DeWalt DC410-XE Instruction Manual

INSTRUCTION MANUAL

CORDLESS CUT-OFF TOOL

MODEL: DC410-XE

DEWALT Industrial Tool Co.

701 East Joppa Road, Baltimore, MD 21286 • 20 Fletcher Road, Mooroolbark, VIC 3138 Australia

(APR04) Form No. 624424-00 DC410-XE Copyright © 2004

The following are trademarks for one or more D

EWALT power tools: the yellow and black color scheme; the “D” shaped

air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps
on the surface of the tool.

SAFETY INSTRUCTIONS FOR POWER TOOLS

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

General Safety Rules

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

SAVE THESE INSTRUCTIONS

1. WORK AREA

a. Keep work area clean and well lit. Cluttered and dark areas invite accidents.
b. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases

or dust. Power tools create sparks which may ignite the dust or fumes.

c. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2. ELECTRICAL SAFETY

a. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs

with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.

b. Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators.

There is an increased risk of electric shock if your body is earthed or grounded.

c. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of elec-

tric 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 suit-

able for outdoor use reduces the risk of electric shock.

3. PERSONAL SAFETY

a. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a

power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inatten-

tion while operating power tools may result in serious personal injury.

b. Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety

shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

c. Avoid accidental starting. Ensure the switch is in the off position before plugging in. Carrying power tools

with your finger on the switch or plugging in power tools that have the switch on invites accidents.

d. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a

rotating part of the power tool may result in personal injury.

e. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool

in unexpected situations.

f. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from

moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.

g. If devices are provided for the connection of dust extraction and collection facilities, ensure these are con-

nected and properly used. Use of these devices can reduce dust related hazards.

4. POWER TOOL USE AND CARE

a. Do not force the power tool. Use the correct power tool for your application. The correct power tool will do

the job better and safer at the rate for which it was designed.

b. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled

with the switch is dangerous and must be repaired.

c. Disconnect the plug from the power source before making any adjustments, changing accessories, or stor-

ing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

d. Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool

or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

e. Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other

condition that may affect the power tools operation. If damaged, have the power tool repaired before use.

Many accidents are caused by poorly maintained power tools.

f. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to

bind and are easier to control.

g. Use the power tool, accessories and tool bits etc., in accordance with these instructions and in the manner

intended for the particular type of power tool, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from those intended could result in a hazardous situa-

tion.

5. BATTERY TOOL USE AND CARE

a. Ensure the switch is in the off position before inserting battery pack. Inserting the batter y pack into power

tools that have the switch on invites accidents.

b. Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of bat-

tery pack may create a risk of fire when used with another battery pack.

c. Use power tools only with specifically designated battery packs. Use of any other battery packs may create a

risk of injury and fire.

d. When battery pack is not in use, keep it away from other metal objects like paper clips, coins, keys, nails,

screws, or other small metal objects that can make a connection from one terminal to another. Shorting the
battery terminals together may cause burns or a fire.

e. Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally

occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the bat­tery may cause irritation or burns.

6. SERVICE

a. Have your power tool serviced by a qualified repair person using only identical replacement parts. This will

ensure that the safety of the power tool is maintained.

Electrical Safety

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

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

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

Extension Cords

CAUTION: Use only extension cords that are approved by the countr y’s Electrical Authority. Before using extension

cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary.

Additional Safety Instructions for Cut-Off Tools

• Always use proper guard with grinding wheel. A guard protects operator from broken wheel fragments and wheel
contact.

• Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other
accessories running over their rated speed can fly apart and cause injur y. Accessory ratings must always be above
tool speed as shown on tool nameplate.

• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hid­den wiring. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

• Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories can result in injury.

• Before using, inspect recommended accessory for cracks or flaws. If such a crack or flaw is evident, discard
the accessory. The accessory should also be inspected whenever you think the tool may have been dropped.

Flaws may cause wheel breakage.

• When starting the tool with a new or replacement wheel, or a new or replacement wire brush installed, hold
the tool in a well protected area and let it run for one minute. If the wheel has an undetected crack or flaw, it

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

• Avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the tool and inspect the wheel for cracks
or flaws.

• Direct sparks away from operator, bystanders or flammable materials. Sparks may be produced while using a sander
or grinder. Sparks may cause burns or start fires.

• Always use side handle. Tighten the handle securely. The side handle should always be used to maintain control
of the tool at all times.

• Clean out your tool often, especially after heavy use. Dust and grit containing metal particles often accumulate on interior
surfaces and could create a hazard.

CAUTION: When not in use, place tool on its side on a stable surface where it will not cause a tripping or falling

hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.

CAUTION: Use extra care when working into a corner or edge because a sudden, sharp movement of the tool may be

experienced when the wheel or other accessory contacts a secondary surface or a surface edge.

CAUTION: Wear appropriate personal hearing protection during use. Under some conditions and duration of use,

noise from this product may contribute to hearing loss.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains

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

• lead from lead-based paints,

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

• arsenic and chromium from chemically-treated lumber (CCA).

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to
these chemicals: work in a well ventilated area, 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 disburse dust, which may cause serious and permanent respiratory or
other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles
away from face and body.

• The label on your tool may include the following symbols. The symbols and their definitions are as follows:

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

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

min..............minutes ..........alternating current

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

n

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

..............Class II Construction ............earthing terminal

..............safety alert symbol .../min........revolutions per minute

Important Safety Instructions for Battery Packs

Your tool uses either a 12, 14.4 or 18 Volt DEWALT battery pack. When ordering replacement battery packs, be sure to
include catalog number and voltage: Extended Run-Time battery packs deliver 25% more run-time than standard battery
packs.

NOTE: Your tool will accept either standard or Extended Run Time battery packs. However, be sure to select proper voltage.
Batteries slowly lose their charge when they are not on the charger, the best place to keep your battery is on the charger at all
times.

The battery pack is not fully charged out of the carton. Before using the batter y pack and charger, read the safety
instructions below. Then follow charging procedures outlined.

READ ALL INSTRUCTIONS

• Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack
can explode in a fire.

• A small leakage of liquid from the battery pack cells may occur under extreme usage or temperature condi-
tions. This does not indicate a failure. However, if the outer seal is broken and this leakage gets on your skin:

a. Wash quickly with soap and water.
b. Neutralize with a mild acid such as lemon juice or vinegar.
c. If battery liquid gets into your eyes, flush them with clean water for a minimum of 10 minutes and seek immediate

medical attention. (Medical note: The liquid is 25–35% solution of potassium hydroxide.)

• Charge the battery packs only in D

EWALT chargers.

• DO NOT splash or immerse in water or other liquids.

NOTE: Your tool uses a 18 Volt DEWALT battery pack. When ordering DEWALT replacement battery packs, be sure to
include catalog number and voltage.

• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 105°F
(40˚C) (such as outside sheds or metal buildings in summer).

DANGER: Never attempt to open the battery pack for any reason. If batter y pack case is cracked or damaged, do not

insert into charger. Electric shock or electrocution may result. Damaged battery packs should be returned to service center
for recycling.

NOTE: Batter y storage and carrying caps are provided for use whenever the battery is out of the tool or
charger. Remove cap before placing battery in charger or tool.

WARNING: Do not store or carry battery so that metal objects can contact exposed battery terminals.

For example, do not place battery in aprons, pockets, tool boxes, product kit boxes, drawers, etc. with loose
nails, screws, keys, etc. without battery cap. Without cap in place, battery could shor t circuit causing fire or
burns or damage to battery.

The RBRC™ Seal

The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the nickel-cadmium battery (or battery
pack) indicates that the costs to recycle the battery (or battery pack) at the end of its useful life have
already been paid by DEWALT. In some areas, it is illegal to place spent nickel-cadmium batteries in the
trash or municipal solid waste stream and the RBRC program provides an environmentally conscious
alternative.

RBRC™ in cooperation with D

EWALT and other battery users, has established programs in the United States to facilitate

the collection of spent nickel-cadmium batteries. Help protect our environment and conserve natural resources by
returning the spent nickel-cadmium battery to an authorized D

EWALT service center or to your local retailer for recycling.

You may also contact your local recycling center for information on where to drop off the spent battery.
RBRC™ is a registered trademark of the Rechargeable Battery Recycling Corporation.

Important Safety Instructions for Battery Chargers

SAVE THESE INSTRUCTIONS: This manual contains important safety instructions for battery chargers.

• Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using
battery pack.

DANGER: 240 volts are present at charging terminals. Do not probe with conductive objects. Electric shock or electro-

cution may result.

WARNING: Do not allow any liquid to get inside charger. Electric shock may result.
CAUTION: To reduce the risk of injury, charge only DEWALT nickel cadmium rechargeable batteries. Other types of

batteries may burst causing personal injury and damage.

CAUTION: Under certain conditions, with the charger plugged in to the power supply, the exposed charging contacts
inside the charger can be shorted by foreign material. Foreign materials of a conductive nature such as, but not limited
to, steel wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities. Always
unplug the charger from the power supply when there is no battery pack in the cavity. Unplug charger before attempting
to clean.

• DO NOT attempt to charge the battery pack with any chargers other than the ones in this manual. The charger
and battery pack are specifically designed to work together.

• These chargers are not intended for any uses other than charging D

EWALT rechargeable batteries. Any other

uses may result in risk of fire, electric shock or electrocution.

• Do not expose charger to rain or snow.

• Pull by plug rather than cord when disconnecting charger. This will reduce risk of damage to electric plug and cord.

• Make sure that cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage

or stress.

• Do not use an extension cord unless it is absolutely necessary. Use of improper extension cord could result in risk
of fire, electric shock, or electrocution.

• 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.
When using more than one extension to make up the total length, be sure each individual extension contains at
least the minimum wire size.

Recommended Minimum Wire Size for Extension Cords

Total Length of Cord

25 ft. 50 ft. 75 f t. 100 ft. 125 ft. 150 ft. 175 ft.

7.6 m 15.2 m 22.9 m 30.5 m 38.1 m 45.7 m 53.3 m

Wire Size AWG

18 18 16 16 14 14 12

• Do not place any object on top of charger or place the charger on a soft surface that might block the ventila-
tion slots and result in excessive internal heat. Place the charger in a position away from any heat source. The
charger is ventilated through slots in the top and the bottom of the housing.

• Do not operate charger with damaged cord or plug — have them replaced immediately.

• Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. Take
it to an authorized service center.

• Do not disassemble charger; take it to an authorized service center when service or repair is required.
Incorrect reassembly may result in a risk of electric shock, electrocution or fire.

• Disconnect the charger from the outlet before attempting any cleaning. This will reduce the risk of electric
shock. Removing the battery pack will not reduce this risk.

• NEVER attempt to connect 2 chargers together.

• The charger is designed to operate on standard household electrical power (240 Volts). Do not attempt to use
it on any other voltage. This does not apply to the vehicular charger.

Using Automatic Tune-Up™ Mode

The Automatic Tune-Up™ Mode equalizes or balances the individual cells in the battery pack allowing it to function at
peak capacity. Battery packs should be tuned up weekly or after 10 charge/discharge cycles or whenever the pack no
longer delivers the same amount of work. To use the Automatic Tune-Up™, place the battery pack in the charger and
leave it for at least 8 hours. The charger will cycle through the following modes.

1. The red light will blink continuously indicating that the 1-hour charge cycle has star ted.

2. When the 1-hour charge cycle is complete, the light will stay on continuously and will no longer blink. This indi­cates that the pack is fully charged and can be used at this time.

3. Whenever the pack is left in the charger af ter the initial 1-hour charge, the charger will begin the Automatic Tune-Up™
Mode. This mode continues up to 8 hours or until the individual cells in the battery pack are equalized. The battery
pack is ready for use and can be removed at any time during the Tune-Up™ Mode.

4. Once the Automatic Tune-Up™ Mode is complete the charger will transition to a maintenance charge; the indicator
light shuts off when the automatic Tune-Up™ Mode is complete.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

Chargers

Your tool uses a 12.0, 14.4, or 18.0 Volt DEWALT Charger. Your battery can be charged in DEWALT 1 Hour Chargers, 15
Minute Chargers or Vehicular 12 volt charger. Be sure to read all safety instructions before using your charger. Consult the
chart on the back cover of this manual for compatibility of chargers and battery packs.

Charging Procedure (Fig. 1)

1. Plug the charger into an appropriate outlet.

2. Inser t the battery pack into the charger. The red
(charging) light will blink continuously indicating
that the charging process has started.

3. The completion of charge will be indicated by the red
light remaining ON continuously. The pack is fully
charged and may be used at this time or left in the
charger.

CAUTION: 240 volts present at charging terminals. Do not probe with conductive objects. Danger of electric shock or

electrocution. Keep battery door closed and latched at all times.

Indicator Light Operation

Charge Indicators

Some chargers are designed to detect certain problems that can arise with battery packs. Problems are indicated by the red
light flashing at a fast rate. If this occurs, reinsert battery pack into the charger. If the problem persists, try a different battery
pack to determine if the charger is OK. If the new pack charges correctly, then the original pack is defective and should be
returned to a service center or other collection site for recycling. If the new battery pack elicits the same trouble indication as
the original, have the charger tested at an authorized service center.

HOT/COLD PACK DELAY

Some chargers have a Hot/Cold Pack Delay feature: when the charger detects a battery that is hot, it automatically
starts a Hot Pack Delay, suspending charging until the battery has cooled. After the battery has cooled, the charger
automatically switches to the Pack Charging mode. This feature ensures maximum battery life. The red light flashes
long, then short while in the Hot Pack Delay mode.

PROBLEM POWER LINE

Some chargers have a Problem Power Line indicator. When the charger is used with some portable power sources such as
generators or sources that convert DC to AC, the charger may temporarily suspend operation, flashing the red light with two
fast blinks followed by a pause. This indicates the power source is out of limits.

LEAVING THE BATTERY PACK IN THE CHARGER

The charger and battery pack can be left connected with the red light glowing indefinitely. The charger will keep the bat­tery pack fresh and fully charged.

NOTE: A battery pack will slowly lose its charge when kept out of the charger. If the battery pack has not been kept on
maintenance charge, it may need to be recharged before use. A battery pack may also slowly lose its charge if left in a
charger that is not plugged into an appropriate AC source.

PACK CHARGING...................

FULLY CHARGED................... 

HOT/COLD PACK DELAY........

REPLACE PACK......................

PROBLEM POWER LINE........

FIG. 1

WEAK BATTERY PACKS: Chargers can also detect a weak battery. Such batteries are still usable but should not be
expected to perform as much work. In such cases, about 10 seconds after batter y insertion, the charger will beep
rapidly 8 times to indicate a weak battery condition. The charger will then go on to charge the battery to the highest
capacity possible.

Important Charging Notes

1. Longest life and best per formance can be obtained if the battery pack is charged when the air temperature is
between 65°F and 75°F (18°- 24°C). DO NOT charge the battery pack in an air temperature below +40°F
(+4.5°C), or above +105°F (+40.5°C). This is important and will prevent serious damage to the battery pack.

2. The charger and batter y pack may become warm to touch while charging. This is a normal condition, and does not
indicate a problem.

3. If the batter y pack does not charge properly:
a. Check current at receptacle by plugging in a lamp or other appliance
b. Check to see if receptacle is connected to a light switch which tur ns power off when you turn out the lights.
c. Move charger and battery pack to a location where the surrounding air temperature is approximately 65°F - 75°F

(18° - 24°C).

d. If charging problems persist, take the tool, batter y pack and charger to your local service center.

4. The batter y pack should be recharged when it fails to produce sufficient power on jobs which were easily done
previously. DO NOT CONTINUE to use under these conditions. Follow the charging procedure. You may also charge
a partially used pack whenever you desire with no adverse affect on the battery pack.

5. Under cer tain conditions, with the charger plugged into the power supply, the exposed charging contacts inside the
charger can be shorted by foreign material. Foreign materials of a conductive nature such as, but not limited to, steel
wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities. Always unplug the
charger from the power supply when there is no battery pack in the cavity. Unplug charger before attempting to clean.

6. Do not freeze or immerse charger in water or any other liquid.

WARNING: Don't allow any liquid to get inside charger. Electric shock may result. To facilitate the cooling of the bat­tery pack after use, avoid placing the charger or battery pack in a warm environment such as in a metal shed, or an unin­sulated trailer.

CAUTION: Never attempt to open the battery pack for any reason. If the plastic housing of the battery pack breaks or

cracks, return to a service center for recycling.

Installing and Removing the Battery Pack (Fig. 2)

NOTE: Make sure your battery pack is fully charged.
To install the battery pack into the tool handle, align the base of the tool

with the notch inside the tool’s handle and slide the battery pack firmly into
the handle until you hear the lock snap into place.

To remove the battery pack from the tool, press the release buttons and
firmly pull the battery pack out of the tool handle. Insert it into the charger
as described in the charger manual.

COMPONENTS (FIG. 3)

A. Trigger Switch F. Abrasive Wheel

B. Lock-Off Button G. Unthreaded Backing Flange (not shown)

C. Spindle Lock Button H. Threaded Clamp Nut (not shown)

D. Spindle (not shown) I. Guard (Type 1, Type 27)

E. Side Handle J. Battery

ASSEMBLY AND ADJUSTMENTS

Attaching Side Handle

The side handle can be fitted to either side of the gear case in the threaded holes. Before
using the tool, check that the handle is tightened securely.

To improve user comfort, the gear case will rotate 90˚ for cutting operations.

Rotating the Gear Case

CAUTION: Turn off tool and remove battery before making any adjustments or removing
or installing attachments or accessories.

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

2. Without separating the gear case from motor housing, rotate the gear case head to
desired position.

NOTE: If the gear case and motor housing become separated by more than 3.31mm (1/8"),
the tool must be serviced and reassembled by a D

EWALT 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 88.96 NM (20 in-lbs.) torque.
Overtightening could cause screws to strip.

ACCESSORIES

It is important to choose the correct guards, backing pads and flanges to use with grinder accessories. See page 3 for
information on choosing the correct accessories.

CAUTION: Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other
accessories running over their rated accessory speed may fly apar t and cause injury. Threaded accessories must have a
14mm x 2 (5/8"-11) hub. Every unthreaded accessory must have a 22mm (7/8") arbor hole. If it does not, it may have
been designed for a circular saw. Use only the accessories shown on page 3 of this manual. Accessory ratings must
always be above tool speed as shown on tool nameplate.

Mounting Guard

MOUNTING AND REMOVING GUARD

CAUTION: Turn off tool and remove battery before making any adjustments or removing or installing attachments

or accessories.

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

tool may be used without a guard only when sanding with conventional sanding discs. DEWALT
model DC410 is provided with a guard intended for use with depressed center wheels (Type

27) and hubbed grinding wheels (Type 27). The same guard is designed for use with sanding
flap discs (Type 27 and 29) and wire cup brushes. Grinding and cutting with wheels other than
Type 27 and 29 require different accessory guards included with tool. A Type 1 guard is
provided for use with a Type 1 wheel. Mounting instructions for these accessory guards are
included in the accessory package.

1. Open the guard latch (J), and align the ar row on the guard (K) with the arrow on the
hub (L). This will align the lugs on the guard with the slots on the gear case cover.

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 (M) with clamp lever
in the closed position with guard installed on the tool.

CAUTION: Do not tighten the adjusting screw with the clamp lever in the open position. Undetectable damage to the

guard or the mounting hub may result.

CAUTION: If the guard cannot be tightened by the adjusting clamp, do not use the tool and take the tool and guard to
a service center to repair or replace the guard.
NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose; 6.35mm
(1/4") thick wheels are designed for surface grinding while 3.31mm (1/8") wheels are designed for edge grinding. Cutting
can also be performed by using a Type 1 wheel and a Type 1 guard.

M

I

J

L

K

FIG. 3

E

F

C

B

A

J

I

FIG. 2