DeWalt DWE4557 User manual

ENGlISH
ANGlE GRINDERS DWE4557, DWE4559, DWE4579,
DWE4579R, DWE4597, DWE4599
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 DWE4557 DWE4597 DWE4559 DWE4579 DWE4599 DWE4579R
Voltage V'" 230 230 230 230 230 230
U.K. & Ireland only V'" 230/115 230/115 230/115 230/115 230/115 230/115
Type 1 1 1 1 1 1
Power input QS W 2400 2600 2400 2600 2600 2600
LX W2200 2200
No-Ioad/rated speed rnrr 8500 8500 6500 6500 6500 6500
Wheel diameter mm 180 180 230 230 230 230
Spindle diameter M14 M14 M14 M14 M14 M14
Spindle length mm 24.0 24.0 24.0 24.0 24.0 24.0
Weight kg 6.5 6.5 6.6 6.6 6.6 6.6
• weightincludessidehandleandguard
4A (sound pressure) dB(A) 97 96 97 96 96 96
K,A (sound pressure dB(A) 3 3 3 3 3 3
uncertainty)
LwA (sound power) dB(A) 108 107 108 107 107 107
<..vA
(sound pressure dB(A) 3 3 3 3 3 3
uncertainty)
lJibrationtotal values (triaxvector sum) delermined according lo EN 60745:
Vibralion emission value ah surface grinding •
ah,AG = mls
2
9.0 8.5 7.0
Uncertainty K = mls
2
1.5 1.5 1.5 7.0
1.5 4.5 1.5 7.0 1.5
Vibrationemissionvalue ah disc sanding
a
h.DS
= mls
2
2.5 2.5
Uncertainty K =' m/s
2
1.5 1.5 2.5
1.5
The vibration emission level given in this information
sheet has been measured in accordance with a
slandardised 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.
A WARNING: The dee/ared vibration
ill 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. Thismay significant/y increase the
exposure level over the total working
periodo
An estimation of the level of exposure to
vibration should a/so take into account
the times when the tool is switched off
or when it is running but not actual/y
doing thelobo Thismay significant/y
reduce the exposure level over the total
working periodo
. 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 pattems.
34
Fuses
ENGLlSH
Europe 230 V tools 10 Amperes, mains
Horst Grossmann
Vice President Engineering
DEWALT, Richard-Klinger-StraBe 11,
D-6551O, Idstein; Germany
30.07.2014
U.K. & Ireland 230V tools 13 Amperes, in plugs
J I\ WARNING: To reduce the risk of injU/y,
\:iiiI read the instruction manual.
Generai Power Tool Safety Warnings
A WARNING Read ali safety warnings
ill and ali instructions. Failure to fol/ow
the wamings and instructions may result
in eleetric shock, .fire and/or serious
injury
SAVE ALL WARNINGS AND INSTRUCTlONS
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 SAFm
a) Keep work area clean and welllit.
Cluttered or dark areas invite accidents.
b) Do not operate power too/s in explosive
atmospheres, such as in the presence of
flammable /iquids, gases or dust. Power
too/s create sparks which may ignite the dust
or fumes. .
c) Keep chHdren and bystanders away
while operating a power tool. Distractions
can cause you to lose control.
2) ELEGTRIGALSAFm
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 toots. Unmodified plugs
and matching outlets wil/reduce risk of
eleetric 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 apower tool will
increase the risk of eleetric shock.
d) Do not abuse tne cord. Never use the
cord for cerrvtnq, pulling or unplugging
the power tool. Keep cord away from
heat, oit, sharp edges or moving parts.
Damaged or entangled cords increase the
risk of electric shock.
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.
A DANGER: Indicates an imminent/y
ill hazardous situation which, if not avoided,
wi/l result in death or serious injury.
A WARNING: Indicates apotentially
ill hazardous situalion which, if not
avoided, could resuft in death or
serious injury.
A CAUTlON:. Indicales a potential/y
ill hazardous situation which, if noi
avoided, may result in minor or
moderate injury.
NOTlCE: Indicates apractice not
relafed fo personal injury which, if
not avoided, may result in property
damage.
& Denotes risk of electric shock.
& Denotes risk of fire.
EC-Declaration of Conformity
MAGHINERY DIREGTIVE
'35
CE
ANGLE GRINDERS
DWE4557, DWE4559, DWE4579, DWE4579R, DWE4597,
DWE4599
DEWALT deelares 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
2014/30/EU and 2011/65/EU. For more information,
please contact DEWALT at the following address or
refer to the back of the rnanual.
The undersigned is responsible for compilation of the
technical file and makes this declaration on behalf of
J/h~~

ENGlISH
e) When operating a power tool outdoors,
use an extension cord suitable for
outdoor use. Use of a cord suitable for
outdoor use reduces the risk of electric
shock.
& If operating apower tool in adamp
location is unavoidable, use a residual
current device (RCD) protected supply.
Use of an RCO reduces the risk of electric
shock.
3) PERSONAL SAFETY
a) Stay alert, watch what you are
doing and use common sense when
operating apower tool. Do not use
apower 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 tuming the power tool ono 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 ali times. This
enables better control of the power tool in
unexpected situations.
& 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 ANO 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 tum 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 too/s 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 poor/y maintained
power tools.
& Keep cutting tools sharp and c/ean.
Proper/y 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.
ADOITIONAL SPECIFIC SAFETY RULES
Safety Instructions for Ali Operations
a) This power tool is intended to function as a
grinder, sander (DWE4557 and DWE4597),
wire brush, or cut-off tool. Read ali safety
warnings, instructions, illustrations and
specifications provided with this power
tool. Fai/ure to follow ali instructions listed below
may result in electric shock, fire and/or serious
injury.
36
ENGlISH
b) Operation such as polishing is not
recommended to be performed with this
powertool.
Operation such as sanding (DWE4559;
DWE4579; DWE4579R and DWE4599) is not
recommended to be performed with this
powertool.
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.
& 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 wheel for chips and cracks,
backing pad for crecks, 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. Atter inspecting
and instal/ing an accessory, position
yourself and bystanders away from the
piane of the rotating accessory and run
the power tool at maximum no-loed 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 smallabrasive 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 expoeote to high intensity noise may
cause hearing loss.
i) Keep bystanders asafe 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
.opereiion where the cutting accessory
may contact hidden wiring or its own corti.
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.
I) Never lay the power tool down unti the
accessory has come to acomplete 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 materia/s.
p) Do not use accessories that require liquid
coolants. Using water or other liquid coolants
may result in electrocution or shock.
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
cause;' the uncontrolled power tool to be forced in
37

ENGLlSH
the direclion opposite of the accessory's rotation at
the point of the bindlng.
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 l17to 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 whee/'s movement at the point of pinching.
Abrasive wheels may also break under these
conditions.
Kickback is the result of power tool misuse and/or
incorrect operating procedures or conditions and
can be avoided by taking proper precautions as
glven below:
a) Maintain afirm grip on the power tool
and position your body and arm to allo w
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 piace your hand near the rotating
accessory. Accessory may klckback over your
hand.
c) Do not position your body in the area
where power tool will move if kickback
occurs. Kickback wlll propel the tool in direction
opposite to the wheel's movement at tre point
of snagging,
d) Use special care when working corners,
sharp edges etc. Avoid bouncing and
snagging the accessory. Comers, sharp
edges or bounclng have a tendency to snag the
rotating accessory and cause loss of control or
klckback.
e) Do not attach asaw chain woodcarving
biade or toothed saw biade. 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. Whee/s 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 the operator from broken
wheel fragments, accidental contact wlth wheel
and sparks that could ignite clothing.
c) Whee/s 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 grindlng, slde forces applied to these
whee/s may cause them to shatler.
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 too/s. Wheel intended for larger power
tool is not suitable far the hlgher 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 app/y
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 directiy al
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 unti the wheel comes to a
complete stop. Never attempt to remove
the cut-off wnee from the cut while tfÌe
wheel is in motion btherwise kickback may
occur. Invesligate and take corrective action to
eliminate the cause of wheel binding.
d) Do not restart the cutting operation in the
workpiece. Let the wheel reach full speed
and carefully reenter the cut. The wheel may
bind, walk up or kickback if the power tool is
restarted in the workpiece.
38
ENGlISH
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 ot
the wheel.
~ Use extra caution when making a"pocket
cui" 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 far Sanding
Operations
DWE4557, DWE4597 ONLY
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 laceralion 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 ro the brush. The wire bristies
can easi/y penetrate lighl clothing and/or skin.
b) /f the use of a guard is recommended
for wire brushing, do not allow any
interference of the wire wheel or brush
with the guardo Wire wheel or brush may
expand in diameter due to work load and
centrifugai forces.
Additional Safety Rules far 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 thal do not match the
mounling hardware of the power tool will run
out of balance, vibrate excesslvely and may
cause loss of control.
oThe grinding surface of the centte depressed
whee/s must be mounled below the piane of
the guard lip. An improperly mounted wheel
that projects through the piane of the guard lip
cannot be adequately prolected.
• Do not use Type 11 (flaring cup) wheels on
this too/. Using inappropriate accessories can
result lil injU/y
• A/ways use side handle. Tighten the handle
securely. The side handle should always be
used to maintain contrai of the tool at ali times.
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 f/ying particles.
- Risk of burns due to accessories becoming hot
during operation.
- Risk of personal injury due to prolonged use.
Markings on Iool .
The following pictograms are shown on the tool:
~ Read instruction mar-ual before use.
O Wear ear protection.
~ Wear eye protection.
DATE CODE POSITION (FIG. 1)
The date code (u), Wllich 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
1Guard
1 Side handle
1 Flange set
1 Keyless flange (DWE4579R only)
1 Spanner (DWE4579R only)
1 Two-pin spanner
1 Instruction manual
39

ENGLlSH
• 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.
Descrlptlon (fig. 1)
A WARNING: Never modify the power
ill tool or any part of lt. Oamage or
personal injury could result.
a. On/off switch
b. Unlocking switch
c. Spindle lock
d. Guard
e. Side handle
f. LED indicator (DWE4579, DWE4579R,
DWE4597,DWE4599)
g. Lock-on button (DWE4579, DWE4579R,
DWE4597,DWE4599)
INTENDED USE
The DWE4557, DWE4597 heavy-duty angle grinders
have been designed for professional grinding,
cutting, sanding and wire brushing.
The DWE4559, DWE4579, DWE4599, DWE4579R
heavy-duty angle grinders have been designed for
professional grinding 'and cutting applications.
DO NOT use grinding wheels other than centre
depressed wheels and fìap-disk.
DO NOT use under wet conditions or in presence 01
flammable liquids or gases.
These heavy-duty angle grinders are prolessional
power tools.
DO NOT let children come into contact with the
tool. Supervision is required when inexperienced
operators use this tool,
• This product is not intended for use by persons
(including children) suffering Irom diminished
physical, sensory or mental abilities; lack 01
experience, knowledge or skills unless they are
supervised by a person responsible lor their
safety. Children should never be left alone with
this product,
Oust Ejection System
The dust ejection system defiects debris that would
be harmful to the motor and allows cleaner air to
pass over the motor.
Overload Protection
DVVE4579,DVVE4579R,DVVE4597,DVVE4599
The power supply to the motor will be reduced in
case 01 motor overload. The power will retum to
normal once the tool has cooled down to suitable
operating temperature.
Electronic Clutch
DVVE4579, DVVE4579R, DVVE4597, DVVE4599
The electronic torque limiting clutch reduces the
maximum torque reaction transmitted to the
operator in case 01 jamming of a disco This leature
also prevents the gearing and electric motor trom
stalling. The level 01 the electronic clutch has been
factory set and cannot be adjusted.
LED Indicator (fig. 1)
DVVE4579, DVVE4579R, DVVE4597, DVVE4599
The LED indicator light (D, mounted at the top 01
the handle, acts as an alert to the activation 01 the
electronic leatures 01 the unit described above.
The light will activate and maintain a constant light
when one 01 the above clutch or overload leatures is
activated. Once the unit has been reset by releasing
the switch or allowing the unit to cool the light will
de-activate. Il the LED light is Ilashing constantly
please consult your local DEWALT service agent
No-volt Release Switch
DVVE4579,DVVE4579R,DVVE4597,DVVE4599
The on/off switch has a no-volt release lunction.
Il the tool should become disconnected frorn the
power source tor any reason, the switch has to be
deliberately reactivated.
Soft Start Feature
DVVE4579, DVVE4579R, DVVE4597, DVVE4599
The soft start feature allows a slow speed build-up
to avoid an initial jerk when starting. This leature is
particularly uselul when working in confined spaces.
Auto-balance Feafure
DVVE4599 ONLY
The auto-balance leature continuously adjusts
balance to reduce the vibration of the tool when it
is running. This improves user comfort during the
operation and is particularly uselul when using the
tool for long periods 01 time.
40
ENGlISH
Electrical Safety
The electric motor has been designed lor one
voltage only. Always check that the power supply
corresponds to the voltage on the rating plate.
[Q]
Your DEWALT tool is double insulated in
D accordancewith EN 60745; therelore no
earth wire i~ required. .
A WARNING: 115 V units have to
ili be operated via a fail-safe isolating
transformer with an earth screen
between the primary and secondary
winding.
Il the supply cord is damaged, it must be replaced
by a specially prepared cord available through the
DEWALT service organization.
Mains Plug Replacement
(U.K. Ireland Only)
If a new mains plug needs to be fitted:
• 5afely dispose of the old plug.
• Connect the brown lead to the live terminai in
theplug.
• Connect the blue lead to the neutral terminai.
/;).. WARNING: No connection is to be
L.:J.::::. made to the earth terminai.
Follow the fitting instructions supplied with gooa
qua/ity plugs. Recommended fuse: 13 A.
Using an Extension Cable
Il an extension cable is required, use an approved
3-core extension cable suitable lor the power input
01 this tool (see Technical Data).The minimum
conductor size is 1.5 mm'; the maximum length
is30 m.
When using a cable reel, always unwind the cable
completely.
ASSEMBLY ANO AOJUSTMENTS
A WARNING: To reduce the risk
ill of serious personal injury, tum
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 i8 off.
Attaching Side Handle (fig. 6)
A WARNING: Before using the tool,
ill check that the handle is tightened
seèurelr
Far grinding, screw the side handle (e) tightly into
one 01 the holes (q) on either side 01 the gear case
(lig.6).
For cutting,:screw the side handle (e) tightly into the
top hole (r) or into one of the holes (q) 011 either side
of the gear case.
Fitting and Removing a
8acking pad/Sanding sheet (fig. 1, 4)
1. Piace the tool on a table or flat surface, with the
guard facing up.
2. Remove the backing flanqe (I).
3. Piace the rubber backing pad correctly onta the
spindle (m).
4. Piace the sanding sheet on the rubber backing
pad,
5. Screw the threaded clamp nut (n) onto the
spindle. The ring on the threaded clamp nut
must tace towards the rubber backing pad.
6. Press the spindle lock bulton (c) and rotate the
spindle (m) until it locks in position.
7. Tighten the threaded clamp nut (n) with the two-
pin spanner.
8. Release the spindle lock.
9. To remove the rubber backing pad, loosen
the threaded clamp nut (n) with the two-pin
spanner.
Fitting a Wire Cup Brush
Screw the wire-cup brush directly onta the spindle
without the use 01 the spacer and threaded Ilange.
Mounting and Removing the Guard
(fig. 2)
A WARNlNG: To reduce the risk
ill of serious personal injury, tum
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
/III this grinder.
-41

ENGLlSH
When using the DWE4557, DWE4559, DWE4579,
DWE4579R, DWE4597 or the DWE4599 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
show other accessaries that can be used with these
9rinders.
1. Piace the angle grinder on a table, spindle up.
2 Release the clamping lock (h) and hold the
guard (d) over the tool as shown.
3. Align the lugs (i)with the notches U)
4. Press the guard down and rotate it to the
required posiiton.
5. If required, increase the clamping force by
tightening the screw (k).
6. Tighten the clamping lock.
To remove the guard, release the clamping lock.
A CAUTION: If the guard cannol be
ill lighlened by Ihe adjusling screw, do
noi use the 1001.Toreduce Ihe risk of
personal injury, lake Ihe 1001and guard
lo <il service cenlre to repair or replace
Ihe guardo
fitting and Bemovìnq a Grinding or
Cutting Dlsc (fig. 1, 3-5)
'" WARNlNG: Do not use a damaged
as=
1. Piace the tool on a table, guard up.
2. Fit the backing flange (I)carrectly onto the
spindle (m) (fig. 3).
3. Piace the disc (o) on the backing flange (I)
(fig. 4). When fitting a disc with a raised centre,
make sure that the raised centre (p) is facing the
backing flange (I).
4. Screw the threaded clamp nut (n) onto the
spindle (m) (fig. 5):
a. The ring on the threaded clamp nut (n) must
face towards the disc when fitting a grinding
disc (fig. 5A);
b. The ring on the threaded clamp nut (n) must
face away from the disc when fitting a cutting
disc (fig. 5B).
5. Press the spindle lock butto n (c) and rotate the
spindle (m) until it locks in position (fig. 4)
6. Tighten the threaded clamp nut (n) with the
two-pin spanner supplied. NOTE: Refer to
Fitting and Removing a Grinding or Cutting
Disc with aKeyless Flange when using the
DWE4579R.
7. Release the spindle lock.
8. To remove the disc, loosen the threaded clamp
nut (n) with the two-pin spanner.
fitting and Removing a Grinding or
Cutting Disc with a Keyless flange
(fig. 7, 8)
DWE4579R ONlY
1. Perform steps 1-5 of Fitting and Removing a
Grinding or Cutting Disc.
2. Tighten the threaded keyless flange (s) by
turning it by hand clockwise firmly. (Only use a
flawless keyless flange.)
a. Be sure that the printed side of the keyless
flange is facing you.
b. The arrow must point to the index mark
(fig. 7).
3. Releas~ the spindle lock.
An undamaged keyless flange can be loosened
by hand when turning the flange ring in an anti-
clockwise direction.
NOTlCE: NEVER loosen aIlghl keyless
flange with pliers. Always use Ihe Ihe
two-pin spanner (I) (fig. 8).
Prior to Operation
• Install the guard and appropriate disc or wheel.
Do not use excessively worn discs or wheels.
o 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 darnaged accessory. Before each
use inspect the accessory such as abrasive
wheels for chipsand cracks, backing pad
for cracks, tear O( 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 piane of
the rotating accessory and run the power tool
at maximum no-Ioad speed far one minute.
Damaged accessories will normally break apart
during this test time.
4
ENGlISH
OPERATION
lnstructions for Use
'" WARNING: Always observe Ihe safety
Lll inslruclions and applicable regulations.
'" WARNING: To reduce the risk
Lll ot serious personal injury, turn
tool off and disconnect tool trom
power source before making any
adjustments or removing/installing
attachments or accessories. Before
reconnecting Ihe tool, depress and
release Ihe Irigger swilch lo ensure Ihat
Ihe 1001is off
'" WARNING:
Lll . Ensure a/l malerials lo be ground or
cui are secured in piace.
o Secure and support the workpiece.
Use clamps or a vice lo hold and
support the workpiece lo a stable
plafform. Il is importanl to clamp and
support I/le workpiece securely to
prevenl movemenl of Ihe workpiece
and loss of control. Movemenl of
the workpiece or loss of control may
create arezera 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
Iheir own weighl. Supports must be
placed under Ihe workpiece near the
line of cut and near Ihe edge of the
workpiece on both sides of the wheel.
• Always wear regular working gloves
while operating this 1001.
• Apply only agentle pressure lo Ihe
1001.Do noi exert side pressure on Ihe
disco
oAvoid overloading. Should the 1001
become hol, lei it run a few minules
under no load condition lo cool Ihe
accessory Do not touch accessories
before they have cooled. The discs
become very hol during use.
• Never work with Ihe grinding cup
withoul a suitable prolection guard in
piace.
o Do not use Ihe power tool with a cut-
off stand.
• Never use blotters logelher wilh
bonded abrasive producls.
• Be aware, tne wheel continues lo
•rotaie after Ihe tools is switched ott.
o The 1001is noi designed lo be used
wilh a grinding cupo
oDo noi use separale reducing
bushings or adapters lo adapl large
hole abrasive wheels.
Proper Hand Positìon (fig. 1)
A WARNING: Toreduce Ihe risk of
ili serious personal injury, ALWAYS use
proper hand posilion es shown.
A. WARNING: Toreduce Ihe risk of
ill serious personal injury, ALWAYS hold
securely in anlicipation of a sudden
reaclion.
Proper hand position rèquires one hand on the side
handle (e), with the other hand Oll the body of the
tool, as shown ill figure 1.
Switching on and OH (fig. 1)
The on/off switch is equipped with an unlockinq
switch.
To run the tool, depress the unlocking switch (b) and
subsequently operate the on/off switch (a).
Release the uillockillg switch (b).To stop the tool,
release the switch.
tock-on Button (fig. 1)
DWE4579, DWE4579R, DWE4597, DWE4599
For continuous operation depress the lock -Oll buttor
(g) and release the on/off trigger switch.
To stop the tool press the on/of switch aqain.
The lock-on button can be permanently removed
without cornprorrisirc compliance with regulatory
agencies shown on the tool's nameplate. Removal
of the lock pin must be done by a DEWALT Service
Centre.
Spindle lock (fig. 1
The spindle lock (c) is provided to prevent the
spindle from rotating when ìnstallinq 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: Toreduce the risk of damage
lo the 1001,do not engage Ihe spindle
lock whi/e the 1001 is operaling. Damage
lo Ihe 1001will resull and attached
43

ENGlISH
accessory may spin off possib/y
resu/ting in injury.
To engage the lock, depress the spindle lock button
and rotate the spindle until you are unable to rotate
the spindle further.
Metal Applications
When using the tool in metal applications, make
sure that a residual current device (RCO) has been
inserted to avoid residual risks caused by metal
swarf.
If the power supply is shGf"OO'bithe1"ìCD;"18:R6the
tool to authorìsed OEWALT repair agent.
lA. WARNING: In extreme working
ili conditions, conductive dust can
accumulate inside the machine housing
when working with metal. This can result
in the protective insulation inthe machine
becoming degraded with a potential risk
of an electrical shock.
To avoid build-up of metal swarf inside the machine,
we recommend to clear the ventilation slots on a
daily basis. Refer to Maintenance.
Cutting Metal
For cutting with bonded abrasives, always use
a protection guarèl type 1.
When cutting, work with moderate feed, adapted to
the material being cut. Do not exert pressure onto
the cutting disc, tilt or oscillate the machine.
Do not reduce the speed of running down cutting
discs by applying sideward pressure.
The machine must always work in an upgrinding
motion. Otherwise, the danger exists of it being
pushed uncontrolled out of the cut.
When cutting profiles and square bar, it is best to
start at the smallest cross section.
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 ìs best to use a diamond
cutting disco Operate the machine bnly 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 ali circumstances. Before beginning
work, consult the responsible structural engineer,
architect or the construction supervisor.
Using Flap Discs
----IA..- WARNING: Metal d st build-up.
ill Extensive use of flap discs in metal
applications can result in the increased
potential for electric shock. To reduce
this risk, insert an RCO before use
and c1ean the ventilation s/ots daily by
blowing dry compressed air into the
ventilation s/ots inaccordance with the
below maintenance instructlon»,
MAINTENANCE
Your OEWALT 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, tum
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 1001is off.
Pop-off Brushes
The motor will be automatically shut off indicating
that the carbon brushes are nearly wom out and
that the tool needs servicing. The carbon brushes
are not user-serviceable. Take the tool to an
authorised OEWALT repair agent.
till
Lubrication
Your power tool requires no additional lubrication.
44
ENGlISH
---
.----
Max. Imml Min. Periphical Threaded
[mml RotatiOfl speed hOlelength
D
b
d[min."] 1m/si Imml
180 12 M14 8,500 80 25.0
230 12 M14 8,500 80 25.0
~
Cleaning
A WARNING: Blow dirt end dust out of
ili the main housing with dry air as often as
dirt is seen cottecting in and around the
air vents. Wear approveçJ eye protection
and approved dust mask when
performing this procedure.
A WARNING: Never use solvents or
ili other harsh chemica/s for cteaning the
non-metallic parts of the tool. These
chemica/s may weaken the materia/s
used in these parts. Use acloth
dampened only with water and mi/d
soap. Never let any liquid get inside the
tool; never immerse any part of the tool
into a liquid.
Optional Accessories
A, WARNING: Since accessories, other
~ than those offered by OEWALT, have
not been tested with this product, use
of such accessories with this tool could
be hazardous. To reduce the risk of
injury, only OEWALT, recommended
accessories should be used with this
producI.
Consult your dealer for further information on the
appropriate accessories.
ACGESSORY GHART
Protecting the Environment
)t
Separate collection. This product must
not be disposed of with normal
. household waste.
Max.
[mml Imml Min.
Rotatlon
[min:'1
Periphical I Threaded
speed hole length
1m/si [mml
-
Should you find one day that your OEWALT 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.
W Separate collection of used products and
n (9 packaging allows materials to be
\Q recycled and used again. Re-use of
recycled materials helps prevent
environmental pollutibn and reduces
the demand for raw materials.
Local regulations may provide for separate collection
of electrical products trom the household, at
municipal waste sites or by the retailer when you
purchase a new product.
OEWALT provides a facility for the collection and
recycling of OEWALT products once they have
reached the end of their working life. To take
advantage of this servi ce please retum 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
OEWALT office at the address indicated in this
manual. Altematively, a list of authorised OEWALT
repair agents and full details of our after-sales
service and contacts are available on the Intemet at:
www.2helpU.com.
D I b
22,231 8,500 I 80
80
45
8,500 I 80
'I
1 1 1
DWE4557 IDWE4597
jdl
b ~:"; I so I." I 8,;00 I
45 I25.0
I D I

ENGLlSH
GRINDING ANO CUTTING ACCESSORV CHART
Guard Type
~TYPE 27
GU RD
Accessory
@Description
Depressed
centre grinding
disc
Flap wheel
Wirewheels
Wire wheels
with threaded
nut
How to Fit Grinder
~
Type 27 guard
~
Backing flange
C§:)
~=
Type 27 depressed
centre wheel
®
Threaded clamp nut
~
Type 27 guard
Wirewheel
u
Wire cup with
threaded nut
~
Type 27 guard
~
~
Wire brush
80
Backing pad
sanding sheet
~
Type 27 guard
~
Rubber backing pad
~
Sanding disc
@
Threaded clamp nut
46
ENGLlSH
GRINDING ANO CUTTING ACCESSORV CHART (cont.)
Gliard Type Accessory Description How to Fit Grinder
~
9
Masonry
~
cutting disc,
-- - 'J
bonded
TYPE1
Type 1 guard
GU RD
@
Metal
cutting disc,
~
bonded
. Backing flange .
~
(O
Diamond
cutting wheels
~
TYPE 1
Cutting wheel
GU RD
OR
®
~
Threaded clamp nut
TYPE 27
GU RD
47
~
il
Il
~
1
"