DeWalt DW402G User Manual

INSTRUCTION MANUAL

GUIDE D'UTILISATION

MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y

PÓLIZADE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUC-

TIVO ANTES DE USAR ELPRODUCTO.

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)

General Safety Instructions for All Tools

WARNING! Read and understand all instructions. Failure to follow all instructions listed

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

SAVE THESE INSTRUCTIONS

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and dark areas invite acci­dents.

• Do not operate power tools in explosive atmospheres, such as in the 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 operating a power tool.

Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Grounded tools must be plugged into an outlet properly installed and grounded in
accordance with all codes and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adaptor plugs. Check with a qualified
electician if you are in doubt as to whether the outlet is properly grounded. If the tools

should electrically malfunction or break down, grounding provides a low resistance path to
carry electricity away from the user. Applicable only to Class I (grounded) tools.

• Double insulated tools are 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 if your body is grounded.

• Don’t expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

• Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an
outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace dam­aged cords immediately. Damaged cords increase the risk of electric shock.

• When operating a power tool outside, use an outdoor extension cord marked “W-A”
or “W.” These cords are rated for outdoor use and reduce the risk of electric shock.

Recommended Minimum Wire Size for Extension Cords

Total Length of Cord

25 ft. 50 ft. 75 ft. 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

18 AWG 18 AWG 16 AWG 16 AWG 14 A WG 14 AWG 12 AWG

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power
tool. Do not use tool while tired or under the influence of drugs, alcohol, or medica­tion. A moment of inattention while operating power tools may result in serious personal

injury,

• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your
hair, clothing , and gloves away from moving parts. Loose clothes, jewelry, or long hair

can be caught in moving parts.

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

• Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with
your finger on the switch or plugging in tools that have the switch on invites accidents.

• Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that
is left attached to a rotating part of the tool may result in personal injury.

• 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.

• 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, breakage 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 manufacturer for your model.

Accessories that may be suitable for one tool, may become hazardous when used on anoth­er tool.

SERVICE

•Tool service must be performed only by qualified repair personnel. Service or mainte­nance performed by unqualified personnel could result in a risk of injury.

• When servicing a tool, use only identical replacement parts. Follow instructions in
the Maintenance section of this manual. Use of unauthorized parts or failure to follow

Maintenance Instructions may create a risk of electric shock or injury.

Additional Specific Safety Instructions for Grinders

• Always use proper guard with grinding wheel. A guard protects operator from broken wheel
fragments. Do not use Type 1 abrasive or diamond wheels without proper guarding.

• Accessories must be rated for at least the speed recommended on the tool warning label.

Wheels and other accessories running over rated speed can fly apart and cause injury. NEVER
use Type II (Flaring Cup Wheels) on this tool.

• Hold tool by insulated gripping surfaces when performing an operation where the cutting
tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed

metal parts of the tool “live” and shock the operator.

• 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.

• When starting the tool (with a new or replacement wheel 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. Never start the tool with a person in line with the wheel. This
includes the operator.

• In operation, avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the
tool and inspect the wheel.

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

• Clean out your tool periodically. Dust and grit containing metal particles often accumulate on
interior surfaces and could create an electric shock hazard.

• Never depress the spindle lock pin when the tool is runnung or coasting. Damage to
the gear and lock pin will result.

• Always use guards with depressed center grinding wheels.

• Clean your tool out periodically.

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.

• The label on your tool may include the following symbols.

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

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

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

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

n

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

......................

Class II Construction …/min ........revolutions or reciprocation

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

..................per minute

SAVE THESE INSTRUCTIONS

Fitting and Removing Guard (Fig. 1)

IMPORTANT:Unplug the tool before fitting or removing the guard. Use the tool without the guard
only when sanding or wire brushing.

FITTING GUARD:

1. Loosen screws (A), allowing the guard ring (B) to slide over the gear case hub (C).

2. Lugs on guard ring must align with groove in gear case hub.

3. Tighten screws to securely attach guard to gear case hub.

REMOVING GUARD:

Follow the above procedure n reverse order.

Installing Auxiliary Handle (Fig. 1)

The side handle (D) can be fitted to the left side, right side or top of the gear case in the thread­ed holes, as shown. The side handle should be used at all times to maintain complete control of
the tool.

Mounting Grinding Wheels (Fig. 2)

Grinding wheels are available as optional accessories. Before fitting a grinding wheel, disconnect
the plug from power source.

1. Locate the inner flange (A) on the machine spindle (B).

2. Place the wheel against the backing flange,(C) centering the grinding wheel on the backing

flange pilot.

3. Screw the threaded clamp nut onto the spindle (D).

4. Rotate the spindle by hand while pressing the spindle lock fully until it has found its locking

location and holds the spindle still (E).

5. Firmly tighten the threaded flange with the supplied hex wrench (F).

DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286

Printed in U.S.A. (MAR02-CD-1) Form No. 382900-01 DW402,402G Copyright © 2002

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 con-

figuration; and the array of lozenge-shaped humps on the surface of the tool.

DW402/DW402G

Heavy Duty Small Angle Grinders

Petites rectifieuses coudées de service intensif

Esmeriladoras de ángulo pequeño para trabajo pesado

Questions? See us in the World Wide Web at www.dewalt.com

Mounting Edge Cutting Wheels (Fig. 2)

Type 27 Edge cutting wheels are available as optional accessories. Before fitting a cutting
wheel, unplug tool from the power source.

1. Locate the inner clamp nut (A) on the machine spindle (B).

2. Place the wheel against the flange,(C) centering the grinding wheel on the backing flange
pilot. (D).

4. Rotate the spindle by hand while pressing the spindle lock (E) fully until it has found its lock­ing location and holds the the spindle still.

5. While depressing spindle lock button, firmly tighten the threaded flange with supplied hex
wrench (F).

Fitting a Sanding Backing Pad and Sanding Disc

Sanding backing pads are available as optional accessories. To fit the pad, unplug the tool, follow
instructions provided with the accessory.

CAUTION: Accessories must be rated for at least the speed recommended on the tool
warning label. Wheels and other accessories running over rated speed can fly apart and
cause injury.

Fitting Wire Cup Brushes

The wire cup brush or wire stringer bead wheel screws directly on the spindle of the machine
without the use of flanges.

Operation
Starting the Tool Fig. 3)

Always be sure the tool is not locked on before plugging it in.

1. To start the grinder, squeeze the paddle switch (A) after rotating the off-lock (B) out of the

way.

2. To turn the tool off, release the paddle.

3. The switch can be locked in the ON position by engaging the button (C) at the rear of the tool

after squeezing the paddle.

4. To turn the tool off while the lock-on feature is engaged, sqeeze and release the paddle.

For Grinding (Fig. 4)

Using a depressed center Type 27 wheel, use the tool at an angle of approximately 10-20
degrees to the work for grinding. Most type 27 wheels are not designed for cutting operations

Edge Cutting (Fig. 5)

Edge cutting can be performed only with Type 27 wheels that are designed and specified for
this purpose. Protect yourself during edge cutting by directing the open side of the guard away
from you and toward a surface.

Sanding With Abrasive Discs (Fig. 6)

When using an abrasive disc, hold the tool so that an angle of 5° to 15° exists between the
disc and the work, as shown. If only the outer edge of the sanding disc is pressed flat against
the work, the sanding action will be irregular and bumpy, and the tool will be difficult to con­trol.

Precautions When Sanding Paint

Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling the con­taminated dust. The greatest danger of lead poisoning is to children and pregnant women.

Since it is difficult to identify whether or not a paint contains lead without a chemical analysis, we
recommend the following precautions when sanding any paint:

A. PERSONAL SAFETY

1. No children or pregnant women should enter the work area where the paint sanding is being
done until all clean up is completed.

2. A dust mask or respirator should be worn by all persons entering the work area. The filter
should be replaced daily or whenever the wearer has difficulty breathing.

NOTE: Only those dust masks suitable for working with lead paint dust and fumes should be
used. Ordinary painting masks do not offer this protection. See your local hardware dealer for
the proper (NIOSH approved) mask.

3. NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingesting
contaminated paint particles. Workers should wash and clean up BEFORE eating, drinking or
smoking. Articles of food, drink, or smoking should not be left in the work area where dust would
settle on them.

B. ENVIRONMENTALSAFETY

1. Paint should be removed in such a manner as to minimize the amount of dust generated.

2. Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils
thickness.

3. Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

C. CLEANING AND DISPOSAL

1. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the duration
of the sanding project. Vacuum filter bags should be changed frequently.

2. Plastic drop cloths should be gathered up and disposed of along with any dust chips or other
removal debris. They should be placed in sealed refuse receptacles and disposed of through
regular trash pick-up procedures. During clean up, children and pregnant women should be
kept away from the immediate work area.

3. All toys, washable furniture and utensils used by children should be washed thoroughly
before being used again.

Cleaning

Blowing dust and grit out of the motor housing using compressed air is a necessary regular
maintenance procedure. Dust and grit containing particles from metal grinding often accumulate
on interior surfaces and could create an electrical shock hazard if not frequently cleaned out.

CAUTION: Never use solvents or other harsh chemicals for cleaning the non-metallic parts

of the tool. Use clean, dry rag only.

Lubrication

DEWALT tools are properly lubricated at the factory and are ready for use. Tools should be relu­bricated regularly every sixty days to six months, depending on usage. (Tools used constantly
on production or heavy-duty jobs and tools exposed to heat may require more frequent lubrica­tion.) This lubrication should only be attempted by trained power tool repairpersons.

Motor Brushes

DEWALT uses an advanced brush system which automatically stops the tool when the brushes
wear out. This prevents serious damage to the motor.

Accessories

Recommended accessories for use with your tool are available at extra cost from your local
dealer or authorized service center. If you need assistance in locating any accessory for your
tool, please contact your local dealer or authorized service center.

CAUTION: The use of any other accessory not recommended for use with this tool could be

hazardous.

Depressed center grinding wheels must fit within the confines of the guard and must be rated
higher than the recommended speed as marked on the nameplate.

WARNING: To reduce the risk of injury, always use proper guards when grinding and wear

eye protection.

Important

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including
brush inspection and replacement) should be performed by authorized service centers or other
qualified service organizations, always using identical replacement parts.

Full Warranty

DEWALT heavy duty industrial tools are warranted for one year from date of purchase. We will
repair, without charge, any defects due to faulty materials or workmanship. For warranty repair
information, call 1-800-4-DEWALT. 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, D

EWALT tools are covered by our:

FIG. 2

10° TO 20°

FIG. 4

A

B

FIG.1

FIG. 3

B

A

FIG. 5

POUR TOUT RENSEIGNEMENT SUPPLÉMENTAIRE SUR CET OUTIL OU TOUT AUTRE
OUTIL D

E

WALT, COMPOSER SANS FRAIS LE NUMÉRO:

1-800-4-DEWALT (1-800-433-9258)

RÈGLES DE SÉCURITÉ GÉNÉRALES

AVERTISSEMENT! Vous devez lire et comprendre toutes les instructions. Le non­respect, même partiel, des instructions ci-après entraîne un risque de choc électrique, d’in­cendie et/ou de blessures graves.

CONSERVEZ CES INSTRUCTIONS.

AIRE DE TRAVAIL

• Veillez à ce que l’aire de travail soit propre et bien éclairée. Le désordre et le manque de

lumière favorisent les accidents.

• N’utilisez pas d’outils électriques dans une atmosphère explosive, par exemple en

présence de liquides, de gaz ou de poussières inflammables. Les outils électriques
créent des étincelles qui pourraient enflammer les poussières ou les vapeurs.

• Tenez à distance les curieux, les enfants et les visiteurs pendant que vous travaillez

avec un outil électrique. Ils pourraient vous distraire et vous faire faire une fausse
manoeuvre.

SÉCURITÉ ÉLECTRIQUE

• Les outils à double isolation sont équipés d’une fiche polarisée (une des lames est

plus large que l’autre), qui ne peut se brancher que d’une seule façon dans une prise
polarisée Ne modifiez pas la fiche de l’outil. La double isolation élimine le besoin d’un

cordon d’alimentation à trois fils avec mise à la terre ainsi que d’une prise de courant mise à
la terre.

• Évitez tout contact corporel avec des surfaces mises à la terre (tuyauterie, radiateurs,

cuisinières, réfrigérateurs, etc.). Le risque de choc électrique est plus grand si votre corps
est en contact avec la terre.

• N’exposez pas les outils électriques à la pluie ou à l’eau. La présence d’eau dans un outil

électrique augmente le risque de choc électrique.

• Ne maltraitez pas le cordon. Ne transportez pas l’outil par son cordon et ne débranchez

pas la fiche en tirant sur le cordon. N’exposez pas le cordon à la chaleur, à des huiles,
à des arêtes vives ou à des pièces en mouvement. Remplacez immédiatement un
cordon endommagé. Un cordon endommagé augmente le risque de choc électrique.

• Lorsque vous utilisez un outil électrique à l’extérieur, employez un prolongateur pour

l’extérieur marqué «W-A» ou «W». Ces cordons sont faits pour être utilisés à l’extérieur et

réduisent le risque de choc électrique. S’assurer que le cordon de rallonge est en bon état.
Lorsqu’on se sert d’un cordon de rallonge, s’assurer qu’il est de calibre approprié pour la
tension nécessaire au fonctionnement de l’outil. L’utilisation d’un cordon de calibre inférieur
occasionne une baisse de tension entraînant une perte de puissance et la surchauffe. Le
tableau suivant indique le calibre approprié selon la longueur du cordon et les mentions de la
plaque signalétique de l’outil. En cas de doute, utiliser un cordon de calibre supérieur. Le
chiffre indiquant le calibre est inversement proportionnel au calibre du cordon.

Calibre minimal des cordons de rallonge

Tension Longueur totale du cordon en pieds

120 V 0-25 26-50 51-100 101-150
240 V 0-50 51-100 101-200 201-300

Intensité (A)

Au Au Calibre moyen de fil (AWG)

moins plus
0- 6 18 161614
6- 10 18 16 14 12
10 - 12 16161412
12 - 16 14 12 Non recommandé

30 DAY NO RISK SATISFACTION GUARANTEE

If you are not completely satisfied with the performance of your D

EWALT heavy duty industrial

tool, simply return it to the participating seller within 30 days for a full refund. Please return the
complete unit, transportation prepaid. Proof of purchase may be required.

FREE WARNING LABELREPLACEMENT: If your warning labels become illegible or are miss­ing, call 1-800-4-DEWALT for a free replacement.

C

C

D

A

B

C

D

E

FIG. 6

10° TO 15°

F