DeWalt DWE4204 User manual

DWE4202
DWE4203
DWE4204
DWE4205
DWE4206
DWE4207
DWE4213
DWE4214
DWE4215
DWE4216
DWE4217

B
English (original instructions) 3
Copyright DEWALT

1
Figure 1
Figure 2 Figure 3
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c
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j
b
DWE4202, DWE4203, DWE4213
DWE4204, DWE4205, DWE4206, DWE4207, DWE4214,
DWE4215, DWE4216, DWE4217
ed

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d
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q
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Figure 7
Figure 4
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d
p
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Figure 5A
Figure 5B
a
b
b
Figure 6

3
ENGLISH
SMALL ANGLE GRINDERS
DWE4202, DWE4203, DWE4204, DWE4205, DWE4206, DWE4207,
DWE4213, DWE4214, DWE4215, DWE4216, DWE4217
Congratulations!
You have chosen a DEWALT tool. Years of experience, thorough product development and innovation make
DEWALT one of the most reliable partners for professional power toolusers.
Technical Data
DWE4202
QS/GB/LX
DWE4203
QS
DWE4204
QS/GB/LX
DWE4205
QS
DWE4206
QS/GB/LX
DWE4207
QS
Voltage VAC 230/230/115 230 230/230/115 230 230/230/115 230
Type 111111
Power input W 1010 1010 1010 1010 1010 1010
No-load/rated speed min-1 11,000 11,000 11,000 11,000 11,000 11,000
Wheel diameter mm 115 125 115 125 115 125
Wheel thickness (max) mm 6.0 6.0 6.0 6.0 6.0 6.0
Spindle diameter M14 M14 M14 M14 M14 M14
Spindle length mm 18.5 18.5 18.5 18.5 18.5 18.5
Weight
* weight includes side handle and guard
kg 1.85 1.85 1.85 1.85 1.85 1.85
Noise and vibration total values (triax vector sum) according to EN 60745-2-3:
L
PA (sound pressure) dB(A)
92.0 92.0 92.0 92.0 92.0 92.0
L
WA (sound power) dB(A)
103.0 103.0 103.0 103.0 103.0 103.0
KWA (uncertainty for the given sound
level)
dB(A) 333333
Vibration emission value a
h
surface grinding
a
h,AG
= m/s² 8.3 8.3 8.3 8.3 8.3 8.3
Uncertainty K = m/s² 1.5 1.5 1.5 1.5 1.5 1.5
Vibration emission value a
h
disc sanding
a
h,DS
= m/s² <2.5 <2.5 <2.5 <2.5 <2.5 <2.5
Uncertainty K = m/s² 1.5 1.5 1.5 1.5 1.5 1.5
CAUTION: Working with the wire brush or the abrasive cutting can lead to different
vibration levels!

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DWE4213
XE
DWE4214
QS/XE
DWE4215
QS/XE
DWE4216
QS
DWE4217
QS
Voltage VAC 230 230 230 230 230
Type 11111
Power input W 1200 1200 1200 1200 1200
No-load/rated speed min-1 11,500 11,000 (QS)
11,500 (XE)
11,000 (QS)
11,500 (XE)
11,000 11,000
Wheel diameter mm 125 115 125 115 125
Wheel thickness (max) mm 6.0 6.0 6.0 6.0 6.0
Spindle diameter M14 M14 M14 M14 M14
Spindle length mm 18.5 18.5 18.5 18.5 18.5
Weight
* weight includes side handle and guard
kg 1.85 1.85 1.85 1.85 1.85
Noise and vibration total values (triax vector sum) according to EN 60745-2-3:
L
PA (sound pressure) dB(A)
92.0 92.0 92.0 92.0 92.0
L
WA (sound power) dB(A)
103.0 103.0 103.0 103.0 103.0
KWA (uncertainty for the given sound level) dB(A) 33333
Vibration emission value a
h
surface grinding
a
h,AG
= m/s² 8.3 8.3 8.3 8.3 8.3
Uncertainty K = m/s² 1.5 1.5 1.5 1.5 1.5
Vibration emission value a
h
disc sanding
a
h,DS
= m/s² <2.5 <2.5 <2.5 <2.5 <2.5
Uncertainty K = m/s² 1.5 1.5 1.5 1.5 1.5
Identify additional safety measures to
protect the operator from the effects of
vibration such as: maintain the tool and
the accessories, keep the hands warm,
organisation of workpatterns.
Fuses
Europe 230 V tools 10 Amperes, mains
U.K. & Ireland 230 V tools 13 Amperes, in plugs
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: Working with the wire brush
or the abrasive cutting can lead to
different vibration levels!
The vibration emission level given in this information
sheet has been measured in accordance with a
standardised test given in 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.

5
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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.
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.
CAUTION: Indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderateinjury.
NOTICE: Indicates a practice not
related to personal injury which, if
not avoided, may result in property
damage.
Denotes risk of electricshock.
Denotes risk offire.
EC-Declaration of Conformity
MACHINERY DIRECTIVE
SMALL ANGLE GRINDERS
DWE4202, DWE4203, DWE4204, DWE4205, DWE4206,
DWE4207, DWE4213, DWE4214, DWE4215, DWE4216,
DWE4217
DEWALT declares that these products described
under Technical Data are in compliance with:
2006/42/EC, EN 60745-1, EN 60745-2-3.
These products also comply with Directive
2004/108/EC and 2011/65/EU. For more
information, please contact DEWALT at the following
address or refer to the back of themanual.
The undersigned is responsible for compilation of the
technical file and makes this declaration on behalf
ofDEWALT.
Horst Grossmann
Vice President Engineering
DEWALT, Richard-Klinger-Strasse 11,
D-65510, Idstein, Germany
31.12.2014
WARNING: 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.

6
ENGLISH
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.
ADDITIONAL SPECIFIC SAFETY RULES
Safety Instructions for All Operations
a) This power tool is intended to function
as a grinder, sander, wire brush or cut-off
tool. Read all safety warnings, instructions,
illustrations and specifications provided with
this power tool. Failure to follow all instructions
listed below may result in electric shock, fire
and/or seriousinjury.
b) Operations such as polishing are not
recommended to be performed with this
power tool. Operations for which the power
tool was not designed may create a hazard and
cause personalinjury.
c) Do not use accessories which are not
specifically designed and recommended
by the tool manufacturer. Just because the
accessory can be attached to your power tool,
it does not assure safeoperation.
d) The rated speed of the accessory must be at
least equal to the maximum speed marked
on the power tool. Accessories running faster
than their rated speed can break and flyapart.
e) The outside diameter and the thickness of
your accessory must be within the capacity
rating of your power tool. Incorrectly sized
accessories can not be adequately guarded
orcontrolled.
f) Threaded mounting of accessories must
match the grinder spindle thread. For
accessories mounted by flanges, the arbour
hole of the accessory must fit the locating
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.
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

7
ENGLISH
n) Regularly clean the power tool’s air vents.
The motor’s fan will draw the dust inside
the housing and excessive accumulation of
powdered metal may cause electricalhazards.
o) Do not operate the power tool near
flammable materials. Sparks could ignite
thesematerials.
p) Do not use accessories that require liquid
coolants. Using water or other liquid coolants
may result in electrocution orshock.
q) Do not use Type 11 (flaring cup) wheels on
this tool. Using inappropriate accessories can
result ininjury.
r) Always use side handle. Tighten the handle
securely.The side handle should always be
used to maintain control of the tool at alltimes.
FURTHER SAFETY INSTRUCTIONS
FOR ALL OPERATIONS
Causes and Operator Prevention
of Kickback
Kickback is a sudden reaction to a pinched or
snagged rotating wheel, backing pad, brush or
any other accessory. Pinching or snagging causes
rapid stalling of the rotating accessory which in turn
causes the uncontrolled power tool to be forced in
the direction opposite of the accessory’s rotation at
the point of thebinding.
For example, if an abrasive wheel is snagged or
pinched by the workpiece, the edge of the wheel
that is entering into the pinch point can dig into
the surface of the material causing the wheel to
climb out or kick out. The wheel may either jump
toward or away from the operator, depending on
direction of the wheel’s movement at the point of
pinching. Abrasive wheels may also break under
theseconditions.
Kickback is the result of tool misuse and/or incorrect
operating procedures or conditions and can be
avoided by taking proper precautions as given
below:
a) Maintain a firm grip on the power tool and
position your body and arm to allow you to
resist kickback forces. Always use auxiliary
handle, if provided, for maximum control
over kickback or torque reaction during start
up. The operator can control torque reaction or
kickback forces, if proper precautions aretaken.
b) Never place your hand near the rotating
accessory. Accessory may kickback over
yourhand.
diameter of the flange. Accessories that do
not match the mounting hardware of the power
tool will run out of balance, vibrate excessively
and may cause loss ofcontrol.
g) Do not use a damaged accessory. Before
each use inspect the accessory such as
abrasive wheel for chips and cracks, backing
pad for cracks, tear or excess wear, wire
brush for loose or cracked wires. If power
tool or accessory is dropped, inspect for
damage or install an undamaged accessory.
After inspecting and installing an accessory,
position yourself and bystanders away from
the plane of the rotating accessory and run
the power tool at maximum no-load speed
for one minute. Damaged accessories will
normally break apart during this testtime.
h) Wear personal protective equipment.
Depending on application, use face
shield, safety goggles or safety glasses.
As appropriate, wear dust mask, hearing
protectors, gloves and workshop apron
capable of stopping small abrasive or
workpiece fragments. The eye protection must
be capable of stopping flying debris generated
by various operations. The dust mask or
respirator must be capable of filtrating particles
generated by your operation. Prolonged
exposure to high intensity noise may cause
hearingloss.
i) Keep bystanders a safe distance away from
work area. Anyone entering the work area
must wear personal protective equipment.
Fragments of workpiece or of a broken
accessory may fly away and cause injury
beyond immediate area ofoperation.
j) Hold the power tool by insulated gripping
surfaces only, when performing an operation
where the cutting accessory may contact
hidden wiring or its own cord. Cutting
accessory contacting a "live" wire may make
exposed metal parts of the power tool "live" and
could give the operator an electricalshock.
k) Position the cord clear of the spinning
accessory. If you lose control, the cord may be
cut or snagged and your hand or arm may be
pulled into the spinningaccessory.
l) Never lay the power tool down until the
accessory has come to a complete stop. The
spinning accessory may grab the surface and
pull the power tool out of yourcontrol.
m) Do not run the power tool while carrying it at
your side. Accidental contact with the spinning
accessory could snag your clothing, pulling the
accessory into yourbody.

8
ENGLISH
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.
c) Do not position your body in the area where
power tool will move if kickback occurs.
Kickback will propel the tool in direction
opposite to the wheel’s movement at the point
ofsnagging.
d) Use special care when working corners,
sharp edges etc. Avoid bouncing and
snagging the accessory. Corners, sharp
edges or bouncing have a tendency to snag
the rotating accessory and cause loss of control
orkickback.
e) Do not attach a saw chain woodcarving
blade or toothed saw blade. Such blades
create frequent kickback and loss ofcontrol.
Safety Warnings Specific for
Grinding and Abrasive Cutting-Off
Operations
a) Use only wheel types that are recommended
for your power tool and the specific guard
designed for the selected wheel. Wheels for
which the power tool was not designed cannot
be adequately guarded and areunsafe.
b) The grinding surface of centre depressed
wheels must be mounted below the plane
of the guard lip. An improperly mounted wheel
that projects through the plane of the guard lip
cannot be adequatelyprotected.
c) The guard must be securely attached
to the power tool and positioned for
maximum safety, so the least amount of
wheel is exposed towards the operator. The
guard helps to protect the operator from broken
wheel fragments, accidental contact with wheel
and sparks that could igniteclothing.
d) Wheels must be used only for recommended
applications. For example: do not grind with
the side of cut-off wheel. Abrasive cut-off
wheels are intended for peripheral grinding, side
forces applied to these wheels may cause them
toshatter.
e) Always use undamaged wheel flanges
that are of correct size and shape for your
selected wheel. Proper wheel flanges support
the wheel thus reducing the possibility of wheel
breakage. Flanges for cut-off wheels may be
different from grinding wheelflanges.
f) Do not use worn down wheels from larger
power tools. Wheel intended for larger power
tool is not suitable for the higher speed of a
smaller tool and mayburst.

9
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Wear eyeprotection.
DATE CODE POSITION
The date code, which also includes the year of
manufacture, is printed into thehousing.
Example:
2014 XX XX
Year of Manufacture
Package Contents
The package contains:
1 Angle grinder
1 Guard
1 Side handle
1 Flange set
1 Hex key
1 Instruction manual
• Check for damage to the tool, parts or
accessories which may have occurred
duringtransport.
• Take the time to thoroughly read and
understand this manual prior tooperation.
Description (fig. 1, 3)
WARNING: Never modify the power
tool or any part of it. Damage or
personal injury couldresult.
a. Spindle lock button
b. Spindle
c. Side handle
d. Backing flange
e. Threaded locking flange
f. Guard
g. Slider switch (DWE4204, DWE4205, DWE4206,
DWE4207, DWE4214, DWE4215, DWE4216,
DWE4217)
h. Paddle switch (DWE4202, DWE4203,
DWE4213)
i. Lock-off lever (DWE4202, DWE4203,
DWE4213)
j. Guard release lever
k. Dust ejection system
Safety Warnings Specific for Wire
Brushing Operations
a) Be aware that wire bristles are thrown by
the brush even during ordinary operation.
Do not overstress the wires by applying
excessive load to the brush. The wire bristles
can easily penetrate llight clothing and/orskin.
b) If the use of a guard is recommended for
wire brushing, do not allow any interference
of the wire wheel or brush with the guard.
Wire wheel or brush may expand in diameter
due to work and centrifugalforces.
Additional Safety Rules for Grinders
• Threaded mounting of accessories must match
the grinder spindle thread. For accessories
mounted by flanges, the arbor hole of the
accessory must fit the locating diameter of
the flange. Accessories that do not match the
mounting hardware of the power tool will run
out of balance, vibrate excessively and may
cause loss ofcontrol.
• The grinding surface of the centre depressed
wheels must be mounted below the plane of
the guard lip. An improperly mounted wheel
that projects through the plane of the guard lip
cannot be adequatelyprotected.
WARNING: We recommend the use of
a residual current device with a residual
current rating of 30mA or less.
Residual Risks
In spite of the application of the relevant safety
regulations and the implementation of safety
devices, certain residual risks cannot be avoided.
These are:
– Impairment ofhearing.
– Risk of personal injury due to flyingparticles.
– Risk of burns due to accessories becoming hot
duringoperation.
– Risk of personal injury due to prolongeduse.
– Risk of dust from hazardoussubstances.
Markings on Tool
The following pictograms are shown on the tool:
Read instruction manual beforeuse.
Wear earprotection.

10
ENGLISH
Your DEWALT tool is double insulated in
accordance with EN 60745; therefore no
earth wire isrequired.
If the supply cord is damaged, it must be replaced
by a specially prepared cord available through the
DEWALT serviceorganisation.
Mains Plug Replacement
(U.K. & Ireland Only)
If a new mains plug needs to be fitted:
• Safely dispose of the oldplug.
• Connect the brown lead to the live terminal in
theplug.
• Connect the blue lead to the neutralterminal.
WARNING: No connection is to be
made to the earthterminal.
Follow the fitting instructions supplied with good
quality plugs. Recommended fuse: 13A.
Using an Extension Cable
If an extension cable is required, use an approved
3–core extension cable suitable for the power input
of this tool (see Technical Data).The minimum
conductor size is 1.5 mm2; the maximum length
is 30m.
When using a cable reel, always unwind the
cablecompletely.
ASSEMBLY AND ADJUSTMENTS
WARNING: To reduce the risk
of serious personal injury, turn
tool off and disconnect tool from
power source before making any
adjustments or removing/installing
attachments or accessories. Before
reconnecting the tool, depress and
release the trigger switch to ensure that
the tool is off.
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.
NTENDED USE
The DWE4202, DWE4203, DWE4204, DWE4205,
DWE4206, DWE4207, DWE4213, DWE4214,
DWE4215, DWE4216 and DWE4217 heavy-
duty small angle grinders have been designed for
professional grinding, sanding, wire brushing and
cuttingapplications.
DO NOT use grinding wheels other than centre
depressed wheels and flapdiscs.
DO NOT use under wet conditions or in the
presence of flammable liquids orgases.
These heavy-duty angle grinders are professional
power tools.
DO NOT let children come into contact with the
tool. Supervision is required when inexperienced
operators use thistool.
• Young children and the infirm. This appliance
is not intended for use by young children or
infirm persons withoutsupervision.
• This product is not intended for use by persons
(including children) suffering from diminished
physical, sensory or mental abilities; lack of
experience, knowledge or skills unless they are
supervised by a person responsible for their
safety. Children should never be left alone with
thisproduct.
Anti-vibration Side Handle
The anti-vibration side handle offers added comfort
by absorbing the vibrations caused by thetool.
Dust Ejection System (fig. 1)
The dust ejection system (k) prevents dust pile-up
around the guard and motor inlet, and minimises the
amount of dust entering the motorhousing.
Soft Start Feature
DWE4206, DWE4207, DWE4216, DWE4217
The soft start feature allows a slow speed build-up
to avoid an initial jerk when starting. This feature is
particularly useful when working in confinedspaces.
No-Volt
DWE4206, DWE4207, DWE4216, DWE4217
The No-volt function stops the grinder restarting
without the switch being cycled if there is a break in
the powersupply.
Electrical Safety
The electric motor has been designed for one
voltage only. Always check that the power supply
corresponds to the voltage on the ratingplate.

11
ENGLISH
2. While holding the guard release lever open,
align the lugs(m) on the guard with the slots (n)
on the gearcase.
3. Keeping the guard release lever open, push the
guard down until the lugs engage then rotate
them into the groove on the gear case hub.
Release the guard releaselever.
4. With the spindle facing the operator, rotate
the guard clockwise into the desired working
position. The guard body should be positioned
between the spindle and the operator to
provide maximum operatorprotection.
5. For easy adjustment, the guard can be rotated
in the clockwise direction. The guards design
allows the guard to be rotated and adjusted
by turning the guard in a clockwise, single
action motion. The lever does not need to
be depressed to turn the guard. The lever is
only used for removal of the guard. The guard
can be repositioned the opposite direction by
depressing the guard release lever. NOTE: The
guard release lever should snap into one of the
alignment holes(o) on the guard collar. This
ensures that the guard is secure.
6. To remove the guard, follow steps 1–3 of these
instructions inreverse.
Fitting and Removing a Grinding or
Cutting Disc (fig. 1, 4, 5)
WARNING: Do not use a
damageddisc.
1. Place the tool on a table, guardup.
2. Fit the backing flange(d) correctly onto the
spindle(b) (fig. 4).
3. Place the disc(p) on the backing flange(d).
When fitting a disc with a raised centre, make
sure that the raised centre(q) is facing the
backing flange(d).
4. Screw the threaded locking flange(e) onto the
spindle(b) (fig. 5):
a. The ring on the threaded locking flange(e)
must face towards the disc when fitting a
grinding disc (fig. 5A);
b. The ring on the threaded locking flange(e)
must face away from the disc when fitting a
cutting disc (fig. 5B).
5. Press the spindle lock button(a) and rotate the
spindle(b) until it locks inposition.
6. Tighten the threaded locking flange(e) with the
hex key (s) provided or a two pinspanner.
7. Release the spindlelock.
Accessories and Attachments
It is important to choose the correct guards, backing
pads and flanges to use with grinder accessories.
Refer to chart at the end of this section for
information on choosing the correctaccessories.
NOTE: Edge grinding 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 a M14 hub. Every unthreaded
accessory must have a 22 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 the chart at the end of this
section. Accessory ratings must be
above listed minimum wheel speed as
shown on toolnameplate.
Mounting Guards
WARNING: To reduce the risk
of serious personal injury, turn
tool off and disconnect tool from
power source before making any
adjustments or removing/installing
attachments or accessories. Before
reconnecting the tool, depress and
release the trigger switch to ensure that
the tool is off.
CAUTION: Guards must be used with
this grinder.
When using the DWE4202, DWE4203, DWE4204,
DWE4205, DWE4206, DWE4207, DWE4213,
DWE4214, DWE4215, DWE4216 or the DWE4217
grinder for cutting metal or masonry, a Type 1 guard
MUST be used. Type1 guards are available at extra
cost from DEWALTdistributors.
NOTE: Please refer to the Grinding and Cutting
Accessory Chart at the end of this section to
see other accessories that can be used with
thesegrinders.
MOUNTING AND REMOVING ONE-TOUCH GUARD (FIG. 2)
NOTE: If your grinder is supplied with a keyless
One-Touch guard, ensure the screw, lever, and
spring are fitted correctly before mounting theguard.
1. Press the guard release lever(j).

12
ENGLISH
7. Release the spindlelock.
8. To remove the rubber backing pad, loosen the
threaded clamp nut(r) with the hex key provided
or a two pin spanner.
Fitting a Wire Cup Brush
Screw the wire cup brush directly onto the spindle
without the use of the spacer and threadedflange.
Prior to Operation
• Install the guard and appropriate disc or wheel.
Do not use excessively worn discs orwheels.
• Be sure the inner and outer flange are mounted
correctly. Follow the instructions given in the
Grinding and Cutting AccessoryChart.
• Make sure the disc or wheel rotates in the
direction of the arrows on the accessory and
thetool.
• Do not use a damaged accessory. Before each
use inspect the accessory such as abrasive
wheels for chips and cracks, backing pad
for cracks, tear or excess wear, wire brush
for loose or cracked wires. If power tool or
accessory is dropped, inspect for damage
or install an undamaged accessory. After
inspecting and installing an accessory, position
yourself and bystanders away from the plane of
the rotating accessory and run the power tool
at maximum no-load speed for one minute.
Damaged accessories will normally break apart
during this testtime.
OPERATION
Instructions for Use
WARNING: Always observe the safety
instructions and applicableregulations.
WARNING: To reduce the risk
of serious personal injury, turn
tool off and disconnect tool from
power source before making any
adjustments or removing/installing
attachments or accessories. Before
reconnecting the tool, depress and
release the trigger switch to ensure that
the tool isoff.
WARNING:
• Ensure all materials to be ground or
cut are secured inplace.
• Secure and support the workpiece.
Use clamps or a vice to hold and
support the workpiece to a stable
platform. It is important to clamp and
8. To remove the disc, loosen the threaded locking
flange(e) with the hex key (s) provided or a two
pinspanner.
NOTE: Edge grinding can be performed with
Type27 wheels designed and specified for this
purpose; 6 mm thick wheels are designed for
surface grinding while 3 mm wheels are designed for
edge grinding. Cutting can be performed by using a
cutting wheel and a Type 1guard.
Mounting Wire Brushes
andWire Wheels
Wire cup brushes or wire wheels screw directly
on the grinder spindle without the use of flanges.
Use only wire brushes or wheels provided with a
M14threaded hub. A Type 27 guard is required
when using wire brushes andwheels.
CAUTION: Wear work gloves when
handling wire brushes and wheels.
They can becomesharp.
CAUTION: Wheel or brush must not
touch guard when mounted or while
in use. Undetectable damage could
occur to the accessory, causing wires to
fragment from accessory wheel orcup.
1. Thread the wheel on the spindle byhand.
2. Depress spindle lock button and use a wrench
on the hub of the wire wheel or brush to tighten
thewheel.
3. To remove the wheel, reverse the
aboveprocedure.
NOTICE: Failure to properly seat the
wheel hub before turning the tool on
may result in damage to tool orwheel.
Fitting and Removing a
Backing Pad/Sanding Sheet (fig. 1, 6)
1. Place the tool on a table or flat surface, with the
guard facingup.
2. Remove the backing flange(d).
3. Place the rubber backing pad correctly onto the
spindle(b).
4. Place the sanding sheet on the rubber
backingpad.
5. While depressing spindle lock (a), thread clamp
nut (r) on spindle, piloting the raised hub on the
clamp nut into the centre of sanding disc and
backingpad.
6. Tighten the threaded clamp nut(r) with the hex
key provided or a two pinspanner.

13
ENGLISH
Proper hand position requires one hand on the side
handle(c), with the other hand on the body of the
tool, as shown in Figure7.
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.
SLIDER SWITCH (FIG. 3)
(DWE4204, DWE4205, DWE4206, DWE4207, DWE4214,
DWE4215, DWE4216, DWE4217)
WARNING: Before connecting the tool
to a power supply, be sure the slider
switch is in the off position by pressing
the rear part of the switch and releasing.
Ensure the slider switch is in the off
position as described above after any
interruption in power supply to the tool,
such as the activation of a ground fault
interrupter, throwing of a circuit breaker,
accidental unplugging, or power failure.
If the slider switch is locked on when
the power is connected, the tool will
startunexpectedly.
To start the tool, slide the ON/OFF slider switch(g)
toward the front of the tool. To stop the tool, release
the ON/OFF sliderswitch.
For continuous operation, slide the switch toward
the front of the tool and press the forward part of
the switch inward. To stop the tool while operating
in continuous mode, press the rear part of the slider
switch andrelease.
PADDLE SWITCH (FIG. 1) (DWE4202, DWE4203, DWE4213)
1. To turn the tool on, push the lock-off lever(i)
toward the back of the tool, then depress the
paddle switch(h). The tool will run while the
switch isdepressed.
2. Turn the tool off by releasing the paddleswitch.
support the workpiece securely to
prevent movement of the workpiece
and loss of control. Movement of
the workpiece or loss of control
may create a hazard and cause
personalinjury.
•Support panels or any oversized
workpiece to minimize the risk
of wheel pinching and kickback.
Large workpieces tend to sag under
their own weight. Supports must be
placed under the workpiece near the
line of cut and near the edge of the
workpiece on both sides of thewheel.
• Always wear regular working gloves
while operating thistool.
• The gear becomes very hot
duringuse.
• Apply only a gentle pressure to the
tool. Do not exert side pressure on
thedisc.
• Always install the guard and
appropriate disc or wheel. Do not use
excessively worn disc or wheel.
• Be sure the inner and outer flange are
mountedcorrectly.
• Make sure the disc or wheel rotates
in the direction of the arrows on the
accessory and thetool.
• Avoid overloading. Should the tool
become hot, let it run a few minutes
under no load condition to cool the
accessory. Do not touch accessories
before they have cooled. The discs
become very hot duringuse.
• Never work with the grinding cup
without a suitable protection guard
inplace.
• Do not use the power tool with a cut-
offstand.
• Never use blotters together with
bonded abrasiveproducts.
• Be aware, the wheel continues to
rotate after the tools is switchedoff.
Proper Hand Position (fig. 7)
WARNING: To reduce the risk of
serious personal injury, ALWAYS use
proper hand position asshown.
WARNING: To reduce the risk of
serious personal injury, ALWAYS
hold securely in anticipation of a
suddenreaction.

14
ENGLISH
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. Position yourself so that the open-underside of
the wheel is facing away fromyou.
4. Once a cut is begun and a notch is established
in the workpiece, do not change the angle of
the cut. Changing the angle will cause the wheel
to bend and may cause wheel breakage. Edge
grinding wheels are not designed to withstand
side pressures caused bybending.
5. Remove the tool from the work surface before
turning the tool off. Allow the tool to stop
rotating before laying itdown.
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 serious personal
injury mayresult.
Mounting and Using Wire Brushes
and Wire Wheels
Wire wheels and brushes can be used for
removing rust, scale and paint, and for smoothing
irregularsurfaces.
NOTE: Please refer to Precautions To Take When
Wire BrushingPaint.
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.
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
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.
Spindle Lock (fig. 1)
The spindle lock(a) is provided to prevent the
spindle from rotating when installing or removing
wheels. Operate the spindle lock only when the tool
is turned off, unplugged from the power supply, and
has come to a completestop.
NOTICE: To reduce the risk of damage
to the tool, do not engage the spindle
lock while the tool is operating. Damage
to the tool will result and attached
accessory may spin off possibly
resulting ininjury.
To engage the lock, depress the spindle lock button
and rotate the spindle until you are unable to rotate
the spindlefurther.
Using Depressed Centre Grinding
Wheels
SURFACE GRINDING WITH GRINDING WHEELS
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 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.
EDGE GRINDING WITH GRINDING WHEELS
WARNING: Wheels used for cutting
and edge grinding may break or
kickback 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 13 mm [1/2"] in depth). The open
side of the guard must be positioned
away from the operator. For deeper
cutting with a cut-off wheel, use a
closed Type 1 guard. Please refer to
the Grinding and Cutting Accessory
Chart at the end of this section to see
other accessories that can be used with
thesegrinders.

15
ENGLISH
3. NO EATING, DRINKING or SMOKING should
be done in the work area to prevent ingesting
contaminated paint particles. Workers should
wash and clean up BEFORE eating, drinking
or smoking. Articles of food, drink, or smoking
should not be left in the work area where dust
would settle onthem.
ENVIRONMENTAL SAFETY
1. Paint should be removed in such a manner as
to minimize the amount of dustgenerated.
2. Areas where paint removal is occurring
should be sealed with plastic sheeting of 4
milsthickness.
3. Wire brushing should be done in a manner
to reduce tracking of paint dust outside the
workarea.
CLEANING AND DISPOSAL
1. All surfaces in the work area should be
vacuumed and thoroughly cleaned daily for the
duration of the wire brushing project. Vacuum
filter bags should be changedfrequently.
2. Plastic drop cloths should be gathered up and
disposed of along with any dust chips or other
removal debris. They should be placed in sealed
refuse receptacles and disposed of through
regular trash pick-upprocedures.
During clean up, children and pregnant women
should be kept away from the immediate
workarea.
3. All toys, washable furniture and utensils used by
children should be washed thoroughly before
being usedagain.
Metal Applications
When using the tool in metal applications, make
sure that a residual current device (RCD) has
been inserted to avoid residual risks caused by
metalswarf.
If the power supply is shut off by the RCD, take the
tool to an authorised DEWALT repairagent.
WARNING: In extreme working
conditions, conductive dust can
accumulate inside the machine housing
when working with metal. This can
result in the protective insulation in the
machine becoming degraded with a
potential risk of an electricalshock.
To avoid build-up of metal swarf inside the machine,
we recommend to clear the ventilation slots on a
daily basis. Refer toMaintenance.
CAUTION: Use extra care when
working over an edge, as a sudden
sharp movement of grinder may
beexperienced.
Using Cutting Wheels
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 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.
Precautions To Take When Wire
Brushing Paint
1. Wire brushing of lead based paint is NOT
RECOMMENDED due to the difficulty of
controlling the contaminated dust. The greatest
danger of lead poisoning is to children and
pregnantwomen.
2. Since it is difficult to identify whether or not a
paint contains lead without a chemical analysis,
we recommend the following precautions when
wire brushing any paint:
PERSONAL SAFETY
1. No children or pregnant women should enter
the work area where the paint removal is being
done until all clean up iscompleted.
2. A dust mask or respirator should be worn by all
persons entering the work area. The filter should
be replaced daily or whenever the wearer has
difficultybreathing.
NOTE: Only those dust masks suitable for
working with lead paint dust and fumes should
be used. Ordinary painting masks do not offer
this protection. See your local hardware dealer
for the proper respiratoryprotection.

16
ENGLISH
Cutting Metal
When cutting, work with moderate feed, adapted to
the material being cut. Do not exert pressure onto
the cutting disc, tilt or oscillate themachine.
Do not reduce the speed of running down cutting
discs by applying sidewardpressure.
The machine must always work in an upgrinding
motion. Otherwise, the danger exists of it being
pushed uncontrolled out of thecut.
When cutting profiles and square bar, it is best to
start at the smallest crosssection.
Rough Grinding
Never use a cutting disc forroughing.
Always use the guard type27.
The best roughing results are achieved when setting
the machine at an angle of 30° to 40°. Move the
machine back and forth with moderate pressure. In
this manner, the workpiece will not become too hot,
does not discolour and no grooves areformed.
Cutting Stone
The machine shall be used only for dry cutting.
For cutting stone, it is best to use a diamond
cutting disc. Operate the machine only with
additional dust protectionmask.
Working Advice
Exercise caution when cutting slots in
structural walls. Slots in structural walls are subject
to the country-specific regulations. These regulations
are to be observed under all circumstances. Before
beginning work, consult the responsible structural
engineer, architect or the constructionsupervisor.
Using Flap Discs
WARNING: Metal dust build-up.
Extensive use of flap discs in metal
applications can result in the increased
potential for electric shock. To reduce
this risk, insert an RCD before use
and clean the ventilation slots daily by
blowing dry compressed air into the
ventilation slots inaccordance with the
below maintenanceinstructions.
MAINTENANCE
Your DEWALT power tool has been designed to
operate over a long period of time with a minimum
of maintenance. Continuous satisfactory operation
depends upon proper tool care and regularcleaning.
WARNING: To reduce the risk
of serious personal injury, turn
tool off and disconnect tool from
power source before making any
adjustments or removing/installing
attachments or accessories. Before
reconnecting the tool, depress and
release the trigger switch to ensure that
the tool is off.
Pop-off Brushes
The motor will be automatically shut off indicating
that the carbon brushes are nearly worn out and
that the tool needs servicing. The carbon brushes
are not user-serviceable. Take the tool to an
authorised DEWALT repairagent.
Lubrication
Your power tool requires no additionallubrication.
Cleaning
WARNING: Blow dirt and dust out of
the main housing with dry air as often as
dirt is seen collecting in and around the
air vents. Wear approved eye protection
and approved dust mask when
performing this procedure.
WARNING: Never use solvents or
other harsh chemicals for cleaning the
non-metallic parts of the tool. These
chemicals may weaken the materials
used in these parts. Use a cloth
dampened only with water and mild
soap. Never let any liquid get inside the
tool; never immerse any part of the tool
into aliquid.

17
ENGLISH
Optional Accessories
WARNING: Since accessories, other
than those offered by DEWALT, have
not been tested with this product, use
of such accessories with this tool could
be hazardous. To reduce the risk of
injury, only DEWALT recommended
accessories should be used with
thisproduct.
Consult your dealer for further information on the
appropriateaccessories.
Max.
[mm]
[mm]
Min.
Rotation
[min.-1]
Periphical
speed
[m/s]
Threaded
hole length
[mm]
Db d
d
D
b
115 6 22,23 11.500 80 -
125 6
22,23 11.500 80 -
D115 - - 11.500 80 -
125 - - 11.500 80 -
D
d
b75 30 M14 11.500 45 20.0
D
115 12 M14 11.500 80 20.0
125 12 M14 11.500 80 20.0
Protecting the Environment
Separate collection. This product must
not be disposed of with normal
householdwaste.
Should you find one day that your DEWALT product
needs replacement, or if it is of no further use to you,
do not dispose of it with household waste. Make this
product available for separatecollection.
Separate collection of used products and
packaging allows materials to be
recycled and used again. Re-use of
recycled materials helps prevent
environmental pollution and reduces the
demand for raw materials.
Local regulations may provide for separate collection
of electrical products from the household, at
municipal waste sites or by the retailer when you
purchase a new product.
DEWALT provides a facility for the collection and
recycling of DEWALT products once they have
reached the end of their working life. To take
advantage of this service please return your product
to any authorised repair agent who will collect them
on our behalf.
You can check the location of your nearest
authorised repair agent by contacting your local
DEWALT office at the address indicated in this
manual. Alternatively, a list of authorised DEWALT
repair agents and full details of our after-sales
service and contacts are available on the Internet at:
www.2helpU.com.

18
ENGLISH
GRINDING AND CUTTING ACCESSORY CHART
Guard Type Accessory Description How to Fit Grinder
TYPE 27
GUARD
Depressed
centre grinding
disc
Type 27 guard
Backing flange
Type 27 depressed
centre wheel
Threaded clamp nut
Flap wheel
Wire wheels
Wire wheels
with threaded
nut
Type 27 guard
Wire wheel
Wire cup with
threaded nut
Type 27 guard
Wire brush
Backing pad/
sanding sheet
Type 27 guard
Rubber backing pad
Sanding disc
Threaded clamp nut