DeWalt DW488, DW493, DW494, DW494-220 Instruction Manual

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 1

DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 Printed in U.S.A. (JUL02-CD-1) Form No. 383763-01

DW488/DW493/DW494/DW494-220 Copyright © 1998

The following are trademarks for one or more DEWALT 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.

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 2

INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW488/DW493/DW494/DW494-220

Right Angle Sanders
Ponceuses à angle droit
Lijadoras de ángulo recto

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 3

Important Safety Instructions

WARNING: Use of this tool can generate dust containing

chemicals known to cause cancer, birth defects or other reproductive
harm. Use appropriate respiratory protection.

WARNING: When using electric tools, basic safety precautions

should always be followed to reduce risk of fire, electric shock, and
personal injury, including the following:

READ ALL INSTRUCTIONS

Grounding Instructions (DW488, DW493,

DW494)

This tool should be grounded while in use to protect the operator from
electric shock. The tool is equipped with a 3-conductor cord and 3­prong grounding type plug to fit the proper grounding type receptacle.
The green (or green and yellow) conductor in the cord is the
grounding wire. Never connect the green (or green and yellow) wire
to a live terminal. If your unit is intended for use on less than 150 V,
it has a plug that looks like that shown in sketch A. If it is for use on
150 to 250 V, it has a plug that looks like that shown in sketch D. An
adapter, sketches B and C, is available for connecting sketch A type
plugs to 2-prong receptacles. The green-colored rigid ear, lug, or the

English

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS
OR ANY D

EWALT TOOL, CALL US TOLL FREE AT:

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

TO CONVERT THE
SANDER TO A
GRINDER, A
GUARD MUST BE
INSTALLED.

SPINDLE

LOCK

BRUSH

INSPECTION

CAP

SWITCH LOCK

BUTTON

TRIGGER

SWITCH

AUXILIARY

HANDLE

GUARD

(NOT SUPPLIED)

DEPRESSED

CENTER WHEEL

AB CD

GROUNDING PIN

GROUNDED

OUTLET

BOX

GROUNDING

MEANS

GROUNDING PIN

ADAPTER

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 4

like, extending from the adapter must be connected to a permanent
ground, such as a properly grounded outlet box. No adapter is
available for a plug as shown in sketch D. ADAPTER SHOWN IN
FIGURES B and C IS NOT FOR USE IN CANADA.

Grounding Instructions

(DW494-220)

This tool should be grounded while in use to protect the operator from
electric shock. The tool is equipped with a 3-conductor cord
to fit the proper grounding type receptacle. The green (or
green and yellow) conductor in the cord is the grounding wire. Never
connect the green (or green and yellow)
wire to a live terminal.

The two grounding contacts and the
grounding receptacle in the plug must be
connected to a permanent ground, such as
a properly grounded outlet. No adapter is
available for a plug as shown in Figure A.

Safety Instructions For
All Tools

• KEEP WORK AREA CLEAN. Cluttered areas and benches invite

injuries.

• CONSIDER WORK AREA ENVIRONMENT. Don’t expose power

tools to rain. Don’t use power tools in damp or wet locations. Keep
work area well lit. Do not use tool in presence of flammable liquids
or gases.

• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact

with grounded surfaces. For example; pipes, radiators, ranges, and
refrigerator enclosures.

• KEEP CHILDREN AWAY. Do not let visitors contact tool or

extension cord. All visitors should be kept away from work area.

• STORE IDLE TOOLS. When not in use, tools should be stored in

dry, and high or locked-up place — out of reach of children.

• DON’T FORCE TOOL. It will do the job better and safer at the

rate for which it was intended.

• USE RIGHT TOOL. Don’t force small tool or attachment to do the

job of a heavy-duty tool. Don’t use tool for purpose not intended.

• DRESS PROPERLY. Do not wear loose clothing or jewelry. They

can be caught in moving parts. Rubber gloves and non-skid
footwear are recommended when working outdoors. Wear
protective hair covering to contain long hair.

Air vents often cover

moving parts and should also be avoided.

• USE SAFETY GLASSES. Also use face or dust mask if operation

is dusty.

• DON’T ABUSE CORD. Never carry tool by cord or yank it to

disconnect from receptacle. Keep cord from heat, oil, and sharp
edges.

• SECURE WORK. Use clamps or a vise to hold work. It’s safer than

using your hand and it frees both hands to operate tool.

• DON’T OVERREACH. Keep proper footing and balance at all

times.

• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for

better and safer performance. Follow instructions for lubricating
and changing accessories. Inspect tool cords periodically and if
damaged, have repaired by authorized service facility. Inspect
extension cords periodically and replace if damaged. Keep
handles dry, clean, and free from oil and grease.

• DISCONNECT OR LOCK OFF TOOLS when not in use, before

servicing, and when changing accessories, such as blades, bits,
cutters.

• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of

checking to see that keys and adjusting wrenches are removed
from tool before turning it on.

• AVOID UNINTENTIONAL STARTING. Don’t carry tool with finger

on switch. Be sure switch is off when plugging in.

• EXTENSION CORDS. Use only 3-wire extension cords that have

1

English

A

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 1

2

3-prong grounding-type plugs and 3-pole receptacles that accept
the tool’s plug. Replace or repair damaged cords. Make sure your
extension cord is in good condition. When using an extension cord,
be sure to use one heavy enough to carry the current your product
will draw. An undersized cord will cause a drop in line voltage
resulting in loss of power and overheating. The following table
shows the correct size to use depending on cord length and
nameplate ampere rating. If in doubt, use the next heavier gage.
The smaller the gage number, the heavier the cord.

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 AWG 14 AWG 12 AWG

• OUTDOOR USE EXTENSION CORDS. When tool is used

outdoors, use only extension cords intended for use outdoors and
so marked.

• STAY ALERT. Watch what you are doing. Use common sense.

Do not operate tool when you are tired.

• CHECK DAMAGED PARTS. Before further use of the tool, a

guard or other part that is damaged should be carefully checked
to determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any other conditions that
may affect its operation. A guard or other part that is damaged
should be properly repaired or replaced by an authorized service
center unless otherwise indicated elsewhere in this instruction
manual. Have defective switches replaced by authorized service
center. Do not use tool if switch does not turn it on and off.

Additional Safety Instructions for
Grinders

• ALWAYS WEAR EYE PROTECTION.

• WHEN GRINDING, ALWAYS KEEP GUARDS IN PLACE.

• Always use proper guard with grinding wheel. A guard protects

operator from broken wheel fragments and wheel contact.

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

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

• 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. Refer to the table
below. Accessory ratings are above rated no-load tool speeds because
actual tool speeds may vary.

• Use only grinding wheels having a maximum operating speed at
least high as “No Load RPM” marked on the tool’s nameplate.

• 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 GUARDS with depressed center wheels or flaring
cup grinding wheels.

• Clean your tool out periodically.

CAUTION: Use extra care when grinding into a corner as a sudden,

sharp movement of the grinder may be experienced when the wheel
contacts a secondary surface.

English

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 2

CAUTION: Wear appropriate 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.

SAVE THESE INSTRUCTIONS

Switch

To start the tool, squeeze the trigger switch shown in Figure 1. To turn
the tool off, release the switch.The tool can be locked on for
continuous use by holding the trigger switch depressed while you
depress the switch locking button next to the trigger, as shown in
Figure1. Hold the locking button in as you gently release the trigger.
Release the locking button and the tool will continue to run. To turn
the tool off from a locked on condition, squeeze and release the
trigger once.

3

English

TRIGGER

SWITCH

SWITCH LOCKING

BUTTON

FIG. 1

FIG. 2

AUXILIARY HANDLE CAN

BE INSTALLED ON EITHER

SIDE OF THE GEAR CASE

AUXILIARY

HANDLE

SPINDLE

DISC NUT

HUB

BACKING PAD

ABRASIVE DISC

FIG. 3

FIG. 4

SPINDLE

LOCK

BUTTON

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4

Auxiliary Handle

An auxiliary handle is provided with your tool for convenience. The
handle can be screwed into either side of the gear case, as shown in
Figure 2, and should be used at all times when sanding or grinding.

Sanding With Abrasive Discs

Abrasive discs can be used for smoothing welds, removing rust and
paint and general smoothing of rough surfaces.

To install an abrasive disc, follow the steps listed below.

1. TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY.

2. Push the hub of the disc nut through the hole in the center of the
abrasive disc and the backing disc as far as it will go.

3. Install the assembled discs onto the tool spindle, as shown in
Figure 3, and engage the disc nut into the disc nut hub.

4. Using a glove or cloth to protect your hand, screw the whole
assembly clockwise onto the tool spindle as far as it will go as
shown in Figure 4.

5. Engage the spindle lock button to lock the spindle in place and
tighten firmly. (See Figure 4)

To remove an abrasive disc, follow the steps listed below.

1. Turn off and unplug the tool from the power supply.

2. Using a glove or cloth to protect your hand, turn the assembled
discs counterclockwise as you depress the spindle lock button.

When sanding, maintain an angle of 10-15 degrees between the
abrasive disc and the surface being sanded, as shown in Figure 5.

If only the outer edge of the abrasive disc is used, a rough cut surface
will result. If the disc is pressed flat against the surface, the sanding
action will be bumpy and irregular and the tool will be difficult to
control.

English

FIG. 5

FIG. 6

GUARD

SKIRT

CLAMPING

SCREWS

10 - 15 degrees

383763-01/DW488 rev. 7/31/2002 1:48 PM Page 4

Grinding With Depressed Center Wheels

CAUTION: BEFORE ANY GRINDING OPERATIONS, THE

CORRECT GUARD MUST BE MOUNTED TO THE SANDER. THE
MOUNTING OF THIS GUARD CONVERTS YOUR SANDER TO AN
ANGLE GRINDER.

To install the guard to your sander, follow the steps listed
below.

1. If you cannot determine which guard is the correct one, check with
your local D

EWALT service center or call toll free:

1-800-4-DeWALT (1-800-433-9258) .

2. TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY.

3. Install the guard as shown in Figure 6. Position the guard skirt
between the spindle and the operator.

4. Securely tighten the two clamping screws supplied with the guard.

Depressed center wheels can be used for moderate metal removal on
flat or contoured surfaces.

To install a depressed center wheel, follow the steps listed
below:

CAUTION: NEVER USE DEPRESSED CENTER WHEELS

WITHOUT THE PROPER GUARD.

1. TURN OFF TOOL AND DISCONNECT FROM POWER SUPPLY.

2. Be sure the guard is securely attached to the gear case.

3. Install the backing flange onto the tool spindle, as shown in
Figure 7.

4. Check rated speed of depressed center wheel. Never use wheel
rated at less than speed on the nameplate of the tool.

5. Install the depressed center wheel onto the tool’s spindle, as
shown in Figure 7.

6. Thread the clamp washer onto the tool’s spindle, as shown in
Figure 7. Hold the spindle in place with the locking button and
tighten with the wrench provided.

5

English

SPINDLE LOCK BUTTON

SPINDLE

BACKING FLANGE

DEPRESSED CENTER WHEEL

CLAMP WASHER

FIG. 7

WRENCH

RAISED PORTION OF

WHEEL TOWARD

FLANGE

RAISED PORTION

OF FLANGE

TOWARD SPINDLE

RAISED SHOULDER

TOWARD WHEEL

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