DeWalt DWE4549N Manuel utilisateur

D28474/D28493/D28493G/D28494/D28494G/D28499/DWE4549N

Heavy-Duty Large Angle Grinders/ Grandes rectifieuses coudées de service intensif/ Esmeriladoras de

ángulo grande para trabajo pesado

D28497

Heavy-Duty Large Angle Sander/ Grandes ponceuse coudées de service intensif/ Lijadora angular

grande para trabajo pesado

INSTRUCTION MANUAL

GUIDE D’UTILISATION

MANUAL DE INSTRUCCIONES

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA DE

GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES DE

USAR EL PRODUCTO.

If you have questions or comments, contact us.

Pour toute question ou tout commentaire, nous contacter.

Si tiene dudas o comentarios, contáctenos.

1-800-4-DEWALT • www.dewalt.com

Deﬁ nitions: Safety Guidelines

The definitions below describe the level of severity for each

signal word. Please read the manual and pay attention to these

symbols.

DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which,

if not avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury.

NOTICE: Indicates a practice not related to personal injury

which, if not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR

ANY D

EWALT TOOL, CALL US TOLL FREE AT: 1-800-4-DEWALT

(1-800-433-9258).

WARNING: To reduce the risk of injury, read the instruction

manual.

General Power Tool Safety Warnings

WARNING! Read all safety warnings and all instructio).

ns. Failure to follow the warnings and instructions may result in

electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE

The term "power tool" in the warnings refers to your mains-operated

(corded) power tool or battery-operated (cordless) power tool.

1) WORK AREA SAFETY

a) Keep work area clean and well lit. Cluttered or dark areas

invite accidents.

b) Do not operate power tools in explosive atmospheres,

such as in the presence of flammable liquids, gases or

dust. Power tools create sparks which may ignite the dust or

fumes.

c) Keep children and bystanders away while operating a

power tool. Distractions can cause you to lose control.

2) ELECTRICAL SAFETY

a) Power tool plugs must match the outlet. Never modify

the plug in any way. Do not use any adapter plugs with

earthed (grounded) power tools. Unmodified plugs and

matching outlets will reduce risk of electric shock.

b) Avoid body contact with earthed or grounded surfaces

such as pipes, radiators, ranges and refrigerators. There

is an increased risk of electric shock if your body is earthed or

grounded.

c) Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of electric

shock.

d) Do not abuse the cord. Never use the cord for carrying,

pulling or unplugging the power tool. Keep cord away

from heat, oil, sharp edges or moving parts. Damaged or

entangled cords increase the risk of electric shock.

e) When operating a power tool outdoors, use an extension

cord suitable for outdoor use. Use of a cord suitable for

outdoor use reduces the risk of electric shock.

f) If operating a power tool in a damp location is unavoidable,

use a ground fault circuit interrupter (GFCI) protected

supply. Use of a GFCI reduces the risk of electric shock.

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3) PERSONAL SAFETY

a) Stay alert, watch what you are doing and use common

sense when operating a power tool. Do not use a power

tool while you are tired or under the influence of drugs,

alcohol or medication. A moment of inattention while

operating power tools may result in serious personal injury.

b) Use personal protective equipment. Always wear eye

protection. Protective equipment such as dust mask, non-

skid safety shoes, hard hat, or hearing protection used for

appropriate conditions will reduce personal injuries.

c) Prevent unintentional starting. Ensure the switch is in

the off position before connecting to power source and/

or battery pack, picking up or carrying the tool. Carrying

power tools with your finger on the switch or energizing 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 jewelry.

Keep your hair, clothing and gloves away from moving

parts. Loose clothes, jewelry or long hair can be caught in

moving parts.

g) If devices are provided for the connection of dust

extraction and collection facilities, ensure these are

connected and properly used. Use of dust collection can

reduce dust-related hazards.

4) POWER TOOL USE AND CARE

a) Do not force the power tool. Use the correct power tool

for your application. The correct power tool will do the job

better and safer at the rate for which it was designed.

b) Do not use the power tool if the switch does not turn it

on and off. Any power tool that cannot be controlled with the

switch is dangerous and must be repaired.

c) Disconnect the plug from the power source and/or the

battery pack from the power tool before making any

adjustments, changing accessories, or storing power

tools. Such preventive safety measures reduce the risk of

starting the power tool accidentally.

d) Store idle power tools out of the reach of children and

do not allow persons unfamiliar with the power tool or

these instructions to operate the power tool. Power tools

are dangerous in the hands of untrained users.

e) Maintain power tools. Check for misalignment or binding

of moving parts, breakage of parts and any other

condition that may affect the power tool’s operation. If

damaged, have the power tool repaired before use. Many

accidents are caused by poorly maintained power tools.

f) Keep cutting tools sharp and clean. Properly maintained

cutting tools with sharp cutting edges are less likely to bind and

are easier to control.

g) Use the power tool, accessories and tool bits, etc. in

accordance with these instructions, taking into account

the working conditions and the work to be performed.

Use of the power tool for operations different from those

intended could result in a hazardous situation.

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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.

SAFETY INSTRUCTIONS FOR

ALL OPERATIONS

Safety Warnings Common for Grinding,

Sanding, Wire Brushing, Polishing or

Abrasive, Cutting-Off Operations

a) This power tool is intended to function as a grinder,

sander, wire brush, polisher or cut-off tool. Read all safety

warnings, instructions, illustrations and specifications

provided with this power tool. Failure to follow all instructions

listed below may result in electric shock, fire and/or serious

injury.

b) 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.

c) 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.

d) 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.

e) The arbor size of wheels, flanges, backing pads or

any other accessory must properly fit the spindle of

the power tool. Accessories with arbor 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.

f) 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.

g) Wear personal protective equipment. Depending on

application, use face shield, safety goggles or safety

glasses. As appropriate, wear dust mask, hearing

protectors, gloves and workshop apron capable of

stopping small abrasive or workpiece fragments. The eye

protection must be capable of stopping flying debris generated

by various operations. The dust mask or respirator must be

capable of filtrating particles generated by your operation.

Prolonged exposure to high intensity noise may cause hearing

loss.

h) 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.

i) Hold power tool by insulated gripping surfaces only,

when performing an operation where the cutting

accessory may contact hidden wiring or its own cord.

Cutting accessory contacting a "live" wire may make exposed

metal parts of the power tool "live" and shock the operator.

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j) 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.

k) 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.

l) 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.

m) 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.

n) Do not operate the power tool near flammable materials.

Sparks could ignite these materials.

o) Do not use accessories that require liquid coolants.

Using water or other liquid coolants may result in electrocution

or shock.

p) Always use side handle. Tighten the handle securely. The

side handle should always be used to maintain control of the

tool at all times.

Causes and Operator Prevention

of Kickback

Kickback is a sudden reaction to a pinched or snagged rotating

wheel, backing pad, brush or any other accessory. Pinching or

snagging causes rapid stalling of the rotating accessory which

in turn causes the uncontrolled power tool to be forced in the

direction opposite of the accessory’s rotation at the point of the

binding.

For example, if an abrasive wheel is snagged or pinched by the

workpiece, the edge of the wheel that is entering into the pinch

point can dig into the surface of the material causing the wheel

to climb out or kick out. The wheel may either jump toward or

away from the operator, depending on direction of the wheel’s

movement at the point of pinching. Abrasive wheels may also

break under these conditions.

Kickback is the result of tool misuse and/or incorrect operating

procedures or conditions and can be avoided by taking proper

precautions as given below:

a) Maintain a firm grip on the power tool and position your

body and arm to allow you to resist kickback forces.

Always use auxiliary handle, if provided, for maximum

control over kickback or torque reaction during start up.

The operator can control torque reaction or kickback forces, if

proper precautions are taken.

b) Never place your hand near the rotating accessory.

Accessory may kickback over your hand.

c) Do not position your body in the area where power tool

will move if kickback occurs. Kickback will propel the tool

in direction opposite to the wheel’s movement at the point of

snagging.

d) Use special care when working corners, sharp edges etc.

Avoid bouncing and snagging the accessory. Corners,

sharp edges or bouncing have a tendency to snag the rotating

accessory and cause loss of control or kickback.

e) Do not attach a saw chain woodcarving blade or toothed

saw blade. Such blades create frequent kickback and loss of

control.

Safety Warnings Speciﬁ c for Grinding and

Abrasive Cutting-Off Operations

a) Use only wheel types that are recommended for your

power tool and the specific guard designed for the

selected wheel. Wheels for which the power tool was not

designed cannot be adequately guarded and are unsafe.

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b) The guard must be securely attached to the power tool

and positioned for maximum safety, so the least amount

of wheel is exposed towards the operator. The guard

helps to protect operator from broken wheel fragments and

accidental contact with wheel.

c) Wheels must be used only for recommended applications.

For example: do not grind with the side of cut-off wheel.

Abrasive cut-off wheels are intended for peripheral grinding,

side forces applied to these wheels may cause them to shatter.

d) Always use undamaged wheel flanges that are of correct

size and shape for your selected wheel. Proper wheel

flanges support the wheel thus reducing the possibility of wheel

breakage. Flanges for cut-off wheels may be different from

grinding wheel flanges.

e) Do not use worn down wheels from larger power tools.

Wheel intended for larger power tool is not suitable for the

higher speed of a smaller tool and may burst.

Additional Safety Warnings Speciﬁ c for

Abrasive Cutting-Off Operations

a) Do not "jam" the cut-off wheel or apply excessive

pressure. Do not attempt to make an excessive depth

of cut. Overstressing the wheel increases the loading and

susceptibility to twisting or binding of the wheel in the cut and

the possibility of kickback or wheel breakage.

b) Do not position your body in line with and behind the

rotating wheel. When the wheel, at the point of operation, is

moving away from your body, the possible kickback may propel

the spinning wheel and the power tool directly at you.

c) When wheel is binding or when interrupting a cut for any

reason, switch off the power tool and hold the power

tool motionless until the wheel comes to a complete

stop. Never attempt to remove the cut-off wheel from

the cut while the wheel is in motion otherwise kickback

may occur. Investigate and take corrective action to eliminate

the cause of wheel binding.

d) Do not restart the cutting operation in the workpiece.

Let the wheel reach full speed and carefully reenter the

cut. The wheel may bind, walk up or kickback if the power tool

is restarted in the workpiece.

e) Support panels or any oversized workpiece to minimize

the risk of wheel pinching and kickback. Large workpieces

tend to sag under their own weight. Supports must be placed

under the workpiece near the line of cut and near the edge of

the workpiece on both sides of the wheel.

f) Use extra caution when making a "pocket cut" into

existing walls or other blind areas. The protruding wheel

may cut gas or water pipes, electrical wiring or objects that can

cause kickback.

Safety Warnings Speciﬁ c for Sanding

Operations

a) Do not use excessively oversized sanding disc paper.

Follow manufacturers recommendations, when selecting

sanding paper. Larger sanding paper extending beyond the

sanding pad presents a laceration hazard and may cause

snagging, tearing of the disc or kickback.

Safety Warnings Speciﬁ c for Polishing

Operations

a) Do not allow any loose portion of the polishing bonnet

or its attachment strings to spin freely. Tuck away or

trim any loose attachment strings. Loose and spinning

attachment strings can entangle your fingers or snag on the

workpiece.

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Safety Warnings Speciﬁ c 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 recommended for wire brushing,

do not allow any interference of the wire wheel or brush

with the guard. Wire wheel or brush may expand in diameter

due to work and centrifugal forces.

Additional Safety Rules for Grinders

WARNING: The grinding wheel or accessory may loosen

during coast-down of the tool when shut off. If grinding wheel

or accessory loosens, it may dismount from the machine and may

cause serious personal injury.

• Use of accessories not specified in this manual is not

recommended and may be hazardous. Use of power boosters

that would cause the tool to be driven at speeds greater than its

rated speed constitutes misuse.

• Use clamps or another practical way to secure and support

the workpiece to a stable platform. Holding the work by hand

or against your body leaves it unstable and may lead to loss of

control.

• Avoid bouncing the wheel or giving it rough treatment. If this

occurs, stop the tool and inspect the wheel for cracks or flaws.

• Always handle and store wheels in a careful manner.

• Never cut into area that may contain electrical wiring or

piping. Serious injury may result.

• Do not operate this tool for long periods of time. Vibration

caused by the operating action of this tool may cause permanent

injury to fingers, hands, and arms. Use gloves to provide extra

cushion, take frequent rest periods, and limit daily time of use.

• Direct the Dust Ejection System (DES) away from operator

and coworkers. Serious injury may result.

• Air vents often cover moving parts and should be avoided.

Loose clothes, jewelry or long hair can be caught in moving parts.

• An extension cord must have adequate wire size (AWG

or American Wire Gauge) for safety. The smaller the gauge

number of the wire, the greater the capacity of the cable, that is

16 gauge has more capacity than 18 gauge. An undersized cord

will cause a drop in line voltage resulting in loss of power and

overheating. When using more than one extension to make up the

total length, be sure each individual extension contains at least the

minimum wire size. The following table shows the correct size to

use depending on cord length and nameplate ampere rating. If in

doubt, use the next heavier gauge. The smaller the gauge number,

the heavier the cord.

Minimum Gauge for Cord Sets

Ampere Rating

Volts

Total Length of Cord

in Feet (meters)

120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)

240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)

More

Than

Not More

Than

AWG

0 6 18 16 16 14

610 18161412

10 12 16 16 14 12

12 16 14 12 Not Recommended

WARNING: ALWAYS use safety glasses. Everyday eyeglasses are

NOT safety glasses. Also use face or dust mask if cutting operation is

dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),

• ANSI S12.6 (S3.19) hearing protection,

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• NIOSH/OSHA/MSHA respiratory protection.

WARNING: Some dust created by power sanding, sawing,

grinding, drilling, and other construction activities contains chemicals

known to the State of California to cause cancer, birth defects or other

reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry

products, and

• arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you

do this type of work. To reduce your exposure to these chemicals:

work in a well ventilated area, and work with approved safety

equipment, such as those dust masks that are specially designed to

filter out microscopic particles.

• Avoid prolonged contact with dust from power sanding,

sawing, grinding, drilling, and other construction activities.

Wear protective clothing and wash exposed areas with

soap and water. Allowing dust to get into your mouth, eyes, or

lay on the skin may promote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disperse dust,

which may cause serious and permanent respiratory or other

injury. Always use NIOSH/OSHA approved respiratory protection

appropriate for the dust exposure. Direct particles away from face

and body.

WARNING: Always wear proper personal hearing protection

that conforms to ANSI S12.6 (S3.19) during use. Under some

conditions and duration of use, noise from this product may

contribute to hearing loss.

• The label on your tool may include the following symbols. The

symbols and their definitions are as follows:

V ............volts A .............amperes

Hz ..........hertz W ............watts

min ........minutes

.....direct current

.......... Class I Construction

(grounded)

.......... Class II Construction

(double insulated)

…/min ...per minute

IPM ........impacts per minute

SPM ......strokes per minute

sfpm ...... surface feet per

minute

......... alternating current

......... alternating or direct

current

n

o ..........no load speed

n ............ rated speed

..........earthing terminal

........... safety alert symbol

BPM ...... beats per minute

RPM ...... revolutions per

minute

SAVE THESE INSTRUCTIONS FOR

FUTUREUSE

Motor

Be sure your power supply agrees with the nameplate marking.

Voltage decrease of more than 10% will cause loss of power and

overheating. D

EWALT tools are factory tested; if this tool does not

operate, check power supply.

FAMILIARIZATION

Large Angle Grinders and Large Angle Sanders are designed for

heavy material removal in extended use applications. The following

grinders and sanders are described in this manual:

D28474 7" Angle Grinder double insulated 8,000 rpm

D28493 9" Angle Grinder double insulated 5,000 rpm

D28493G 9" Angle Grinder grounded 5,000 rpm

D28494 7"/9" Angle Grinder double insulated 6,000 rpm

D28494G 7"/9" Angle Grinder grounded 6,000 rpm

D28497 7"/9" Angle Sander grounded 6,000 rpm

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D28499 7"/9" Angle Grinder double insulated 6,000 rpm

DWE4549N 7"/9" Angle Grinder double insulated 6,000 rpm

A

B

D

E

F

C

G

H

FIG. 1

COMPONENTS (FIG. 1)

WARNING: Never modify the power tool or any part of it. Damage

or personal injury could result.

A. Trigger switch

B. Lock-on button

C. Spindle lock button

D. Side handle

E. Spindle

F. Soft mount

G. Top bumper

H. Trigger lock-off lever

INTENDED USE

This grinder is designed for professional grinding, sanding, wire

brushing, polishing or abrasive, cutting-off applications.

DO NOT use under wet conditions or in presence of flammable

liquids or gases.

This 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.

Features

SWITCH

The tool is controlled by a trigger switch (A). A lock-on button (B)

provides increased comfort in extended use applications.

ROTATING REAR HANDLE (D28499 ONLY)

The rear handle can be positioned 30°, 60°, and 90° left and right of

center position.

ROTATING GEAR CASE (D28474, D28493, D28494, D28497)

For applications in which a tool will be dedicated for uses in edge

grinding and finishing work, the gear case may be rotated 90° left or

right of its original position. See page 10 for instructions on rotating

the gear case.

MULTIPLE SIDE HANDLE POSITIONS

The side handle can be properly positioned in five lo ca tions based on

personal preference and application. The side handle must be used

at all times to maintain proper control of the tool.

TOP BUMPER (FIG. 2)

The gear case top bumper may wear with

FIG. 2

use. The bumper can be replaced with part

num ber 397711-00 available at extra cost

from D

EWALT authorized service centers.

Replacement should be performed by

D

EWALT authorized service centers or

qualified service personnel.

SPINDLE LOCK (FIG. 3)

The spindle lock pin is provided to prevent the

C

FIG. 3

spindle from rotating when installing or

removing wheels. Operate the spindle lock pin

only when the tool is turned off and unplugged

from the power source. To engage the lock,

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depress the spindle lock button (C) and rotate the spindle until you are

unable to rotate it further.

CAUTION: Never depress the spindle lock button while the grinder

is running. Never turn on the grinder while the spindle lock button is

depressed. Damage to your tool or personal injury may result.

SOFT MOUNT

The grinder is equipped with a soft mount, enabling easy wheel

installation and removal.

Accessories and Attachments

It is important to choose the correct guards, backing pads

and flanges to use with grinder accessories. See the chart on

pages 11–13 for information on 3choosing the correct accessories.

WARNING: Accessories must be rated for at least the speed

recom mended on the tool warning label. Wheels and other

accessories running over rated speed can fly apart and cause injury.

Accessory ratings must always be above tool speed as shown on

tool nameplate.

ATTACHMENTS

Attachments designed specifically for this grinder can be

purchased through D

EWALT dealers and DEWALT Factory Service

centers.

9" Type 27 guard

9" Type 28 guard

7" Type 27 guard

6" Type 11 Flaring cup guard with flange

4" Type 11 Flaring cup guard with flange

Type 11 Flaring cup wheel backing flange

Type 1 Flange set

7" Type 1 Guard

Grinding backing flange

Clamp nut

Wheel Wrench

Soft mount spindle protector

Top gear case bumper

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of injury, turn unit off

and disconnect it from power source before installing and

removing accessories, before adjusting or when making

repairs. An accidental start-up can cause injury.

Attaching the Side Handle (Fig. 4)

To install the side handle, thread the handle into

FIG. 4

one of the five positions listed below and

tighten securely by turning clockwise.

• Two front positions: Forward handle

positions are designed for optimized

balance in surface finishing applications.

• Two rear positions: Rear handle positions

are designed for optimized balance in edge

grinding applications.

• One top position: Top handle position is

designed for edge grinding applications.

NOTE: D28497 includes only three handle positions.

Rotating the Rear Handle (Fig. 5)

(D28499 ONLY)

1. Unlock the rear handle by

I

FIG. 5

pulling out the handle re lease

lever (I) as shown.

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2. Rotate handle into available 0°, 30°, 60°, or 90° position left OR

right of center.

3. Push in the handle release lever.

4. Before turning the tool on, ensure that the handle is locked into a

position and the handle release lever has returned to the original

position flush with the tool housing.

Rotating the Gear Case (Fig. 6)

1. Remove guard and flanges from

90˚

FIG. 6

tool.

2. Remove the four corner screws

attaching the gear case to motor

housing.

3. Separate the gear case from

motor housing, not more than

1/4" (6.35 mm), rotate the gear

case head to desired position.

NOTE: If the gear case and motor housing become separated

by more than 1/4" (6.35 mm), the tool must be serviced and

re-assembled by a D

EWALT service center. Failure to have the tool

serviced may cause brush, motor and bearing failure.

4. Re-install screws to attach the gear case to the motor housing.

Tighten screws to 20 in./lbs. torque. Overtightening could cause

screws to strip.

OPERATION

WARNING: To reduce the risk of injury, turn unit off

and disconnect it from power source before installing and

removing accessories, before adjusting or when making

repairs. An accidental start-up can cause injury.

Power Source

Plug the large angle grinder into a dedicated elec trical circuit.

Operating this tool on a circuit with other tools will decrease tool

performance.

Switch (Fig. 7)

WARNING: Before connecting the tool to a power source or

after a power failure, depress and release the trigger switch (A) once

without depressing the lock-on button (B) to ensure that the switch is

in the off position. If the trigger switch is locked on, the tool will start

unexpectedly when power is reconnected to the tool. Hold the side

handle and rear handle firmly to maintain control of tool at start up

and during use.

TRIGGER OPERATION

To turn the tool on, depress the trigger switch

A

H

B

FIG. 7

(A). The tool will remain running while the trigger

is depressed. øTurn the tool off by releasing the

trigger.

TRIGGER OPERATION (DWE4549N ONLY)

To turn the tool on, depress the trigger lock-off lever (H) then the

trigger switch. The trigger switch (A) can be feathered as long as the

trigger lock-off lever is depressed. The tool will remain running while

the trigger is depressed. Turn the tool off by releasing the trigger.

TRIGGER OPERATION WITH LOCK-ON FEATURE

(D28474, D28493, D28493G, D28494, D28494G, D28499)

To turn tool on, depress trigger. Depress and hold lock-on button (B)

while releasing trigger. Lock-on button will remain depressed and tool

will remain on.

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To turn the tool off, depress and release trigger. The lock pin button

will pop out, permitting the trigger to disengage and causing the tool

to turn off.

NOTE: Allow the tool to reach full speed before touching tool to work

surface. Lift the tool from the work surface before turning the tool off.

CAUTION: Make sure the wheel has come to a complete stop

be fore setting the tool down.

REMOVAL OF LOCK-ON FEATURE

(D28474, D28493, D28493G, D28494, D28494G, D28499)

The lock-on button (B) can be permanently removed without

compromising compliance with regulatory agencies shown on the

tool’s nameplate. Removal of the lock pin must be done by a D

EWALT

Service Center.

Mounting and Using Depressed Center

Grinding Wheels and Sanding Flap Discs

IMPORTANT INFORMATION ABOUT GUARDS (FIG. 8)

Guards must be used with all grinding

GRINDING

WHEEL

SURFACE

GUARD

LIP

GUA

RD

LIP

FIG. 8

wheels, sanding flap discs, wire brushes

and wire wheels. The tool may be used

without a guard only when sanding with

conventional sanding discs. D

EWALT

models D28493, D28494, D28474, D28499

are provided with a guard intended for use

with depressed center wheels (Type 27),

and hubbed grinding wheels (Type 27). The

same guard is designed for use with sanding

flap discs, wire brushes and wire wheels.

Grinding and cutting with wheels other than

Type 27 and 29 require different accessory guards not included with

the tool. Mounting instructions for these accessory guards are

included in the accessory package.

Sanding Flap Discs

soft mount

Type 27 guard

D284937/D284939

Type 27 guard

D284937/D284939

hubbed sanding flap

disc

non-hubbed sanding

flap disc

clamp nut

22191-00

backing flange

54339-00

NOTE: Wheel size must match guard size; i.e., a new 7" wheel may

not be used with a 9" guard. The bottom surface of wheel must be

inside the bend of the guard lip.

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11

Grinding Wheels

soft mount

Type 27 guard

D284937/D284939

Type 27 hubbed wheel

soft mount

Type 28 guard

D284938

Type 28 hubbed wheel

soft mount

Type 27 guard

D284937/D284939

backing flange

54339-00

Type 27 non-hubbed

wheel

clamp nut

22191-00

Sanding Discs

soft mount

rubber backing pad

D4947

sanding disc

clamp nut

included with

D4947

soft mount

Type 28 guard

D284937/D284939

backing flange

54339-00

Type 28 non-hubbed

wheel

clamp nut

22191-00

NOTE: Wheel size must match guard size; i.e., a new 7" wheel may not be used with a 9"

guard. The bottom surface of wheel must be inside the bend of the guard lip.

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12

Flaring Cup Stones

Wire Wheels

soft mount

wire wheel

Type 11 flaring cup guard

D284934 4"

D284936 6"

backing flange

608368-00

flaring cup stone

NOTE: Wheel size must match guard size; i.e., a 7" wheel

may not be used with a 9" guard.

Cutting Wheels

Type 27 guard

D284937/D284939

soft mount

wire cup brush

Type 27 guard

D284937/D284939

Type 1 guard

D284931

abrasive cutting wheel

clamp nut

608463-00

backing flange

608370-00

Type 1 guard

D284931

diamond cutting wheel

clamp nut

608463-00

backing flange

608370-00

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13

CAUTION: When using a grinding wheel with a Type 27, 28, or 29

guard, be sure that the bottom surface of the grinding wheel is inside

the guard lip.

CAUTION: DEWALT model D28497 angle sander may only be

used for grinding by using appropriate accessory guard.

MOUNTING AND REMOVING GUARD (FIG. 9)

1. Open the guard latch (J), and align the lugs with slots on the gear

case cover. Position the guard facing backward, as shown.

2. Push the guard down until the guard

J

K

FIG. 9

lugs engage and rotate freely in the

groove on the gear case hub.

3. With the guard latch open, rotate

the guard into the desired working

position that provides maximum

protection to the user as shown.

4. Close the guard latch to secure the

guard on the gear case. You should

be unable to rotate the guard by

hand when the latch is closed. Do

not operate the grinder with a loose

guard or the guard latch in open

position.

5. To remove the guard, follow the

procedure above in reverse order.

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 (K) with clamp in the

closed position.

NOTICE: Do not tighten the adjusting screw with the guard latch in

open position. Undetectable damage to the guard or the mounting

hub may result.

Mounting and Removing Hubbed Wheels

Hubbed wheels install directly on the 5/8"–11 threaded spindle.

1. Thread the wheel on the spindle by hand, seating the wheel

against the soft mount.

2. Depress the spindle lock button and use a wrench to tighten the

hub of the wheel.

3. Reverse the above procedure to remove the wheel.

CAUTION: Failure to properly seat the wheel against the soft

mount before turning the tool on may result in damage to the tool or

the wheel.

MOUNTING NON-HUBBED WHEELS (FIG. 10)

Depressed center, Type 27 grinding wheels

must be used with available accessory flanges.

See the chart on pages 11–13 of this manual for

more information.

1. Install the metal backing flange (L) on spindle

(F) against the soft mount.

2. Place wheel against the backing flange,

centering the wheel on the backing flange

pilot.

3. While depressing the spindle lock button,

thread the clamp nut (M) on spindle, piloting

the raised hub on clamp nut in the center of

grinding wheel.

4. Tighten the clamp nut with a wrench.

5. Reverse the above procedure to remove the

wheel.

M

L

F

FIG. 10

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14

SURFACE GRINDING WITH GRINDING WHEELS (FIG. 11)

1. Allow the tool to reach full speed before touching tool to work

surface.

2. Apply minimum pressure to work surface,

20˚–30˚

FIG. 11

to allow the tool to operate at high speed.

3. Maintain a 20˚ to 30˚ angle between the tool

and work surface.

4. Continuously move the tool in a forward and back motion to avoid

creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow

the tool to stop rotating before setting it down.

EDGE GRINDING WITH GRINDING WHEELS

WARNING: Wheels used for cutting and edge grinding may break

or kick back if they bend or twist while the tool is being used to do

cut-off work or deep grinding. To reduce the risk of serious injury, limit

the use of these wheels with a standard Type 27 guard to shallow

cutting and notching [less than 1/2" (13 mm) in depth]. The open side

of the guard must be positioned away from the operator. For deeper

cutting with a Type 1 wheel, use a closed, Type 1 guard. Type 1

guards are available at extra cost from your local dealer or authorized

service center.

1. Allow the tool to reach full speed before touching the tool to the

work surface.

2. Apply minimum pressure to work surface, to allow the tool to

operate at high speed.

3. Protect yourself during edge finishing by directing the open side

of the guard away from you.

4. Move the tool continuously in a forward and back motion to avoid

creating gouges in the work surface.

5. Remove tool from work surface before turning the tool off. Allow

the tool to stop rotating before setting it down.

WARNING: Do not use edge grinding wheels for surface grinding

applications because edge grinding wheels are not designed for

side pressures encountered with surface grinding. Wheel breakage

and injury may result.

SURFACE FINISHING WITH SANDING FLAP DISCS (FIG. 12)

1. Allow the tool to reach full speed before touching tool to work

surface.

2. Apply minimum pressure to work surface, to

FIG. 12

5˚–10˚

allow the tool to operate at high speed.

3. Maintain a 5˚ to 10˚ angle between the tool

and work surface.

4. Continuously move the tool in a forward and back motion to avoid

creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow

the tool to stop rotating before setting it down.

Mounting and Using Sanding

Backing Pads

Sanding pads and sanding discs must be rated above minimum

accessory speed as shown on tool. Recommended sanding

backing pads and sanding discs are available at extra cost from

D

EWALT service centers and DEWALT dealers.

NOTE: Guard may be removed for sanding applications with backing

pads and sanding discs. Sanding flap discs are considered grinding

wheels by ANSI standards and require the use of a guard. (See

Mounting and Using Depressed Center Grinding Wheels and

Sanding Flap Discs).

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15

MOUNTING SANDING BACKING PADS (FIG. 13)

CAUTION: Proper guard must be re-installed for grinding wheel,

sanding flap disc, wire brush, or wire wheel applications after sanding

applications are complete.

1. Place or appropriately thread rubber

FIG. 13

P

N

O

backing pad (N) down to soft mount.

2. Place the sanding disc (O) on the rubber

backing pad (N).

3. While depressing spindle lock, thread

clamp nut (P) on spindle, piloting the raised

hub on the clamp nut into the center of

san ding disc and backing pad.

4. Tighten the clamp nut with the proper

wrench.

5. To remove the wheel, reverse the above

procedure.

USING SANDING BACKING PADS (FIG. 14)

Choose the proper grit sandpaper for your application. Sandpaper

is available in various grits. Coarse grits yield faster material re moval

rates and a rougher finish. Finer grits yield slower material removal

and a smoother finish.

Begin with coarser grit discs for fast, rough material removal. Move to

a medium grit paper and finish with a fine grit disc for optimal finish.

Coarse 16–30 grit

Medium 36–80 grit

Fine Finishing 100–120 grit

Very Fine Finishing 150–180 grit

1. Allow the tool to reach full speed before touching tool to work

surface.

2. Apply minimum pressure to work surface, allowing tool to operate

at high speed.

3. Maintain a 5˚ to 15˚ angle between the

5˚–15˚

FIG. 14

tool and work surface. The san ding

disc should contact approximately one

inch of work surface.

4. Move the tool constantly in a straight line to prevent burning and

swirling of work surface. Allowing the tool to rest on the work

surface without moving, or moving the tool in a circular motion

causes burning and swirling marks on the work surface.

5. Remove the tool from the work surface before turning the tool off.

Allow the tool to stop rotating before setting it down.

Mounting and Using Wire Brushes

and Wire Wheels

Wire brushes and wire wheels must be rated above minimum

accessory speed as shown on tool. Use only wire brushes and

wheels provided with a 5/8"–11 threaded hub. A Type 27 guard is

required when using wire brushes and wheels.

WARNING: Wear work gloves when handling wire brushes or

wheels. Wire brushes and wheels can become sharp.

MOUNTING WIRE BRUSHES AND WIRE WHEELS

1. Thread the wheel on the spindle by hand, seating the wheel

against the soft mount.

2. Depress the spindle lock button and use a wrench on the hub of

the wire brush or wheel to tighten the wheel.

3. To remove the wheel, depress the spindle lock button and use a

wrench on the hub of the wire brush or wheel to loosen it.

NOTE: Failure to properly seat the wheel hub against the soft mount

before turning the tool on may result in damage to the tool or wheel.

USING WIRE CUP BRUSHES AND WIRE WHEELS

(FIG. 15)

Wire wheels and brushes can be used for removing rust, scale and

paint, and for smoothing irregular surfaces.

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16

1. Allow tool to reach full speed before touching tool to work

surface.

2. Apply minimum pressure to work surface, to allow the tool to

operate at high speed.

3. Maintain a 5˚ to 10˚ angle between the tool

FIG. 15

5˚–10˚

and work surface for wire cup brushes.

4. Maintain contact between the edge of

the wheel and the work surface with wire

wheels.

5. Continuously move the tool in a forward

and back motion to avoid creating gouges

in the work surface. Allowing the tool to

rest on the work surface without moving,

or moving the tool in a circular motion

causes burning and swirling marks on the

work surface.

6. Remove the tool from the work surface

before turning the tool off. Allow the tool to

stop rotating before setting it down.

Mounting and Using Flaring Cup

(Type 11) Wheel

MOUNTING FLARING CUP WHEEL GUARD (FIG. 16)

WARNING: The flaring cup wheel guard is not included with this

tool. Flaring cup wheels require proper flanges and guards. 4" flaring

cup wheel guard D284934 and 6" flaring cup wheel guard D284936

are available as accessories and include proper flange. Failure to use

the proper flange and guard can result in injury resulting from wheel

break age and wheel contact.

1. Install the guard as shown.

2. Guard body should be positioned

FIG. 16

Q

between the spindle and the operator

to provide maximum operator

protection.

3. Securely tighten the two clamping

screws (Q) supplied with the guard.

MOUNTING FLARING CUP WHEEL

(FIG. 17)

1. Remove the soft mount (F).

2. Install the flaring cup wheel backing flange, aligning the flats on

spindle (R) with the flats on backing flange (S).

3. Thread the flaring cup wheel on spindle by hand, seating wheel

against backing flange.

4. Depress the spindle lock button and tighten the wheel by hand.

5. To remove the wheel, reverse the above procedure.

FIG. 17

F

R

S

NOTICE: Failure to properly seat the wheel against backing flange

before turning the tool on may result in damage to the tool or the

wheel.

NOTE: Adjust the guard skirt so that only 1/8" (3.17 mm) of the wheel

is exposed by loosening the bolts, allowing the guard to lengthen.

Tighten the guard skirt bolts securely before using the grinder.

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17

USING A FLARING CUP WHEEL (FIG. 18)

Flaring cup wheels are designed for heavy material removal.

1. Allow the tool to reach full speed before touching tool to work

surface.

2. Apply minimum pressure to work surface,

FIG. 18

5˚

–

10˚

allowing the tool to oper ate at high speed.

3. Maintain a 5˚ to 10˚ angle between the tool

and the work surface.

4. Continuously move the tool in a forward and back motion to avoid

creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow

the tool to stop rotating before setting it down.

Mounting and Using Cutting

(Type 1) Wheels

Cutting wheels include diamond wheels and

FIG. 19

J

T

abrasive discs. Abrasive cutting wheels for

metal and concrete use are available. Diamond

blades for concrete cutting can also be used.

WARNING: A closed, cutting wheel guard

is not included with this tool. Cutting wheels

require proper flanges and guards. A 7" cutting

guard, D284931, is available as an accessory

and includes proper, matching flanges. Failure

to use proper flange and guard can result in

injury resulting from wheel breakage and wheel

contact.

MOUNTING CLOSED (TYPE 1) GUARD (FIG. 19, 20)

1. Open the guard latch (J), and align the lugs with slots on the gear

case cover. Position the guard facing backward, as shown.

2. Push the guard down until the guard lug engages and rotates

freely in the groove on the gear case hub.

3. Rotate guard (T) into 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 cover.

You should be unable to rotate the guard by hand when the latch

is in closed position. Do not operate grinder with a loose guard or

guard latch in open position.

NOTE: The guard is pre-adjusted to the

FIG. 20

K

dia met er of the gear case hub at the factory. If,

after a period of time, the guard be comes

loose, tighten the adjusting screw (K) with the

guard latch in the closed position.

NOTICE: Do not tighten adjusting screw with

guard latch in open position. Undetectable

damage to guard or mounting hub may result.

MOUNTING CUTTING WHEELS (FIG. 21)

1. Remove soft mount (F).

2. Install wheel backing flange, aligning flats on spindle (R) with flats

on backing flange (U).

3. Place the wheel on the backing flange, centering the wheel on the

backing flange pilot.

4. Install the clamp nut, ensuring that the wheel remains centered on

the backing flange.

5. Depress the spindle lock button and tighten clamp nut with

wrench.

6. Reverse the above procedure to remove the wheel.

English

18

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