DeWalt DWE4203 Service Manual

Final Page size: A5 (148mm x 210mm)

DWE4203
DWE4213
DWE4233
DWE4263

DeWALT

English (original instructions) 3

Copyright

B

Fig. A

9

2

6

7

8

Fig. B Fig. C

3

1

10

5

4

12

9

13

1

Fig. D

Fig. E

20

15

5

16

14

13

11

9

Fig. F Fig. G

19

18

17

4

2

3

2

SMALL ANGLE GRINDERS

DeWALT

DeWALT

DWE4203, DWE4213, DWE4233, DWE4263

Congratulations!

You have chosen a
most reliable partners for professional power toolusers.

Technical Data

Voltage V
Type 3 3 3 1
Power input W
No-load/rated speed min
Wheel diameter mm
Wheel thickness (max) mm
Spindle diameter
Spindle length mm
Weight kg

* weight includes side handle and guard

Noise and vibration total values (triax vector sum) according to EN 60745-2-3:

LPA (emission sound pressure level) dB(A) 92.0 92.0 92.0 –
LWA (sound power level) dB(A) 103.0 103.0 103.0 –
K (uncertainty for the given sound level) dB(A) 3 3 3 –

Surface grinding

Vibration emission value a
Uncertainty K = m/s² 1.5 1.5 1.5 –

Disc sanding

Vibration emission value a
Uncertainty K = m/s² 1.5 1.5 1.5 –

tool. Years of experience, thorough product development and innovation make

DWE4203 DWE4213 DWE4233 DWE4263

230 230 230 230

AC

1010 1200

-1

11,000 11,500 11500 10000

125 125

6.0 6.0

M14 M14

18.5 18.5

1.85 1.85

h,AG

h,DS

=

=

m/s²

m/s²

8.3 8.3 8.3 –

3.0 3.0 3.0 –

1400 1400

125 125

6.0 6.0

M14 M14

18.5 18.5

1.85* 2.5*

one of the

ENGLISH

CAUTION: Working with the wire brush or the abrasive cutting can lead to different vibration levels!



The vibration emission level given in this information sheet has
been measured in accordance with a standardised test given in
EN60745 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.

Fuses:
Europe 230V tools 10 Amperes. mains
U.K. & Ireland 230V tools 13 Amperes. in plugs

3

ENGLISH

DeWALT

DeWALT

DeWALT

DeWALT

EC-Declaration of Conformity

Machinery Directive

Small Angle Grinders

DWE4203, DWE4213, DWE4233

declares that these products described under
Technical Data are in compliance with:
2006/42/EC, EN60745-1:2009+A11:2010, EN60745-2­3:2011+A2:2013+A11:2014 +A12:2014+A13:2015.

These products also comply with Directive 2014/30/EU and
2011/65/EU. For more information, please contact
the following address or refer to the back of themanual.

The undersigned is responsible for compilation of the technical
file and makes this declaration on behalf of

Markus Rompel
Director Engineering

, Richard-Klinger-Straße 11,
D-65510, Idstein, Germany

15.07.16

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

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.

Denotes risk of electricshock.



Denotes risk offire.



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.

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

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

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.

at

.

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

4

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.

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.

ENGLISH

ADDITIONAL SPECIFIC SAFETY RULES

Safety Instructions for All 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 ) Operations such as polishing are not recommended

to be performed with this power tool. 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 can not be

adequately guarded orcontrolled.

f ) Threaded mounting of accessories must match the

grinder spindle thread. For accessories mounted by
flanges, the arbour 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.

g ) Do not use a damaged accessory. Before each use

inspect the accessory such as abrasive wheel 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 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.

5

ENGLISH

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 the 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
could give the operator an electricalshock.

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.

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.

FURTHER SAFETY INSTRUCTIONS FOR ALL
OPERATIONS

Causes and Operator Prevention
of Kickback

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:

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 grinding surface of 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.

c ) 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 the operator from broken wheel
fragments, accidental contact with wheel and sparks that
could igniteclothing.

d ) 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.

e ) 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.

f ) 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.

6

Additional Safety Warnings Specific for

DeWALT

DeWALT

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 cut­off 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 llight clothing and/
orskin.

ENGLISH

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 Safety Rules for Grinders

• 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: We recommend the use of a residual current
device with a residual current rating of 30mA or less.



Residual Risks

In spite of the application of the relevant safety regulations
and the implementation of safety devices, certain residual risks
cannot be avoided. These are:

• Impairment ofhearing.

• Risk of personal injury due to flyingparticles.

• Risk of burns due to accessories becoming hot
duringoperation.

• Risk of personal injury due to prolongeduse.

• Risk of dust from hazardoussubstances.

Electrical Safety

The electric motor has been designed for one voltage only.
Always check that the power supply corresponds to the voltage
on the rating plate.

Your
with EN60745; therefore no earth wire is required.

If the supply cord is damaged, it must be replaced by a
specially prepared cord available through the
serviceorganisation.

Mains Plug Replacement
(U.K. & Ireland Only)

If a new mains plug needs to be fitted:

• Safely dispose of the oldplug.

• Connect the brown lead to the live terminal in theplug.

• Connect the blue lead to the neutralterminal.

WARNING: No connection is to be made to the
earthterminal.



Follow the fitting instructions supplied with good quality plugs.
Recommended fuse: 13A.

tool is double insulated in accordance

7

ENGLISH

Using an Extension Cable

An extension cord should not be used unless absolutely
necessary. Use an approved extension cable suitable for
the power input of your charger (see Technical Data). The
minimum conductor size is 1.5 mm2; the maximum length
is30m.

When using a cable reel, always unwind the cablecompletely.

Package Contents

The package contains:
1 Angle grinder
1 Guard
1 Side handle
1 Backing flange
1 Threaded clamp nut
1 Hex key
1 Instruction manual

• Check for damage to the tool, parts or accessories which may
have occurred duringtransport.

• Take the time to thoroughly read and understand this manual
prior tooperation.

Markings on Tool

The following pictograms are shown on the tool:

Read instruction manual before use.

Wear ear protection.

Wear eye protection.

Date Code Position (Fig. D)

The date code
is printed into thehousing.

Example:

11

, which also includes the year of manufacture,

2016 XX XX

Year of Manufacture

Description (Fig. A, B)

WARNING: Never modify the power tool or any part of it.
Damage or personal injury couldresult.



1

Spindle lock button

2

Spindle

3

Side handle

4

Backing flange

5

Clamp nut

6

Guard

7

Paddle switch

8

Lock-off lever

9

Guard release lever

10

Dust ejection system

Intended Use

Your heavy-duty small angle grinder has been designed
for professional grinding, sanding, wire brushing and
cuttingapplications.

DO NOT use grinding wheels other than centre depressed
wheels and flapdiscs.

DO NOT use under wet conditions or in the presence of
flammable liquids orgases.

Your heavy-duty 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.

• Young children and the infirm. This appliance is not

intended for use by young children or infirm persons
without supervision.

• This product is not intended for use by persons (including
children) suffering from diminished physical, sensory or
mental abilities; lack of experience, knowledge or skills
unless they are supervised by a person responsible for their
safety. Children should never be left alone with thisproduct.

Anti-vibration Side Handle

The anti-vibration side handle offers added comfort by
absorbing the vibrations caused by thetool.

Dust Ejection System (Fig. A)

The dust ejection system
the guard and motor inlet, and minimises the amount of dust
entering the motorhousing.

10

prevents dust pile-up around

Soft Start Feature

DWE4263

The soft start feature allows a slow speed build-up to avoid an
initial jerk when starting. This feature is particularly useful when
working in confinedspaces.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal
injury, turn tool off and disconnect tool from power



source before making any adjustments or removing/
installing attachments or accessories. Be sure the

trigger switch is in the OFF position. An accidental start-up
can cause injury.

Attaching Side Handle (Fig. B)

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



Screw the side handle
side of the gear case. The side handle should always be used to
maintain control of the tool at alltimes.

3

tightly into one of the holes on either

Guards

CAUTION: Guards must be used with all grinding
wheels, cutting wheels, sanding flap discs, wire



brushes, and wire wheels. The tool may be used
without a guard only when sanding with conventional

8

sanding discs. Refer to Figure A to see guards provided
with the unit. Some applications may require purchasing
the correct guard from your local dealer or authorized
service centre.

NOTE: Edge grinding and cutting can be performed with Type
27 wheels designed and specified for this purpose; 6.35 mm
thick wheels are designed for surface grinding while thinner
Type 27 wheels need to be examined for the manufacturer's
label to see if they can be used for surface grinding or only
edge grinding/cutting. A Type 1 guard must be used for any
wheel where surface grinding is forbidden. Cutting can also be
performed by using a Type41 wheel and a Type 1guard.

NOTE: See the Accessories Chart to select the proper guard /
accessory combination.

Adjusting and Mounting Guard (Fig. C, D)

CAUTION: Turn unit off and unplug the tool before
making any adjustments or removing or installing



attachments or accessories.
CAUTION: BEFORE operating the tool, identify which

guard adjustment option your tool is set to.



Adjustment Options

Two-Touch

9

engages one of

TM

15

on the guard

For guard adjustment, the guard release lever
the alignment holes
feature. Your grinder offers two options for this adjustment.

• One-touchTM: In this position the engaging face is slanted

and will ride over to the next alignment hole when guard
is rotated in a clockwise direction (spindle facing user) but
self-locks in the anti-clockwise direction.

• Two-touchTM: In this position the engaging face is straight

and squared off. It will NOT ride over to the next alignment
hole unless guard release lever is pressed and held while
simultaneously rotating the guard in either a clockwise or
anti-clockwise direction (spindle facing user).

Setting Guard Adjustment Options

To adjust the guard release lever
adjustmentoption:

1. Remove screw

2. Remove the guard release lever taking note of the spring
position. Choose the end of the lever for the desired
adjustment option. One-touch will use the slanted end of
the lever
collar. Two-touch will use the squaredend to engage the
alignmnet holes

3. Replace the lever, positioning the chosen end under the
spring
thespring.

15

on the guard collar using a ratcheting

TM

One-Touch

9

for desired

12

using a T20 bit.

9

to engage the alignment holes

15

on the guard collar.

13

. Ensure the lever is in proper contact with

ENGLISH

4. Replace screw and torque to 2.0-3.0N-m. Ensure proper
installation with spring return function by depressing guard
release lever

Mounting Guard (Fig. D)



1. With the spindle facing the operator, press and hold the
guard release lever

2. Align the lugs
gearcase.

3. Push the guard down until the guard lugs engage and
rotate them in the groove on the gear case hub. Release the
guard release lever.

4. To position the guard:
One-touchTM: Rotate the guard clockwise into the desired
working position. Press and hold the guard release lever
release lever to rotate the guard in the anti-clockwise
direction.
Two-touchTM: Press and hold the guard release lever
Rotate the guard clockwise or anti-clockwise into the
desired working position.
NOTE: The guard body should be positioned between the
spindle and the operator to provide maximum operator
protection.
The guard release lever should snap into one of the
alignment holes
the guard is secure.

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

9

.

CAUTION: Prior to mounting guard, ensure the screw,
lever, and spring are fitted correctly before mounting
theguard.

9

.

13

on the guard with the slots

15

on the guard collar. This ensures that

14

on the

9

Flanges and Wheels

Mounting Non-Hubbed Wheels (Fig. E)

WARNING: Failure to properly seat the flange/ clamp nut/
wheel could result in serious injury (or damage to the tool



or wheel).
CAUTION: Included flanges must be used with depressed

centre Type 27 and Type 42 grinding wheels and Type41



cutting wheels. See the Accessories Chart for more
information.

WARNING: A closed, two-sided cutting wheel guard is
re quired when using cutting wheels.



WARNING: Use of a damaged flange or guard or fail ure
to use proper flange and guard can re sult in injury due to



wheel breakage and wheel contact. See the Accessories
Chart for more information.

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

2. Install the unthreaded backing flange
the raised centre (pilot) facing the wheel.

3. Place wheel
wheel on the raised centre (pilot) of the backing flange.

4. While depressing the spindle lock button and with the
hex depressions facing away from the wheel, thread the
clampnut
slots in the spindle.

16

against the backing flange, centreing the

5

on spindle so that the lugs engage the two

4

on spindle

2

with

9

.

9

ENGLISH

5. While depressing the spindle lock button, tighten the
locking flange with a wrench

6. To remove the wheel, depress the spindle lock button and
loosen the threaded locking flange with a wrench.

Mounting Sanding Backing Pads (Fig. F)

NOTE: Use of a guard with sanding discs that use backing pads,
often called fiber resin discs, is not required. Since a guard is
not required for these accessories, the guard may or may not fit
correctly if used.

WARNING: Failure to properly seat the flange/ clamp nut/
wheel could result in serious injury (or damage to the tool



or wheel).
WARNING: Proper guard must be reinstalled for grinding

wheel, cutting wheel, sanding flap disc, wire brush or



wire wheel applications after sanding applications are
complete.

1. Place or appropriately thread backing pad
thespindle.

2. Place the sanding disc

3. While depressing spindle lock
spindle, piloting the raised hub on the clamp nut into the
centre of san ding disc and backingpad.

4. Tighten the clamp nut by hand. Then depress the spindle
lock button while turning the sanding disc until the sanding
disc and clamp nut are snug.

5. To remove the wheel, grasp and turn the backing pad and
sanding pad while depressing the spindle lock button.

Mounting and Removing Hubbed Wheels
(Fig. A)

Hubbed wheels install directly on the M14 threaded spindle.
Thread of accessory must match thread of spindle.

1. Remove backing flange by pulling away from tool.

2. Thread the wheel on the spindle

3. Depress the spindle lock button
tighten the hub of the wheel.

4. Reverse the above procedure to remove the wheel.

NOTICE: Failure to properly seat the wheel before turning
the tool on may result in damage to the tool or the wheel.

Mounting Wire Cup Brushes and
Wire Wheels (Fig. A)

WARNING: Failure to properly seat the flange/ clamp nut/
wheel could result in serious injury (or damage to the tool



or wheel).

CAUTION: To reduce the risk of personal injury,
wear work gloves when handling wire brushes and



wheels. They can become sharp.
CAUTION: To reduce the risk of damage to the tool,

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.

20

.

18

on the backing pad

1

, thread clamp nut

2

by hand.

1

and use a wrench to

17

on

17

.

19

on

Wire cup brushes or wire wheels install directly on the threaded
spindle without the use of flanges. Use only wire brushes or
wheels provided with a M14 threaded hub. These accessories
are available at extra cost from your local dealer or authorised
service centre.

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

2. Thread the wheel on the spindle by hand.

3. Depress spindle lock button
hub of the wire wheel or brush to tighten the wheel.

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

NOTICE: To reduce the risk of damage to the tool, properly
seat the wheel hub before turning the tool on.

1

and use a wrench on the

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 flange are mounted correctly.
Follow the instructions given in the Grinding and Cutting

AccessoryChart.

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

• 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 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.

OPERATION

Instructions for Use

WARNING: Always observe the safety instructions and
applicableregulations.



WARNING: To reduce the risk of serious personal
injury, turn tool off and disconnect tool from power



source before making any adjustments or removing/
installing attachments or accessories. Be sure the

trigger switch is in the OFF position. An accidental start-up
can cause injury.

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 important 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.

10

• 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.

• Always wear regular working gloves while operating
thistool.

• The gear becomes very hot duringuse.

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

• Always install the guard and appropriate disc or
wheel. Do not use excessively worn disc or wheel.

• Be sure the inner and outer flange are
mountedcorrectly.

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

• Avoid overloading. Should the tool become hot, let it
run a few minutes under no load condition to cool the
accessory. Do not touch accessories before they have
cooled. The discs become very hot duringuse.

• Never work with the grinding cup without a suitable
protection guard inplace.

• Do not use the power tool with a cut-offstand.

• Never use blotters together with bonded
abrasiveproducts.

• Be aware, the wheel continues to rotate after the tools
is switchedoff.

Proper Hand Position (Fig. G)

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
with the other hand on the body of the tool, as shown in
FigureG.

3

Paddle Switch (Fig. A)

CAUTION: 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 surface before turning the tool off. Allow the tool
to stop rotating before putting itdown.

1. To turn the tool on, push the lock-off lever
back of the tool, then depress the paddle switch
will run while the switch isdepressed.

2. Turn the tool off by releasing the paddleswitch.

8

toward the

7

. The tool

Spindle Lock (Fig. B)

The spindle lock
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.

To engage the lock, depress the spindle lock button and rotate
the spindle until you are unable to rotate the spindlefurther.

1

is provided to prevent the spindle from

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.

Surface Grinding, Sanding and Wire
Brushing

CAUTION: Always use the correct guard per the
instructions in this manual.



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.

To perform work on a the surface of a workpiece:

1. Allow the tool to reach full speed before touching the tool
to the work surface.

2. Apply minimum pressure to the work surface, allowing
the tool to operate at high speed. Material removal rate is
greatest when the tool operates at high speed.

Angle

3. Maintain an appropriate angle between the tool and work

,

surface. Refer to the chart according to particularfunction.

Function Angle
Grinding 20˚-30˚
Sanding with Flap Disc 5˚-10˚
Sanding with Backing Pad 5˚-15˚
Wire Brushing 5˚-10˚

4. Maintain contact between the edge of the wheel and the
work surface.

- If grinding, sanding with flap discs or wire brushing
move the tool continuously in a forward and back
motion to avoid creating gouges in the worksurface.

- If sanding with a backing pad, move the tool constantly
in a straight line to prevent burning and swirling of
worksurface.

NOTE: Allowing the tool to rest on the work surface without
moving will damage the work piece.

ENGLISH

11

ENGLISH

5. Remove the tool from work surface before turning tool off.
Allow the tool to stop rotating before laying it down.

CAUTION: Use extra care when working over an edge, as
a sudden sharp movement of grinder may be experienced.



Precautions To Take When Working on a
Painted Workpiece

1. Sanding or wire brushing 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

1. No children or pregnant women should enter the work area
where the paint sanding or wire brushing is being done
until all clean up is completed.

2. 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.

3. 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

1. Paint should be removed in such a manner as to minimize
the amount of dust generated.

2. Areas where paint removal is occurring should be sealed
with plastic sheeting of 4 mils thickness.

3. Sanding should be done in a manner to reduce tracking of
paint dust outside the work area.

Cleaning and Disposal

1. All surfaces in the work area should be vacuumed and
thoroughly cleaned daily for the duration of the sanding
project. Vacuum filter bags should be changedfrequently.

2. 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.
During clean up, children and pregnant women should be
kept away from the immediate work area.

3. All toys, washable furniture and utensils used by children
should be washed thoroughly before being used again.

Edge Grinding and Cutting

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.

12

CAUTION: Wheels used for edge grinding and cutting
may break or kick back if they bend or twist while the tool



is being used. In all edge grinding/cutting operations, the
open side of the guard must be positioned away from
theoperator.

NOTICE: Edge grinding/cutting with a Type27 wheel
must be limited to shallow cutting and notching—less
than 13mm in depth when the wheel is new. Reduce the
depth of cutting/notching equal to the reduction of the
wheel radius as it wears down. Refer to the Accessories
Chart for more information. Edge grinding/cutting with a
Type 41 wheel requires usage of a Type 1 guard.

1. Allow the tool to reach full speed before touching the tool
to the work surface.

2. Apply minimum pressure to the work surface, allowing
the tool to operate at high speed. Grinding/cutting rate is
greatest when the tool operates at high speed.

3. Position yourself so that the open-underside of the wheel is
facing away from you.

4. 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. Edge grinding wheels are not designed to
withstand side pressures caused bybending.

5. Remove the tool from the work surface before turning
the tool off. Allow the tool to stop rotating before laying
itdown.

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 an
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.

Cutting Metal

For cutting with bonded abrasives, always use the
guardtype 1.

When cutting, work with moderate feed, adapted to the
material being cut. Do not exert pressure onto the cutting disc,
tilt or oscillate the machine.

Do not reduce the speed of running down cutting discs by
applying sideward pressure.

The machine must always work in an upgrinding motion.
Otherwise, the danger exists of it being pushed uncontrolled
out of the cut.

When cutting profiles and square bar, it is best to start at the
smallest cross section.

ENGLISH

DeWALT

DeWALT

DeWALT

D

b

D

D

d

D

Rough Grinding

Never use a cutting disc for roughing.
Always use the guard type 27.

The best roughing results are achieved when setting the
machine at an angle of 30° to 40°. Move the machine back and
forth with moderate pressure. In this manner, the workpiece
will not become too hot, does not discolour and no grooves
areformed.

Cutting Stone

The machine shall be used only for dry cutting.

For cutting stone, it is best to use a diamond cutting disc.
Operate the machine only with additional dust protection mask.

Working Advice

Exercise caution when cutting slots in structural walls.

Slots in structural walls are subject to the country-specific
regulations. These regulations are to be observed under all
circumstances.Before beginning work, consult the responsible
structural engineer, architect or the construction supervisor.

MAINTENANCE

Your
over a long period of time with a minimum of maintenance.
Continuous satisfactory operation depends upon proper tool
care and regularcleaning.

power tool has been designed to operate

WARNING: To reduce the risk of serious personal
injury, turn tool off and disconnect tool from power



source before making any adjustments or removing/
installing attachments or accessories. Be sure the

trigger switch is in the OFF position. An accidental start-up
can cause injury.

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 user-serviceable. Take the
tool to an authorised DeWALT repairagent.

Lubrication

Your power tool requires no additionallubrication.

Optional Accessories

WARNING: Since accessories, other than those offered
by



of such accessories with this tool could be hazardous.
To reduce the risk of injury, only
accessories should be used with thisproduct.

Consult your dealer for further information on the
appropriateaccessories.

b

, have not been tested with this product, use

Max.
[mm]

D b d

d

115 6 22,23 11,500 80 –

125 6 22,23 11,500 80 –

115 – – 11,500 80 –

125 – – 11,500 80 –

75 30 M14 11,500 45 20.0

115 12 M14 11,500 80 20.0

125 12 M14 11,500 80 20.0

[mm]

Min.

Rotation
[min.–1]

recommended

Periphical

speed

hole length

[m/s]

Threaded

[mm]

Protecting the Environment

Separate collection. Products and batteries marked
with this symbol must not be disposed of with normal
household waste.

Products and batteries contain materials that can
be recovered or recycled reducing the demand for raw
materials. Please recycle electrical products and batteries
according to local provisions. Further information is available at
www.2helpU.com.

Cleaning

WARNING: Blow dirt and dust out of the main housing
with dry air as often as dirt is seen collecting in and around



the air vents. Wear approved eye protection and approved
dust mask when performing thisprocedure.

WARNING: Never use solvents or other harsh chemicals
for cleaning the non-metallic parts of the tool. These



chemicals may weaken the 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.

13

ENGLISH

Grinding and Cutting Accessory Chart

Guard Type Accessory Description How to Fit Grinder

Depressed centre

grinding disc

Type 27

Guard

Flap wheel

Wire wheels

Wire wheels with

threaded nut

Wire cup with

threaded nut

Type 27 guard

Backing flange

Type 27 depressed centre wheel

Threaded clamp nut

Type 27 guard

Wire wheel

Type 27 guard

Wire brush

Backing pad/

sanding sheet

Type 27 guard

Rubber backing pad

Sanding disc

Threaded clamp nut

14

Grinding and Cutting Accessory Chart (cont.)

Guard Type Accessory Description How to Fit Grinder

Masonry cutting

disc, bonded

ENGLISH

Type 1

Guard

Type 1

Guard

OR

Type 27

Guard

Metal

cutting disc,

bonded

Diamond cutting

wheels

Type 1 guard

Backing flange

Cutting wheel

Threaded clamp nut

15

161718

Belgique et
Luxembourg België
en Luxemburg

DeWALT - Belgium BVBA
Egide Walschaertsstraat 16
2800 Mechelen

Tel: NL 32 15 47 37 63
Tel: FR 32 15 47 37 64
Fax: [phone]

www.dewalt.be
[e-mail]

Danmark DeWALT

Roskildevej 22
2620 Albertslund

Tel: [phone]
Fax: [phone]

www.dewalt.dk
[e-mail]

Deutschland DeWALT

Richard Klinger Str. 11
65510 Idstein

Tel: [phone]
Fax: [phone]

www.dewalt.de
[e-mail]

Ελλάς DeWALT (Ελλάς) Α.Ε.

EΔΡΑ-ΓΡΑΦΕΙΑ : Στράβωνος 7
& Λ. Βουλιαγμένης, Γλυφάδα 166 74, Αθήνα
SERVICE : Ημερος Τόπος 2 (Χάνι Αδάμ) – 193 00 Ασπρόπυργος

Τηλ: 00302108981616
Φαξ: 00302108983570

www.dewalt.gr
[e-mail]

España DeWALT Ibérica, S.C.A.

Parc de Negocios “Mas Blau”
Edificio Muntadas, c/Bergadá, 1, Of. A6
08820 El Prat de Llobregat (Barcelona)

Tel: [phone]
Fax: [phone]

www.dewalt.es
[e-mail]

France DeWALT

5, allée des Hêtres
BP 30084, 69579 Limonest Cedex

Tel: [phone]
Fax: [phone]

www.dewalt.fr
[e-mail]

Schweiz
Suisse
Svizzera

DeWALT
In der Luberzen 42
8902 Urdorf

Tel: 044 - 755 60 70
Fax: 044 - 730 70 67

www.dewalt.ch
[e-mail]

Ireland DeWALT

Calpe House Rock Hill
Black Rock, Co. Dublin

Tel: [phone]
Fax: [phone]

www.dewalt.ie

Italia DeWALT

via Energypark
20871 Vimercate (MB), IT

Tel: [phone]
39 039 9590200
Fax: [phone]

www.dewalt.it

Nederlands DeWALT Netherlands BV

Holtum Noordweg 35
6121 RE BORN, Postbus 83, 6120 AB BORN

Tel: [phone]
Fax: [phone]

www.dewalt.nl

Norge DeWALT

Postboks 4613, Nydalen
0405 Oslo

Tel: [phone]
Fax: [phone]

www.dewalt.no
[e-mail]

Österreich DeWALT

Werkzeug Vertriebsges m.b.H
Oberlaaerstrasse 248, A-1230 Wien

Tel: 01 - 66116 - 0
Fax: 01 - 66116 - 614

www.dewalt.at
[e-mail]

Portugal DeWALT Limited, SARL

Centro de Escritórios de Sintra Avenida
Almirante Gago Coutinho, 132/134, Edifício 14
2710-418 Sintra

Tel: [phone]
Fax: [phone]

www.dewalt.pt
[e-mail]

Suomi DeWALT

PL 47
00521 Helsinki

Puh: 010 400 4333
Faksi: 0800 411 340

www.dewalt.fi
[e-mail]

Sverige DeWALT

Box 94
431 22 Mölndal

Tel: [phone]
Fax: [phone]

www.dewalt.se
[e-mail]

Türkiye KALE Hırdavat ve Makina A.Ş.

Defterdar Mah. Savaklar Cad. No:15
Edirnekapı / Eyüp / İSTANBUL 34050 TÜRKİYE

Tel: [phone]
Faks: 0212 533 10 05

www.dewalt.com.tr

United
Kingdom

DeWALT, 210 Bath Road;
Slough, Berks SL1 3YD

Tel: [phone]
Fax: [phone]

www.dewalt.co.uk
[e-mail]

Australia DeWALT

810 Whitehorse Road Box Hill
VIC 3103 Australia

Tel: Aust 1800 338 002
Tel: NZ 0800 339 258

www.dewalt.com.au
www.dewalt.co.nz

Middle East Africa DeWALT

P.O. Box - 17164,
Jebel Ali Free Zone (South), Dubai, UAE

Tel: [phone]
Fax: [phone]

www.dewalt.ae
[e-mail]

N485430

07/16