DeWalt D284741 User manual

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INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES
INSTRUCTIVO DE OPERACION, CENTROS DE SERVICIO Y POLIZA
DE GARANT[A. ADVERTENCIA: LEASE ESTE INSTRUCTIVO
ANTES DE USAR EL PRODUCTO.
®
D284741D284931D28493GID284941D28494GID28499 Heavy Duty Large Angle Grinders
Grandes rectifieuses coud_es de service intensif
Esmeriladoras de _ngulo grande para trabajo pesado
D28497 Heavy Duty Large Angle Sander
Grandes ponceuse coud_es de service intensif
Lijadora angular grande para trabajo pesado

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)
SAVE THESE INSTRUCTIONS!
General Safety Instructions
AWARNIN!! Read and understand allinstructions. Failure to foflow aft instructions
listed below, may result in electric shock, fire
and/or serious personal injury.
SAVE THESE INSTRUCTIONS
WORK AREA
AKeep your work area clean and well lit. Cluttered benches
and dark areas invite accidents.
_Do not operate power tools in explosive atmospheres,
such as in the presence of flammable liquids, gases, or
dust. Power tools create sparks which may ignite the dust or
fumes.
Keep bystanders, children, and visitors away while oper-
ating a power tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly
installed and grounded in accordance with all codes and
ordinances. Never remove the grounding prong or modify
the plug in any way. Do not use any adapter plugs. Check
with a qualified electrician if you are in doubt as to whether
the outlet is properly grounded, ff the tools should electrically
malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user. This tool may use
grounded construction (3 prong plug) to provide a means to
transfer electrical energy safely away from the user in the event
the tool electrically malfunctions, breaks down, or the tool case
becomes live. Damage to, or loss of, one of the 3 plug blades;
damage to the plug or cord, or failure to have the tool plugged
into a verified and continuously grounded electrical system, may
result in electric shock, serious injury, or death. To avoid these
risks of inju04 the tool must, at all times, be maintained and in
proper working order (cord, plug blades) and plugged into a con-
tinuously grounded electrical system. (See also "Cleaning" in the
Maintenance section, page 15.) Applicable only to Class I
(grounded) tools.
Double insulated tools are equipped with apolarized plug
(one blade is wider than the other.) This plug will fit in a
polarized outlet only one way. If the plug does not fit fully in
the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install a polarized outlet. Do not
change the plug in any way. Double insulation _eliminates
the need for the three wire grounded power cord and grounded
power supply system. Applicable only to Class II (double
insulated) tools.
_Avoid body contact with grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk
of electric shock if your body is grounded.
_Don't expose power tools to rain or wet conditions. Water
entering a power tool will increase the risk of electric shock.
_, Do not abuse the cord. Never use the cord to carry the
tools or pull the plug from an outlet. Keep cord away from
heat, oil, sharp edges or moving parts. Replace damaged
cords immediately. Damaged cords increase the risk of elec-
tric shock.
AWhen operating a power tool outside, use an outdoor exten-
sion cord marked "W-A" or "W." These cords are rated for out-
door use and reduce the risk of electric shock.

Minimum Gage for Cord Sets
Volts Total Length of Cord in Feet
120V 0-25 26-50 51-100 101-150
Ampere Rating
More Not more AWG
Than Than
12 16 14 12 Not Recommended
PERSONAL SAFETY
Stay alert, watch what you are doing and use common
sense when operating a power tool. Do not use tool while
tired or under the influence of drugs, alcohol, or medica-
tion. A moment of inattention while operating power tools may
result in serious personal injurjz.
J_ Dress properly. Do not wear loose clothing or jewelry.
Contain long hair. Keep your hair, clothing, and gloves
away from moving parts. Loose clothes, jewelry, or long hair
can be caught in moving parts. Air vents often cover moving
parts and should also be avoided.
AAvoid accidental starting. Be sure switch is off before plug-
ging in. Carrying tools with your finger on the switch or plugging
in tools that have the switch on invites accidents.
_, Remove adjusting keys or wrenches before turning the
tool on. A wrench or a key that is left attached to a rotating part
of the tool may result in personal injury.
ADo not overreach. Keep proper footing and balance at all
times. Proper footing and balance enables better control of the
tool in unexpected situations.
_, Use safety equipment. Always wear eye protection. Dust
mask, non-skid safety shoes, hard hat, or hearing protection
must be used for appropriate conditions.
TOOL USE AND CARE
_Use clamps or other practical way to secure and support
the workpiece to a stable platform. Holding the work by hand
or against your body is unstable and may lead to loss of control.
Do not force tool. Use the correct tool for your application.
The correct tool will do the job better and safer at the rate for
which it is designed.
_Do not use tool if switch does not turn it on or off. Any tool
that cannot be controlled with the switch is dangerous and must
be repaired.
Disconnect the plug from the power source before making
any adjustments, changing accessories, or storing the
tooL Such preventative safety measures reduce the risk of
starting the tool accidentally.
_k Store idle tools out of reach of children and other untrained
persons. Tools are dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools sharp and
clean. Properly maintained tools, with sharp cutting edges are
less likely to bind and are easier to control
_Check for misalignment or binding of moving parts, break-
age of parts, and any other condition that may affect the
tools operation. If damaged, have the tool serviced before
using. Many accidents are caused by poorly maintained tools.
_, Use only accessories that are recommended by the manu-
facturer for your model Accessories that may be suitable for
one tool may become hazardous when used on another tool.
SERVICE
_, Tool service must be performed only by qualified repair per-
sonneL Service or maintenance performed by unqualified per-
sonnel could result in a risk of injury

When servicing a tool, use only identical replacement parts.
Follow instructions in the Maintenance section of this man-
ual. Use of unauthorized parts or failure to follow Maintenance
instructions may create a risk of electric shock or injury.
Specific Safety Rules for Grinders
Always use proper guard with grinding wheel. A guard pro-
tects operator from broken wheel fragments and wheel contact.
AAccessories must be rated for at least the speed recom-
mended on the tool warning label. Wheels and other acces-
sories running over rated speed can fly apart and cause injury.
Refer to the table below. Accessory ratings must always be
above tool speed as shown on tool nameplate.
NOTE: The rated no load tool speed is printed on the name plate
and embossed on the gear case.
Rated no
(no load)
Tool Speed
5000 RPM
6000 RPM
8000 RPM
Minimum
Accessory
Rating
5500 RPM
6600 RPM
8500 RPM
AHold tool by insulated gripping surfaces when performing
an operation where the cutting tool may contact hidden
wiring or its own cord. Contact with a "five" wire will make
exposed metal parts of the tool "live" and shock the operator.
ABefore using, inspect recommended accessory for cracks
or flaws. If such a crack or flaw is evident, discard the acces-
sory. The accessory should also be inspected whenever you
think the tool may have been dropped. Flaws may cause wheel
breakage.
_When starting the tool with a new or replacement wheel, a
new or replacement wire brush installed, or if you are
unsure of the condition of the wheel, hold the tool in a well
protected area and let it run for one minute. If the wheel has
an undetected crack or flaw, it should burst in less than one
minute. 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 operator.
_In operation, avoid bouncing the wheel or giving #rough
treatmenL If this occurs, stop the tool and inspect the wheel for
cracks and flaws.
ADirect sparks away from operator, bystanders or flamma-
ble materials. Sparks may be produced while using a sander
or grinder. Sparks may cause bums or start fires.
AAlways use side handle. Tighten the handle securely. The
side handle should always be used to maintain control of the tool
at all times.
_Clean out your tool often, especially after heavy use. Dust
and grit containing metal particles often accumulate on interior
surfaces and could create a risk of serious injury, electric
shock or electrocution.
_, Do not operate this tool for long periods of time. Vibration
caused by tool action may be harmful to your hands and arms.
Use gloves to provide extra cushion and lim# exposure by taking
frequent rest periods.
_WARNING: Some dust created by power sanding, sawing,
grinding, drilling, and other construction activities contains chem-
icals known to cause cancer, birth defects, or other reproductive
harm. Some examples of these chemicals are:
•lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry
products, and

•arsenic and chromium from chemically-treated lumber
(CCA).
Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
work in a well ventilated area, and work with approved safety equip-
ment, such as those dust masks that are specially designed to filter
out microscopic particles.
•Avoid prolonged contact with dust from power sanding,
sawing, grinding, drilling, and other construction activities.
Wear protective clothing and wash exposed areas with
soap and water. Allowing dust to get into your mouth, eyes, or
lay on the skin may promote absorption of harmful chemicals.
WARNING: Use of this tool can generate and/or disburse dust,
which may cause serious and permanent respiratory or other injury.
Always use NIOSH/OSHA approved respiratory protection appro-
priate for the dust exposure. Direct particles away from face and
body.
_CAUTION: Use extra care when grinding into a corner
because a sudden, sharp movement of the grinder may be expe-
rienced when the wheel contacts a secondary surface.
_,CAUTION: Wear appropriate personal hearing protection
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 definitions are as follows:
V............ volts
Hz .......... hertz
min .......... minutes
.... ........direct current
[] ............Class II Construction
_, ............safety alert symbol
A............ amperes
W............ watts
.......... alternating current
no .......... no load speed
............earthing terminal
.../min ......revolutions
per minute
FAMILIARIZATION
Large Angle Grinders and Large Angle Sanders are designed for
heavy material removal in extended use applications. The following
grinders and sanders are described in this manual:
D28474 7"Angle Grinder double insulated
D28493 9"Angle Grinder double insulated
D28493G 9" Angle Grinder grounded
D28494 7"/9"Angle Grinder double insulated
D28494G 7"/9"Angle Grinder grounded
D28497 7"/9" Angle Sander grounded
D28499 7"/9"Angle Grinder double insulated
Components
A. Trigger Switch B. Lock On Button
C. Spindle Lock D. Side Handle
E. Spindle E Soft Mount
G. Top Bumper
8,000 rpm
5,000 rpm
5,000 rpm
6,000 rpm
6,000 rpm
6,000 rpm
6,000 rpm
D
A
E
C

Features
SWITCH
The tool is controlled by a trigger switch (A). A lock-on button (B)
provides increased comfort in extended use applications.
ROTATING REAR HANDLE (D28499 ONLY)
The rear handle can be positioned 30°, 60°, and 90° left and right
of center position.
ROTATING GEAR CASE (D28474, D28493, D28494, D28497)
For applications in which a tool will be dedicated for uses in edge
grinding and finishing work, the gear case may be rotated 90° left
or right of its original position. See page 9 for instructions on
rotating the gear case.
MULTIPLE SIDE HANDLE POSITIONS
The side handle can be properly positioned in five locations based
on personal preference and application. The side handle must be
used at all times to maintain proper control of the tool.
TOP BUMPER
The gear case top bumper may wear with
use. The bumper can be replaced with part
number 397711-00 available at extra cost
from DEWALT authorized service centers.
Replacement should be performed by
DEWALT authorized service centers or
qualified service personnel.
SPINDLE LOCK
The spindle lock pin is provided to prevent the spindle from rotating
when installing or removing wheels. Operate the spindle lock pin
only when the tool is turned off and unplugged from the power
Sanding Flap Discs
soft mount
Type 27 guard
D284937/D284939
hubbed sanding flap
disc
soft mount
Type 27 guard
D284937/D284939
backing flange
54339-00
non-hubbed sanding
flap disc
clamp nut
22191-00
NOTE: Wheel size must match guard size; i.e., a new 7" wheel may
not be used with a 9" guard. The bottom surface of wheel must be
inside the bend of the guard lip.

softmount
Type27guard
D284937/D284939
Type27hubbedwheel
softmount
Type28guard
D284938
Type28hubbedwheel
Grinding Wheels
soft mount
Type 27 guard
D284937/D284939
backing flange
54339-00
Type 27 non-hubbed
wheel
clamp nut
22191-00
soft mount
Type 28 guard
D284938
backing flange
54339-00
Type 28 non-hubbed
wheel
clamp nut
22191-00
Sanding Discs
soft mount
rubber backing pad
DW4947
sanding disc
clamp nut
included with
D4947
NOTE: Wheel size must match guard size; i.e., a new 7" wheel may not be used with a
9" guard. The bottom surface of wheel must be inside the bend of the guard lip.

Wire Wheels
soft mount
Type 27 guard
D284937/D284939
wire cup brush
soft mount
Type 27 guard
D284937/D284939
wire wheel
Flaring Cup Stones Cutting Wheels
Type 11flaring cup guard
D284934i4 ''
D284936--6"
backingflange
_oo_ovw_w001D2849:
flaring cup stone
31
Type 1 guard
D284931
backingflange
_nooTn nN
Type 1 guard
D284931
backingflange
_nooTn nN
[D284932 backing flange & clamp nutJ
abrasive cutting wheel diamond cutting wheel
clamp nut
_no A_O nr_
NOTE: Wheel size must match guard size; i.e., a 7" wheel may not
be used with a 9" guard.

source.Toengagethelock,depressthespin-
dlelockbutton(C)androtatethespindleuntil C
youareunabletorotateitfurther.
ACAUTION:Never depress the spindle lock
button while the grinder b running. Never turn
on the grinder while the spindle lock button is
depressed. Damage to your tool or personal
injury may result.
SOFT MOUNT
The grinder is equipped with a soft mount, enabling easy wheel
installation and removal.
Accessories and Attachments
It is important to choose the correct guards, backing pads and
flanges to use with grinder accessories. See the chart on pages
5-7 for information on choosing the correct accessories.
ACAUTION: Accessories must be rated for at least the speed
recommended on the tool warning label Wheels and other acces-
sories running over rated speed can fly apart and cause injury.
Accessory ratings must always be above tool speed as shown on
tool nameplate.
ATTACHMENTS
Attachments designed specifically for this grinder can be
purchased through
Service centers.
D284939
D284948
D284937
D284936
D284934
D284933
D284932
DEWALT dealers and DEWALT Factory
9" Type 27 guard
9" Type 28 guard
7" Type 27 guard
6" Type 11 Flaring cup guard with flange
4" Type 11 Flaring cup guard with flange
Type 11 Flaring cup wheel backing flange
Type 1 Flange set
D284931
054339-00
22191-00
61820-01
445928-01
397711-00
7" Type 1 Guard
Grinding backing flange
Clamp nut
Wheel Wrench
Soft mount spindle protector
Top gear case bumper
ASSEMBLY AND ADJUSTMENTS
Attaching the Side Handle
To install the side handle, thread the handle into one of the five
positions listed below and tighten securely by turning clockwise.
• Two front positions: Forward handle
positions are designed for optimized bal-
ance in surface finishing applications.
• Two rear positions: Rear handle positions
are designed for optimized balance in edge
grinding applications.
• One top position: Top handle position is
designed for edge grinding applications.
NOTE: D28497 includes only three handle
positions.
Rotating the Rear Handle
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the Ag_
trigger switch to ensure that the f
tool is off. 60
1. Unlock the rear handle by
pulling out the Handle Release
Lever (G) as shown.

2.Rotatehandleintoavailable0°,30°,60°,or90°positionleftOR
rightofcenter.
3.Pushinthehandlereleaselever.
4.Beforeturningthetoolon,ensurethatthehandleislockedinto
apositionandthehandlereleaseleverhasreturnedtotheorig-
inalpositionflushwiththetoolhousing.
Rotating the Gear Case
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the trigger switch to ensure that the
tool is off.
1. Remove the four corner screws
attaching the gear case to motor
housing.
2. Without separating the gear 90°
case from motor housing, rotate 90°
the gear case head to desired
position.
NOTE: If the gear case and motor housing become separated by
more than 1/8", 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. Re-install screws to attach the gear case to the motor housing.
Tighten screws to 20 in./Ibs, torque. Overtightening could cause
screws to strip.
OPERATION
Power Source
Plug the large angle grinder into a dedicated electrical circuit.
Operating this tool on a circuit with other tools will decrease tool
performance.
Switch
CAUTION: Before connecting the tool to apower source or after
a power failure, depress and release the trigger switch (A) once
without depressing the lock-on button (B) to ensure that the switch
is in the off position, ff the trigger switch is locked on, the tool will
start unexpectedly when power is reconnected to the tool Hold the
side handle and rear handle firmly to maintain control of tool at start
up and during use. B
TRIGGER OPERATION
To turn the tool on, depress the trigger switch
(A). The tool will remain running while the
trigger is depressed. Turn the tool off by
releasing the trigger.
TRIGGER OPERATION WITH LOCK-ON FEATURE
To turn tool on, depress trigger. Depress and hold lock-on button
(B) while releasing trigger. Lock-on button will remain depressed
and tool will remain on.
To turn the tool off, depress and release trigger. The lock pin but-
ton will pop out, permitting the trigger to disengage and causing the
tool to turn off.
NOTE: Allow the tool to reach full speed before touching tool to
work surface. Lift the tool from the work surface before turning the
tool off.
i_CAUTION: Make sure the wheel has come to a complete stop
before setting the tool down.
REMOVAL OF LOCK-ON FEATURE
The lock-on button can be permanently removed without compro-
mising compliance with regulatory agencies shown on the tool's
nameplate. Removal of the lock pin must be done by a DEWALT
Service Center.

Mounting and Using Depressed Center
Grinding Wheels and Sanding Flap Discs
MOUNTING AND REMOVING GUARD
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the trigger switch to ensure that the
tool is off.
IMPORTANT INFORMATION ABOUT GUARDS
Guards must be used with all grinding
wheels, sanding flap discs, wire brushes GRINDING
and wire wheels. The tool may be used with- WHEEL
out a guard only when sanding with conven- SURFACE
tional sanding discs. DEWALT models
D28493, D28494, D28474, D28499 are pro-
vided with a guard intended for use with
depressed center wheels (Type 27), and GUARD
hubbed grinding wheels (Type 27). The LIP
same guard is designed for use with sand-
ing flap discs, wire brushes and wire wheels.
Grinding and cutting with wheels other than Type 27 and 29 require
different accessory guards not included with the tool. Mounting
instructions for these accessory guards are included in the acces-
sory package.
_CAUTION: When using a grinding wheel with a Type 27, 28, or
29 guard, be sure that the bottom surface of the grinding wheel is
inside the the guard lip.
•& CAUTION: DEWALT model D28497 Angle Sander may only be
used for grinding by using appropriate accessory guard.
1. Open the guard latch (H), and align the lugs with slots on the
gear case cover. Position the guard facing backward, as
shown. 10
2. Push the guard down until the guard
lugs engage and rotate freely in the
groove on the gear case hub.
3. With the guard latch open, rotate the
guard into the desired working posi-
tion that provides maximum protec-
tion to the user as shown.
4. Close the guard latch to secure the
guard on the gear case. You should
be unable to rotate the guard by hand
when the latch is closed. Do not
operate the grinder with a loose
guard or the clamp lever in open
position.
5. To remove the guard, follow the pro-
cedure above in reverse order.
NOTE: The guard is pre-adjusted to the
diameter of the gear case hub at the fac-
tory. If, after a period of time, the guard
becomes loose, tighten the adjusting
screw (I) with clamp in the closed posi- I
tion.
CAUTION: Do not tighten the adjusting screw with the clamp
lever in open position. Undetectable damage to the guard or the
mounting hub may result.
MOUNTING AND REMOVING HUBBED WHEELS
Hubbed wheels install directly on the 5/8''i 11 threaded spindle.
1. Thread the wheel on the spindle by hand, seating the wheel
against the soft mount.
2. Depress the spindle lock button and use a wrench to tighten the
hub of the wheel.

3.Reversetheaboveproceduretoremovethewheel.
_CAUTION:Failure to properly seat the wheel against the soft
mount before turning the tool on may result in damage to the tool
or the wheel
MOUNTING NON-HUBBED WHEELS
Depressed center, Type 27 grinding wheels
must be used with available accessory flanges.
See the chart on pages 5-7 of this manual for
more information.
1. Install the metal backing flange (J) on spin-
dle (E) against the soft mount.
2. Place wheel against the backing flange,
centering the wheel on the backing flange
pilot.
3. While depressing the spindle lock button,
thread the clamp nut (K) on spindle, piloting
the raised hub on clamp nut in the center of
grinding wheel.
4. Tighten the clamp nut with a wrench.
5. Reverse the above procedure to remove the wheel.
SURFACE GRINDING WITH GRINDING WHEELS
1. Allow the tool to reach full speed before touching tool to work
surface.
2. Apply minimum pressure to work surface,
to allow the tool to operate at high speed.
3. Maintain a 20° to 30° 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 setting it down. 11
EDGE GRINDING WITH GRINDING WHEELS
[_CAUTION: Wheels used for cutting and edge grinding may
break or kick back 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 operator. For
deeper cutting with a Type 1 wheel, use a closed, Type 1 guard.
Type 1guards are available at extra cost from your local dealer or
authorized service center.
1. Allow the tool to reach full speed before touching the tool to the
work surface.
2. Apply minimum pressure to work surface, to allow the tool to
operate at high speed.
3. Protect yourself during edge finishing by directing the open side
of the guard away from you.
4. Move the tool continuously in a forward and back motion to
avoid creating gouges in the work surface.
5. Remove tool from work surface before turning the tool off. Allow
the tool to stop rotating before setting it down.
/_ WARNING: Do not use edge grinding wheels for surface grind-
ing applications because edge grinding wheels are not designed for
side pressures encountered with surface grinding. Wheel breakage
and injury may result.
SURFACE FINISHING WITH SANDING FLAP DISCS
1. Allow the tool to reach full speed before touching tool to work
surface.
2. Apply minimum pressure to work surface, to allow the tool to
operate at high speed.
3. Maintain a 5° to 10°angle between the tool
and work surface.

4.Continuouslymovethetoolinaforwardandbackmotionto
avoidcreatinggougesintheworksurface.
5.Removethetoolfromworksurfacebeforeturningtooloff.Allow
thetooltostoprotatingbeforesettingitdown.
MOUNTING AND USING SANDING
BACKING PADS
Sanding pads and sanding discs must be rated above minimum
accessory speed as shown on tool. Recommended sanding
backing pads and sanding discs are available at extra cost from
DEWALT service centers and DEWALT dealers.
NOTE: Guard may be removed for sanding applications with
backing pads and sanding discs. Sanding flap discs are considered
grinding wheels by ANSI standards and require the use of a guard.
(See Mounting and Using Depressed Center Grinding Wheels and
Sanding Flap Discs).
MOUNTING SANDING BACKING PADS
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the trigger switch to ensure that the
tool is off.
J_CAUTION: Proper guard must be re- N
installed for grinding wheel, sanding flap disc, M
wire brush, or wire wheel applications after
sanding applications are complete, f--_
i'\ f_
1. Place or appropriately thread rubber back- ,_
ing pad (L) down to soft mount.
2. Place the sanding disc (M) on the rubber
backing pad (L).
3. While depressing spindle lock, thread
clamp nut (N) on spindle, piloting the 12
raised hub on the clamp nut into the center of sanding disc and
backing pad.
4. Tighten the clamp nut with the proper wrench.
5. To remove the wheel, reverse the above procedure.
USING SANDING BACKING PADS
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 materi-
al removal and a smoother finish.
Begin with coarser 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 - 30 grit
Medium 36 - 80 grit
Fine Finishing 100 - 120 grit
Very Fine Finishing 150 - 180 grit
1. Allow the tool to reach full speed before touching tool to work
surface.
2. Apply minimum pressure to work surface, allowing tool to oper-
ate at high speed.
3. Maintain a 5° to 15° angle between the
tool and work surface. The sanding
disc should contact approximately one 5°
inch of work surface.
4. Move the tool constantly in a straight line to prevent burning
and swirling of 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.
5. Remove the tool from the work surface before turning the tool
off. Allow the tool to stop rotating before setting it down.

Mounting and Using Wire Brushes
and Wire Wheels
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the trigger switch to ensure that the
tool is off.
Wire brushes and wire wheels must be rated above minimum
accessory speed as shown on tool. Use only wire brushes and
wheels provided with a 5/8"- 11threaded hub. AType 27 guard is
required when using wire brushes and wheels.
i_CAUTION: Wear work gloves when handling wire brushes or
wheels. Wire brushes and wheels can become sharp.
MOUNTING WIRE BRUSHES AND WIRE WHEELS
1. Thread the wheel on the spindle by hand, seating the wheel
against the soft mount.
2. Depress the spindle lock button and use a wrench on the hub
of the wire brush or wheel to tighten the wheel.
3. To remove the wheel, depress the spindle lock button and use
a wrench on the hub of the wire brush or wheel to loosen it.
NOTE: Failure to properly seat the wheel hub against the soft
mount before turning the tool on may result in damage to the tool
or wheel.
USING WIRE CUP BRUSHES AND WIRE WHEELS
Wire wheels and brushes can be used for removing rust, scale and
paint, and for smoothing irregular surfaces.
1. Allow tool to reach full speed before touching tool to work
surface.
2. Apply minimum pressure to work surface, to allow the tool to
operate at high speed.
13
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 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. Remove the tool from the work surface
before turning the tool off. Allow the tool to
stop rotating before setting it down.
Mounting and Using Flaring Cup
(Type 11) Wheel
MOUNTING FLARING CUP WHEEL GUARD
•&WARNING: The flaring cup wheel guard is not included with
this tool. Flaring cup wheels require proper flanges and guards.
4" flaring cup wheel guard D284934 and 6" flaring cup wheel
guard D284936 are available as accessories and include proper
flange. Failure to use the proper flange and guard can result in
injury resulting from wheel breakage and wheel contact.
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the trigger switch to ensure that the
tool is off.
1. Install the guard as shown.
2. Guard body should be positioned between the spindle and the
operator to provide maximum operator protection.

3.Securelytightenthetwoclamping.... ...........• ._-.
MOUNTINGscrews(W)FLARINGsuppliedcuPwithWHEELtheguard. _......
1.Removethesoftmount(F)
2.Installtheflaringcupwheelbacking
flange,aligningtheflatsonspindle W
(O)withtheflatsonbackingflange(P).
3.Threadtheflaringcupwheelonspindlebyhand,seatingwheel
againstbackingflange.
4.Depressthespindlelockbuttonandtightenthewheelbyhand.
5.Toremovethewheel,reversetheaboveprocedure.
_,CAUTION:Failure to properly seat the wheel against backing
flange before turning the tool on may result in damage to the tool
or the wheel
NOTE: Adjust the guard skirt so that only 1/8" of the wheel is
exposed by loosening the bolts, allowing the guard to lengthen.
Tighten the guard skirt bolts securely before using the grinder.
USING A FLARING CUP WHEEL
Flaring cup wheels are designed for heavy material removal.
1. Allow the tool to reach full speed before touching tool to work
surface.
2. Apply minimum pressure to work surface, allowing the tool to
operate at high speed.
14
3. Maintain a 5° to 10° angle between the tool
and the 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 setting it down.
Mounting and Using Cutting
(Type 1) Wheels
Cutting wheels include diamond 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, cutting wheel guard is not included with this
tool Cutting wheels require proper flanges and guards. A 7" cutting
guard, D284931, is available as an accessory and includes proper,
matching flanges. Failure to use proper flange and guard can result
in injury resulting from wheel breakage and wheel contact.
MOUNTING CLOSED (TYPE 1) GUARD
Turn off and unplug tool before making any
adjustments or removing or installing
accessories. Before reconnecting the tool,
depress and release the trigger switch to
ensure that the tool is off.
1. Open the guard latch (H), and align the lugs
with slots on the gear case cover. Position
the guard facing backward, as shown.
2. Push the guard down until the guard lug
engages and rotates freely in the groove
on the gear case hub.
3. Rotate guard (Q) into desired working
position. The guard body should be posi- Q

tionedbetweenthespindleandtheoperatortoprovidemaxi-
mumoperatorprotection.
4.Closetheguardlatchtosecuretheguardonthegearcase
cover.Youshouldbeunabletorotatetheguardbyhandwhen
thelatchisinclosedposition.Donotoperategrinderwitha
looseguardorclampleverinopenposition.
NOTE:Theguardispre-adjustedtothedia-
meterofthegearcasehubatthefactory.If,
aftera periodoftime,theguardbecomes
loose,tightentheadjustingscrew(I)withthe
clampleverintheclosedposition. I
CAUTION: Do not tighten adjusting screw
with clamp lever in open position. Undetectable damage to guard
or mounting hub may result.
MOUNTING CUTTING WHEELS
1. Remove Soft Mount (F).
2. Install wheel backing flange, aligning flats on spindle (O) with
flats on backing flange (R).
3. Place the wheel on the backing flange, centering the wheel on
the backing flange pilot.
R
15
4. Install the clamp nut, ensuring that the wheel remains centered
on the backing flange.
5. Depress the spindle lock button and tighten clamp nut with
wrench.
6. Reverse the above procedure to remove the wheel.
USING CUTTING WHEELS
AWARNING: 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 touching tool to work
surface.
2. Apply minimum pressure to work surface, allowing tool to oper-
ate at high speed.
3. Once you begin a cut, maintain the angle of the cutting wheel
to the work surface. This will keep you from bending the wheel
which could result in wheel breakage and injury.
4. Remove the tool from work surface before turning tool off. Allow
the tool to stop rotating before setting it down.
MAINTENANCE
Cleaning
i_ WARNING: Blowing dust and grit out of the motor housing using
clean, dry compressed air is a necessary regular maintenance pro-
cedure. Dust and grit containing metal particles often accumulate on
interior surfaces and could create an electrical shock or electrocu-
tion if not frequently cleaned out. ALWAYS WEAR SAFETY
GLASSES.
_CAUTION: Never use solvents or other harsh chemicals for
cleaning the non-metallic parts of the tool Use a clean, dry rag only.

Lubrication
DEWALT tools are properly lubricated at the factory and are ready
for use.
Repairs
To assure product SAFETY and RELIABILITY, repairs, mainte-
nance and adjustment should be performed by authorized service
centers or other qualified service personnel. Always use identical
replacement parts.
Motor Brushes
When brushes become worn, the tool will automatically stop, pre-
venting damage to the motor. Brush replacement should be per-
formed by DEWALT authorized service centers or other qualified
service personnel. Qualified service personnel should follow the
procedures below when replacing motor brushes.
Turn off and unplug tool before making any adjustments or
removing or installing accessories. Before reconnecting the
tool, depress and release the trigger switch to ensure that the
tool is off.
1. Remove the brush doors located on the sides of motor housing.
2. To remove the brush, hold the female terminal, which is
attached to the brush lead wire, and disconnect the female ter-
minal from the male terminal.
3. Pull the brush straight up out of the brush holder.
4. Replace brushes, in pairs, with original DEWALT brushes avail-
able from DEWALT authorized service centers.
5. Ensure that the brushes slide freely in brush box.
6. Reconnect the brush lead wire to brush box terminal.
7. Re-install the brush doors before using the tool. Torque screws
to 10 in./Ibs., maximum. Overtightening may cause screws to
strip.
Purchasing Accessories
Recommended accessories for use with your tool are available at
extra cost from you local dealer or authorized service center. If you
need assistance in locating any accessory for your tool, contact:
DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD
21286.
_CAUTION: Accessories must be rated for at least the speed
recommended on the tool warning label Wheels and other acces-
sories running over rated speed can fly apart and cause injuoz.
Accessory ratings must always be above tool speed as shown on
tool nameplate.
ACAUTION: The use of any other accessory not recommended
for use with this tool could be hazardous.
Three Year Limited Warranty
DEWALT will repair, without charge, any defects due to faulty mate-
rials 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.
In addition to the warranty, DEWALT tools are covered by our:
1YEAR 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
16

DEWALTPowerTool,Laser,or Nailerforanyreason,youcan
returnitwithin90daysfromthedateofpurchasewithareceiptfor
afullrefund- noquestionsasked.
FREEWARNINGLABELREPLACEMENT:Ifyourwarninglabels
becomeillegibleoraremissing,call1-800-4-DEWALTforafree
replacement.Torequestreplacementlabels,youwillneedtoknow
theratedrpmofyourtool.Therpmofyourtoolisstampedintothe
toolhousing.
17

POURTOUTRENSEIGNEMENTSUPPLI2MENTAIRESURCET
OUTILOUTOUTAUTREOUTILDEWALT,COMPOSERSANS
FRAISLENUMI2RO:
18004-DEWALT(1800433-9258)
CONSERVER CES
DIRECTIVES!
MESURES DE S_'CURIT_"-
G_'N_'RALIT_'S
_AVERTISSEMENT! Lire et comprendre
toutes les directives, car/e non-respect
des directives suivantes pourrait entrafner
un risque de choc electrique, d'incendie ou
de blessures graves.
CONSERVER CES DIRECTIVES
ZONE DE TRAVAIL
Garder la zone de travail propre et bien eclairee; les 6tablis
encombr6s et les endroits sombres sont propices aux accidents.
Ne pas utiliser les outils electriques clans une atmosphere
explosive, comme a proximite de liquides, de gaz ou de
poussieres inflammables; le moteur peut cr6er des 6tincelles
et enflammer les vapeurs ou les poussieres environnantes.
_Tenir les enfants, les visiteurs ou toute autre personne
I'ecart Iorsqu'on utilise un outil electrique; les distractions
peuvent faire perdre la maftrise de ce demier.
MESURES DE SI_CURITI_ - I_LECTRICITI_
Les outils mis ala terre doivent 6tre branches clans une prise
bien installee et mise alaterre conformement atousles codes 18
A
et reglements en vigueur. Ne jamais retirer la broche de terre
ni modifier la fiche. Ne pas utiliser d'adaptateur. Verifier
aupres d'un electricien qualifie en cas de doute quant ala
mise ala terre de la prise. En cas de d6fai//ance 6/ectrique ou
de bris de I'outil, la mise a la terre procure un chemin de faible
r6sistance au courant qui autrement traverserait I'utilisateur.
Pour 6viter que I'utilisateur ne soit 61ectrocut6 en cas de
d6faillance, de bris ou de conductivit6 de Ibutil, celui-ci est dot6
d'une fiche a trois broches afin d'assurer la mise a la terre, fly a
risque d'61ectrocution, de blessures graves ou de mort Iorsqu'on
utilise un outil dont une broche est endommag6e ou absente ou
dont la fiche ou le cordon est endommag6 ou qui n'est pas
branch6 dans une prise conforme mise continuellement a la
terre. Pour 6viter les risques de blessures, Ibutil do# toujours
6tre bien entretenu et en bon 6tat de marche (cordon, broches
de la fiche) et doit 6tre branch6 dans une prise mise a la terre
continuellement. (Voir 6galement la rubrique ,, Nettoyage ,
dans la section Entretien, page 34.) S'applique uniquement
aux outils de classe I (mis ala terre).
Les outils adouble isolation sont pourvus d'une fiche
polarisee (une lame est plus large que I'autre). Cette fiche
ne peut #tre branchee clans une prise polarisee que clans
un seul sens. Si la fiche ne peut #tre branchee clans la
prise, inverser la fiche. Si on n'arrive pas a/a brancher, com-
muniquer avec un _lectricien qualifi_ afin qu'il installe une prise
polaris#e. Ne pas modifier la fiche. La double isolation _ #lim-
ine le besoin du systeme de rallonge d'alimentation a trois ills et
de bloc d'alimentation avec mbe a la terre. S'applique unique-
ment aux outils de classe II (a double isolation).
Eviter tout contact entre le corps et les elements mis ala
terre, comme les tuyaux, les radiateurs, les cuisinieres et
les refrigerateurs, afin de r_duire les risques de choc
_letrique.

Ne pas utiliser I'outil electrique clans des endroits mouilles,
ni /'exposer a/a p/uie; /'infiltration d'eau a/'int6rieur de/'outi/
augmente les risques de choc 61ectrique.
Ne pas utiliser le cordon de maniere abusive; on ne doit pas
transporter I'outil en le tenant par le cordon, ou utiliser ce demier
pour le d6brancher. On doit tenir le cordon a 1'6cartdes sources
de chaleur, de I'huile, des bords tranchants ou des pieces
mobiles. Remplacer imm6diatement les cordons endommag6s,
car ces derniers augmentent les risques de choc 61ectrique.
Lorsqu'on utilise un outil electrique a I'exterieur, on ne dolt
utiliser que des rallonges con_ues pour cet usage, comme
celles de type ,W-A,> ou ,W,>, afin de r6duire les risques de
choc 61ectrique.
Calibre minimal des cordons de rallonge
TensionLongueur totale du cordon en meters
120V De0&7 De7&15 De 15&30 De 30&45
Intensit6 (A)
Au Au Calibre moyen de fil
moins plus
12 16 14 12 Nonrecommand6
SC'CURIT¢' PERSONNELLE
Rester vigilant en tout temps et faire preuve de jugement
Iorsqu'on utilise un outil electrique; ne pas utiliser I'outil
Iorsqu'on est fatigue ou sous I'influence de drogues,
d'alcool ou de medicaments, car un moment d'inattention
pourrait entrainer des blessures graves.
Porter des v6tements appropries; ne pas porter de
v6tements amples ni de bijoux. Couvrir ou attacher les
cheveux longs. Garder les cheveux, les v_tements, les bijoux
et les gants 61oign6s des pieces mobiles, car ceux-ci peuvent
19
s'y coincer. Se tenir 61oign6 des 6vents puisque ces demiers
pourraient camoufler des pieces mobiles.
Eviter les demarrages accidentels; s'assurer que
I'interrupteur est en position d'arr6t avant de brancher
I'outil. Ne pas transporter I'outil en laissant le doigt sur
I'interrupteur nile brancher Iorsque I'interrupteur est en position
de marche, car cela pourrait causer un accident.
_Retirer les cles de reglage avant de demarrer I'outil; une cl6
laiss6e sur une piece rotative pourrait entrainer des blessures.
Ne pas trop etendre les bras; les pieds doivent rester ancr6s
fermement sur lesol afin de maintenir son 6quilibre en tout temps
et de mieux maitriser I'outil clans des situations impr6vues.
_1, Utiliser le materiel de securite approprie; toujours porter
des lunettes de protection. Porter un masque anti-poussiere,
des chaussures antid6rapantes, un casque de s6curit6 ou des
protecteurs auditifs Iorsque la situation le requiert.
UTILISATION ET ENTRETIEN DE L'OUTIL
_Fixer et soutenir le materiau sur une plate-forme stable au
moyen d'une bride de serrage ou de tout autre dispositif
semblable; le mat6riau est instable Iorsqu'on le retient
manuellement ou qu'on I'appuie contre le corps, ce qui pourrait
faire perdre la maitrise de I'outiL
Ne pas forcer I'outil ni I'utiliser pour des travaux autres que
ceux pour lesquels il a ete con_u. Pour obtenir de meilleurs
r6sultats etpr6venir les risques de blessure, laisser I'outil couper
la vitesse pour laquelle il a 6t6 congu.
_Ne pas utiliser I'outil Iorsque I'interrupteur marche-arr6t ne
fonctionne pas; tout outil qui ne peut 6tre command6 au
moyen de I'interrupteur est dangereux et doit 6tre r6par6.