DeWalt DW828 Instruction Manual
DEWA LT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 (FEB04 CD1)
Form No. 622422-00 DW828 Copyright © 2004
The following are trademarks for one or more DEWA LT 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.
IF YOU HAVE A N Y QUESTIONS OR COMMENTS A B O U T THIS OR A N Y DEWA LT TO O L ,
C A L L US TO L L FREE AT: 1 - 8 0 0 - 4 - DEWA LT (1-800-433-9258)
General Safety Rules
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 A R E A
• 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
f u m e s .
• Keep bystanders, children, and visitors away while operating a power tool. D i s t r a c t i o n s
can cause you to lose control.
E L E C T R I C A L S A F E T Y
• 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 adapter plugs. Check with a qualified
electrician 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
o t h e r .) 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. A p p l i c a b l e
only to Class II (double insulated) tools.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and
r e f r i g e r a t o r s . There is an increased risk of electric shock if your body is grounded.
• D o n ’ 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. When using
an extension cord, be sure to use one heavy enough to carry the current your product will
d r a w . 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
n u m b e r, 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 AW G
1 8 1 8 1 6 1 6 1 4 14 1 2
P E R S O N A L S A F E T Y
• 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
h a i r, 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 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.
TO O L 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
c o n t r o l .
• 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
u s i n g . 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
t o o l .
S E R V I C E
• 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 Cut-Off To o l s
• 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
l a b e l . Wheels and other accessories running over rated speed can fly apart and cause
i n j u r y. Accessory ratings must be above listed minimum wheel speed as shown on tool
n a m e p l a t e .
• 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.
• Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories
can result in injury.
• Use only 6" x 1/8" or less thick cutting wheels on this tool. Using other accessories is
not recommended and may cause injury and tool damage.
• Always use Type 1 guard with cutting wheel. A guard protects operator from broken
wheel fragments and wheel contact. Type 1 guards cover both sides of the wheel and offer
maximum protection for cutting operation.
• A L WAYS WEAR EYE PROTECTION WHEN USING THIS TO O L .
• Use of accessories not specified in this manual is not recommended and may be
hazardous. Use of power boosters that would cause the tool to be driven at speeds greater
than its rated speed constitutes misuse.
• Do not use circular saw blades or any other toothed blades with this tool. S e r i o u s
injury may result.
• Before using, inspect recommended accessory for cracks or flaws. If such a crack or
flaw is evident, discard the accessor y. The accessory should also be inspected
whenever you think the tool may have been dropped. Flaws may cause wheel break -
age. Do not set unit down on wheel.
• When starting the tool with a new or replacement wheel installed, or if you are unsure
of the condition of the wheel, 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.
• 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 cutting. 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.
• Never cut into area that may contain electrical wiring or piping. Serious injury may
r e s u l t .
• Clean out your tool often, especially after heavy use. Dust and grit containing metal par ticles often accumulate on interior surfaces and could create an electric shock hazard.
• Do not operate this tool for long periods of time. Vibration caused by the operating
action of this tool may cause permanent injury to fingers, hands, and arms. Use gloves to
provide extra cushion, take frequent rest periods, and limit daily time of use.
• The label on your tool may include the following symbols:
V . . . . . . . . . . . . . . . . . . . . . .v o l t s A . . . . . . . . . . . . . . . . . . . .a m p e r e s
H z . . . . . . . . . . . . . . . . . . . .h e r t z W . . . . . . . . . . . . . . . . . .w a t t s
m i n . . . . . . . . . . . . . . . . . .m i n u t e s . . . . . . . . . . . . . . . . . .alternating current
. . . . . . . . . . . . . . . .dire ct current
n
o . . . . . . . . . . . . . . . . . .no load speed
. . . . . . . . . . . . . . . . . . . .Cla ss II . . . . . . . . . . . . . . . . . .safety alert symbol
. . . . . . . . . . . . . . . . . . . . . . . .C o n s t r u c t i o n . . . . . . . . . . . . . . . . . .earthing terminal
… / m i n . . . . . . . . . . . . . .rev olutions per minute s f p m . . . . . . . . . . . . . .surface feet per minute
Causes and Operator Prevention
of Kickback
• Kickback is a sudden reaction to a pinched, bound or misaligned cutting wheel, causing an
uncontrolled cut-off tool to lift up and out of the workpiece toward the operator.
• When the wheel is pinched or bound tightly by the workpiece, the wheel stalls and the motor
reaction drives the unit rapidly back toward the operator.
• 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:
• Maintain a firm grip with both hands on the unit and position your body and arm
to allow you to resist kickback forces. Kickback forces can be controlled by the oper a t o r , if proper precautions are taken.
• When wheel is binding, or when interrupting a cut for any reason, release the trig -
ger and hold the unit motionless in the material until the wheel comes to a com plete stop. Never attempt to remove the unit from the work or pull the unit back ward while the wheel is in motion or kickback may occur. Investigate and take cor -
rective actions to eliminate the cause of wheel binding.
• When restarting a cut-off tool in the workpiece, check that the wheel is not
engaged into the material. If wheel is binding, it may walk up or kickback from the work piece as the tool is restarted.
• Support large panels to minimize the risk of wheel pinching and kickback. L a r g e
panels tend to sag under their own weight. Support must be placed under the panel on
both sides, near the line of cut and near the edge of the panel.
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 pro -
mote 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 pro tection appropriate for the dust exposure. Direct particles away from face and body.
CAUTION: Use extra care when working into a corner because a sudden, sharp move -
ment of the cut-off 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.
COMPONENTS (Fig. 1)
A . Paddle Switch F. 6" Cutting Wheel
B . L o c k - O f f Lever G . Anti-Lockup Backing Flange
C . Spindle Lock Button H . Threaded Clamp Nut
D . Spindle (not shown) I . G u a r d
E . Side Handle
ASSEMBLY
Attaching Side Handle (Fig. 1)
The side handle (E) 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.
OPERATION
Guards and Flanges
It is important to choose the correct guards and flanges to use with the cut-off tool accessories.
See Figure 2 for 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 rated accessory speed may fly
apart and cause injury. Every unthreaded accessory must have a 7/8" arbor hole. If it does not,
it may have been designed for a circular saw. Use only the accessories shown in Figure 2.
Accessory ratings must be above listed minimum wheel speed as shown on tool nameplate.
Mounting and Using Cutting Wheels (Type 1)
Cutting wheels include diamond wheels and abrasive discs. Abrasive cutting wheels for metal
and concrete use are available. Diamond cutting wheels for concrete cutting can also be used.
WARNING: A 4-1/2" closed, 2-sided cutting wheel guard is not included with this tool but is
required when using 4-1/2" cutting wheels. Failure to use proper flange and guard can result
in injury resulting from wheel breakage and wheel contact. See Figure 2 for more information.
MOUNTING GUARD (FIG. 3, 4)
CAUTION: Turn off and unplug the tool before making any adjustments or remov -
ing/installing attachments or accessories.
1 . Open the guard latch (J), and align the arrow (K) on the guard with the arrow (L) on the
hub. This will align the lugs with slots on the gear case cover. Position the guard facing
b a c k w a r d .
2 . Push the guard down until the guard lug engages and rotates freely in the groove on the
gear case hub.
3 . Rotate guard (I) into 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 cover. You should be unable
to rotate the guard by hand when the latch is in closed position. Do not operate grinder
with a loose guard or 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.
N O T E : 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 the clamp lever
in the closed position (Fig. 5).
CAUTION: Do not tighten adjusting screw with clamp lever in open position. Undetectable
damage to guard or mounting hub may result.
MOUNTING CUTTING WHEELS
CAUTION: Turn off and unplug the tool before making any adjustments or removing
/installing attachments or accessories.
C A U T I O N : Matching diameter threaded backing flange and clamp nut (included with tool)
must be used.
1 . Place the anti-lockup backing flange on spindle with the pilot (N) facing up. Be sure the
backing flange recess is seated onto the flats of the spindle before placing wheel. The pilot
(N) on the backing flange will be against the wheel when the wheel is installed.
2 . Place the wheel on the backing flange, centering the wheel on the pilot.
3 . Install the threaded clamp nut with the pilot facing away from the wheel.
4 . Depress the spindle lock button and tighten clamp nut with a wrench.
5 . To remove the wheel, grasp the wheel and turn while depressing the spindle lock button.
WA R N I N G : When wheel is tightened, always make sure the clamp nut has rotated at least
1-1/2 turns to ensure proper thread engagement. Failure to do so could result in wheel dis mount and may result in injury.
SWITCH
C A U T I O N : Hold the side handle and body of the tool firmly to maintain control of the tool at
start up and during use and until the wheel stops rotating. Make sure the wheel has come to
a complete stop before laying the tool down.
PADDLE SWITCH (FIG. 6)
To turn the tool on, push the lock-off lever (B) toward the back of the tool, then depress the
paddle switch (A). The tool will run while the switch is depressed. Turn the tool off by releasing the paddle switch.
WA R N I N G: Do not disable the lock-off lever. If the lock-off lever is disabled, the tool may
start unexpectedly when it is laid down.
C A U T I O N : Allow the tool to reach full speed before touching tool to the work surface. Lift
the tool from the work surface before turning the tool off.
SPINDLE LOCK
The spindle lock pin is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock pin only when the tool is turned off, unplugged from the
power supply, and has come to a complete stop. Do not engage the spindle lock while the tool
is operating because damage to the tool will result. To engage the lock, depress the spindle
lock button and rotate the spindle until you are unable to rotate the spindle further.
USING CUTTING WHEELS (FIG. 7)
WA R N I N G : Do not use cutting wheels for surface grinding applications because these
wheels are not designed for side pressures encountered with surface grinding. Wheel break age and injury may result.
1 . Allow tool to reach full speed before touching tool to work surface.
2 . Apply minimum pressure to work surface, allowing tool to operate at high speed. Cutting
rate is greatest when the tool operates at high speed.
3. Once a cut is begun and a notch is established in the workpiece, do not change the
angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel
breakage.
4 . Remove the tool from work surface before turning tool off. Allow the tool to stop rotating
before setting it down.
MAINTENANCE
Cleaning
WARNING: Blow dust and grit out of the motor housing regularly using clean, dry com -
pressed air. Dust and grit containing metal particles often accumulate on interior surfaces and
could create an electrical shock hazard if not frequently cleaned out. A L WAYS WEAR SAFET Y
G L A S S E S .
WA R N I N G : Never use solvents or other harsh chemicals for cleaning the non-metallic parts
of the tool. Use a clean, dry cloth only.
Lubrication
DEWA LT tools are properly lubricated at the factory and are ready for use.
Motor Brushes
When brushes become worn, the tool will automatically stop and prevent damage to the motor.
Brush replacement should be performed by a DEWA LT authorized service center or other
qualified service personnel.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments should
be performed by authorized service centers or other qualified service personnel. Always use
identical replacement parts.
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: DEWA LT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286.
WARNING: The use of any other accessory not recommended for use with this tool could
be hazardous.
Three Year Limited Warranty
DEWA LT will repair, without charge, any defects due to faulty materials or workmanship for
three years from the date of purchase. For warranty repair information, call 1-800-4-DEWA LT.
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, DEWA LT tools are covered by our:
1 YEAR FREE SERV I C E
DEWA LT will maintain the tool and replace worn parts caused by normal use, for free, any time
during the first year after purchase.
90 DAY M O N E Y BACK GUARANTEE
If you are not completely satisfied with the performance of your DEWA LT Power Tool, Laser,
or Nailer for any reason, you can return it within 90 days from the date of purchase with a
receipt for a full refund – no questions asked.
FREE WARNING LABEL R E P L A C E M E N T : If your warning labels become illegible or are
missing, call 1-800-4-DEWA LT for a free replacement.
I
L
K
6" Cutting Wheels
Meules à tronçonner
de 152 mm (6 po.)
Disco de corte
de 152 mm (6 pulg.)
4-1/2" Cutting Wheels
Meules à tronçonner de 114 mm (4-1/2 po.)
Disco de corte de 114 mm (4-1/2 pulg.)
Type 1 guard
protège-lame de type 1
Protector Tipo 1
backing flange
bride de soutien
pestaña de respaldo
abrasive cutting wheel
meule abrasive
disco de corte abrasivo
clamp nut
écrou de blocage
tuerca de fijación
diamond cutting wheel
meule diamant
disco de corte de diamante
M
J
A
B
FIG. 3
FIG. 4
FIG. 5
FIG. 6
FIG. 7
FIG. 2
H
A
B
C
F
G
I
E
FIG. 1
N
Type 1 guard
protège-lame de type 1
Protector Tipo 1
backing flange
bride de soutien
pestaña de respaldo
clamp nut
écrou de blocage
tuerca de fijación
Type 1 guard
protège-lame de type 1
Protector Tipo 1
backing flange
bride de soutien
pestaña de respaldo
clamp nut
écrou de blocage
tuerca de fijación
abrasive cutting wheel
meule abrasive
disco de corte abrasivo
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