DeWalt XR DCG440 User manual

DCG440

B
Copyright DEWALT
English (original instructions) 4
Pусский (перевод соригинала инструкции) 19
Українська (переклад з оригінальної інструкції) 40

1
Fig. A
Fig. B
1
2
45
9
12
3
10
7
8
13
11
6
27
12
11
Fig.C

2
Fig.D Fig.E
Fig.F
5
90˚ 90˚
14
15
Fig.H Fig.I
23
18
19
3
4
8
6
7
4
Fig.G
10
9
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4
XXXX XX XX
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Fig.J Fig.K
Fig.L
11
12
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26
21 22
13
Fig.M
Fig.N

4
ENGLISH
DECLARATION OF CONFORMITY
THE SUPPLY OF MACHINERY SAFETY
REGULATIONS 2008
Cordless 180mm Angle Grinder
DCG440
DEWALT declares that these products described under
“technical data” are in compliance with:
BS EN62841:2015, BS EN62841‑2‑3:2021+A11:2021.
These products conform to the following UK Regulations
The Supply of Machinery (Safety) Regulations, 2008, S.I.
2008/1597 (asamended).
Electromagnetic Compatibility Regulations, 2016, S.I.2016/1091
(asamended).
The Restriction of the Use of Certain Hazardous Substances
in Electrical and Electronic Equipment Regulations 2012, S.I.
2012/3032 (as amended).
For more information, please contact DEWALT at the following
address or refer to the back of the manual.
EC-Declaration of Conformity
Machinery Directive
o
Cordless 180mm Angle Grinder
DCG440
DEWALT declares that these products described under
Technical Data are in compliance with:
2006/42/EC, EN62841‑1:2015, EN62841‑2‑3:2021+A11:2021.
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manual.
The undersigned is responsible for compilation of the technical
file and makes this declaration on behalf ofDEWALT.
Markus Rompel
Vice‑President Engineering, PTE‑Europe
DEWALT, Richard‑Klinger‑Straße 11,
65510, Idstein, Germany
01.11.2021
The vibration and/or noise emission level given in this
information sheet has been measured in accordance with
a standardised test given in EN62841 and may be used to
compare one tool with another. It may be used for a preliminary
assessment ofexposure.
WARNING: The declared vibration and/or noise 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 and/or
noise emission may differ. This may significantly increase
the exposure level over the total workingperiod.
An estimation of the level of exposure to vibration and/
or noise 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 and/or noise such
DCG440
Voltage VDC 54
Type 1
Battery type Li‑Ion
Max. Power Output W2300
Rated speed min‑1 6500
Wheel diameter mm 180
Wheel thickness (max) mm 8
Wire wheel thickness (max) mm 20
Spindle diameter M14
Spindle length mm 15.3
Weight (without battery pack) kg 2.6
Noise values and/or vibration values (triax vector sum) according to EN62841‑2‑3:
LPA (emission sound pressure level) dB(A) 87
LWA (sound power level) dB(A) 95
K (uncertainty for the given sound level) dB(A) 3
Surface grinding
Vibration emission value a
h,AG
= m/s24.5
Uncertainty K = m/s21.5
Disc sanding
Vibration emission value a
h,DS
= m/s23.3
Uncertainty K = m/s21.5
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
CORDLESS 180MM ANGLE GRINDER
DCG440
as: maintain the tool and the accessories, keep the
hands warm (relevant for vibration), organisation of
workpatterns.

5
ENGLISH
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.
b ) Use personal protective equipment. Always wear eye
protection. Protective equipment such as a dust mask,
GENERAL POWER TOOL SAFETY WARNINGS
WARNING: 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.
SAVE ALL WARNINGS AND INSTRUCTIONS
FOR FUTUREREFERENCE
aWARNING: To reduce the risk of injury, read the
instructionmanual.
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.
Denotes risk of electricshock.
Denotes risk offire.
The undersigned is responsible for compilation of the technical
file and makes this declaration on behalf of DEWALT.
Karl Evans
Vice President Professional Power Tools EANZ GTS
270Bath Road, Slough
SL1 4DX
England
01.11.2021
Batteries Chargers/Charge Times (Minutes)**
Cat # VDC Ah Weight (kg) DCB104 DCB107 DCB112 DCB113 DCB115 DCB116 DCB117 DCB118 DCB132
DCB546 18/54 6.0/2.0 1.08 60 270 170 140 90 80 40 60 90
DCB547 18/54 9.0/3.0 1.46 75* 420 270 220 135* 110* 60 75* 135*
DCB548 18/54 12.0/4.0 1.46 120 540 350 300 180 150 80 120 180
DCB549 18/54 15.0/5.0 2.12 125 730 450 380 230 170 90 125 230
*Date code 201811475B or later

6
ENGLISH
ADDITIONAL SPECIFIC SAFETY RULES
Safety Warnings Common for Grinding,
Sanding, Wire Brushing, or 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.
performed. Use of the power tool for operations different
from those intended could result in a hazardoussituation.
h ) Keep handles and grasping surfaces dry, clean and
free from oil and grease. Slippery handles and grasping
surfaces do not allow for safe handling and control of the
tool in unexpectedsituations.
5) Battery Tool Use and Care
a ) Recharge only with the charger specified by the
manufacturer. A charger that is suitable for one type
of battery pack may create a risk of fire when used with
another batterypack.
b ) Use power tools only with specifically designated
battery packs. Use of any other battery packs may create
a risk of injury andfire.
c ) When battery pack is not in use, keep it away from
other metal objects, like paper clips, coins, keys,
nails, screws or other small metal objects, that can
make a connection from one terminal to another.
Shorting the battery terminals together may cause burns
or afire.
d ) Under abusive conditions, liquid may be ejected
from the battery; avoid contact. If contact
accidentally occurs, flush with water. If liquid
contacts eyes, additionally seek medical help. Liquid
ejected from the battery may cause irritation orburns.
e ) Do not use a battery pack or tool that is damaged or
modified. Damaged or modified batteries may exhibit
unpredictable behaviour resulting in fire, explosion or risk
ofinjury.
f ) Do not expose a battery pack or tool to fire or
excessive temperature. Exposure to fire or temperature
above 130°C may causeexplosion.
g ) Follow all charging instructions and do not charge
the battery pack or tool outside the temperature
range specified in the instructions. Charging
improperly or at temperatures outside the specified range
may damage the battery and increase the risk offire.
6) 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.
b ) Never service damaged battery packs. Service
of battery packs should only be performed by the
manufacturer or authorized serviceproviders.
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 and clothing 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.
h ) Do not let familiarity gained from frequent use of
tools allow you to become complacent and ignore
tool safety principles. A careless action can cause severe
injury within a fraction of asecond.
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 remove the battery pack, if detachable, 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 and accessories. 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

7
ENGLISH
metal parts of the power tool "live" and could give the
operator an electricalshock.
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.
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:
a ) Maintain a firm grip with both hands on the power
tool and position your body and arms 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
b ) Operations such as polishing, sanding or hole
cutting are not 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 convert this power tool to operate in a way
which is not specifically designed and specified by
the tool manufacturer. Such a conversion may result in
a loss of control and cause serious personal injury
d ) Do not use accessories which are not specifically
designed and specified by the tool manufacturer.
Just because the accessory can be attached to your power
tool, it does not assure safeoperation.
e ) 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.
f ) 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.
g ) The dimensions of the accessory mounting must fit
the dimensions of the mounting hardware of the
power tool. 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.
h ) 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.
i ) 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 the particular operation. Prolonged exposure to high
intensity noise may cause hearingloss.
j ) 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.
k ) Hold the power tool by insulated gripping surfaces
only, when performing an operation where the
cutting accessory may contact hidden wiring. Cutting
accessory contacting a "live" wire may make exposed

8
ENGLISH
c ) When wheel is binding or when interrupting a cut
for any reason, switch off the power tool and hold it
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.
g ) Do not attempt to do curved cutting.
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, which can lead to seriousinjury.
Additional Safety Instructions for
SandingOperations
a ) Use proper sized sanding disk paper. Follow
manufacturers recommendations, when selecting
sanding paper. Larger sanding paper extending too far
beyond the sanding pad presents a laceration hazard and
may cause snagging, tearing of the disc or kickback.
Additional Safety Instructions for Wire
Brushing Operations
a ) Be aware that wire bristles are thrown by the brush
even during ordinary operation. Do not overstress
the wires by applying excessive load to the brush. The
wire bristles can easily penetrate light clothing and/orskin.
b ) If the use of a guard is specified 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
a ) Do not use Type 11(flaring cup) wheels on this tool.
Using inappropriate accessories can result ininjury.
b ) Always use side handle. Tighten the handle securely.
The side handle should always be used to maintain control
of the tool at alltimes.
c ) When using segmented diamond wheels, use
only diamond wheels with a peripheral gap not
greater than 10mm and negative rakeangle.
(refer to Additional Information for Guards and
Accessorieschart).
snag the rotating accessory and cause loss of control
orkickback.
e ) Do not attach a saw chain woodcarving blade,
segmented diamond wheel with a peripheral gap
greater than 10mm or toothed sawblade.Such
blades create frequent kickback and loss ofcontrol.
Safety Warnings Specific for Grinding and
Cutting-Off Operations
a ) Use only wheel types that are specified 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 specified 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. A wheel intended for larger power tool is not
suitable for the higher speed of a smaller tool and
mayburst.
g ) When using dual purpose wheels always use the
correct guard for the application being performed.
Failure to use the correct guard may not provide
the desired level of guarding, which could lead to
seriousinjury.
Additional Safety Warnings Specific for
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.

9
ENGLISH
CAUTION: Burn hazard. To reduce the risk of injury,
charge only DEWALT rechargeable batteries. Other types of
batteries may burst causing personal injury anddamage.
CAUTION: Children should be supervised to ensure that
they do not play with theappliance.
NOTICE: Under certain conditions, with the charger
plugged into the power supply, the exposed charging
contacts inside the charger can be shorted by foreign
material. Foreign materials of a conductive nature such
as, but not limited to, steel wool, aluminum foil or any
buildup of metallic particles should be kept away from
charger cavities. Always unplug the charger from the
power supply when there is no battery pack in the cavity.
Unplug charger before attempting toclean.
• DO NOT attempt to charge the battery pack with any
chargers other than the ones in this manual. The charger
and battery pack are specifically designed to worktogether.
• These chargers are not intended for any uses other than
charging DEWALT rechargeable batteries. Any other uses
may result in risk of fire, electric shock orelectrocution.
• Do not expose charger to rain orsnow.
• Pull by plug rather than cord when disconnecting
charger. This will reduce risk ofdamage to electric plug
andcord.
• Make sure that cord is located so that it will not be
stepped on, tripped over, or otherwise subjected to
damage orstress.
• Do not use an extension cord unless it is absolutely
necessary. Use of improper extension cord could result in risk
of fire,electric shock, orelectrocution.
• Do not place any object on top of charger or place
the charger on a soft surface that might block the
ventilation slots and result in excessive internal heat.
Place the charger in a position away from any heat source. The
charger is ventilated through slots in the top and the bottom
of thehousing.
• Do not operate charger with damaged cord or plug—
have them replacedimmediately.
• Do not operate charger if it has received a sharp blow,
been dropped, or otherwise damaged in any way. Take it
to an authorised servicecentre.
• Do not disassemble charger; take it to an authorised service
centre when service or repair is required. Incorrect reassembly
may result in a risk of electric shock, electrocution orfire.
• In case of damaged power supply cord, the supply cord must
be replaced immediately by the manufacturer, its service agent
or similar qualified person to prevent anyhazard.
• Disconnect the charger from the outlet before attempting
any cleaning. This will reduce the risk of electric shock.
Removing the battery pack will not reduce thisrisk.
• NEVER attempt to connect two chargerstogether.
• The charger is designed to operate on standard
230V household electrical power. Do not attempt to
use it on any other voltage. This does not apply to the
vehicularcharger.
Chargers
DEWALT chargers require no adjustment and are designed to be
as easy as possible tooperate.
Electrical Safety
The electric motor has been designed for one voltage only.
Always check that the battery pack voltage corresponds to the
voltage on the rating plate. Also make sure that the voltage of
your charger corresponds to that of yourmains.
iYour DEWALTcharger is double insulated in
accordance with EN60335; therefore no earth wire
isrequired.
If the supply cord is damaged, it must be replaced only by
DEWALT or an authorised 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: 3A.
Using an Extension Cable
An extension cord should not be used unless absolutely
necessary. Use an approved extension cable suitable for the
power input of your charger (see Technical Data). The minimum
conductor size is 1mm2; the maximum length is30m.
When using a cable reel, always unwind the cablecompletely.
Important Safety Instructions for All BatteryChargers
SAVE THESE INSTRUCTIONS: This manual contains important
safety and operating instructions for compatible battery
chargers (refer to TechnicalData).
• Before using charger, read all instructions and cautionary
markings on charger, battery pack, and product using
batterypack.
WARNING: Shock hazard. Do not allow any liquid to get
inside charger. Electric shock mayresult.
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.
SAVE THESE INSTRUCTIONS

10
ENGLISH
Battery Packs
Important Safety Instructions for All
BatteryPacks
When ordering replacement battery packs, be sure to include
catalogue number andvoltage.
The battery pack is not fully charged out of the carton. Before
using the battery pack and charger, read the safety instructions
below. Then follow charging proceduresoutlined.
READ ALL INSTRUCTIONS
• Do not charge or use battery in explosive atmospheres,
such as in the presence of flammable liquids, gases or
dust. Inserting or removing the battery from the charger may
ignite the dust orfumes.
• Never force battery pack into charger. Do not modify
battery pack in any way to fit into a non‑compatible
charger as battery pack may rupture causing serious
personalinjury.
• Charge the battery packs only in DEWALTchargers.
• DO NOT splash or immerse in water or otherliquids.
• Do not store or use the tool and battery pack in locations
where the temperature may fall below 4˚C (39.2˚F)
(such as outside sheds or metal buildings in winter), or
reach or exceed 40˚C (104˚F) (such as outside sheds or
metal buildings insummer).
• Do not incinerate the battery pack even if it is severely
damaged or is completely worn out. The battery pack can
explode in a fire. Toxic fumes and materials are created when
lithium‑ion battery packs areburned.
• If battery contents come into contact with the skin,
immediately wash area with mild soap and water. If
battery liquid gets into the eye, rinse water over the open eye
The tool will automatically turn off if the Electronic Protection
System engages. If this occurs, place the lithium‑ion battery
pack on the charger until it is fullycharged.
Wall Mounting
These chargers are designed to be wall mountable or to sit
upright on a table or work surface. If wall mounting, locate the
charger within reach of an electrical outlet, and away from a
corner or other obstructions which may impede air flow. Use
the back of the charger as a template for the location of the
mounting screws on the wall. Mount the charger securely using
drywall screws (purchased separately) at least 25.4mm long
with a screw head diameter of 7–9mm, screwed into wood to
an optimal depth leaving approximately 5.5mm of the screw
exposed. Align the slots on the back of the charger with the
exposed screws and fully engage them in theslots.
Charger Cleaning Instructions
WARNING: Shock hazard. Disconnect the charger
from the AC outlet before cleaning. Dirt and grease
may be removed from the exterior of the charger using a
cloth or soft non‑metallic brush. Do not use water or any
cleaning solutions. Never let any liquid get inside the tool;
never immerse any part of the tool into aliquid.
Charging a Battery (Fig.B)
1. Plug the charger into an appropriate outlet before inserting
batterypack.
2. Insert the battery pack 11 into the charger, making sure the
battery pack is fully seated in the charger. The red (charging)
light will blink repeatedly indicating that the charging
process hasstarted.
3. The completion of charge will be indicated by the red
light remaining ON continuously. The battery pack is fully
charged and may be used at this time or left in the charger.
To remove the battery pack from the charger, push the
battery release button 12 on the batterypack.
NOTE: To ensure maximum performance and life of lithium‑ion
battery packs, charge the battery pack fully before firstuse.
Charger Operation
Refer to the indicators below for the charge status of the
batterypack.
Charge Indicators
FCharging I
GFully Charged J
HHot/Cold Pack Delay* K
*The red light will continue to blink, but a yellow indicator light
will be illuminated during this operation. Once the battery pack
has reached an appropriate temperature, the yellow light will
turn off and the charger will resume the chargingprocedure.
The compatible charger(s) will not charge a faulty battery pack.
The charger will indicate faulty battery by refusing tolight.
NOTE: This could also mean a problem with acharger.
If the charger indicates a problem, take the charger and battery
pack to be tested at an authorised servicecentre.
Hot/Cold Pack Delay
When the charger detects a battery pack that is too hot or too
cold, it automatically starts a Hot/Cold Pack Delay, suspending
charging until the battery pack has reached an appropriate
temperature. The charger then automatically switches to the pack
charging mode. This feature ensures maximum battery packlife.
A cold battery pack will charge at a slower rate than a warm
battery pack. The battery pack will charge at that slower rate
throughout the entire charging cycle and will not return to
maximum charge rate even if the battery packwarms.
The DCB118 charger is equipped with an internal fan designed to
cool the battery pack. The fan will turn on automatically when the
battery pack needs to be cooled. Never operate the charger if the
fan does not operate properly or if ventilation slots are blocked.
Do not permit foreign objects to enter the interior of thecharger.
Electronic Protection System
XR Li‑Ion tools are designed with an Electronic Protection
System that will protect the battery pack against overloading,
overheating or deepdischarge.

11
ENGLISH
batteries (combo kits) can be air shipped as excepted if the Watt
Hour rating of the battery pack is no greater than 100Wh.
Regardless of whether a shipment is considered excepted
or fully regulated, it is the shipper's responsibility to consult
the latest regulations for packaging, labeling/marking and
documentationrequirements.
The information provided in this section of the manual is
provided in good faith and believed to be accurate at the time
the document was created. However, no warranty, expressed or
implied, is given. It is the buyer’s responsibility to ensure that its
activities comply with the applicableregulations.
Transporting the FLEXVOLTTM Battery
The DEWALT FLEXVOLTTM battery has two modes: Use
andTransport.
Use Mode: When the FLEXVOLTTM battery stands alone or is in
a DEWALT 18V product, it will operate as an 18V battery. When
the FLEXVOLTTM battery is in a 54V or a 108V (two 54V batteries)
product, it will operate as a 54Vbattery.
Transport Mode: When the cap is attached to the FLEXVOLTTM
battery, the battery is in Transport mode. Keep the cap
forshipping.
When in Transport mode, strings
of cells are electrically
disconnected within the pack
resulting in 3batteries with a
lower Watt hour (Wh) rating as compared to 1battery with a
higher Watt hour rating. This increased quantity of 3batteries
with the lower Watt hour rating can exempt the pack from
certain shipping regulations that are imposed upon the higher
Watt hour batteries.
For example, the Transport
Wh rating might indicate
3x36Wh, meaning
3batteries of 36Wh each.
The Use Wh rating might
indicate 108Wh (1batteryimplied).
Storage Recommendations
1. The best storage place is one that is cool and dry away
from direct sunlight and excess heat or cold. For optimum
battery performance and life, store battery packs at room
temperature when not inuse.
2. For long storage, it is recommended to store a fully charged
battery pack in a cool, dry place out of the charger for
optimalresults.
NOTE: Battery packs should not be stored completely
depleted of charge. The battery pack will need to be recharged
beforeuse.
Labels on Charger and Battery Pack
In addition to the pictographs used in this manual, the
labels on the charger and the battery pack may show the
followingpictographs:
LRead instruction manual beforeuse.
Example of Use and Transport Label Marking
for 15minutes or until irritation ceases. If medical attention
is needed, the battery electrolyte is composed of a mixture of
liquid organic carbonates and lithiumsalts.
• Contents of opened battery cells may cause respiratory
irritation. Provide fresh air. If symptoms persists, seek
medicalattention.
WARNING: Burn hazard. Battery liquid may be flammable
if exposed to spark orflame.
WARNING: Never attempt to open the battery pack for
any reason. If battery pack case is cracked or damaged,
do not insert into charger. Do not crush, drop or damage
battery pack. Do not use a battery pack or charger that
has received a sharp blow, been dropped, run over or
damaged in any way (i.e., pierced with a nail, hit with
a hammer, stepped on). Electric shock or electrocution
may result. Damaged battery packs should be returned to
service centre forrecycling.
WARNING: Fire hazard. Do not store or carry the
battery pack so that metal objects can contact
exposed battery terminals. For example, do not place
the battery pack in aprons, pockets, tool boxes, product kit
boxes, drawers, etc., with loose nails, screws, keys,etc.
CAUTION: When not in use, place tool on its side on
a stable surface where it will not cause a tripping
or falling hazard. Some tools with large battery packs
will stand upright on the battery pack but may be easily
knockedover.
Transportation
WARNING: Fire hazard. Transporting batteries can
possibly cause fire if the battery terminals inadvertently
come in contact with conductive materials. When
transporting batteries, make sure that the battery
terminals are protected and well insulated from
materials that could contact them and cause a short
circuit. NOTE: Lithium‑ion batteries should not be put in
checkedbaggage.
DEWALT batteries comply with all applicable shipping
regulations as prescribed by industry and legal standards which
include UN Recommendations on the Transport of Dangerous
Goods; International Air Transport Association (IATA) Dangerous
Goods Regulations, International Maritime Dangerous Goods
(IMDG) Regulations, and the European Agreement Concerning
The International Carriage of Dangerous Goods by Road
(ADR). Lithium‑ion cells and batteries have been tested to
section 38.3of the UN Recommendations on the Transport of
Dangerous Goods Manual of Tests andCriteria.
In most instances, shipping a DEWALT battery pack will be
excepted from being classified as a fully regulated Class
9Hazardous Material. In general, only shipments containing a
lithium‑ion battery with an energy rating greater than 100Watt
Hours (Wh) will require being shipped as fully regulated Class 9.
All lithium‑ion batteries have the Watt Hour rating marked on
the pack. Furthermore, due to regulation complexities, DEWALT
does not recommend air shipping lithium‑ion battery packs
alone regardless of Watt Hour rating. Shipments of tools with

12
ENGLISH
Description (Fig.A)
WARNING: Never modify the power tool or any part of it.
Damage or personal injury couldresult.
1 Trigger switch
2 Lock‑off lever
3 Spindle lock button
4 Spindle
5 Auxiliary handle
6 Grinding wheel
7 Unthreaded backing flange (fixed to spindle)
8 Locking flange
9 Type BGuard 180mm (Do not use for cut‑off operations)
10 Guard release lever
11 Battery pack
12 Battery release button
13 Main Handle
14 Type AGuard 180mm
15 Side handle extension
Intended Use
The DCG440 cordless angle grinder has been designed
for professional cutting, grinding, sanding and wire
brushapplications.
DO NOT use under wet conditions or in the presence of
flammable liquids orgases.
This cordless 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.
Date Code Position (Fig.B)
The date code 30, which also includes the year of manufacture,
is printed into thehousing.
Example:
2020XX XX
Year and Week of Manufacture
Markings on Tool
The following pictograms are shown on the tool:
a Read instruction manual beforeuse.
g Wear earprotection.
f Wear eyeprotection
n Visible radiation. Do not stare intolight.
such marks by DEWALT is under license. Other trademarks and
trade names are those of their respectiveowners.
• 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.
Package Contents
The package contains:
1 Angle grinder
1 180mm Guard (Type B)
1 180mm Guard (Type A)
1 Side handle
1 Side handle extension
1 Hex wrench
2 Li‑Ion battery pack (T2, X2 models)
1 Li‑Ion battery pack (C1, D1, L1, M1, P1, S1, T1, X1, Y1 models)
2 Li‑Ion battery packs (C2, D2, L2, M2, P2, S2, T2, X2, Y2 models)
3 Li‑Ion battery packs (C3, D3, L3, M3, P3, S3, T3, X3, Y3 models)
1 Instruction manual
NOTE: Battery packs, chargers and kitboxes are not included
with N models. Battery packs and chargers are not included with
NT models. Bmodels include Bluetooth® batterypacks.
NOTE: The Bluetooth® word mark and logos are registered
trademarks owned by the Bluetooth®, SIG, Inc. and any use of
Battery Type
The following tools operate on a 54 volt battery pack: DCG440
These battery packs may be used: , DCB546, DCB547, DCB548,
DCB549. Refer to Technical Data for moreinformation.
p See Technical Data for chargingtime.
q Do not probe with conductiveobjects.
r Do not charge damaged batterypacks.
s Do not expose towater.
t Have defective cords replacedimmediately
u Charge only between 4˚C and 40˚C.
v Only for indooruse.
x Discard the battery pack with due care for
theenvironment.
y Charge battery packs only with designated DEWALT
chargers. Charging battery packs other than the
designated DEWALT batteries with a DEWALT
charger may make them burst or lead to other
dangeroussituations.
z Do not incinerate the batterypack.
B USE (without transport cap). Example: Wh rating
indicates 108Wh (1battery with 108Wh).
A TRANSPORT (with built‑in transport cap). Example: Wh
rating indicates 3x 36Wh (3batteries of 36Wh).

13
ENGLISH
Guards
CAUTION: Guards must be used with all grinding
wheels, cutting wheels, sanding flap discs, wire
brushes, and wire wheels. The tool may be used without
a guard only when sanding with conventional sanding
discs. Refer to Figure A to see guards provided with the unit.
Some applications may require purchasing the correct
guard from your local dealer or authorised servicecentre.
CAUTION: When using a Type A (cut‑off) wheel guard
for facial grinding, the wheel guard may interfere with
the workpiece causing poorcontrol.
CAUTION: When using a Type B (grinding) wheel guard
for cutting‑off operations with bonded abrasive wheels,
there is an increased risk of exposure to emitted sparks and
particles, as well as exposure to wheel fragments in the
event of wheelburst.
CAUTION: When using a Type A (cut‑off), Type B (grinding)
wheel guard for cutting‑off and facial operations in
Rotating the Gear Case (Fig.E)
To improve user comfort, the gear case will rotate 90° for
cuttingoperations.
1. Remove the four corner screws attaching the gear case to
motorhousing.
2. Without separating the gear case from motor housing,
rotate the gear case head to desiredposition.
NOTE: If the gear case and motor housing become
separated by more than 3mm, the tool must be serviced
and re‑assembled by a DEWALT service center. Failure to
have the tool serviced may motor and bearingfailure.
3. Reinstall screws to attach the gear case to the motor
housing. Tighten screws to 12.5 in.‑lbs. torque.
Overtightening could cause screws tostrip.
Attaching the Auxiliary Handle (Fig.D)
WARNING: This handle SHOULD BE USED AT ALL
TIMES to maintain complete control of the tool.
Always make sure the handle istight.
Screw the auxiliary handle5 tightly into one of the threaded
mounting holes7 of the gearcase.
2. Insert battery pack into the charger as described in the
charger section of thismanual.
Fuel Gauge Battery Packs (Fig.B)
Some DEWALT battery packs include a fuel gauge which
consists of three green LED lights that indicate the level of
charge remaining in the batterypack.
To actuate the fuel gauge, press and hold the fuel gauge
button27. A combination of the three green LED lights will
illuminate designating the level of charge left. When the level
of charge in the battery is below the usable limit, the fuel gauge
will not illuminate and the battery will need to berecharged.
NOTE: The fuel gauge is only an indication of the charge left on
the battery pack. It does not indicate tool functionality and is
subject to variation based on product components, temperature
and end‑userapplication.
Inserting and Removing the Battery Pack
from the Tool (Fig.B)
NOTE: Make sure your battery pack 11 is fullycharged.
To Install the Battery Pack into the Tool Handle
1. Align the battery pack with the rails inside the tool’s
handle(Fig. B).
2. Slide it into the handle until the battery pack is firmly seated
in the tool and ensure that you hear the lock snap intoplace.
To Remove the Battery Pack from the Tool
1. Press the battery release button 12 and firmly pull the
battery pack out of the toolhandle.
Features
E‑Clutch™
This unit is equipped with an E‑Clutch™ (Electronic Clutch),
which in the event of a high‑load the unit will be shut off to
reduce the reaction torque to the user. The switch needs to be
cycled (turned on and off) to restarttool.
Kickback Brake™
When a pinch, stall, or bind‑up event is sensed the electronic
brake engages with maximum force to quickly stop the wheel,
reduce the movement of the grinder, and shut the grinder off.
The switch needs to be cycled (turned on and off) to restart
thetool.
Power‑Off™ Overload Protection
The power supply to the motor will be reduced in case of motor
overload. With continued motor overload, the tool will shut
off. The switch needs to be cycled (turned on and off) to restart
tool. The tool will power off each time the current load reaches
the overload current value (motor burn‑up point). If continued
overload shutdowns occur, apply less force/weight on the tool
until the tool will function without the overloadengaging.
Electronic Soft Start
This feature limits the initial start up speed, allowing the tool to
build up to full speed gradually over a 1secondperiod.
ASSEMBLY AND ADJUSTMENTS
WARNING: To reduce the risk of serious personal
injury, turn tool off and disconnect battery pack
before making any adjustments or removing/
installing attachments or accessories. An accidental
start‑up can causeinjury.
WARNING: Use only DEWALT battery packs andchargers.
• 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.

14
ENGLISH
Flanges and Wheels
WARNING: To reduce the risk of serious personal
injury, turn unit off and remove the battery pack
before making any adjustments or removing/
installing attachments or accessories. An accidental
can causeinjury.
Mounting Non‑Hubbed Wheels (Fig.G)
WARNING: Failure to properly seat the flanges and/or
wheel could result in serious injury (or damage to the tool
orwheel).
CAUTION: Included flanges must be used with depressed
centre Type 27/42 grinding wheels and Type1/41 cutting
wheels. Refer to the Accessory and Guard Applications
Chart for moreinformation.
WARNING: A closed, two‑sided cutting wheel guard is
required when using abrasive cutting wheels or diamond
coated cutting wheels, referred to as a Type A cut‑off
wheelguard.
WARNING: Use of a damaged flange or guard or fail‑
ure to use proper flange and guard can result in injury
due to wheel breakage and wheel contact. Refer to
the Accessory and Guard Applications Chart for
moreinformation.
1. Place the tool on a table, guardup.
2. Place wheel6 against the backing flange7, centreing the
wheel on the raised centre (pilot) of the backingflange.
3. While depressing the spindle lock button and with the
hex depressions facing away from the wheel, thread the
threaded locking flange8 on spindle so that the lugs
engage the two slots in thespindle.
4. While depressing the spindle lock button, tighten the
threaded locking flange8 using a hexwrench.
5. To remove the wheel, depress the spindle lock button and
loosen the threaded lockingflange.
Mounting Sanding Backing Pads (Fig.A, H)
NOTE: Use of a guard with sanding discs that use backing pads,
often called fiber resin discs, is not required. Since a guard is
not required for these accessories, the guard may or may not fit
correctly ifused.
WARNING:
Failure to properly seat the clamp nut and/
or pad could result in serious injury (or damage to the
tool orwheel).
WARNING: Proper guard must be reinstalled for grinding
wheel, cutting wheel, sanding flap disc, wire brush or
wire wheel applications after sanding applications
arecomplete.
1. Place or appropriately thread backing pad19on thespindle.
2. Place the sanding disc18 on the backing pad19.
3. While depressing spindle lock button3, thread the sanding
clamp nut23 on spindle, piloting the raised hub on the
clamp nut into the centre of sanding disc and backingpad.
4. Tighten the clamp nut by hand. Then depress the spindle
lock button while turning the sanding disc until the sanding
disc and clamp nut aresnug.
concrete or masonry, there is an increased risk of exposure
to dust and loss of control resulting inkickback.
NOTE: Edge grinding and cutting can be performed with Type
27wheels designed and specified for this purpose; 6mm thick
wheels are designed for surface grinding while thinner Type
27wheels need to be examined for the manufacturer's label to
see if they can be used for surface grinding or only edge grinding/
cutting. A Type A (cut‑off) wheel guard must be used for any
wheel where surface grinding is forbidden. A Type A (cut‑off)
(previously called type 1/41) wheel guard must be used for for
any dual purpose (combined grinding and cutting‑off abrasive)
wheels. Cutting can also be performed by using a Type1/41
wheel and a Type A cut‑off wheel guard previously called Type
1/41guard.
NOTE: See the Accessory and Guard Applications Chart to
select the proper guard / accessorycombination.
Mounting and Removing Guard (Fig.F)
CAUTION: Guards must be used with all grinding wheels,
cut‑off wheels, diamond coated wheels, sanding flap
discs, wire brushes, and wire wheels. The tool may be used
without a guard only when sanding with conventional
sanding discs. Some DEWALT models are provided with a
guard intended for use with depressed centre wheels (Type
27) and hubbed grinding wheels (Type 27). The same
guard is designed for use with sanding flap discs (Type
27and 29) and wire brushes. A Type A guard must be used
for any cutting application. Grinding with wheels other
than Type 27and 29require different accessory guards.
Mounting instructions for these accessory guards are
included in the accessorypackage.
1. Open the guard release lever10. Align the lugs14 on the
guard with the slots15 on the gearcase.
2. Push the guard down until the guard lugs engage and
rotate freely in the groove on the gear casehub.
3. With the guard latch open, rotate the guard9 into the
desired working position. The guard body should be
positioned between the spindle and the operator to provide
maximum operatorprotection.
4. Close the guard latch to secure the guard on the gear case.
You should not be able to rotate the guard by hand when
the latch is closed. Do not operate the grinder with a loose
guard or the clamp lever in openposition.
5. To remove the guard, open the guard latch, rotate the guard
so that the arrows are aligned and pull up on theguard.
NOTE: The guard is pre‑adjusted to the diameter of the gear
case hub at the factory. If, after a period of time, the guard
becomes loose, tighten the adjusting screw16 with clamp
lever in the closedposition.
CAUTION: Do not tighten the adjusting screw with the
clamp lever in open position. Undetectable damage to the
guard or the mounting hub mayresult.
CAUTION: If guard cannot be tightened by adjusting
clamp, do not use tool and take the tool and guard to a
service centre to repair or replace theguard.

15
ENGLISH
Surface Grinding, Sanding and Wire
Brushing (Fig.M)
CAUTION: Always use the correct guard per the
instructions in thismanual.
To perform work on the surface of a workpiece:
Spindle Lock (Fig.A)
The spindle lock button3 is provided to prevent the spindle
from rotating when installing or removing wheels. Operate
the spindle lock only when the tool is turned off, the battery is
removed 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.
Trigger Switch and Lock-off Lever (Fig.A)
WARNING: Before using the tool, check that the auxilliary
handle is tightenedsecurely.
WARNING: Hold the auxilliary handle and main handle
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.
1. To turn the tool on, push the lock‑off lever2 toward the
back of the tool, then depress the trigger switch1. The tool
will run while the switch isdepressed.
2. Turn the tool off by releasing the releasingswitch.
WARNING: Allow the tool to reach full speed before
touching tool to the work surface. Lift the tool from the
work surface before turning the tooloff.
NOTE: This tool has no provision to lock the switch in the ON
position, and should never be locked ON by any othermeans.
Proper Hand Position (Fig.G)
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.
Proper hand position requires one hand on the main handle13
and the other hand on the auxilliary handle5, as shown in Fig.G.
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 battery pack
before making any adjustments or removing/
installing attachments or accessories. An accidental
start‑up can causeinjury.
5. To remove the wheel, grasp and turn the backing pad and
sanding pad while depressing the spindle lockbutton.
Mounting and Removing Hubbed Wheels (Fig.I)
Hubbed wheels install directly on the spindle. Thread of
accessory must match thread ofspindle.
1. Thread the wheel on the spindle4 byhand.
2. Depress the spindle lock button3 and use a wrench to
tighten the hub of thewheel.
3. Reverse the above procedure to remove thewheel.
NOTICE: Failure to properly seat the wheel before turning
the tool on may result in damage to the tool or thewheel.
Mounting Wire Cup Brushes and WireWheels (Fig.A,I)
WARNING: Failure to properly seat the brush/wheel could
result in serious injury (or damage to the tool orwheel).
CAUTION: To reduce the risk of personal injury,
wear work gloves when handling wire brushes and
wheels. They can becomesharp.
C
AUTION: To reduce the risk of damage to the tool,
wheel or brush must not touch guard when mounted
or while in use. When using a Type A (cut‑off), or Type B
(grinding) wheel guard with a wheel‑type wire brush with a
thickness greater than the maximum thickness as specified in
the Accessory and Guard Applications Chart , the wires
may catch on the guard leading to breaking of thewires.
Wire cup brushes or wire wheels install directly on the threaded
spindle without the use of locking flange. Use only wire brushes
or wheels provided with a M14 threaded hub. These accessories
are available at extra cost from your local DEWALT dealer or
authorised DEWALT
servicecentre.
1. Place the tool on a table, guardup.
2. Thread the wheel on the spindle4 byhand.
3. Depress spindle lock button3 and use a wrench on the
hub of the wire wheel or brush to tighten thewheel.
4. To remove the wheel, reverse the aboveprocedure.
NOTICE: To reduce the risk of damage to the tool, properly
seat the wheel hub before turning the toolon.
Prior to Operation
• Install the guard and appropriate disc or wheel. Do not use
excessively worn discs orwheels.
• Be sure the threaded locking flange are mounted correctly.
Follow the instructions given in the Accessory and Guard
Application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.

16
ENGLISH
MAINTENANCE
Your power tool has been designed to operate over a long
period of time with a minimum of maintenance. Continuous
Edge Grinding and Cutting (Fig.N)
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.
CAUTION:
Wheels used for edge grinding and cutting may
break or kick back if they bend or twist while the tool is being
used. In all edge grinding/cutting operations, the open side
of the guard must be positioned away from theoperator.
NOTICE: Edge grinding/cutting with a Type27wheel
must be limited to shallow cutting and notching—less
than 13mm in depth when the wheel is new. Reduce the
depth of cutting/notching equal to the reduction of the
wheel radius as it wears down. Refer to the Accessory
and Guard Application Chart for more information.
Edge grinding/cutting with a Type 41wheel requires usage
of a Type 1guard.
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/cutting 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.
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. Sanding 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 sanding
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.
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. Material removal rate is
greatest when the tool operates at highspeed.
3. Maintain an appropriate angle between the tool and work
surface. Refer to the chart according to particularfunction.
Function Angle
Grinding 20˚‑30˚
Sanding with Flap Disc 5˚‑10˚
Sanding with Backing Pad 5˚‑15˚
Wire Brushing 5˚‑10˚
4. Maintain contact between the edge of the wheel and the
worksurface.
‑If grinding, sanding with flap discs, or wire brushing,
move the tool continuously in a forward and back
motion to avoid creating gouges in the worksurface.
‑If sanding with a backing pad, move the tool constantly
in a straight line to prevent burning and swirling of
worksurface.
NOTE: Allowing the tool to rest on the work surface without
moving will damage theworkpiece.
5. Remove the tool from work surface before turning tool off.
Allow the tool to stop rotating before laying itdown.
CAUTION: Use extra care when working over an edge, as
a sudden sharp movement of grinder may beexperienced.
Precautions To Take When Working on a Painted
Workpiece
1. Sanding or 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 sanding any paint:
Personal Safety
1. No children or pregnant women should enter the work area
where the paint sanding or wire brushing 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 N.I.O.S.H. approvedmask.
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.

17
ENGLISH
Protecting the Environment
wSeparate collection. Products and batteries marked
with this symbol must not be disposed of with
normal householdwaste.
Products and batteries contain materials that can be
recovered or recycled reducing the demand for raw materials.
Please recycle electrical products and batteries according to local
provisions. Further information is available at www.2helpU.com.
Rechargeable Battery Pack
This long life battery pack must be recharged when it fails to produce
sufficient power on jobs which were easily done before. At the end
of its technical life, discard it with due care for ourenvironment:
• Run the battery pack down completely, then remove it from
thetool.
• Li‑Ion cells are recyclable. Take them to your dealer or a
local recycling station. The collected battery packs will be
recycled or disposed ofproperly.
Tool Connect™ Chip (Fig.I)
WARNING: To reduce the risk of serious personal
injury, turn unit off and disconnect it from power
source and lock off the toolremove the battery
pack before making any adjustments or removing/
installing attachments or accessories. An accidental
start‑up can causeinjury.
Your tool is Tool Connect™ Chip ready and has a location for
installation of a Tool Connect™ Chip.
Tool Connect™ Chip is an optional application for your
smart device (such as a smart phone or tablet) that connects
the device to utilize the mobile application for inventory
management functions.
Refer to Tool Connect™Chip Instruction Sheet for
moreinformation.
Installing the Tool Connect™ Chip
1. Remove the retaining screws26 that hold the Tool
Connect™ Chip protective cover21into thetool.
2. Remove the protective cover and insert the Tool Connect™
Chip into the empty pocket22.
3. Ensure that the Tool Connect™ Chip is flush with the
housing. Secure it with the retaining screws and tighten
thescrews.
4. Refer to Tool Connect™Chip Instruction Sheet for
furtherinstructions.
free from high humidity, freezing temperatures or extreme
temperaturechanges.
The capacity of this tool is 180mm diameterx8mm thick
grinding or cutting wheels. It is important to choose the
correct guards, backing pads and flanges to use with grinder
accessories. See the Accessory and Guard Applications Chart
for information on choosing the correctaccessories.
WARNING:Accessories must be rated for at least
the speed recommended on the tool warning label.
Wheels and other accessories running over their rated
accessory speed may fly apart 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. Use
only the accessories shown in the Accessory and
Guard Applications Chart of this manual. Accessory
ratings must always be above tool speed as shown on
toolnameplate.
WARNING:Handle and store all abrasive wheels
carefully to prevent damage from thermal shock, heat,
mechanical damage, etc. Store in a dry protected area
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.
D
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.
C
Lubrication
Your power tool requires no additionallubrication.
satisfactory operation depends upon proper tool care and
regularcleaning.
WARNING: To reduce the risk of serious personal
injury, turn tool off and disconnect battery pack
before making any adjustments or removing/
installing attachments or accessories. An accidental
start‑up can causeinjury.
The charger and battery pack are notserviceable.

18
ENGLISH
Type 1/41 guard **
Diamond cutting
wheel
Locking flange
Sanding Discs
Rubber backing pad**
Sanding disc
Sanding clamp nut
(Included with rubber
backing pad**)
Hubbed Wheel Wrench
Hubbed wheel
wrench **
Type 1/41 guards are intended for use with Type
1/41 cutting wheels and Type 27wheels marked for
cutting only. Grinding with wheels other than Type
27and Type 29require different accessory guards.
Always use the smallest proper guard possible that
does not contact theaccessory.
** NOTE: Available at extra cost from your local dealer or
authorized servicecenter.
DCG440 ACCESSORIES CHART
Approved wheels for use wtih DCG440
Type 1 / T1
Type 27 / T27
Non-approved wheels for DCG440
Type 11 / T11
Type 27Depressed Center Grinding Wheels
Type 27 guard
(Shallow)
Type 27 depressed
center wheel
Locking flange
Non-Hubbed Sanding Flap Discs
Type 27 guard
(Shallow)
Non‑Hubbed sanding
flap disc
Locking flange
Hubbed Wire Cup Wheels
Type 27 guard
(Shallow)
Hubbed wire
cup wheel
Hubbed Wire Wheels
Type 27 guard
(Shallow)
Hubbed wire wheel
Type 1/41 Cutting Wheels
Type 1/41 guard **
Type 1/41 abrasive
cutting wheel
Locking flange
Diamond Cutting Wheels