DeWalt DWE4012 TYPE 1, N359279 Owner’s Manual

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iNSTRUCTiON MANUAL GUIDE D'UTILISATION MANUAL DE INSTRUCCIONES

DWE4012

Small Angle Grinder

Petite meuleuse angulaire Esmeriladora angular peque_a

INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y P©LIZA DE GARANT[A. ADVERTENClA: LEASE ESTE INSTRUCTIVO ANTES DE

USAR EL PRODUCTO.

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.

A 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 TOLL FREE AT: 1-800-4-DEWALT

(1-800-433-9258}.

_ ARNING: To reduce the risk of injury, 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,

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

The term "power tool" in the warnings refers to your mains-operated

(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.

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.

If °perating a powerto°l in a damp l°cati°n is unav°idable' use a ground fault circuff interrupter (GFCI) protected supply. Use of a GFC/ 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 energizing 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 jewelry.

Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry 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 ff

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. Oheck 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. 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.

SAFETY INSTRUCTIONS FOR

ALL OPERATIONS

Safe_ Warnings Common for Grinding_ Sandingj Wire Brushing_ Polishing or

Abrasivej Cu_ing-Off Operations

a) This power tool is intended to function as a grinder,

sander, wire brush, polisher or cut-off tool Read all safety warnings, instructions, illustrations and

specifications provided with this power tool Failure to follow a// instructions listed below may result in electric shock, fire and/or serious injury.

b) 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.

c) 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.

d) 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.

e) 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 willrun out of balance, vibrate excessively and may cause loss of control.

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.

g) 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.

h) 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.

i) 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 electric shock.

j) Positionthecord 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.

k) 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

I) 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.

m) 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.

n) Do not operate the power tool near flammable materials.

Sparks could ignite these materials.

o) Do not use accessories that require liquid coolants.

Using water or other liquid coolants may result in electrocution or shock.

p) When starting the tool with a new or replacement wheel,

or a new or replacement wire brush installed, hold the tool in a well protected area and let ff run for one minute.

If the wheel has an undetected crack or flaw, it should burst in less than one minute. If the wire brush has loose wires, they will

be detected. Never start the tool with a person in line with the wheel This includes the operato_

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 fomed 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 operatod 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 power 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. Comers, 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 center 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 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 fomes applied to these wheels may cause them to shatte_

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 too/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 operation, 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 reenter the cut. The wheel may bind, walk up or kickback ifthe power too/

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.

0 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 manufacturers 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 Polishing Operations:

a) Do not allow any loose portion of the polishing bonnet

or its attachment strings to spin freely. Tuck away or trim

any loose attachment strings. Loose and spinning attachment strings can entangle your fingers or snag on the workpiece.

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.

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 load and centrifugal fomes.

c) Safety goggles or safety glasses with side shields and a full

face shield compliant with ANSI Z87.1 MUST be worn by the operator and others that are within 50' (15.2 m) of the use of

this product.

Additional Safety Rules for Grinders

A WARNING: The grinding wheel or accessory may loosen during coast-down of the tool when shut off. If grinding wheel or

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

• Use of accessories not specified in this manual is not recommended and may be hazardous. Use of power boosters

that would cause the too/to be driven at speeds greater than its rated speed constitutes misuse.

• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by hand

or against your body leaves it unstable and may lead to loss of control.

Avoid bouncing the wheel or giving it rough treatment. If this

occurs, stop the too/and inspect the wheel for cracks or flaws.

Always handle and store wheels in a careful manne_

• Never cut into area that may contain electrical wiring or piping. Serious injury may result.

• Do not operate this tool for long periods of time. Vibration caused by the operating action of this too/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.

• Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories can result in injury.

Always use side handle. Tighten the handle securely. The

side handle should always be used to maintain control of the too/ at all times.

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.

An extension cord must have adequate wire size (AWG

or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is

16gaugehasmorecapacitythan18gauge.Anundersizedcord willcausea dropinlinevoltageresultinginlossofpowerand

overheating.Whenusingmorethanoneextensiontomakeupthe totallength,besureeachindividualextensioncontainsatleastthe

minimumwiresize.Thefollowingtableshowsthecorrectsizeto usedependingoncordlengthandnameplateampererating.Ifin doubt,usethenextheaviergauge.Thesmallerthegaugenumbed

theheavierthecord.

Minimum Gauge for Cord Sets

Volts Total Length of Cord

Ampere Rating

More Not More Than Than

0 6 18 16 16 14

6 10 18 16 14 12 10 12 16 16 14 12 12 16 14 12 Not Recommended

,_ WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask %cutting operation is

dusty. ALWAYS WEAR CERTIFIEDSAFETY EQUIPMENT_

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),

• ANSI $12.6 ($3.19) hearing protection,

• NIOSH/OSHA/MSHA respiratory protection.

,_,WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals

known to the State of Cal%omiato cause canced birth defects or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,

120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7) 240V 50 (15.2) 100 '(30.5) 200 (61.0) 300 i91.4')

in Feet (meters}

AWG

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumbe_

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.

i_,WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury.

Always use NIOSH/OSHA approved respiratory protection appropriate

for the dust exposure. Direct particles away from face and body. A WARNING: Always wear proper personal hearing protection

that conforms to ANSI $12.6 ($3.19) 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

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

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

- -- or DC... direct current

(_)................. Class I Construction

(grounded)

[] ................. Class II Construction no .................... no load

(double insulated) speed

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

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

or AC.......... alternating

current

_-_or AC/DC... alternating or

direct current

.../min........... per minute n ...................... rated speed

BPM ............. beats per minute _ ..................... earthing

IPM............... impacts per minute terminal

RPM ............. revolutions per _,..................... safety alert

minute symbol

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

SAVE THESE INSTRUCTIONS FOR

FUTURE USE

Motor

Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than 10% will cause loss of power and overheating. DFiWALTtools are factory tested; if this tool does not operate, check power supply.

COMPONENTS (Fig. 1j 6)

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

A. Spindle lock button G. Paddle switch B. Spindle H. Lock-on button C. Side handle I. Lock-off lever (Fig. 6) D. Backing flange J. Guard release lever

E. Threaded clamp nut

R Guard

FIG. 1

INTENDED USE

This grinder is designed for professional grinder, sander, wire brush or

cut-off applications.

DO NOT use under wet conditions or in presence of flammable

liquids or gases.

This 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 injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

ATTACHING SIDE HANDLE (FIG. 2) FIG.2 c The side handle (C)can be fitted to either side of

the gear case in the threaded holes, as shown. Before using the tool, check that the handle is

tightened securely. Use a wrench to firmly tighten the side handle.

Ftotating the Gear Case

(Fig. 3)

1. Remove the four corner screws FIG.3 attaching the gear case to motor

housing.

2. Without separating the gear case from

motor housing, rotate the gear case

head to desired position. 90° NOTE: If the gear case and motor housing become separated by more than 1/8"

(3.17 mm), the tool must be serviced and re-assembled by a DEWALT service center. Failure to have the tool serviced may cause brush,

motor and bearing failure.

3. Reinstall screws to attach the gear case to the motor housing. Tighten screws to 18 in.-Ibs, torque. Overtightening could cause

screws to strip.

A WARNING: Before reconnecting the tool, depress and

release the trigger switch to ensure that the tool is off.

Accessories and Attachments

The capacity of this tool is 4-1/2" (114.3 ram) diameter x 1/4"

(6.35 mm) thick grinding or cutting wheels. It is important to choose the correct guards, backing pads and flanges to use with grinder accessories. See pages 9-10 for information on choosing the correct

accessories.

4=1/2" (114.3 mmJ Grinding Wheels

Type 27 guard

backing flange

Type 27 depressed

center wheel

threaded clamp nut

Type 27 guard

Type 27 hubbed wheel

Wire Wheels

Type 27 guard

3" (76.2 ram)

wire cup brush

Type 27 guard

4" (101.6 mm) wire wheel

4-1/2" (114.3 mrn

Type 1 guard

Cutting Wheels

Type 1guard

Sanding Discs

rubber backing pad

4-1/2" (114.3 ram) Sanding Flap Discs

Type 27 guard

backing flange

sanding disc

threaded clamp nut

abrasive cutting wheel

clamp nut

diamond cutting wheel

clamp nut

A WARNING: Accessories must be rated for at least the speed

recommended on the tool warning label Wheels and other accessories running over rated accessory speed may burst and cause injury. Threaded accessories must have a 5/8"-11 hub. Every unthreaded accessory must have a 7/8" 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 on pages 9-10 of this manual

Accessory ratings must be above listed minimum wheel speed as

shown on tool nameplate.

backing flange

hubbed sanding

flap disc

non-hubbed sanding

flap disc

threaded clamp nut

._WARNING: Handle and store all abrasive wheels carefully to prevent damage from thermal shock, heat, mechanical damage, etc.

Store in a dry protected area free from high humidity, freezing temperatures or extreme temperature changes.

Mounting Guard

CAUTION: Guards must be used with all grinding wheels,

cutting wheels, sanding flap discs, wire brushes, and wire wheels. The too/may be used without a guard only when sanding

with conventional sanding discs. A Type 1guard (intended for use with cut off wheels) is available at extra cost from your local dealer or

authorized service cente_ Grinding and cutting with wheels other than

Type 27 and 29 require different accessory guards not included with

tool A Type 27 guard is provided for use with the Type 27 wheel Mounting instructions for accessory guards are shown below and are also included in the accessory package.

MOUNTING AND REMOVING {TYPE 27 & TYPE 1} ONE-TOUCH TM GUARD (FIG. 4, 5} FIG.4

NOTE: If your grinder is supplied with a keyless ONE TOUCH TM guard, ensure the screw, lever and spring are fitted correctly before mounting the guard.

1. Press the guard release lever (K).

2. While holding the guard release lever open, align the lugs (L) on the guard with the slots on the gear case (M).

3. Keeping the guard release lever open, 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. With the spindle facing the operator, rotate FIG.5 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 (N) on the guard collar. This insures that the guard is secure. The guard can be repositioned the opposite direction by depressing the guard release lever.

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

NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose; 1/4" (6.35 mm) thick wheels are designed for surface grinding while 1/8" (3.17 mm) wheels are designed for edge grinding. Cutting can also be performed by using a Type 1 wheel and a Type 1 guard.

OPERATION

i_ WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

Guards and Flanges

It is important to choose the correct guards and flanges to use with the grinder accessories. See page 9-10 and this page for the correct

accessories.

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

i_,WARNING: Accessories must be rated for at least the speed

recommended on the tool warning label Wheels and other accessories running over rated accessory speed may burst and cause injury. Every unthreaded accessory must have a 7/8" arbor hole. If it does not, it may have been designed for a circular saw and should not be used. Use only the accessories shown on pages 9-10.

Accessory ratings must be above listed minimum wheel speed as

shown on tool nameplate.

Switches

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 before 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.

PADDLE SWITCH (FIG. 6) _, CAUTION: Before connecting the tool to a power source depress

and release the paddle switch (G) to ensure that the switch is off. Depress and release the paddle switch as described above after any interruption in power supply to the tool, such as the activation of a ground fault interrupte_ throwing of a circuit breake_ accidental unplugging, or power failure.

To turn the tool on, push the lock-off lever (I)toward the back of the

tool, then depress the paddle switch (G). The tool will run while the switch is depressed. Turn the tool off by releasing the paddle switch.

A WARNING: Do not disable the Iock-offlever If the Iock-offlever is

disabled, the tool may start unexpectedly when it is laid down.

LOCK-ON BUTTON (FIG. 6)

The lock-on button (H) offers increased comfort in extended use

applications. To lock the tool on, push the FIG.6 lock-off lever (I)toward the back of the tool then depress the paddle switch (G).

With the tool running, depress the lock-on button (H).The tool will continue

to run after the paddle switch is released.

To unlock the tool, depress and release G I H

the paddle switch. This will cause the tool to stop.

_, CAUTION: Allow the tool to reach full speed before touching tool

to the work surface. Lift the tool from the work surface before tuming the tool off.

SPINDLE LOCK (FIG. 7)

The spindle lock button (A) is provided to FIG.7

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. Do not engage the spindle lock button while the tool is operating because damage to the tool will result. To engage the lock, depress the spindle lock button and rotate the spindle until you are unable to rotate the spindle further.

Mounting and Using Depressed Center Grinding Wheels and Sanding Flap Discs

MOUNTING AND REMOVING HUBBED WHEELS (FIG. 8}

nubbed wheels install directly on the 5/8"-11 threaded spindle.

Thread of accessory must match thread of spindle.

1. Remove backing flange (D) by pulling away from the tool.

2. Thread the wheel on the spindle (B) by hand. FIG.8

3. Depress the spindle lock button and use a wrench to 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 NON-HUBBED WHEELS (FIG. 8, 9) Depressed center Type 27 grinding wheels must be used with

included flanges. Refer to Accessories and Attachments for more information.

1. Install the backing flange (D) on spindle (B)with the raised section (pilot) against the wheel. Be sure the backing flange recess is

seated onto the flats of the spindle by pushing and twisting the flange before placing wheel.

2. Place wheel against the backing flange, centering the wheel on the raised section (pilot)of the backing flange.

3. While depressing the spindle lock button, thread the clamp nut (E)on spindle. Ifthe wheel you are installing is more than 1/8" (3.17 mm) thick, place the threaded clamp nut on the spindle so

that the raised section (pilot) fits into the center of the wheel. If the wheel you are installing is 1/8" (3.17 mm) thick or less, place the threaded clamp nut on the spindle so that the raised section

(pilot) is not against tile wheel.

FIG. 9

Wheels thicker than

1/8" (3.17 mm)

Clamp Nut

BackingFlange

Wheels 1/8"

(3.17 mm) and thinner

Clamp Nut

BackingFlange

4. While depressing the spindle lock button, tighten the clamp nut

with a wrench.

5. To remove the wheel, depress the spindle lock button and loosen the threaded clamp nut with a wrench.

NOTE: If the wheel spins after the clamp nut is tightened, check the orientation of the threaded clamp nut. If a thin wheel is installed with the pilot on the clamp nut against the wheel, it will spin because the height of the pilot prevents the clamp nut from holding the wheel.

SURFACE GRINDING WITH GRINDING WHEELS (FIG. 10)

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 rate is greatest when the tool operates at high speed.

3. Maintain a 20° to 30°angle between the FIG.10 tool and work surface.

4. Continuously move the tool in a forward ..........

and back motion to avoid creating 20_30° gouges in the work surface.

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

EDGE GRiNDiNG WITH GRINDING WHEELS (FIG. 11}

i_ WARNING: Wheels used for cutting and edge grinding may break

if they bend or twist while the tool is being used to do cut-off work or deep grinding. To reduce the risk of serious injury, limit the use of these wheels with a standard Type 27 guard to shallow cutting and notching (less than 1/2" in depth). The open side of the guard must be positioned away from the opemto_ For deeper cutting with a

Type 1 cut-off wheel, use a closed, Type 1 guard. See the chart on

pages 9-10 for more information. Type 1 guards are available at extra cost from your local dealer or authorized service cente_

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

2.Applyminimumpressuretothework surface,allowingthetooltooperateat

highspeed.Grindingrateisgreatest

whenthetooloperatesathighspeed.

3.Positionyourselfso thattheopen-

undersideofthewheelisfacingaway

fromyou.

4.Oncea cutisbegunanda notchis establishedintheworkpiece,do not changetheangleofthecut.Changing theanglewillcausethewheeltobend andmaycausewheelbreakage.Edge grindingwheelsarenotdesignedto _ withstandsidepressurescausedby bending.

5.Removethetoolfromtheworksurfacebeforeturningthetooloff.

Allowthetooltostoprotatingbeforelayingitdown.

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.

SURFACE FINISHING WITH SANDING FLAP DISCS (FIG. 12}

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

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

high speed.

3. Maintain a 5° to 10° angle between the tool and work surface.

4. Continuously move the tool in a forward and back motion to avoid creating gouges in the work surface.

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

MOUNTING SANDING BACKING PADS (FIG. 13}

_'_WARNING: Proper guard must be FIG. 13 P

reinstalled for grinding wheel, sanding flap disc, wire brush or wire wheel applications after sanding applications are complete.

1. Place or appropriately thread backing pad (O)on the spindle.

2. Place the sanding disc (P) on the backing pad.

3. While depressing spindle lock, thread the clamp nut (E) on spindle, piloting

the raised hub on the clamp nut into the center of sanding 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.

USING SANDING BACKING PADS (FIG. 14} Choose the proper grit sandpaper for your application. Sandpaper

is available in various grits. Coarse grits yield faster material removal rates and a rougher finish. Finer grits yield slower material removal

and a smoother finish.

Begin with coarse grit discs for fast, rough material removal. Move

to a medium grit paper and finish with a fine grit disc for optimal finish.

Coarse 16-30grit

Medium 36-80grit FineFinishing 100-120grit

VeryFineFinishing 150-180grit

1.Allowthetooltoreachfullspeedbeforetouchingtooltothework surface.

2.Applyminimumpressureto work FIG.14 surface,allowingthetooltooperateat

highspeed.Sandingrateisgreatest

whenthetooloperatesathighspeed.

3.Maintaina5°to15°anglebetweenthe ..........

toolandworksurface.Thesanding 5_15° discshouldcontactapproximately

oneinchofworksurface.

4.Movethetoolconstantlyinastraightlinetopreventburningand swirlingofworksurface.Allowingthetooltorestonthework surfacewithoutmoving,ormovingthetoolinacircularmotion causesburningandswirlingmarksontheworksurface.

5.Removethetoolfromworksurfacebeforeturningtooloff.Allow thetooltostoprotatingbeforelayingitdown.

Mounting and Using 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 a 5/8"-11 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.

A CAUTION: Wheel or brash 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.

MOUNTING WIRE CUP BRUSHES AND WIRE WHEELS

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

USING WIRE CUP BRUSHES AND WIRE WHEELS (FIG 15, 16) Wire wheels and brushes can be used for removing rust, scale and

paint, and for smoothing irregularsurfaces.

1. Allow the tool to reach full speed before FIG.15 touching the tool to the work surface.

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

3. Maintain a 5°to 10°angle between the tool and work surface for wire cup brushes.

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

5. Continuously move the tool in a forward and FIG.16 back motion to avoid creating gouges in the work surface. Allowing the tool to rest on the work surface without moving, or moving the tool in a circular motion causes burning and swirling marks on the work surface.

6.Removethetoolfromtheworksurfacebeforeturningthetooloff. Allowthetooltostoprotatingbeforesettingitdown.

ACAUTION:Use extra care when working over an edge, as a

sudden sharp movement of grinder may be experienced.

Mounting and Using Cutting (Type 1) Wheels

Cutting wheels includediamond wheels and abrasive discs, Abrasive cutting wheels for metal and concrete use are available, Diamond

blades for concrete cutting can also be used. i_,WARNING: A closed, 2-sided cutting wheel guard is not included

with this tool but is required when using cutting wheels. Failure to use proper flange and guard can result in injury resulting from wheel

breakage and wheel contact. See page 10 for more information.

MOUNTING CUTTING WHEELS (FIG. 8)

,_ CAUTION: Matching diameter threaded backing flange and clamp nut (included with tool) must be used for cutting wheels.

1. Place the unthreaded backing flange on spindle with the raised section (pilot) facing up. The raised section (pilot) on the backing flange will be against the wheel when the wheel is installed.

2. Place the wheel on the backing flange, centering the wheel on the raised section (pilot).

3. Install the threaded clamp nut with the raised section (pilot) facing away from the wheel.

4. Depress the spindle lock button and tighten clamp nut with a wrench.

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

USING CUTTING WHEELS (FIG. 17) _, 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.

1. Allow tool to reach full speed before FIG._17 • touching tool to work surface.

2. Apply minimum pressure to work surface, allowing tool to operate at high speed. Cutting rate is greatest

when the tool operates at high speed.

3. Once a cut is begun and a notch is _ established in the workpiece, do not

change the angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel breakage.

4. Remove the tool from work surface before turning tool off. Allow the tool to

stop rotating before setting it down.

MAINT£NANCE

A WARNING: To reduce the risk of injury, turn unit off and disconnect it from power source before installing and removing accessories, before adjusting or when making repairs. An accidental start-up can cause injury.

Cleaning

_, WARNING: Blow dirt and dust out of all air vents with dean, dry air at least once a week. To minimize the risk of eye injury, always wear

ANSI Z87.1 approved eye protection when performing this.

i_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.

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 D,_-:WALTrecommended accessories should be used with this product.

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. Ifyou need assistance in locating any accessory, please contact DE.:.WALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286,

call 1-800-4-DEWALT (1-800-433-9258) or visit our website: www. DE.:.WALT.com.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance

and adjustment (including brush inspection and replacement) should be performed by a DEiWALT factory service center, a DE.:.WALT

authorized service center or other qualified service personnel. Always use identical replacement parts.

Thank you for your purchase. Register your product now for:

• WARRANTY SERVICE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.

• CONFIRMATION OF OWNERSHIP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will

serve as your proof of purchase. FOR YOUR SAFETY: Registering your product will allow us to

contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.

Three Year Limited Warranty

DEWALTwill repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800-

433-9258). This warranty does not apply to accessories or damage

caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

Inaddition to the warranty, DEWALT tools are covered by our:

1 YEAR FREE SERVICE

DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your

DEWALTPower Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund - no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information.

FREEWARNINGLABELREPLACEMENT: If your warning labels

become illegible or are missing, call 1-800-4-DE.:.WALT(1-800-433-

9258) for a free replacement.

'_WE4012A.GLEG.I.OE.4_]2"1t15"'!

EYE PROTECTION. USE ONLY ACCESSORIES RATED AT LEAST EQUAL T0 THE MAXIMUM SPEED MARKED ON THE TOOL. ALWAYS USE PROPER GUARDS

WHEN GRiNNiNG. ALWAYS USE PROPER RESPIRATORY PROTECTION. DEWALT iNDUSTRiAL TOOL CO., BALTIMORE, MD 21286 USA

TO REDUCE THE RiSK OF INJURY, USER MUST I_REAG iNSTRUCTiON MANUAL ALWAYS WEAR

D_finitions : Iignes directrices en

mati_re de s_curit_

Les definitions ci-dessous decrivent le niveau de danger pour

chaque mot-indicateur employe. LiFele mode d'emploi et porter

une attention particuliere _.ces symboles.

j_ DANGER : indique une situation dangereuse imminente qui, si elle n'est pas evitee, entrainera la mort ou des blessures

graves. _AVERTISSEMENT : indique une situation potentie//ement

dangereuse qui, si e//e n'est pas evitee, pourraff entra?ner /a mort ou des blessures graves.

j_ATTENTION : indique une situation potentie//ement dangereuse qui, si e//en'est pas evitee, pourrait entra?ner des blessures I_g_res ou mod_r6es.

AVIS : indique une pratique ne posant aucun risque de dommages corporels mais qui par contre, si rien n'est fair pour I'evited pourrait poser des risques de dommages

mat6riels.

POUR TOUTE QUESTION OU REMARQUE AU SUJET DE OET OUTIL OU DE TOUT AUTRE OUTIL DEWALT, COMPOSE LE

NUMC:RO SANS FRAIS :1-800-4-DEWALT (1-800-433-9258}.

_ VERTISSEMENT afin de reduire le risque de blessures, life

le mode d'emploi de I'outil.

Aver_issements de s_curit_ g_n_raux

pour les outils _lectriques

s6curit_ et toutes les directives. Le non-respect des

_ AVERTISSEMENT ! LiFe tousles avertissements de

avertissements et des directives pourrait se so/der par un choc dectrique, un incendie et/ou une blessure grave.

CONSERVER TOUSLES AVERTISSEMENTS

ET TOUTES LES DIRECTIVES POUR UN

USAGE ULTERIEUR

Le terme _outi/dectrique _ cite dans /es avertissements se rapporte

votre outil dectrique a a/imentation sur secteur (avec f/i) ou par piles

(sansfil).

1} S(-=CURIT# DU LIEU DE TRAVAIL

a) Tenir I'aire de travail propre et bien 6clair6e. Les /ieux

encombres ou sombres sont propices aux accidents.

b) Ne pas faire fonctionner d'outils 61ectriques clans un

milieu d_flagrant, tel qu'en pr6sence de liquides, de gaz ou de poussi_res inflammables. Les outi/s e/ectriques

produisent des etincelles qui pourraient enflammer la poussiere

ou les vapeurs.

c) Eloigner les enfants et les personnes b proximit6 pendant

I'utilisation d'un out# 61ectrique. Une distraction pourrait en faire perdre la ma?trisea I'utilisateu_

2) SECURITE EN MATIERE D'ELECTRICITE

a) Les fiches des outils 61ectriques doivent correspondre

la prise. Ne jamais modifier la fiche d'aucune faqon. Ne jamais utiliser de fiche d'adaptation avec un out# 61ectrique mis _ la terre. Le risque de choc dectrique sera reduit par/'uti/isation de fiches non modifiees correspondant la prise.

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