DeWalt DW818, DW824, DW821, DW827 User Manual

DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 (JAN03) Form No. 615104-00 DW818, DW821, DW824, DW827

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.

DW818/DW821/DW824/DW827 Heavy Duty Small Angle Grinders Petites meuleuses angulaires de service intensif Esmeriladoras angulares pequeñas para trabajo pesado

INSTRUCTION MANUAL GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

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

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

English

GENERAL SAFETY 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 quali-

fied 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 out-

let, 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 exten- sion cord marked “W-A” or “W.” These cords are rated for outdoor 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 240V 0-50 51-100 101-200 201-300

Ampere Rating

More Not more AWG Than Than 6-10 18 16 14 12 10 - 12 16 16 14 12

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.

SAVE THESE

INSTRUCTIONS

WARNING! Read and understand all

instructions. Failure to follow all instructions

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

English

• 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 tool’s 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 manufac- turer 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 person-

nel 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 and wheel contact. Do not use Type 1 abrasive or diamond wheels without proper guarding.

• Accessories must be rated for at least the speed recom- mended on the tool warning label. Wheels and other accessories running over rated speed can fly apart and cause injury. Accessory ratings are above rated no-load tool speeds because actual tool speeds may vary.

• Do not use type 11 (flaring cup) wheels on this tool. Using inap- propriate accessories can result in injury.

• Hold the tool by insulated gripping surfaces when performing

an operation where the cutting tool may contact hidden wiring

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

English

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. Flaws may cause wheel break-

age.

• In operation, avoid bouncing the wheel or giving it rough treat- ment. If this occurs, stop the tool and inspect the wheel for cracks or flaws.

• 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.

• 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.

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

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

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

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.

• 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, saw-

ing, 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.

CAUTION: Wear appropriate 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.

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

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

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

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

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

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

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

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

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

Class II Construction

…/min..............revolutions or reciprocation per minute

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

..................safety alert symbol

English

INTRODUCTION

COMPONENTS (FIG. 1-5)

A. ON/OFF Switch B. Guard (Type 27, open beneath wheel or accessory) C. Spindle Lock Button D. Side Handle (Not Shown) E. Type 1 Guard, closed beneath wheel or accessory (available at

extra cost from your local dealer or authorized service center.)

F. Matching Flanges

G. Depressed Center Flanges (for DW827 only)

ASSEMBLY

CAUTION: Turn off and unplug the tool before making any

adjustments or removing or installing attachments or accessories. Before reconnecting the tool, depress and release the rear part of the switch to ensure that the tool is off.

Fitting and Removing the Guard (FIG. 6-7)

CAUTION: Unplug the tool before mounting or removing the

guard. Guards must be used with all grinding wheels and sanding flap discs, wire brushes and wire wheels. The tool may be used without the guard only when sanding with conventional sanding discs.

FITTING GUARD NOTE: Follow the directions below to attach

either the type 27 or type 1 guard to your grinder. Refer to figures 6 and 7 for the type 27 guard and to figures 8 and 9 for the type 1 guard.

1. Open the guard latch (FIG. 6E or 8E) and align the arrow on the guard with the arrow on the gear case (FIG. 6F or 8F).

2. Push the guard down until the guard lugs engage and rotate freely in the groove on the gear case.

3. With the guard latch (FIG. 7B or 9B) open, rotate the guard into the working position providing maximum protection to the user .

4. Close the guard latch to secure guard on gear case (FIG. 7E or 9E).

NOTE: The guard is pre-adjusted to the diameter of the spindle hub at the factory. If the guard needs further adjustment after a period of use, perform the following adjustment. With the guard latch in the closed position (FIG. 7E or 9E) tighten or loosen the adjustment screw (Fig. 7H or 9H).

FIG. 1

FIG. 2

FIG. 4

FIG. 5

FIG. 3

FIG. 6

FIG. 7

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CAUTION: Do not tighten adjustment screw with guard latch in

open position. Undetectable damage to the guard or the mounting hub may result.

CAUTION: Do not operate the grinder with a loose guard or

the guard latch in open position.

REMOVING GUARD

Follow the procedure above in reverse order.

Side-handle (FIG. 10)

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

Mounting Grinding Wheels and Sanding Flap Discs Using Depressed Center Flange (FIG. 11, 12-15)

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

1. Place the backing flange on the grinder spindle (FIG. 11).

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

3. Screw the threaded flange onto the spindle (FIG. 13).

4. Rotate the spindle by hand while pressing the spindle lock button until the spindle locks, preventing the spindle from rotating. (FIG.

14).

5. Firmly tighten the threaded flange with the supplied spanner wrench (FIG. 15).

Mounting Grinding Wheels and Sanding Flap Discs Using Matching Flanges (FIG. 12-15)

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

1. Place the backing flange on the grinder spindle (FIG. 11 or 12).

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

3. Screw the threaded flange onto the spindle (FIG. 13).

4. Rotate the spindle by hand while pressing the spindle lock button until the spindle locks, preventing the spindle from rotating. (FIG. 14).

5. Firmly tighten the threaded flange with the supplied hex wrench (FIG. 15).

Mounting and Using Cutting and Edge Grinding Wheels (FIG. 11-15)

Cutting wheels, designed specifically for cutting, and edge grinding wheels, designed specifically for edge grinding, are available at extra cost from your local dealer or authorized service center. Edge grinding and cutting wheels are not designed for applications that will subject wheels to side pressure. For safety, it is important to use the correct flanges and guards with these wheels. Flat, type 1, cutting wheels must be mounted with flat, relieved, matching flanges. Depressed center, type 27, edge-grinding wheels may be mounted

FIG. 10

FIG. 8 FIG. 9

F B

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1. Place the backing flange on the machine spindle (FIG. 11 or FIG 12).

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

3. Screw the threaded flange onto the spindle, piloting the wheel on the backing flange hub (FIG. 13).

4. Rotate the spindle by hand while pressing the spindle lock button until the spindle locks, preventing the spindle from rotating (Fig. 14).

5. While depressing spindle lock button, firmly tighten the threaded flange with supplied hex wrench (Fig. 15).

FIG. 11

FIG. 13

FIG. 14

FIG. 15

with either matching flanges or with depressed center flanges if they are under 5" in diameter. 6" depressed center edge-grinding wheels (for DW827 only) must be mounted with depressed center flanges only. Refer to the chart below to select the appropriate flange and guard for your wheel.

CAUTION: Wheels used for cutting and edge grinding may break

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 (FIG. 2). Type 1 guards are available at extra cost from your local dealer or authorized service center.

FIG. 12

Application

Shape

Wheel

Type

Flange

Guard

Type

shallow cutting

all cutting

depressed center, 5"

or smaller

depressed center, 6"

flat, 6" or

smaller

depressed

grinding

center, 5"

or smaller

grinding

depressed center, 6"

type

matching flanges

or depressed

center flanges

type 27depressed center

flanges

type

matching flanges

or depressed

center flanges

type 27depressed center

flanges

type

type 1

only

type

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Mounting Backing Pads and Sanding Flap Discs

Sanding backing pads are available as optional accessories. Before fitting the pad, unplug the tool from the power supply and follow instructions provided with the accessory backing pad.

Mounting Hubbed Wheels

Hubbed wheels screw directly on the grinder spindle without the use of flanges.

Fitting Wire Cup Brushes and Wheels

Wire cup brushes or wire wheels screw directly on the grinder spindle without the use of flanges. A type 27 guard is required when using wire brushes and wheels.

CAUTION: Accessories must be rated for at least the speed

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

CAUTION: Wire brushes can become sharp. Wear work gloves

when handling wire cup brushes.

OPERATION Starting and Stopping the Tool (FIG. 16)

1. Before connecting the tool to a power supply, be sure the switch is in the off position by pressing the rear part of the switch and releasing. If the switch is locked on when the power is connected, the tool will start unexpectedly.

2. To start the tool, slide the ON/OFF switch (A) toward the front of the tool.

2. To stop the tool, release the ON/OFF switch.

3. For continuous operation, slide the switch toward the front of the tool and press the forward part of the switch inward.

4. To stop the tool while operating in continuous mode, press the rear part of the switch and release.

NOTE: To reduce unexpected tool movement, do not switch the tool on or off while under load conditions. Allow the grinder to run up to full speed before touching the work surface. Lift the tool from the surface before turning the tool off. Allow the tool to stop rotating before putting it down.

Grinding (FIG. 17)

Using a depressed center Type 27 wheel, hold the tool at an angle of approximately 20˚- 30° to the work for grinding. Most Type 27 wheels are not designed for cutting operations.

Wire Brushing (FIG. 18 & 19)

Use wire brushes to clean welds, metal corners, and angles, and to remove paint.

CAUTION: Use a Type 27 guard with wire

brushes and wheels. Operators and others in the area should wear appropriate eye, face and body protection. Strands of wire may break and fly off when wire wheels and brushes are in use.

Sanding With Abrasive Discs (FIG. 20)

When using an abrasive disc and rubber backing pad, hold the tool so that an angle of 5° to 15° exists between the disc and the work, as shown. Using an angle of 5° to 15° will allow you to produce a smooth surface. 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.

FIG. 16

FIG. 17

20˚-30˚

FIG. 18

FIG. 19

FIG. 20

5˚ - 15°

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Precautions To Take When Sanding Paint

1. 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.

2. 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:

PERSONAL SAFETY

a. No children or pregnant women should enter the work area

where the paint sanding is being done until all clean up is completed.

b. 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 N.I.O.S.H. approved mask.

c. 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.

ENVIRONMENTAL SAFETY

a. Paint should be removed in such a manner as to minimize

the amount of dust generated.

b. Areas where paint removal is occurring should be sealed

with plastic sheeting of 4 mils thickness.

c. Sanding should be done in a manner to reduce tracking of

paint dust outside the work area.

CLEANING AND DISPOSAL

a. All surfaces in the work area should be vacuumed and thor-

oughly cleaned daily for the duration of the sanding project. Vacuum filter bags should be changed frequently.

b. 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.

c. During clean up, children and pregnant women should be

kept away from the immediate work area.

d. All toys, washable furniture and utensils used by children

should be washed thoroughly before being used again.

Edge Grinding and Cutting (FIG. 21)

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.

Edge grinding and cutting can be performed with type 27 wheels designed and specified for this purpose. Protect yourself during edge grinding and cutting by directing the open side of the guard toward a surface. Edge grinding and cutting wheels should contact the work surface only at the edge of the wheel, not on the top or bottom of the wheel. Side pressure on the wheel could lead to breakage of the wheel.

Type 1 wheels can be used for edge cutting. See the instruction manual included with the accessory type 1 guard for specific instructions.

FIG. 21

English

MAINTENANCE Cleaning

Blowing dust and grit out of the motor housing using compressed air is a necessary regular maintenance procedure. Dust and grit containing metal particles often accumulate on interior surfaces and could create an electrical shock hazard 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. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap.

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 repair-persons, such as those at D

EWALT

service centers or by other qualified service personnel.

Motor Brushes

When brushes become worn, the tool will automatically stop and prevent damage to the motor. Brush replacement should be performed by a D

EWALT authorized service center or other qualified

service personnel.

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, contact: DeWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD

21286.

CAUTION: The use of any other accessory not recommended

for use with this tool could be hazardous.

Repairs

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 personnel, 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-D

EWALT. 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:

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 partici-

pating seller within 30 days for a full refund. Please return the complete unit, transportation prepaid. Proof of purchase may be required.

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

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