderwithalooseguardorclampleverinopenposition.

5.Toremovetheguard,opentheguardlatch,rotatetheguardso thatthearrowsarealignedandpullupontheguard.

NOTE:If,afteraperiodoftime,theguardFIG.19 becomesloose,tightenthe adjusting

screw(P)withtheclampleverintheclosed position.

i_,CAUTION:Do not tighten adjusting

screw with clamp lever in open position. Undetectable damage to guard or mounting hub may result.

MOUNTING CUTTING WHEELS A CAUTION: Matching diameter backing flange and threaded clamp

nut (included with tool) must be used for cutting wheels.

1. Place the unthreaded backing flange on spindle with the raised section (pilot) facing up. The raised section (pilot) on the backing flange will be against the wheel when the wheel is installed.

2. Place the wheel on the quick-change backing flange, centering the wheel on the raised section (pilot).

3. Install the threaded clamp nut with the raised section (pilot) facing away from the wheel.

4. Depress the spindle lock button and tighten clamp nut with a wrench.

5. To remove the wheel, grasp and turn while depressing the spindle lock button.

USING CUTTING WHEELS (FIG. 20)

A WARNING: Do not use edge grinding/cutting FIG.20

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 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.

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

MAINT£NANC£

h_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.

Cleaning

_ WARNING: Blow dirt and dust out of all air vents with clean, dry air at 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 anypart 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 DE.:.WALT 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 DE.:.WALT 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.

90DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your DE.:.WALTPower 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.

DXXXXX,o.. ..G,EG.=.OE. t

_ UNDERSTAND iNSTRUCTiON MANUAL ALWAYS USE PROPER UUAROS WHEN GRINDING AND WEAR EYE PROTECTION, USE ONLYACCESSORIES RATEO

AT LEAST XXXXX/mifl. ALWAYS USE PROPER RESPIRATORY PROTECT|ON.

FUR SERVICE INFORMATi0N, CALL 1-80O-@R_INALT w_.DEWALT.com

UEBE LEER Y COMPUENUER EL MANUAL RE INSTRUSCiONES ANTES DE

UTILIZAR EL PRURUCTO. UTHLJCESIEMPRE LAS GUARUAS APROPgAOAS. UTILIUE SiEMPRE LA PROTEOCION AOECUAOA PARA LA VISTA YPARA

LAS ViAS RESPISATOSIAS. UTiLICE SOLAMENTE LOS ACCESORIO$ CALIFICADOS COMO MiNIMO PARA XX_X RPM/MIN.

_ RISQUES DR SLESSURES,

TOUJOURS UTJLMER LES PROTECTEUR$ APPROPSHES.TOUJOURS PORTER RE UI_UUIPEMENT UE PROTECTION OCULAJRE ETRESPgRATUJRE

_JUTILISATEUR DOlT LME ET COMPRENORE LE GUIDE D'UTUJSATION. [E I APPROPME. UTiLISER SEULEMENT DES ACSESSOiRES OON_US POUR

%ONE REGIME OE XXJ0(XTR/MIN.

TO SEDUCE TOE RiSK OF iNJURY, USES MUST READ AND ]

U_WALT iNDUSTRiAL TOOL CO.,RALTIMOSE, MO 21286 USA |

PARA UEUUClS ELRIssoo RE LEMONES PERSONALES, MEMPRE SEI

AFiN DE REDUBRELES

D_finitions : lignes directrices en

rnati_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 _.ces symboles.

j_ DANGER : indique une situation dangereuse imminente qui, si elle n'est pas evitee, entrainera la mort ou des blessures

graves. AAVERTISSEMENT : indique une situation potentie//ement

dangereuse qui, si e//e n'est pas evitee, pourraff entra?ner/a mort ou des blessures graves.

j_ATTENTION : indique une situation potentie//ement dangereuse qui, si e//en'est pas evitee, pourrait entra?nerdes blessures I_g_res ou mod_r6es.

AVIS : indique une pratique ne posant aucun risque de

dommages corporels mais qui par contre, si rien n'est fair pour I'evited pourrait poser des risques de dommages

materiels.

_,_ .j

POUR TOUTE QUESTION OU REMARQUE AU SUJET DE OET OUTIL OU DE TOUT AUTRE OUTIL DEWALT, COMPOSEZ LE NUMC:RO SANS FRAIS : 1-800-4-DEWALT (1-800-433-9258}.

AVERTISSEMENT afin de reduire le de life

le mode d'emploi de I'outil.

risque

blessures,

Avertissements de sdcurit6, g_n_raux

pour les outils _lectriques

s6curit_ et toutes les directives. Le non-respect des

_ AVERWSSEMENT! lire 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 clans les avertissements se rapporte

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

(sans fil).

1} Si'-=CURIT# DU LIEU DE TRAVAIL

a) Tenir I'aire de travail propre et bien 6clair6e. Les /ieux

encombres ou sombres sont propices aux accidents.

b) Ne pas faire fonctionner d'outils 61ectriques clans un

milieu d_flagrant, tel qu'en pr6sence de liquides, de gaz ou de poussibres inflammables. Les outi/s e/ectriques

produisent des etincelles qui pourraient enflammer la poussiere

ou les vapeurs.

c) Eloigner les enfants et les personnes b proximit6 pendant

I'utilisation d'un outil 61ectrique. Une distraction pourrait en faire perdre la ma?trisea I'utilisateu_

2) SECURITE EN MATIERE D'ELECTRICITE

a) Les fiches des outils 61ectriques doivent correspondre

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

Ne jamais utiliser de fiche d'adaptation avec un outil 61ectrique mis _ la terre. Le risque de choc dectrique sera

reduit par/'uti/isation de fiches non modifiees correspondant la prise.

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