DeWalt D28494N TYPE 3, D28494N TYPE 2 Owner’s Manual

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INSTRUCTION MANUAL GUIDE D'UTILISATION

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

ANTES DE USAR EL PRODUCTO.

MANUAL DE INSTRUCCIONES

D284741D284931D28493GID284941D28494GID28499 Heavy Duty Large Angle Grinders Grandes rectifieuses coud_es de service intensif

Esmeriladoras de _ngulo grande para trabajo pesado

D28497 Heavy Duty Large Angle Sander Grandes ponceuse coud_es de service intensif

Lijadora angular grande para trabajo pesado

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)

SAVE THESE INSTRUCTIONS!

General Safety Instructions

A WARNIN!! Read and understand allinstructions. Failure to foflow aft instructions

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

SAVE THESE INSTRUCTIONS

WORK AREA

A 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 presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or

fumes. Keep bystanders, children, and visitors away while oper-

ating 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 adapter plugs. Check with a qualified electrician if you are in doubt as to whether

the outlet is properly grounded, ff the tools should electrically malfunction or break down, grounding provides a low resistance

path to carry electricity away from the user. This tool may use

grounded construction (3 prong plug) to provide a means to

transfer electrical energy safely away from the user in the event the tool electrically malfunctions, breaks down, or the tool case becomes live. Damage to, or loss of, one of the 3 plug blades;

damage to the plug or cord, or failure to have the tool plugged into a verified and continuously grounded electrical system, may result in electric shock, serious injury, or death. To avoid these risks of inju04 the tool must, at all times, be maintained and in

proper working order (cord, plug blades) and plugged into a con- tinuously grounded electrical system. (See also "Cleaning" in the Maintenance section, page 15.) Applicable only to Class I

(grounded) tools.

Double insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a

polarized outlet only one way. If the plug does not fit fully in

the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not

change the plug in any way. Double insulation _ eliminates

the need for the three wire grounded power cord and grounded

power supply system. 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 ifyour 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.

A When operating a power tool outside, use an outdoor exten-

sion cord marked "W-A" or "W." These cords are rated for out- door use and reduce the risk of electric shock.

Minimum Gage for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150 Ampere Rating

More Not more AWG

Than Than

12 16 14 12 Not Recommended

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 medica- tion. A moment of inattention while operating power tools may

result in serious personal injurjz.

J_ Dress properly. Do not wear loose clothing or jewelry.

Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair

can be caught in moving parts. Air vents often cover moving parts and should also be avoided.

A Avoid accidental starting. Be sure switch is off before plug-

ging 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.

A Do not overreach. Keep proper footing and balance at all

times. Proper footing 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.

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.

_k 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 maintained tools, with sharp cutting edges are less likely to bind and are easier to control

_ Check for misalignment or binding of moving parts, break-

age of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.

_, Use only accessories that are recommended by the manu-

facturer 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 per-

sonneL Service or maintenance performed by unqualified per- sonnel could result in a risk of injury

When servicing a tool, use only identical replacement parts.

Follow instructions in the Maintenance section of this man- ual. Use of unauthorized parts or failure to follow Maintenance

instructions may create a risk of electric shock or injury.

Specific Safety Rules for Grinders

Always use proper guard with grinding wheel. A guard pro-

tects operator from broken wheel fragments and wheel contact.

A Accessories must be rated for at least the speed recom-

mended on the tool warning label. Wheels and other acces-

sories running over rated speed can fly apart and cause injury. Refer to the table below. Accessory ratings must always be above tool speed as shown on tool nameplate.

NOTE: The rated no load tool speed is printed on the name plate and embossed on the gear case.

Rated no (no load)

Tool Speed

5000 RPM 6000 RPM

8000 RPM

A 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 "five" wire will make

exposed metal parts of the tool "live" and shock the operator.

A Before using, inspect recommended accessory for cracks

or flaws. If such a crack or flaw is evident, discard the acces- sory. The accessory should also be inspected whenever you

think the tool may have been dropped. Flaws may cause wheel breakage.

Minimum

Accessory

Rating

5500 RPM 6600 RPM

8500 RPM

_ When starting the tool with a new or replacement wheel, a

new or replacement wire brush installed, or if you are unsure of the condition of the wheel, 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.

_ In operation, avoid bouncing the wheel or giving # rough

treatmenL If this occurs, stop the tool and inspect the wheel for cracks and flaws.

A Direct sparks away from operator, bystanders or flamma-

ble materials. Sparks may be produced while using a sander or grinder. Sparks may cause bums or start fires.

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

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

_ Clean out your tool often, especially after heavy use. Dust

and grit containing metal particles often accumulate on interior surfaces and could create a risk of serious injury, electric

shock or electrocution.

_, Do not operate this tool for long periods of time. Vibration

caused by tool action may be harmful to your hands and arms.

Use gloves to provide extra cushion and lim# exposure by taking

frequent rest periods.

_ WARNING: Some dust created by power sanding, sawing,

grinding, drilling, and other construction activities contains chem- icals 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, and work with approved safety equip-

ment, 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 appro- priate for the dust exposure. Direct particles away from face and

body.

_CAUTION: Use extra care when grinding into a corner

because a sudden, sharp movement of the grinder may be expe- rienced when the wheel contacts a secondary surface.

_,CAUTION: Wear appropriate personal hearing protection

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 definitions are as follows:

V ............ volts

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

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

.... ........direct current

[] ............Class II Construction

_, ............ safety alert symbol

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

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

.......... alternating current

no .......... no load speed

............earthing terminal

.../min ......revolutions

per minute

FAMILIARIZATION

Large Angle Grinders and Large Angle Sanders are designed for heavy material removal in extended use applications. The following

grinders and sanders are described in this manual: D28474 7"Angle Grinder double insulated D28493 9"Angle Grinder double insulated D28493G 9" Angle Grinder grounded

D28494 7"/9"Angle Grinder double insulated D28494G 7"/9"Angle Grinder grounded D28497 7"/9" Angle Sander grounded D28499 7"/9"Angle Grinder double insulated

8,000 rpm 5,000 rpm 5,000 rpm 6,000 rpm 6,000 rpm 6,000 rpm 6,000 rpm

Components

A. Trigger Switch B. Lock On Button C. Spindle Lock D. Side Handle

E. Spindle E Soft Mount

G. Top Bumper

Features

SWITCH The tool is controlled by a trigger switch (A). A lock-on button (B)

provides increased comfort in extended use applications. ROTATING REAR HANDLE (D28499 ONLY)

The rear handle can be positioned 30°, 60°, and 90° left and right of center position.

ROTATING GEAR CASE (D28474, D28493, D28494, D28497) For applications in which a tool will be dedicated for uses in edge

grinding and finishing work, the gear case may be rotated 90° left or right of its original position. See page 9 for instructions on rotating the gear case.

MULTIPLE SIDE HANDLE POSITIONS The side handle can be properly positioned in five locations based

on personal preference and application. The side handle must be used at all times to maintain proper control of the tool.

TOP BUMPER The gear case top bumper may wear with

use. The bumper can be replaced with part number 397711-00 available at extra cost

from DEWALT authorized service centers. Replacement should be performed by

DEWALT authorized service centers or qualified service personnel. SPINDLE LOCK

The spindle lock pin is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock pin

only when the tool is turned off and unplugged from the power

Sanding Flap Discs

soft mount

Type 27 guard

D284937/D284939

hubbed sanding flap

disc

NOTE: Wheel size must match guard size; i.e., a new 7" wheel may not be used with a 9" guard. The bottom surface of wheel must be inside the bend of the guard lip.

soft mount

Type 27 guard

D284937/D284939

backing flange

54339-00

non-hubbed sanding

flap disc

clamp nut 22191-00

Grinding Wheels

Sanding Discs

softmount

Type27guard

D284937/D284939

Type27hubbedwheel

softmount

Type28guard

D284938

Type28hubbedwheel

NOTE: Wheel size must match guard size; i.e., a new 7" wheel may not be used with a 9" guard. The bottom surface of wheel must be inside the bend of the guard lip.

soft mount

Type 27 guard

D284937/D284939

backing flange

54339-00

Type 27 non-hubbed

wheel

clamp nut

22191-00

soft mount

Type 28 guard

D284938

backing flange

54339-00

Type 28 non-hubbed

wheel

clamp nut 22191-00

soft mount

rubber backing pad

DW4947

sanding disc

clamp nut

included with

D4947

Wire Wheels

soft mount

Type 27 guard

D284937/D284939

wire cup brush

Flaring Cup Stones Cutting Wheels

Type 11flaring cup guard

D284934i4 '' D284936--6"

backingflange

_oo_ovw_w001D2849:

Type 1 guard

D284931

backingflange

_nooTn nN

[D284932 backing flange & clamp nutJ

Type 1 guard

backingflange

D284931

_nooTn nN

soft mount

Type 27 guard

D284937/D284939

wire wheel

flaring cup stone

NOTE: Wheel size must match guard size; i.e., a 7" wheel may not be used with a 9" guard.

abrasive cutting wheel

diamond cutting wheel

clamp nut

_no A_O nr_

source.Toengagethelock,depressthespin- dlelockbutton(C)androtatethespindleuntil C

youareunabletorotateitfurther. ACAUTION:Never depress the spindle lock

button while the grinder b running. Never turn on the grinder while the spindle lock button is

depressed. Damage to your tool or personal injury may result.

SOFT MOUNT

The grinder is equipped with a soft mount, enabling easy wheel installation and removal.

Accessories and Attachments

It is important to choose the correct guards, backing pads and flanges to use with grinder accessories. See the chart on pages

5-7 for information on choosing the correct accessories. ACAUTION: Accessories must be rated for at least the speed

recommended on the tool warning label Wheels and other acces- sories running over rated speed can fly apart and cause injury.

Accessory ratings must always be above tool speed as shown on

tool nameplate.

ATTACHMENTS Attachments designed specifically for this grinder can be

purchased through Service centers.

D284939 D284948

D284937 D284936

D284934 D284933 D284932

DEWALT dealers and DEWALT Factory

9" Type 27 guard 9" Type 28 guard

7" Type 27 guard 6" Type 11 Flaring cup guard with flange 4" Type 11 Flaring cup guard with flange Type 11 Flaring cup wheel backing flange Type 1 Flange set

D284931 054339-00

22191-00

61820-01 445928-01 397711-00

7" Type 1 Guard Grinding backing flange

Clamp nut Wheel Wrench

Soft mount spindle protector

Top gear case bumper

ASSEMBLY AND ADJUSTMENTS Attaching the Side Handle

To install the side handle, thread the handle into one of the five

positions listed below and tighten securely by turning clockwise.

• Two front positions: Forward handle positions are designed for optimized bal-

ance in surface finishing applications.

• Two rear positions: Rear handle positions are designed for optimized balance in edge

grinding applications.

• One top position: Top handle position is designed for edge grinding applications.

NOTE: D28497 includes only three handle positions.

Rotating the Rear Handle

Turn off and unplug tool before making any adjustments or

removing or installing accessories. Before reconnecting the tool, depress and release the Ag_ trigger switch to ensure that the

tool is off. 60

1. Unlock the rear handle by pulling out the Handle Release Lever (G) as shown.

2.Rotatehandleintoavailable0°,30°,60°,or90°positionleftOR rightofcenter.

3.Pushinthehandlereleaselever.

4.Beforeturningthetoolon,ensurethatthehandleislockedinto apositionandthehandlereleaseleverhasreturnedtotheorig- inalpositionflushwiththetoolhousing.

Rotating the Gear Case

Turn off and unplug tool before making any adjustments or

removing or installing accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the

tool is off.

1. Remove the four corner screws attaching the gear case to motor

housing.

2. Without separating the gear 90° case from motor housing, rotate 90°

the gear case head to desired position.

NOTE: If the gear case and motor housing become separated by more than 1/8", the tool must be serviced and re-assembled by a DEWALT service center. Failure to have the tool serviced may cause brush, motor and bearing failure.

3. Re-install screws to attach the gear case to the motor housing. Tighten screws to 20 in./Ibs, torque. Overtightening could cause screws to strip.

OPERATION

Power Source

Plug the large angle grinder into a dedicated electrical circuit. Operating this tool on a circuit with other tools will decrease tool performance.

Switch

CAUTION: Before connecting the tool to apower source or after a power failure, depress and release the trigger switch (A) once without depressing the lock-on button (B) to ensure that the switch is in the off position, ff the trigger switch is locked on, the tool will start unexpectedly when power is reconnected to the tool Hold the side handle and rear handle firmly to maintain control of tool at start up and during use. B

TRIGGER OPERATION To turn the tool on, depress the trigger switch

(A). The tool will remain running while the

trigger is depressed. Turn the tool off by

releasing the trigger.

TRIGGER OPERATION WITH LOCK-ON FEATURE To turn tool on, depress trigger. Depress and hold lock-on button

(B) while releasing trigger. Lock-on button will remain depressed and tool will remain on.

To turn the tool off, depress and release trigger. The lock pin but- ton will pop out, permitting the trigger to disengage and causing the

tool to turn off.

NOTE: Allow the tool to reach full speed before touching tool to

work surface. Lift the tool from the work surface before turning the tool off.

i_CAUTION: Make sure the wheel has come to a complete stop

before setting the tool down.

REMOVAL OF LOCK-ON FEATURE

The lock-on button can be permanently removed without compro-

mising compliance with regulatory agencies shown on the tool's nameplate. Removal of the lock pin must be done by a DEWALT

Service Center.

Mounting and Using Depressed Center Grinding Wheels and Sanding Flap Discs

MOUNTING AND REMOVING GUARD

Turn off and unplug tool before making any adjustments or removing or installing accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the

tool is off.

IMPORTANT INFORMATION ABOUT GUARDS

Guards must be used with all grinding wheels, sanding flap discs, wire brushes GRINDING and wire wheels. The tool may be used with- WHEEL out a guard only when sanding with conven- SURFACE tional sanding discs. DEWALT models

D28493, D28494, D28474, D28499 are pro- vided with a guard intended for use with depressed center wheels (Type 27), and GUARD

hubbed grinding wheels (Type 27). The LIP same guard is designed for use with sand-

ing flap discs, wire brushes and wire wheels. Grinding and cutting with wheels other than Type 27 and 29 require different accessory guards not included with the tool. Mounting

instructions for these accessory guards are included in the acces- sory package.

_CAUTION: When using a grinding wheel with a Type 27, 28, or

29 guard, be sure that the bottom surface of the grinding wheel is

inside the the guard lip.

•& CAUTION: DEWALT model D28497 Angle Sander may only be

used for grinding by using appropriate accessory guard.

1. Open the guard latch (H), and align the lugs with slots on the gear case cover. Position the guard facing backward, as

shown.

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 into the desired working posi-

tion that provides maximum protec- tion to the user as shown.

4. Close the guard latch to secure the guard on the gear case. You should be unable 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, follow the pro- cedure above in reverse order.

NOTE: The guard is pre-adjusted to the diameter of the gear case hub at the fac-

tory. If, after a period of time, the guard

becomes loose, tighten the adjusting screw (I) with clamp in the closed posi- I

tion.

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.

MOUNTING AND REMOVING HUBBED WHEELS Hubbed wheels install directly on the 5/8''i 11threaded spindle.

1. Thread the wheel on the spindle by hand, seating the wheel against the soft mount.

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

3.Reversetheaboveproceduretoremovethewheel.

_CAUTION:Failure to properly seat the wheel against the soft

mount before turning the tool on may result in damage to the tool or the wheel

MOUNTING NON-HUBBED WHEELS Depressed center, Type 27 grinding wheels

must be used with available accessory flanges.

See the chart on pages 5-7 of this manual for

more information.

1. Install the metal backing flange (J) on spin- dle (E) against the soft mount.

2. Place wheel against the backing flange, centering the wheel on the backing flange

pilot.

3. While depressing the spindle lock button, thread the clamp nut (K) on spindle, piloting

the raised hub on clamp nut in the center of

grinding wheel.

4. Tighten the clamp nut with a wrench.

5. Reverse the above procedure to remove the wheel.

SURFACE GRINDING WITH GRINDING WHEELS

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

2. Apply minimum pressure to work surface, to allow the tool to operate at high speed.

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

4. Continuously move the tool in a forward and back 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 setting it down.

EDGE GRINDING WITH GRINDING WHEELS

[_CAUTION: Wheels used for cutting and edge grinding may break or kick back 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" in depth). The open side of the guard must be positioned away from the operator. For deeper cutting with a Type 1 wheel, use a closed, Type 1 guard.

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 work surface, to allow the tool to operate at high speed.

3. Protect yourself during edge finishing by directing the open side of the guard away from you.

4. Move the tool continuously in a forward and back motion to avoid creating gouges in the work surface.

5. Remove tool from work surface before turning the tool off. Allow

the tool to stop rotating before setting it down.

/_ WARNING: Do not use edge grinding wheels for surface grind-

ing applications because edge grinding wheels are not designed for side pressures encountered with surface grinding. Wheel breakage and injury may result.

SURFACE FINISHING WITH SANDING FLAP DISCS

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

2. Apply minimum pressure to work surface, to allow the tool to operate at high speed.

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

4.Continuouslymovethetoolinaforwardandbackmotionto avoidcreatinggougesintheworksurface.

5.Removethetoolfromworksurfacebeforeturningtooloff.Allow

thetooltostoprotatingbeforesettingitdown.

MOUNTING AND USING SANDING BACKING PADS

Sanding pads and sanding discs must be rated above minimum accessory speed as shown on tool. Recommended sanding backing pads and sanding discs are available at extra cost from

DEWALT service centers and DEWALT dealers.

NOTE: Guard may be removed for sanding applications with backing pads and sanding discs. Sanding flap discs are considered grinding wheels by ANSI standards and require the use of a guard.

(See Mounting and Using Depressed Center Grinding Wheels and Sanding Flap Discs).

MOUNTING SANDING BACKING PADS

Turn off and unplug tool before making any adjustments or

removing or installing accessories. Before reconnecting the

tool, depress and release the trigger switch to ensure that the

tool is off. J_CAUTION: Proper guard must be re- N

installed for grinding wheel, sanding flap disc, M

wire brush, or wire wheel applications after

sanding applications are complete, f--_

1. Place or appropriately thread rubber back- ,_ ing pad (L) down to soft mount.

2. Place the sanding disc (M) on the rubber backing pad (L).

3. While depressing spindle lock, thread

clamp nut (N) on spindle, piloting the

i '\ f_

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

4. Tighten the clamp nut with the proper wrench.

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

USING SANDING BACKING PADS 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 materi-

al removal and a smoother finish. Begin with coarser 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 work surface.

2. Apply minimum pressure to work surface, allowing tool to oper- ate at high speed.

3. Maintain a 5°to 15° angle between the

tool and work surface. The sanding

disc should contact approximately one 5° inch of work surface.

4. Move the tool constantly in a straight line 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 the work surface before turning the tool off. Allow the tool to stop rotating before setting it down.

Mounting and Using Wire Brushes and Wire Wheels

Turn off and unplug tool before making any adjustments or removing or installing accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the

tool is off.

Wire brushes and wire wheels must be rated above minimum accessory speed as shown on tool. Use only wire brushes and

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

i_CAUTION: Wear work gloves when handling wire brushes or

wheels. Wire brushes and wheels can become sharp.

MOUNTING WIRE BRUSHES AND WIRE WHEELS

1. Thread the wheel on the spindle by hand, seating the wheel against the soft mount.

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

3. To remove the wheel, depress the spindle lock button and use a wrench on the hub of the wire brush or wheel to loosen it.

NOTE: Failure to properly seat the wheel hub against the soft mount before turning the tool on may result in damage to the tool

or wheel. USING WIRE CUP BRUSHES AND WIRE WHEELS

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

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

2. Apply minimum pressure to work surface, to allow the tool to operate 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. Continuously move the tool in a forward and back 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.

Mounting and Using Flaring Cup (Type 11) Wheel

MOUNTING FLARING CUP WHEEL GUARD

•& WARNING: The flaring cup wheel guard is not included with

this tool. Flaring cup wheels require proper flanges and guards. 4" flaring cup wheel guard D284934 and 6" flaring cup wheel

guard D284936 are available as accessories and include proper

flange. Failure to use the proper flange and guard can result in injury resulting from wheel breakage and wheel contact.

Turn off and unplug tool before making any adjustments or removing or installing accessories. Before reconnecting the

tool, depress and release the trigger switch to ensure that the tool is off.

1. Install the guard as shown.

2. Guard body should be positioned between the spindle and the operator to provide maximum operator protection.

3.Securelytightenthetwoclamping.... ...........• ._-.

MOUNTINGscrews(W)FLARINGsuppliedcuPwithWHEELtheguard. _......

1.Removethesoftmount(F)

2.Installtheflaringcupwheelbacking flange,aligningtheflatsonspindle W

(O)withtheflatsonbackingflange(P).

3.Threadtheflaringcupwheelonspindlebyhand,seatingwheel

againstbackingflange.

4.Depressthespindlelockbuttonandtightenthewheelbyhand.

5.Toremovethewheel,reversetheaboveprocedure.

_,CAUTION:Failure to properly seat the wheel against backing

flange before turning the tool on may result in damage to the tool or the wheel

NOTE: Adjust the guard skirt so that only 1/8" of the wheel is exposed by loosening the bolts, allowing the guard to lengthen. Tighten the guard skirt bolts securely before using the grinder.

USING A FLARING CUP WHEEL

Flaring cup wheels are designed for heavy material removal.

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

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

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

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

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

Mounting and Using Cutting

(Type 1) Wheels

Cutting wheels include diamond wheels and abrasive discs. Abrasive cutting wheels for metal and concrete use are available.

Diamond blades for concrete cutting can also be used. i_,WARNING: A closed, cutting wheel guard is not included with this

tool Cutting wheels require proper flanges and guards. A 7" cutting

guard, D284931, is available as an accessory and includes proper, matching flanges. Failure to use proper flange and guard can result

in injury resulting from wheel breakage and wheel contact.

MOUNTING CLOSED (TYPE 1) GUARD

Turn off and unplug tool before making any

adjustments or removing or installing accessories. Before reconnecting the tool, depress and release the trigger switch to

ensure that the tool is off.

1. Open the guard latch (H), and align the lugs with slots on the gear case cover. Position the guard facing backward, as shown.

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

3. Rotate guard (Q) into desired working position. The guard body should be posi-

tionedbetweenthespindleandtheoperatortoprovidemaxi- mumoperatorprotection.

4.Closetheguardlatchto securetheguardonthegearcase cover.Youshouldbeunabletorotatetheguardbyhandwhen thelatchis inclosedposition.Donotoperategrinderwitha looseguardorclampleverinopenposition.

NOTE:Theguardispre-adjustedtothedia- meterofthegearcasehubatthefactory.If, aftera periodoftime,theguardbecomes loose,tightentheadjustingscrew(I)withthe

clampleverintheclosedposition. 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

1. Remove Soft Mount (F).

2. Install wheel backing flange, aligning flats on spindle (O) with flats on backing flange (R).

3. Place the wheel on the backing flange, centering the wheel on the backing flange pilot.

4. Install the clamp nut, ensuring that the wheel remains centered on the backing flange.

5. Depress the spindle lock button and tighten clamp nut with

wrench.

6. Reverse the above procedure to remove the wheel.

USING CUTTING WHEELS

A 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 tool to work surface.

2. Apply minimum pressure to work surface, allowing tool to oper- ate at high speed.

3. Once you begin a cut, maintain the angle of the cutting wheel

to the work surface. This will keep you from bending the wheel which could result in wheel breakage and injury.

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

the tool to stop rotating before setting it down.

MAINTENANCE Cleaning

i_ WARNING: Blowing dust and grit out of the motor housing using

clean, dry compressed air is a necessary regular maintenance pro- cedure. Dust and grit containing metal particles often accumulate on

interior surfaces and could create an electrical shock or electrocu- tion if not frequently cleaned out. ALWAYS WEAR SAFETY

GLASSES.

_CAUTION: Never use solvents or other harsh chemicals for

cleaning the non-metallic parts of the tool Use aclean, dry rag only.

Lubrication

DEWALT tools are properly lubricated at the factory and are ready

for use.

Repairs

To assure product SAFETY and RELIABILITY, repairs, mainte-

nance and adjustment should be performed by authorized service

centers or other qualified service personnel. Always use identical

replacement parts.

Motor Brushes

When brushes become worn, the tool will automatically stop, pre- venting damage to the motor. Brush replacement should be per-

formed by DEWALT authorized service centers or other qualified service personnel. Qualified service personnel should follow the

procedures below when replacing motor brushes.

Turn off and unplug tool before making any adjustments or removing or installing accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the

tool is off.

1. Remove the brush doors located on the sides of motor housing.

2. To remove the brush, hold the female terminal, which is attached to the brush lead wire, and disconnect the female ter-

minal from the male terminal.

3. Pull the brush straight up out of the brush holder.

4. Replace brushes, in pairs, with original DEWALT brushes avail- able from DEWALT authorized service centers.

5. Ensure that the brushes slide freely in brush box.

6. Reconnect the brush lead wire to brush box terminal.

7. Re-install the brush doors before using the tool. Torque screws

to 10 in./Ibs., maximum. Overtightening may cause screws to strip.

Purchasing Accessories

Recommended accessories for use with your tool are available at extra cost from you local dealer or authorized service center. Ifyou need assistance in locating any accessory for your tool, contact: DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD

21286. _CAUTION: Accessories must be rated for at least the speed

recommended on the tool warning label Wheels and other acces- sories running over rated speed can fly apart and cause injuoz.

Accessory ratings must always be above tool speed as shown on

tool nameplate.

A CAUTION: The use of any other accessory not recommended

for use with this tool could be hazardous.

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty mate- rials 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

DEWALTPowerTool,Laser,orNailerforanyreason,youcan returnitwithin90daysfromthedateofpurchasewithareceiptfor afullrefund- noquestionsasked.

FREEWARNINGLABELREPLACEMENT:Ifyourwarninglabels becomeillegibleoraremissing,call1-800-4-DEWALTforafree

replacement.Torequestreplacementlabels,youwillneedtoknow theratedrpmofyourtool.Therpmofyourtoolisstampedintothe toolhousing.

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