DeWalt DW830, DW840, DW841 Instruction Manual

D

EWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 Printed in China (98-1) Form No. 569590-01

DW830,DW840,DW841 Copyright © 1998

DW830,etc./569590-01 8/3/00 2:46 PM Page 2

INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES

DW830,DW840,DW841
5"(127mm)Heavy Duty Angle Grinder
Rectifieuse coudée de service intensif de 127 mm (5 po)

Esmeriladora angular para trabajo pesado de 127 mm (5")

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

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

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English

General Safety 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.

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.

• 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. Applicable only to Class II
(double insulated ) tools.

• 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.

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
ThanThan
0-618161614
6 - 10 18 16 14 12
10-1216161412
12 - 16 14 12 Not Recommended

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.

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)

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English

• 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.

• 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.

• Hold tool by insulated gripping surfaces when performing an
operation where the cutting tool may contact hidden wiring
or its own cord. Cortact 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

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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.

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.

• 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 per minute

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

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

English

FIG. 1

FIG. 1A

FIG. 2

FIG. 3

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Fitting and Removing the Guard DW830
(Fig. 1 & 1A)

A guard is not required when using the tool for sanding with the
backing pad. To fit the guard for other applications:

1. Align the lug on the guard with the slot in the bracket fixed to the
base of the gear case (Fig. 1).

2. Press the guard down toward the gear case, and then rotate the
guard in the direction of the arrow (Fig. 1A).

3. In this position, the guard locking pin located in the slot prevents the
guard from coming loose, but allows rotation through 105°.

To remove the guard:

1. Place the tool upside down on a flat surface.

2. Hold the tool, and using your thumb, rotate the guard in the
direction of the arrow (Fig. 2). At the same time, using a screwdriver
or other pointed instrument, press the locking pin in the slot so the
lug on the guard comes into view (Fig. 3).

3. The locking pin does not hold the guard, and the guard can be
pushed free.

Fitting and Removing the Guard DW840
and DW841 (Fig 4)

1. Place the angle grinder on a table, spindle up.

2. Press the guard down.

4. Position the guard between your body and the work piece.

5. T ighten the cinch collar firmly around the neck of the spindle..

IMPORTANT: Unplug the tool before mounting or removing the guard.
Use the tool without the guard only when sanding with the rubber
backing pad.

Switch (Fig. 5)

To start the tool, squeeze the trigger switch (A) shown in Figure 5. 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

3

English

FIG. 4

FIG. 5

B

A

FIG. 6

FIG. 7

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English

FIG. 8

FIG. 10

FIG. 11

FIG. 9

depress the switch locking button next to the trigger (B). Hold the
locking button in as you gently release the trigger. Release the locking
button and the tool will continue to run. T o turn the tool off from a locked
on condition, squeeze and release the trigger once.

Fitting a Rubber Backing Pad (Fig. 6)

The rubber backing pad is available as an optional accessory. To fit the
pad:

1. Unplug the tool.

2. Remove the guard from the tool.

3. Insert the backing pad onto the machine spindle (Fig. 6). The inner
driven flange in Fig. 9 is not needed.

4. Position the abrasive disc on the pad.

5. Screw the outer flange with the two grip holes, together with the pad
fitted, onto the machine spindle (Fig. 7).

6. With your finger firmly on the spindle lock (Fig. 8), tighten the outer
flange with the pin spanner supplied.

7. Release the spindle lock. You can now plug the tool in and start
work.

8. To remove the backing pad, follow the instructions in reverse order.

IMPORTANT: When using the tool for sanding, allow only a segment
of the disc to contact the work and refrain from high-pressure
application.

Mounting Grinding Wheels

The grinding wheels are available as optional accessories. To fit a
grinding wheel:

1. Disconnect the plug.

2. Locate the inner driven flange on the drive flats on the machine
spindle (Fig. 9).

3. Place the wheel against the flange.

4. Screw the threaded flange onto the spindle (Fig. 10).

5. Rotate the grinding wheel while pressing the spindle lock (on the
front of the gear case) fully until it has found its locking location and
hold the spindle still.

FIG. 12

10° - 15°

FIG. 13

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