DeWalt DWE4000-XE User manual

DWE4000-XE, DWE4001-XE
HEAVY-DUTY SMALL ANGLE GRINDER
INSTRUCTION MANUAL

1
Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal
word. Please read the manual and pay attention to these symbols.
DANGER: Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE: Indicates a practice not related to personal injury which, if
not avoided, may result in property damage.
IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US AT: 1800 338 002 (Aust) or 0800 339 258 (NZ).
Technical Data
DWE4000-XE DWE4001-XE
Voltage V 220–240 220–240
Power input W 720 800
No-load/rated speed min-1 12000 12000
Wheel diameter mm 100 100
Spindle diameter M10 M10
Weight kg 2.0* 2.0*
* weight includes side handle and guard
LPA (sound pressure) dB(A) 90.5 90.5
KPA (sound pressure uncertainty) dB(A) 3 3
LWA (sound power) dB(A) 101.3 101.3
KWA (sound power uncertainty) dB(A) 3 3
Vibration total values (triax vector sum) determined according to EN 60745:
Vibration emission value a
h
surface grinding
a
h.AG
= m/s² 9.3 9.3
Uncertainty K = m/s² 1.5 1.5
Vibration emission value a
h
disc sanding
a
h.DS
= m/s² 6.8 6.8
Uncertainty K = m/s² 1.5 1.5
Vibration emission value a
h
wire brushing
a
h.AG
= m/s² 9.9 9.9
Uncertainty K = m/s² 1.5 1.5
The vibration emission level given in this information sheet has been measured in
accordance with a standardised test given in EN 60745 and may be used to compare
one tool with another. It may be used for a preliminary assessment of exposure.
WARNING: The declared vibration emission level represents the main applications
of the tool. However if the tool is used for different applications, with different
accessories or poorly maintained, the vibration emission may differ. This may
significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account
the times when the tool is switched off or when it is running but not actually doing
the job. This may significantly reduce the exposure level over the total working
period.
Identify additional safety measures to protect the operator from the effects of
vibration such as: maintain the tool and the accessories, keep the hands warm,
organisation of work patterns.
SAFETY INSTRUCTIONS FOR POWER TOOLS
When using power tools, always observe the safety regulations applicable in your
country to reduce the risk of fire, electric shock and personal injury. Read the following
safety instructions before attempting to operate this product. Keep these instructions in
a safe place.

2
WARNING: To reduce the risk of injury, user must read the instruction manual.
GENERAL POWER TOOL SAFETY WARNINGS
WARNING! Read all safety warnings and all instructions Failure to follow
the warnings and instructions may result in electric shock, fire and/or serious
injury.
The term “power tool” in the warnings refers to your mains-operated (corded) power
tool or battery-operated (cordless) power tool.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR
FUTURE REFERENCE
1) WORK AREA SAFETY
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
c) Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
2) ELECTRICAL SAFETY
a) Power tool plugs must match the outlet. Never modify the plug in any
way. Do not use any adapter plugs with earthed (grounded) power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes,
radiators, ranges and refrigerators. There is an increased risk of electric
shock if your body is earthed or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or
unplugging the power tool. Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords increase the risk of electric
shock.
e) When operating a power tool outdoors, use an extension cord suitable
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is unavoidable, use a residual
current device (RCD) protected supply. Use of an RCD reduces the risk of
electric shock.
3) PERSONAL SAFETY
a) Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use a power tool while you are tired or
under the influence of drugs, alcohol or medication. A moment of inattention
while operating power tools may result in serious personal injury.
b) Use personal protective equipment. Always wear eye protection. Protective
equipment such as dust mask, non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch is in the off position
before connecting to power source and/or battery pack, picking up or
carrying the tool. Carrying power tools with your finger on the switch or
energising power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key left attached to a rotating part of the power tool may result in
personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewellery or
long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of dust
collection can reduce dust-related hazards.
4) POWER TOOL USE AND CARE
a) Do not force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and safer at the rate
for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and must
be repaired.

3
c) Disconnect the plug from the power source and/or the battery pack from
the power tool before making any adjustments, changing accessories,
or storing power tools. Such preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many
accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits, etc. in accordance with
these instructions, taking into account the working conditions and the work
to be performed. Use of the power tool for operations different from those
intended could result in a hazardous situation.
5) SERVICE
a) Have your power tool serviced by a qualified repair person using only
identical replacement parts. This will ensure that the safety of the power tool
is maintained.
Electrical Safety
The electric motor has been designed for one voltage range only. Always check that
the power supply corresponds to the voltage on the rating plate. 220–240 V AC
means your tool will operate on alternating current. Operation at a voltage outside this
range can cause loss of power and can result in overheating. All DEWALT tools are
factory tested; if this tool does not operate, check the power supply. Your DEWALT
tool is double insulated, therefore no earth wire is required.
• Young children and the infirm. This appliance is not intended for use by young
children or infirm persons without supervision.
– This appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
– Children should be supervised to ensure that they do not play with the appliance.
•Replacement of the supply cord. If the supply cord or plug is damaged, it must
be replaced by the manufacturer or an authorised DEWALT Service Centre in
order to avoid a hazard.
Extension Cords
CAUTION: Use only extension cords that are approved by the country’s Electrical
Authority. Before using extension cords, inspect them for loose or exposed wires,
damaged insulation and defective fittings. Replace the cord if necessary.
Safety Warnings Common for Grinding, Sanding, Wire Brushing,
or Abrasive Cutting-Off Operations:
a) This power tool is intended to function as a grinder, sander, wire brush, or cut-
off tool. Read all safety warnings, instructions, illustrations and specifications
provided with this power tool. Failure to follow all instructions listed below may
result in electric shock, fire and/or serious injury.
b) This power tool is not recommended for polishing. Operations for which the
power tool was not designed may create a hazard and cause personal injury.
c) Do not use accessories which are not specifically designed and recommended
by the tool manufacturer. Just because the accessory can be attached to your
power tool, it does not assure safe operation.
d) The rated speed of the accessory must be at least equal to the maximum
speed marked on the power tool. Accessories running faster than their rated
speed can break and fly apart.
e) The outside diameter and the thickness of your accessory must be within
the capacity rating of your power tool. Incorrectly sized accessories cannot be
adequately guarded or controlled.
f) The arbour size of wheels, flanges, backing pads or any other accessory must
properly fit the spindle of the power tool. Accessories with arbour holes that
do not match the mounting hardware of the power tool will run out of balance,
vibrate excessively and may cause loss of control.
g) Do not use a damaged accessory. Before each use, inspect the accessory
such as abrasive wheels for chips and cracks, backing pad for cracks, tear or
excess wear, wire brush for loose or cracked wires. If power tool or accessory
is dropped, inspect for damage or install an undamaged accessory. After
inspecting and installing an accessory, position yourself and bystanders away

4
q) Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate
accessories can result in injury.
r) Always use side handle. Tighten the handle securely. The side handle should
always be used to maintain control of the tool at all times.
STANDARD WHEEL DIMENSIONS
Wheel Type
Wheel dimensions
(diameter × thickness × bore diameter)
mm
Type 27
115 × 6 × 22.3
125 × 6 × 22.3
180 × 6 × 22.3
230 × 6 × 22.3
Type 11 125 × 50 × 22.3
150 × 50 × 22.3
Type 1 125 × 25 × 26
155 × 25 × 16
Further Safety Instructions for All Operations
KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad,
brush or any other accessory. Pinching or snagging causes rapid stalling of the
rotating accessory which in turn causes the uncontrolled power tool to be forced in
the direction opposite of the accessory’s rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of
the wheel that is entering into the pinch point can dig into the surface of the material
causing the wheel to climb out or kick out. The wheel may either jump toward or
away from the operator, depending on direction of the wheel’s movement at the point
of pinching. Abrasive wheels may also break under these conditions.
Kickback is the result of tool misuse and/or incorrect operating procedures or
conditions and can be avoided by taking proper precautions as given below:
from the plane of the rotating accessory and run the power tool at maximum
no-load speed for one minute. Damaged accessories will normally break apart
during this test time.
h) Wear personal protective equipment. Depending on application, use face
shield, safety goggles or safety glasses. As appropriate, wear dust mask,
hearing protectors, gloves and workshop apron capable of stopping small
abrasive or workpiece fragments. The eye protection must be capable of
stopping flying debris generated by various operations. The dust mask or
respirator must be capable of filtrating particles generated by your operation.
Prolonged exposure to high intensity noise may cause hearing loss.
i) Keep bystanders a safe distance away from work area. Anyone entering the
work area must wear personal protective equipment. Fragments of workpiece
or of a broken accessory may fly away and cause injury beyond immediate area
of operation.
j) Hold power tool by insulated gripping surfaces only, when performing an
operation where the cutting accessory may contact hidden wiring or its own
cord. Cutting accessory contacting a “live” wire may make exposed metal parts
of the power tool “live” and shock the operator.
k) Position the cord clear of the spinning accessory. If you lose control, the cord
may be cut or snagged and your hand or arm may be pulled into the spinning
accessory.
l) Never lay the power tool down until the accessory has come to a complete
stop. The spinning accessory may grab the surface and pull the power tool out
of your control.
m) Do not run the power tool while carrying it at your side. Accidental contact with
the spinning accessory could snag your clothing, pulling the accessory into your
body.
n) Regularly clean the power tool’s air vents. The motor’s fan will draw the dust
inside the housing and excessive accumulation of powdered metal may cause
electrical hazards.
o) Do not operate the power tool near flammable materials. Sparks could ignite
these materials.
p) Do not use accessories that require liquid coolants. Using water or other liquid
coolants may result in electrocution or shock.

5
a) Maintain a firm grip on the power tool and position your body and arm to
allow you to resist kickback forces. Always use auxiliary handle, if provided,
for maximum control over kickback or torque reaction during start up. The
operator can control torque reaction or kickback forces, if proper precautions are
taken.
b) Never place your hand near the rotating accessory. Accessory may kickback
over your hand.
c) Do not position your body in the area where power tool will move if kickback
occurs. Kickback will propel the tool in direction opposite to the wheel’s
movement at the point of snagging.
d) Use special care when working corners, sharp edges etc. Avoid bouncing and
snagging the accessory. Corners, sharp edges or bouncing have a tendency to
snag the rotating accessory and cause loss of control or kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such
blades create frequent kickback and loss of control.
Safety Warnings Specific for Grinding and Abrasive Cutting-Off
Operations
a) Use only wheel types that are recommended for your power tool and the
specific guard designed for the selected wheel. Wheels for which the power
tool was not designed cannot be adequately guarded and are unsafe.
b) The guard must be securely attached to the power tool and positioned for
maximum safety, so the least amount of wheel is exposed towards the
operator. The guard helps to protect operator from broken wheel fragments and
accidental contact with wheel.
c) Wheels must be used only for recommended applications. For example: do
not grind with the side of cut-off wheel. Abrasive cut-off wheels are intended
for peripheral grinding, side forces applied to these wheels may cause them to
shatter.
d) Always use undamaged wheel flanges that are of correct size and shape for
your selected wheel. Proper wheel flanges support the wheel thus reducing the
possibility of wheel breakage. Flanges for cut-off wheels may be different from
grinding wheel flanges.
e) Do not use worn down wheels from larger power tools. Wheel intended for
larger power tool is not suitable for the higher speed of a smaller tool and may
burst.
Additional Safety Warnings Specific for Abrasive Cutting-Off
Operations
a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt to
make an excessive depth of cut. Overstressing the wheel increases the loading
and susceptibility to twisting or binding of the wheel in the cut and the possibility
of kickback or wheel breakage.
b) Do not position your body in line with and behind the rotating wheel. When the
wheel, at the point of operations, is moving away from your body, the possible
kickback may propel the spinning wheel and the power tool directly at you.
c) When wheel is binding or when interrupting a cut for any reason, switch off
the power tool and hold the power tool motionless until the wheel comes to a
complete stop. Never attempt to remove the cut-off wheel from the cut while
the wheel is in motion otherwise kickback may occur. Investigate and take
corrective action to eliminate the cause of wheel binding.
d) Do not restart the cutting operation in the workpiece. Let the wheel reach full
speed and carefully re-enter the cut. The wheel may bind, walk up or kickback
if the power tool is restarted in the workpiece.
e) Support panels or any oversized workpiece to minimize the risk of wheel
pinching and kickback. Large workpieces tend to sag under their own weight.
Supports must be placed under the workpiece near the line of cut and near the
edge of the workpiece on both sides of the wheel.
f) Use extra caution when making a “pocket cut” into existing walls or other
blind areas. The protruding wheel may cut gas or water pipes, electrical wiring
or objects that can cause kickback.
Safety Warnings Specific for Sanding Operations
a) Do not use excessively oversized sanding disc paper. Follow manufacturer's
recommendations, when selecting sanding paper. Larger sanding paper
extending beyond the sanding pad presents a laceration hazard and may cause
snagging, tearing of the disc or kickback.
Safety Warnings Specific for Wire Brushing Operations
a) Be aware that wire bristles are thrown by the brush even during ordinary
operation. Do not overstress the wires by applying excessive load to the
brush. The wire bristles can easily penetrate light clothing and/or skin.

6
b) If the use of a guard is recommended for wire brushing, do not allow any
interference of the wire wheel or brush with the guard. Wire wheel or brush
may expand in diameter due to work and centrifugal forces.
Additional Specific Safety Warnings for Grinders
• Check that the grinding wheel backing flange has a yellow rubber ring (C)
installed, see Figure 1. Replace rubber ring if missing, damaged or worn. See
pages 8, 10–11 for details regarding proper accessory installation.
• Threaded mounting of accessories must match the grinder spindle thread. For
accessories mounted by flanges, the arbor hole of the accessory must fit the
locating diameter of the flange. Accessories that do not match the mounting
hardware of the power tool will run out of balance, vibrate excessively and may
cause loss of control.
• The grinding surface of the centre depressed wheels must be mounted below the
plane of the guard lip. An improperly mounted wheel that projects through the
plane of the guard lip cannot be adequately protected.
WARNING: The grinding wheel or accessory may loosen during coast-down of
the tool when shut off if rubber ring is missing or damaged. If grinding wheel or
accessory loosens, it may dismount from the machine and may cause serious
personal injury.
• Do not use circular saw blades or any other toothed blades with this tool.
Serious injury may result.
• Avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the
tool and inspect the wheel for cracks or flaws.
• Do not operate this tool for long periods of time. Vibration caused by the
operating action of this tool may cause permanent injury to fingers, hands, and
arms. Use gloves to provide extra cushion, take frequent rest periods, and limit
daily time of use.
• Direct the Dust Ejection System (DES) away from operator and coworkers.
Serious injury may result (Fig. 1, I).
WARNING: We recommend the use of a residual current device with a residual
current rating of 30mA or less.
WARNING: ALWAYS wear approved protective safety equipment complying with
the following standards:
• Eye protection: AS/NZS1337 Eye Protectors for Industrial Applications;
• Hearing protection: AS/NZS1270 Acoustics – Hearing Protection;
• Respiratory protection: AS/NZS1716 Respiratory Protective Devices.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to cause cancer, birth defects
or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of
work. To reduce your exposure to these chemicals: work in a well ventilated area, and
work with approved safety equipment, such as those dust masks that are specially
designed to filter out microscopic particles.
• Avoid prolonged contact with dust from power sanding, sawing, grinding,
drilling, and other construction activities. Wear protective clothing and wash
exposed areas with soap and water. Allowing dust to get into your mouth, eyes,
or lay on the skin may promote absorption of harmful chemicals.
WARNING: Use of this tool can generate and/or disburse dust, which may cause
serious and permanent respiratory or other injury. Always use AS/NZS1716 approved
respiratory protection appropriate for the dust exposure. Direct particles away from
face and body.
WARNING: Always wear proper personal hearing protection that conforms to
AS/NZS1270 during use. Under some conditions and duration of use, noise from this
product may contribute to hearing loss.
• The label on your tool may include the following symbols. The symbols and their
definitions are as follows:
V......................volts A.........................amperes
Hz ....................hertz W........................watts
min ..................minutes or AC ............alternating current
or DC.....direct current or AC/DC......alternating or
...................Class I Construction direct current
(grounded) no .......................no load speed
...................Class II Construction n .........................rated speed
(double insulated) .......................earthing terminal

7
…/min .............per minute .......................safety alert symbol
BPM.................beats per minute IPM .....................impacts per minute
RPM.................revolutions per minute SPM....................strokes per minute
sfpm ................surface feet per minute
SAVE ALL WARNINGS AND INSTRUCTIONS FOR
FUTURE REFERENCE
COMPONENTS (Fig. 1)
WARNING: Never modify the power tool or any part of it. Damage or personal
injury could result.
A. Spindle lock button E. Threaded clamp nut
B. Spindle F. Guard
C. Side handle G. On/Off switch
D. Backing flange H. Guard release lever (Fig. 2)
INTENDED USE
The DWE4000-XE and DWE4001-XE are heavy-duty small angle grinders and have
been designed for professional grinding and cutting applications.
DO NOT use grinding wheels other than center depressed wheels and flap-disk.
DO NOT use under wet conditions or in presence of flammable liquids or gases.
This small angle grinder is a professional power tool. DO NOT let children come into
contact with the tool. Supervision is required when inexperienced operators use this
tool.
ASSEMBLY AND ADJUSTMENTS
WARNING: To reduce the risk of serious personal injury, turn off and unplug the
tool before making any adjustments or removing or installing attachments or
accessories. Before reconnecting the tool, depress and release the paddle switch to
ensure that the tool is off. An accidental start-up can cause injury.
FIG. 1
E
D
A
CH
BF
C
G

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Attaching Side Handle (Fig. 1)
WARNING: Before using the tool, check that the handle is tightened securely.
Screw the side handle (C) tightly into one of the holes on either side of the gear case.
The side handle should always be used to maintain control of the tool at all times.
Accessories and Attachments
It is important to choose the correct guards, backing pads and flanges to use with
grinder accessories. Refer to chart on pages 8 and 9 for information on choosing the
correct accessories.
NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and
specified for this purpose.
WARNING: Accessories must be rated for at least the speed recommended on the
tool warning label. Wheels and other accessories running over rated accessory speed
may burst and cause injury. Threaded accessories must have an M10 hub. Every
unthreaded accessory must have a 16 mm arbor hole.
If it does not, it may have been designed for a circular saw and should not be used.
Use only the accessories shown in chart on pages 8 and 9. Accessory ratings must
be above listed minimum wheel speed as shown on tool nameplate.
Mounting Guards
CAUTION: Guards must be used with this grinder.
NOTE: Please refer to the Grinding and Cutting Accessory Chart on pages 8 and 9 to
see other accessories that can be used with these grinders.
MOUNTING AND REMOVING (TYPE 27) ONE-TOUCH GUARD (FIG. 2)
NOTE: If your grinder is supplied with a keyless One-Touch guard, ensure the screw
and spring are fitted correctly before mounting the guard
1. Press the guard release lever (H).
2. While holding the guard release lever open, align the lugs (I) on the guard (F) with
the slots on the gear case (J).
3. Keeping the guard release lever open, push the guard down until the guard engages
the lugs and rotate them in the groove on the gear case hub. Release the guard
release lever.
115 mm and 125 mm (4-1/2" and 5") Sanding Flap Discs
Quick-change
backing flange
Non-hubbed sanding flap
disc
Threaded clamp nut
Type 27 guard
Hubbed sanding flap
disc
Type 27 guard