DeWalt DCG412-XE, DCG422-XE Instruction Manual
DCG412-XE, DCG422-XE
18 V CORDLESS CUT-OFF TOOL
INSTRUCTION MANUAL
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Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal
word. Please read the manual and pay attention to these symbols.
DANGER: Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
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 AT: 1800 444 224 (Aust) or 0800 339 258 (NZ).
Technical Data
DCG412-XE DCG422-XE
Voltage V 18 14.4
Power input W 405 350
No-load/rated speed rpm 7000 5000
Wheel diameter mm 125 125
Spindle diameter M14 M14
Weight kg 3.0* 3.0*
* weight includes side handle and guard
LPA (sound pressure) dB(A)
87 84
KPA (sound pressure uncertainty) dB(A)
5 3
LWA (sound power) dB(A)
98 95
KWA (sound power uncertainty) dB(A)
5 3
Vibration total values (triax vector sum) determined according to EN 60745:
Vibration emission value ah surface grinding
a
h.AG
=
m/s²
6.0 4.7
Uncertainty K = m/s²
1.5 1.5
The vibration emission level given in this information sheet has been measured in
accordance with a standardised test given in EN 60745 and may be used to compare
one tool with another. It may be used for a preliminary assessment of exposure.
WARNING: The declared vibration emission level represents the main applications
of the tool. However if the tool is used for different applications, with different
accessories or poorly maintained, the vibration emission may differ. This may
significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account
the times when the tool is switched off or when it is running but not actually doing
the job. This may significantly reduce the exposure level over the total working
period.
Identify additional safety measures to protect the operator from the effects of
vibration such as: maintain the tool and the accessories, keep the hands warm,
organisation of work patterns.
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.
WARNING: To reduce the risk of injury, read the instruction manual.
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SAVE ALL WARNINGS AND INSTRUCTIONS FOR
FUTURE REFERENCE
WARNING! R ead all safety warnings and all instructions Failure to follow
the warnings and instructions may result in electric shock, fire and/or serious
injury.
The term “power tool” in the warnings refers to your mains-operated (corded) power
tool or battery-operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1) WORK AREA SAFETY
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
2) ELECTRICAL SAFETY
a) Power tool plugs must match the outlet. Never modify the plug in any
way. Do not use any adapter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords increase the risk of electric
shock.
e) When operating a power tool outdoors, use an extension cord suitable
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is unavoidable, use a residual
current device (RCD) protected supply. Use of an RCD 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
energising 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 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.
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c) Disconnect the plug from the power source and/or the battery pack from
the power tool before making any adjustments, changing accessories,
or storing power tools. Such preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
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, 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) BATTERY TOOL USE AND CARE
a) Recharge only with the charger specified by the manufacturer. A charger
that is suitable for one type of battery pack may create a risk of fire when
used with another battery pack.
b) Use power tools only with specifically designated battery packs. Use of any
other battery packs may create a risk of injury and fire.
c) 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.
d) 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 range only. Always check that
the power supply corresponds to the voltage on the rating plate. 220–240 V AC
means your tool will operate on alternating current. Operation at a voltage outside this
range 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 is not intended for use by young
children or infirm persons without supervision.
– This appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
– Children should be supervised to ensure that they do not play with the appliance.
• Replacement of the supply cord. If the supply cord or plug is damaged, it must
be replaced by the manufacturer or an authorised D
EWALT Service Centre in
order to avoid a hazard.
Extension Cords
CAUTION: Use only extension cords that are approved by the country’s Electrical
Authority. Before using extension cords, inspect them for loose or exposed wires,
damaged insulation and defective fittings. Replace the cord if necessary.
SAFETY INSTRUCTIONS FOR ALL OPERATIONS
Safety Warnings Common for Grinding, Sanding, Wire Brushing,
Polishing or Abrasive, Cutting-Off Operations
a) This power tool is intended to function as a grinder, sander, wire brush,
polisher or cut-off tool. Read all safety warnings, instructions, illustrations
and specifications provided with this power tool. Failure to follow all
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.
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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.
l) Do not run the power tool while carrying it at your side. Accidental contact
with the spinning accessory could snag your clothing, pulling the accessory
into your body.
m)
Regularly clean the power tool’s air vents. The motor’s fan will draw the
dust inside the housing and excessive accumulation of powdered metal may
cause electrical hazards.
n) Do not operate the power tool near flammable materials. Sparks could
ignite these materials.
o) Do not use accessories that require liquid coolants. Using water or other
liquid coolants may result in electrocution or shock.
p) Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate
accessories can result in injury.
q) Always use side handle. Tighten the handle securely. The side handle
should always be used to maintain control of the tool at all times.
KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing
pad, brush or any other accessory. Pinching or snagging causes rapid stalling
of the rotating accessory which in turn causes the uncontrolled power tool to
be forced in the direction opposite of the accessory’s rotation at the point of the
binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the
edge of the wheel that is entering into the pinch point can dig into the surface
of the material causing the wheel to climb out or kick out. The wheel may either
jump toward or away from the operator, depending on direction of the wheel’s
movement at the point of pinching. Abrasive wheels may also break under these
conditions.
Kickback is the result of tool misuse and/or incorrect operating procedures or
conditions and can be avoided by taking proper precautions as given below:
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 tool will run out of
balance, vibrate excessively and may cause loss of control.
f) 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 and electric
shock.
j) Position the cord clear of the spinning accessory. If you lose control, the
cord may be cut or snagged and your hand or arm may be pulled into the
spinning accessory.
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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 Cutting-Off
Operations
a) Use only wheel types that are recommended for your power tool and the
specific guard designed for the selected wheel. Wheels for which the power
tool was not designed cannot be adequately guarded and are unsafe.
b) The guard must be securely attached to the power tool and positioned for
maximum safety, so the least amount of wheel is exposed towards the
operator. The guard helps to protect operator from broken wheel fragments
and accidental contact with wheel and sparks that could ignite clothing.
c) Wheels must be used only for recommended applications. For example: do
not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended
for peripheral grinding, side forces applied to these wheels may cause them to
shatter.
d) Always use undamaged wheel flanges that are of correct size and shape
for your selected wheel. Proper wheel flanges support the wheel thus
reducing the possibility of wheel breakage. Flanges for cut-off wheels may be
different from grinding wheel flanges.
e) Do not use worn down wheels from larger power tools. Wheel intended for
larger power tool is not suitable for the higher speed of a smaller tool and may
burst.
Additional Safety Warnings Specific for Abrasive Cutting-Off
Operations
a) Do not “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. Investigate and
take corrective action to eliminate the cause of wheel binding.
d) Do not restart the cutting operation in the workpiece. Let the wheel reach
full speed and carefully reenter the cut. The wheel may bind, walk up or
kickback if the power tool is restarted in the workpiece.
e) Support panels or any oversized workpiece to minimize the risk of wheel
pinching and kickback. Large workpieces tend to sag under their own weight.
Supports must be placed under the workpiece near the line of cut and near
the edge of the workpiece on both sides of the wheel.
f) 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.
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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 and centrifugal forces.
Additional Safety Warnings
• Air vents often cover moving parts and should be avoided. Loose clothes,
jewelry or long hair can be caught in moving parts.
WARNING: We recommend the use of a residual current device with a residual
current rating of 30mA or less.
WARNING: ALWAYS wear approved protective safety equipment complying with
the following standards:
• Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications;
• Hearing protection: AS/NZS1270 Acoustics – Hearing Protection;
• Respiratory protection: AS/NZS1716 Respiratory Protective Devices.
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.
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 AS/NZS1716 approved
respiratory protection appropriate for the dust exposure. Direct particles away from
face and body.
WARNING: Always wear proper personal hearing protection that conforms to
AS/NZS1270 during use. Under some conditions and duration of use, noise from this
product may contribute to hearing loss.
• The label on your tool may include the following symbols. The symbols and their
definitions are as follows:
V ................. volts A ...............amperes
Hz ............... hertz W ..............watts
min ............. minutes ...........alter nating current
........ direct current ...........alternating or direct current
.............. Class I Construction no ..............no load speed
................... (grounded) .............earthing terminal
.............. Class II Construction ..............safety alert symbol
................... (double insulated) BPM ..........beats per minute
…/min ........per minute RPM ..........revolutions per minute
IPM ............. impacts per minute
Important Safety Instructions for All Battery Packs
When ordering replacement battery packs, be sure to include the catalog number and
voltage. Consult the chart at the end of this manual for compatibility of chargers and
battery packs.
The battery pack is not fully charged out of the carton. Before using the battery pack
and charger, read the safety instructions below and then follow charging procedures
outlined.
READ ALL INSTRUCTIONS
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