DeWalt DWE4000-XE, DWE4001-XE, DWE4100-XE, DWE4151-XE Instruction Manual

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DWE4000-XE, DWE4001-XE

HEAVY-DUTY SMALL ANGLE GRINDER

INSTRUCTION MANUAL

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Definitions: Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

DANGER: Indicates an imminently hazardous situation which, if

not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. NOTICE: Indicates a practice not related to personal injury which, if

not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US AT: 1800 338 002 (Aust) or 0800 339 258 (NZ).

Technical Data

DWE4000-XE DWE4001-XE

Voltage V 220–240 220–240 Power input W 720 800 No-load/rated speed min-1 12000 12000 Wheel diameter mm 100 100 Spindle diameter M10 M10 Weight kg 2.0* 2.0*

* weight includes side handle and guard

LPA (sound pressure) dB(A)

90.5 90.5

KPA (sound pressure uncertainty) dB(A)

3 3

LWA (sound power) dB(A)

101.3 101.3

KWA (sound power uncertainty) dB(A)

3 3

Vibration total values (triax vector sum) determined according to EN 60745:

Vibration emission value a

surface grinding

h.AG

m/s²

9.3 9.3

Uncertainty K = m/s²

1.5 1.5

Vibration emission value a

disc sanding

h.DS

m/s²

6.8 6.8

Uncertainty K = m/s²

1.5 1.5

Vibration emission value a

wire brushing

h.AG

m/s²

9.9 9.9

Uncertainty K = m/s²

1.5 1.5

The vibration emission level given in this information sheet has been measured in accordance with a standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.

WARNING: The declared vibration emission level represents the main applications of the tool. However if the tool is used for different applications, with different accessories or poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.

An estimation of the level of exposure to vibration should also take into account

the times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.

Identify additional safety measures to protect the operator from the effects of

vibration such as: maintain the tool and the accessories, keep the hands warm, organisation of work patterns.

SAFETY INSTRUCTIONS FOR POWER TOOLS

When using power tools, always observe the safety regulations applicable in your country to reduce the risk of fire, electric shock and personal injury. Read the following safety instructions before attempting to operate this product. Keep these instructions in a safe place.

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WARNING: To reduce the risk of injury, user must read the instruction manual.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING! Read all safety warnings and all instructions Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE

1) WORK AREA SAFETY

a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) 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.

c) Keep children and bystanders away while operating a power tool.

Distractions can cause you to lose control.

2) ELECTRICAL SAFETY a) Power tool plugs must match the outlet. Never modify the plug in any

way. Do not use any adapter plugs with earthed (grounded) power tools.

Unmodified plugs and matching outlets will reduce risk of electric shock.

b) Avoid body contact with earthed or grounded surfaces such as pipes,

radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

c) Do not expose power tools to rain or wet conditions. Water entering a power

tool will increase the risk of electric shock.

d) Do not abuse the cord. Never use the cord for carrying, pulling or

unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric

shock.

e) When operating a power tool outdoors, use an extension cord suitable

for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

f) If operating a power tool in a damp location is unavoidable, use a residual

current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.

3) PERSONAL SAFETY a) Stay alert, watch what you are doing and use common sense when

operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention

while operating power tools may result in serious personal injury.

b) Use personal protective equipment. Always wear eye protection. Protective

equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

c) Prevent unintentional starting. Ensure the switch is in the off position

before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or

energising power tools that have the switch on invites accidents.

d) Remove any adjusting key or wrench before turning the power tool on. A

wrench or a key left attached to a rotating part of the power tool may result in personal injury.

e) Do not overreach. Keep proper footing and balance at all times. This

enables better control of the power tool in unexpected situations.

f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair,

clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.

g) If devices are provided for the connection of dust extraction and collection

facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

4) POWER TOOL USE AND CARE a) Do not force the power tool. Use the correct power tool for your

application. The correct power tool will do the job better and safer at the rate

for which it was designed.

b) Do not use the power tool if the switch does not turn it on and off. Any

power tool that cannot be controlled with the switch is dangerous and must be repaired.

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c) Disconnect the plug from the power source and/or the battery pack from

the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of

starting the power tool accidentally.

d) Store idle power tools out of the reach of children and do not allow

persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

e) Maintain power tools. Check for misalignment or binding of moving parts,

breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many

accidents are caused by poorly maintained power tools.

f) Keep cutting tools sharp and clean. Properly maintained cutting tools with

sharp cutting edges are less likely to bind and are easier to control.

g) Use the power tool, accessories and tool bits, etc. in accordance with

these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those

intended could result in a hazardous situation.

5) SERVICE a) Have your power tool serviced by a qualified repair person using only

identical replacement parts. This will ensure that the safety of the power tool

is maintained.

Electrical Safety

The electric motor has been designed for one voltage range only. Always check that the power supply corresponds to the voltage on the rating plate. 220–240 V AC means your tool will operate on alternating current. Operation at a voltage outside this range can cause loss of power and can result in overheating. All DEWALT tools are factory tested; if this tool does not operate, check the power supply. Your DEWALT tool is double insulated, therefore no earth wire is required.

• Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision.

– This appliance is not intended for use by persons (including children) with

reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

– Children should be supervised to ensure that they do not play with the appliance.

• Replacement of the supply cord. If the supply cord or plug is damaged, it must be replaced by the manufacturer or an authorised D

EWALT Service Centre in

order to avoid a hazard.

Extension Cords

CAUTION: Use only extension cords that are approved by the country’s Electrical Authority. Before using extension cords, inspect them for loose or exposed wires, damaged insulation and defective fittings. Replace the cord if necessary.

Safety Warnings Common for Grinding, Sanding, Wire Brushing, or Abrasive Cutting-Off Operations:

a) This power tool is intended to function as a grinder, sander, wire brush, or cut-

off tool. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may

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

b) This power tool is not recommended for polishing. Operations for which the

power tool was not designed may create a hazard and cause personal injury.

c) Do not use accessories which are not specifically designed and recommended

by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.

d) The rated speed of the accessory must be at least equal to the maximum

speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.

e) The outside diameter and the thickness of your accessory must be within

the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.

f) The arbour size of wheels, flanges, backing pads or any other accessory must

properly fit the spindle of the power tool. Accessories with arbour holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

g) Do not use a damaged accessory. Before each use, inspect the accessory

such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away

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q) Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate

accessories can result in injury.

r) Always use side handle. Tighten the handle securely. The side handle should

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

STANDARD WHEEL DIMENSIONS

Wheel Type

Wheel dimensions

(diameter × thickness × bore diameter)

Type 27

115 × 6 × 22.3

125 × 6 × 22.3

180 × 6 × 22.3

230 × 6 × 22.3

Type 11

125 × 50 × 22.3

150 × 50 × 22.3

Type 1

125 × 25 × 26

155 × 25 × 16

Further Safety Instructions for All Operations

KICKBACK AND RELATED WARNINGS

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory’s rotation at the point of the binding.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel’s movement at the point of pinching. Abrasive wheels may also break under these conditions.

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:

from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart

during this test time.

h) Wear personal protective equipment. Depending on application, use face

shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or

respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.

i) Keep bystanders a safe distance away from work area. Anyone entering the

work area must wear personal protective equipment. Fragments of workpiece or of a broken accessory may fly away and cause injury beyond immediate area of operation.

j) Hold power tool by insulated gripping surfaces only, when performing an

operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts

of the power tool “live” and shock the operator.

k) Position the cord clear of the spinning accessory. If you lose control, the cord

may be cut or snagged and your hand or arm may be pulled into the spinning accessory.

l) Never lay the power tool down until the accessory has come to a complete

stop. The spinning accessory may grab the surface and pull the power tool out of your control.

m) Do not run the power tool while carrying it at your side. Accidental contact with

the spinning accessory could snag your clothing, pulling the accessory into your body.

n) Regularly clean the power tool’s air vents. The motor’s fan will draw the dust

inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

o) Do not operate the power tool near flammable materials. Sparks could ignite

these materials.

p) Do not use accessories that require liquid coolants. Using water or other liquid

coolants may result in electrocution or shock.

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a) Maintain a firm grip on the power tool and position your body and arm to

allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start up. The

operator can control torque reaction or kickback forces, if proper precautions are taken.

b) Never place your hand near the rotating accessory. Accessory may kickback

over your hand.

c) Do not position your body in the area where power tool will move if kickback

occurs. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.

d) Use special care when working corners, sharp edges etc. Avoid bouncing and

snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.

e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such

blades create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and Abrasive Cutting-Off Operations

a) Use only wheel types that are recommended for your power tool and the

specific guard designed for the selected wheel. Wheels for which the power

tool was not designed cannot be adequately guarded and are unsafe.

b) The guard must be securely attached to the power tool and positioned for

maximum safety, so the least amount of wheel is exposed towards the operator. The guard helps to protect operator from broken wheel fragments and

accidental contact with wheel.

c) Wheels must be used only for recommended applications. For example: do

not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.

d) Always use undamaged wheel flanges that are of correct size and shape for

your selected wheel. Proper wheel flanges support the wheel thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.

e) Do not use worn down wheels from larger power tools. Wheel intended for

larger power tool is not suitable for the higher speed of a smaller tool and may burst.

Additional Safety Warnings Specific for Abrasive Cutting-Off Operations

a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt to

make an excessive depth of cut. Overstressing the wheel increases the loading

and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.

b) Do not position your body in line with and behind the rotating wheel. When the

wheel, at the point of operations, is moving away from your body, the possible kickback may propel the spinning wheel and the power tool directly at you.

c) When wheel is binding or when interrupting a cut for any reason, switch off

the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt to remove the cut-off wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take

corrective action to eliminate the cause of wheel binding.

d) Do not restart the cutting operation in the workpiece. Let the wheel reach full

speed and carefully re-enter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the workpiece.

e) Support panels or any oversized workpiece to minimize the risk of wheel

pinching and kickback. Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

f) Use extra caution when making a “pocket cut” into existing walls or other

blind areas. The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

Safety Warnings Specific for Sanding Operations

a) Do not use excessively oversized sanding disc paper. Follow manufacturer's

recommendations, when selecting sanding paper. Larger sanding paper

extending beyond the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.

Safety Warnings Specific for Wire Brushing Operations

a) Be aware that wire bristles are thrown by the brush even during ordinary

operation. Do not overstress the wires by applying excessive load to the brush. The wire bristles can easily penetrate light clothing and/or skin.

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b) If the use of a guard is recommended for wire brushing, do not allow any

interference of the wire wheel or brush with the guard. Wire wheel or brush may expand in diameter due to work and centrifugal forces.

Additional Specific Safety Warnings for Grinders

• Check that the grinding wheel backing flange has a yellow rubber ring (C) installed, see Figure 1. Replace rubber ring if missing, damaged or worn. See pages 8, 10–11 for details regarding proper accessory installation.

• Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbor hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

• The grinding surface of the centre depressed wheels must be mounted below the plane of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.

WARNING: The grinding wheel or accessory may loosen during coast-down of

the tool when shut off if rubber ring is missing or damaged. If grinding wheel or

accessory loosens, it may dismount from the machine and may cause serious personal injury.

• Do not use circular saw blades or any other toothed blades with this tool. Serious injury may result.

• Avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the tool and inspect the wheel for cracks or flaws.

• 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.

• Direct the Dust Ejection System (DES) away from operator and coworkers. Serious injury may result (Fig. 1, I).

WARNING: We recommend the use of a residual current device with a residual

current rating of 30mA or less.

WARNING: ALWAYS wear approved protective safety equipment complying with

the following standards:

• Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications;

• Hearing protection: AS/NZS1270 Acoustics – Hearing Protection;

• Respiratory protection: AS/NZS1716 Respiratory Protective Devices.

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,

• cr ystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumber.

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.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. Always use AS/NZS1716 approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

WARNING: Always wear proper personal hearing protection that conforms to

AS/NZS1270 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. The symbols and their

definitions are as follows:

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

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

min ..................minutes or AC ............alternating current

or DC .....direct current or AC/DC ......alternating or

...................Class I Construction direct current

(grounded) no .......................no load speed

...................Class II Construction n .........................rated speed

(double insulated) .......................earthing terminal

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…/min .............per minute

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

BPM .................beats per minute IPM .....................impacts per minute

RPM .................revolutions per minute SPM ....................strokes per minute

sfpm ................surface feet per minute

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE

COMPONENTS (Fig. 1)

WARNING: Never modify the power tool or any part of it. Damage or personal

injury could result.

A. Spindle lock button E. Threaded clamp nut B. Spindle F. Guard C. Side handle G. On/Off switch D. Backing flange H. Guard release lever (Fig. 2)

INTENDED USE

The DWE4000-XE and DWE4001-XE are heavy-duty small angle grinders and have been designed for professional grinding and cutting applications.

DO NOT use grinding wheels other than center depressed wheels and flap-disk. DO NOT use under wet conditions or in presence of flammable liquids or gases.

This small angle grinder is a professional power tool. DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, 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 paddle switch to

ensure that the tool is off. An accidental start-up can cause injury.

FIG. 1

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Attaching Side Handle (Fig. 1)

WARNING: Before using the tool, check that the handle is tightened securely. Screw the side handle (C) tightly into one of the holes on either side of the gear case. The side handle should always be used to maintain control of the tool at all times.

Accessories and Attachments

It is important to choose the correct guards, backing pads and flanges to use with grinder accessories. Refer to chart on pages 8 and 9 for information on choosing the correct accessories.

NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose.

WARNING: Accessories must be rated for at least the speed recom mended on the tool warning label. Wheels and other accessories running over rated accessory speed may burst and cause injury. Threaded accessories must have an M10 hub. Every unthreaded accessory must have a 16 mm arbor hole.

If it does not, it may have been designed for a circular saw and should not be used. Use only the accessories shown in chart on pages 8 and 9. Accessory ratings must be above listed minimum wheel speed as shown on tool nameplate.

Mounting Guards

CAUTION: Guards must be used with this grinder. NOTE: Please refer to the Grinding and Cutting Accessory Chart on pages 8 and 9 to

see other accessories that can be used with these grinders.

MOUNTING AND REMOVING (TYPE 27) ONE-TOUCH GUARD (FIG. 2) NOTE: If your grinder is supplied with a keyless One-Touch guard, ensure the screw

and spring are fitted correctly before mounting the guard

1. Press the guard release lever (H).

2. While holding the guard release lever open, align the lugs (I) on the guard (F) with

the slots on the gear case (J).

3. Keeping the guard release lever open, push the guard down until the guard engages

the lugs and rotate them in the groove on the gear case hub. Release the guard release lever.

115 mm and 125 mm (4-1/2" and 5") Sanding Flap Discs

Quick-change

backing flange

Non-hubbed sanding flap

disc

Threaded clamp nut

Type 27 guard

Hubbed sanding flap

disc

Type 27 guard

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115 mm and 125 mm (4-1/2" and 5") Cutting Wheels

Type 1 guard

Quick-change

backing flange

Threaded clamp nut

Type 1 abrasive

cutting wheel

Type 1 guard

Quick-change

backing flange

Threaded clamp nut

Diamond cutting wheel

Sanding Discs

Wire Wheels

Type 27 guard

76.2 mm (3")

Wire cup brush

Type 27 guard

101.6 mm (4") Wire wheel

Rubber backing pad

Sanding disc

Threaded clamp nut

115 mm and 125 mm (4-1/2" and 5") Grinding Wheels

Type 27 hubbed wheel

Type 27 guard

Quick-change

backing flange

Threaded clamp nut

Type 27 depressed center

wheel

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4. With the spindle facing the operator, rotate the guard clockwise into the desired working position. The guard body should be positioned between the spindle and the operator to provide maximum operator protection.

5. For easy adjustment, the guard can be rotated in the clockwise direction.

NOTE: The guard release lever should snap into one of the alignment holes (K)

on the guard collar. This ensures that the guard is secure. The guard can be repositioned in the opposite direction by depressing the guard release lever.

6. To remove the guard, follow steps 1–3 of these instructions in reverse.

FIG. 2

Fitting and Removing a Grinding Disc (Fig. 1, 3)

WARNING: Do not use a damaged disc.

1. Place the tool on a table, guard up.

2. Fit the backing flange (D) correctly onto the spindle (B) (Fig. 3).

3. Place the disc (M) on the backing flange (D). When fitting a disc with a raised centre, make sure that the raised centre (L) is facing the backing flange (D).

4. Screw the threaded clamp nut (E) onto the spindle (B) (Fig. 3):

The ring on the threaded clamp nut (E) must face towards the disc when fitting a

grinding disc.

5. Press the spindle lock button (A) and rotate the spindle (B) until it locks in position.

6. Tighten the threaded clamp nut (E) with the hex

FIG. 3

key provided or a two pin spanner.

7. Release the spindle lock.

8. To remove the disc, loosen the threaded clamp nut (E) with the hex key provided or a two pin spanner.

NOTE: Edge grinding can be performed with Type 27 wheels designed and specified for this purpose; 6 mm thick wheels are designed for surface grinding while 3 mm wheels are designed for edge grinding.

Mounting Wire Brushes and Wire Wheels

Wire cup brushes or wire wheels screw directly on the grinder spindle without the use of flanges. Use only wire brushes or wheels provided with an M10 threaded hub. A Type 27 guard is required when using wire brushes and wheels.

CAUTION: Wear work gloves when handling wire brushes and wheels. They can

become sharp.

CAUTION: Wheel or brush must not touch guard when mounted or while in use.

Undetectable damage could occur to the accessory, causing wires to fragment from accessory wheel or cup.

1. Thread the wheel on the spindle by hand.

2. Depress spindle lock button and use a wrench on the hub of the wire wheel or brush to tighten the wheel.

3. To remove the wheel, reverse the above procedure.

NOTICE: Failure to properly seat the wheel hub before turning the tool on

may result in damage to tool or wheel.

Fitting and Removing a Backing Pad/Sanding Sheet (Fig. 1)

1. Place the tool on a table or flat sur face, with the guard facing up.

2. Remove the backing flange (D).

3. Place the rubber backing pad correctly onto the spindle (B).

4. Place the sanding sheet on the rubber backing pad.

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• Apply only a gentle pressure to the tool. Do not exert side pressure on

the disc.

• Avoid overloading. Should the tool become hot, let it run a few minutes

under no load condition.

Proper Hand Position (Fig. 1, 4)

WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand

position as shown.

WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in

anticipation of a sudden reaction. Proper hand position requires one hand on the side handle (C), with the other hand on the body of the tool, as shown in Figure 1.

Switches

WARNING: 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 or accessory stops rotating. Make sure the wheel has come to a complete stop be fore laying the tool down. 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 sur face before turning the tool off. Allow the tool to stop rotating before putting it down.

FIG. 4

5. Screw the threaded clamp nut (E) onto the spindle. The ring on the threaded clamp nut must face towards the rubber backing pad.

6. Press the spindle lock button (A) and rotate the spindle (B) until it locks in position.

7. Tighten the threaded clamp nut (E) with the hex key provided or a two pin spanner.

8. Release the spindle lock.

9. To remove the rubber backing pad, loosen the threaded clamp nut (E) with the hex key provided or a two pin spanner.

Fitting a Wire Cup Brush

Screw the wire cup brush directly onto the spindle without the use of the spacer and threaded flange.

Prior to Operation

• Install the guard and appropriate disc or wheel. Do not use excessively worn discs or wheels.

• Be sure the inner and outer flanges are mounted correctly.

• Make sure the disc or wheel rotates in the direction of the arrows on the accessory and the tool.

OPERATIONS

WARNING: Always observe the safety instructions and applicable regulations.

WARNING:

• Ensure all materials to be ground or cut are secured in place.

• Secure and support the workpiece. Use clamps or a vice to hold and

support the workpiece to a stable platform. It is impor tant to clamp and support the workpiece securely to prevent movement of the workpiece and loss of control. Movement of the workpiece or loss of control may create a hazard and cause personal injury.

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SWITCHING ON AND OFF (FIG. 4)

WARNING: Before using the tool, check that the handle is tightened securely.

To turn on the tool, lift up the button (G) to "1" position. To turn off the tool, push the toggle switch button (G) to the "0" position.

WARNING: Do not switch the tool on or off when under load.

Spindle Lock (Fig. 1)

The spindle lock (A) is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock only when the tool is turned off, unplugged from the power supply, and has come to a complete stop.

NOTICE: To reduce the risk of damage to the tool, do not engage the

spindle lock while the tool is operating. Damage to the tool will result and

attached accessory may spin off possibly resulting in injury. To engage the lock, depress the spindle lock button and rotate the spindle until you are unable to rotate the spindle further.

Metal Applications

When using the tool in metal applications, make sure that a residual current device (RCD) has been inserted to avoid residual risks caused by metal swarf.

If the power supply is shut off by the RCD, take the tool to authorised DEWALT repair agent.

WARNING: In extreme working conditions, conductive dust can accumulate inside

the machine housing when working with metal. This can result in the protective insulation in the machine becoming degraded with a potential risk of an electrical shock. To avoid build-up of metal swarf inside the machine, we recommend to clear the ventilation slots on a daily basis. Refer to Maintenance.

Using Flap Discs

WARNING: Metal dust build-up. Extensive use of flap discs in metal applications

can result in the increased potential for electric shock. To reduce this risk, insert an RCD before use and clean the ventilation slots daily by blowing dry compressed air into the ventilation slots inaccordance with the below maintenance instructions.

MAINTENANCE

Pop-off Brushes

The motor will be automatically shut off indicating that the carbon brushes are nearly worn out and that the tool needs servicing. The carbon brushes are not userserviceable. Take the tool to an authorised DEWALT repair agent.

Lubrication

Your power tool requires no additional lubrication.

Cleaning

WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear AS/NZS51337 approved eye protection when performing this.

WARNING: 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. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Repairs

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

ACCESSORIES

WARNING: Since accessories, other than those offered by DEWALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DEWALT recommended accessories should be used with this product.

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Recommended accessories for use with your tool are available at extra cost from your local service center. If you need any assistance in locating any accessory, please contact Stanley Black & Decker, 82 Tar yn Drive, Epping, VIC 3076 Australia or call 1800 338 002 or (NZ) 0800 339 258.

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Stanley Black & Decker

82 Taryn Drive, Epping, VIC 3076 Australia • 1800 338 002 (Aust) or 0800 339 258 (NZ)

www.dewalt.com.au • www.dewalt.co.nz

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.