DEWALT DWE4056 Angle Grinder Instruction Manual

: June 4, 2024
: Dewalt

DWE4056
DWE4057
DWE4120
DWE4156
DWE4157
Angle Grinder ****
www.DEWALT.COM
original instructions

HILTI SR 6-22 DEWALT DWE4056 Angle Grinder - fig 1

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Technical Data

| | DWE4056| DWE4057| DWE4120| OWE4156| DWE4157
---|---|---|---|---|---|---
Voltage| VA(| 230| 230| 230| 230| 230
U.K. & Ireland| V| 230/115| 230| | –|
Type| | 1| 1| 1| 1| 1
Power input| W| 800| 800| 900| 900| 900
No-load/rated speed| mind| 11800| 11800| 11800| 11800| 11800
Wheel diameter| mm| 115| 125| 115| 115| 125
Spindle diameter| | M14| M14| M14| M14| M14
Spindle length| mm| 14.| 14.| 14.| 14.| 14.
Weight| kg| 1.8| 1.9| 2.05| 2.0| 2.05*

weight includes side handle and guard|
| | | |
Noise values and vibration values (triax vector sum) according to EN 60745-2-3:| | | |
LW, (sound pressure)| dB(A) 90.5| 91.| 92.| 92.| 92.
LWA (sound power)| dB(A) 101.3| 101.| 103.| 103.| 103.
K (sound power uncertainty)| dB(A) 3.0| 3.0| 3.0| 3.0| 3.0
| | | | |
Surface grinding
Vibration emission value ah,AG = Uncertainty K =| M/S2 9.4
m/s’ 1.5| 9.4
1.5| 11.0
1.5| 11.0
1.5| 11.0
1.5
Disc sanding
Vibration emission value atos = Uncertainty K=| m/s2 7.5
m/s2 1.5| 7.5
1.5| 6.8
1.5| 6.8
1.5| 6.8
1.5

The vibration emission level given in this information sheet has been measured in accordance with a standardized test given in EN60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.
WARNING: The declared vibration emission level represents the main applications of the tool. However, if the tool is used for different applications, with different accessories, or poorly maintained, the vibration emission may differ. This may significantly increase the exposure level over the total working period.
An estimation of the level of exposure to vibration should also take into account times when the tool is switched off or when it is running but not actually doing the job. This may significantly reduce the exposure level over the total working period.
Identify additional safety measures to protect the operator from the effects of vibration such as: maintaining the tool and the accessories, keeping the hands warm, and organization of work patterns.

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 that, if not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury
CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
NOTICE: Indicates a practice not related to personal injury that, if not avoided, may result in property damage.

Denotes risk of electric shock.
Denotes risk of fire.

EC-Declaration of Conformity
MACHINERY DIRECTIVE

DeWALT declares that these products described under Technical Data are in compliance with:
2006/42/EC, EN60745-1:2009+A11:2010, EN60745-2-3:2011+A2:2013+A11:2014 +A12:2014+A13:2015.
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 the compilation of the technical file and makes this declaration on behalf of DeWALT.

Markus Rompel
Director Engineering
DeWALT, Richard-Klinger-Straße 11,
D-65510, Idstein, Germany
05.03.2018

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

General Power Tool Safety Warnings

WARNING! Read all safety warnings and all instructions. Failure to followthe 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.

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 that may ignite the dust
or fumes.
c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
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 the 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. The 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.
The use of an RCD reduces the risk of electric shock.
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 masks, non-skid safety shoes, hard hats, 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 a 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. The use of dust collection can reduce dust-related hazards.
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 at 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.
SERVICE
a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

ADDITIONAL SPECIFIC SAFETY RULES

Safety Instructions for All Operations
SAFETY WARNINGS COMMON FOR GRINDING, SANDING, WIRE BRUSHING, OR ABRASIVE CUTTING-OFF OPERATIONS:

a) This power tool is intended to function as a grinder, sander, wire brush, or cut-off tool. Read all safety warnings, instructions, illustrations, and specifications provided with
this power tool. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury.
b) Operations such as polishing are not recommended to be performed with this power tool. Operations for which the power tool was not designed and may create a hazard and cause personal injury.
c) Do not use accessories that are not specifically designed and recommended by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.
d) The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
e) The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories can not be adequately guarded or controlled.
f) Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbor hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively, and may cause loss of control.
g) Do not use a damaged accessory. Before each use inspects the accessory such as the abrasive wheel for chips and cracks, backing pad for cracks, tear, or excess wear, and wire brush for loose or cracked wires. If a power tool or accessory is dropped, inspect for damage or install an undamaged accessory.
After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed
for one minute. Damaged accessories will normally break apart during this test time.
h) Wear personal protective equipment.
Depending on the application, use a face shield, safety goggles, or safety glasses.
As appropriate, wear a dust mask, hearing protectors, gloves, and a workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation.
Prolonged exposure to high-intensity noise may cause hearing loss.
i) Keep bystanders a safe distance away from the work area. Anyone entering the work area must wear personal protective equipment. Fragments of a workpiece or of a broken
accessory may fly away and cause injury beyond the immediate area of operation.
j) Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting
accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
k) Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
l) Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.
m) Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
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

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 the 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 an 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. The accessory may kick back over your hand.
c) Do not position your body in the area where the power tool will move if kickback occurs. Kickback will propel the tool in the direction opposite to the wheel’s movement at the point of snagging.
d) Use special care when working corners, sharp edges, etc. Avoid bouncing and snagging the accessory. Corners, sharp edges, or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and Abrasive Cutting-Off Operations

a) Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel. Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.
b) The grinding surface of center 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 to the operator. The guard helps to protect the operator from broken wheel fragments, accidental contact with the wheel, and sparks that could ignite clothing.
d) Wheels must be used only for recommended applications. For example: do not grind with the side of the 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 the 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. The wheel intended for a larger power tool is not suitable for the higher speed of a smaller tool and may burst.

Additional Safety Warnings Specific for Abrasive Cutting-Off Operations

a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.
b) Do not position your body in line with and behind the rotating wheel. When the wheel, at the point of operations, is moving away from your body, the possible kickback may propel the spinning wheel and the power tool directly at you.
c) When wheel is binding or when interrupting a cut for any reason, switch off the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt to remove the cut-off wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause
of wheel binding.
d) Do not restart the cutting operation in the workpiece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may bind, walk up or kick back if the power tool is restarted in the workpiece.
e) Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.
f) Use extra caution when making a “pocket cut” into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring, or objects that can cause kickback.

Safety Warnings Specific for Sanding Operations

a) Do not use excessively oversized sanding disc paper. Follow manufacturer’s recommendations, when selecting sanding paper. Larger sanding paper extending beyond the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.
Safety Warnings Specific for Wire Brushing Operations
a) Be aware that wire bristles are thrown by the brush even during ordinary operations. 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

Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbor hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
The grinding surface of the center 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.
Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories can result in injury.
Always use a side handle. Tighten the handle securely. The side handle should always be used to maintain control of the tool at all times.
WARNING: We recommend the use of a residual current device with a residual current rating of 30mA or less. \

Residual Risks

In spite of the application of the relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided.
These are:

Impairment of hearing.
Risk of personal injury due to flying particles.
Risk of burns due to accessories becoming hot during operation.
Risk of personal injury due to prolonged use.
Risk of dust from hazardous substances.

Markings on Tool
The following pictograms are shown on the tool:

Read the instruction manual before use.
Wear ear protection.
**** Wear eye protection.

DATE CODE POSITION (FIG. 1)
The date code (P), which also includes the year of manufacture, is printed at the front of the gear case.
Example:
2018 XX XX
Year of Manufacture

Package Contents

The package contains:

1 Angle grinder
1 Guard
1 Side handle
1 Flange set
1 Hex key
1 Instruction manual

Check for damage to the tool, parts, or accessories which may have occurred during transport.
Take the time to thoroughly read and understand this manual prior to operation.

Description (fig. 1, 3)

WARNING: Never modify the power tool or any part of it. Damage or personal injury could result.

A. Spindle lock button
B. Spindle
C. Side handle
D. Backing flange
E. Threaded clamp nut| F. Guard
G. Slider switch
H. Paddle switch (DWE4120 only)
I. Lock-off lever (DWE4120 only)
J. Guard release lever
---|---

INTENDED USE
The DWE4056, DWE4057, DWE4120, DWE4156, and WE4157 heavy-duty angle grinders have been designed for professional grinding, sanding, wire brushing, and cutting applications.
DO NOT use grinding wheels other than center depressed wheels and flap discs.
DO NOT use under wet conditions or in the presence of flammable liquids or gases.
These heavy-duty angle grinders are professional power tools.
DO NOT let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

Young children and the infirm. This appliance is not intended for use by young children or infirm persons without supervision.
This product is not intended for use by persons (including children) suffering from diminished physical, sensory or mental abilities; lack of experience, knowledge, or skills unless they are supervised by a person responsible for their safety. Children should never be left alone with this product.

Soft Start Feature

(DWE4056, DWE4057, DWE4156, DWE4157)
The soft start feature allows a slow-speed build-up to avoid an initial jerk when starting. This feature is particularly useful when working in confined spaces.
No-Volt
(DWE4056, DWE4057, DWE4156, DWE4157)
The No-volt function stops the grinder restarting without the switch being cycled if there is a break in the power supply.

Electrical Safety
The electric motor has been designed for one voltage only. Always check that the power supply corresponds to the voltage on the rating plate.
**Your DeWALT tool is double insulated in accordance with EN 60745; therefore no earth wire is required.
WARNING:** 115 V units have to be operated via a fail-safe isolating transformer with an earth screen between the primary and secondary winding.
If the supply cord is damaged, it must be replaced by a specially prepared cord available through the DeWALT service organization.

Mains Plug Replacement

(U.K. & Ireland Only)
If a new mains plug needs to be fitted:

Safely dispose of the old plug.
Connect the brown lead to the live terminal in the plug.
Connect the blue lead to the neutral terminal.

WARNING: No connection is to be made to the earth terminal. Follow the fitting instructions supplied with good quality plugs. Recommended fuse: 13 A.

Using an Extension Cable
If an extension cable is required, use an approved 3–core extension cable suitable for the power input of this tool (see Technical Data). The minimum conductor size is 1.5 mm
2; the maximum length is 30 m. When using a cable reel, always unwind the cable completely.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, turn the tool off and disconnect the tool from the power source before making any adjustments or removing/installing attachments or accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off.

Attaching Side Handle (fig. 1)
WARNING: Before using the tool, check that the handle is tightened securely.
Screw the side handle (C) tightly into one of the holes on either side of the gear case. The side handle should always be used to maintain control of the tool at all times.
Accessories and Attachments It is important to choose the correct guards, backing pads, and flanges to use with grinder accessories. Refer to the chart at the end of this section for information on choosing the correct accessories.
NOTE: Edge grinding can be performed with Type 27 wheels designed and specified for this purpose.

WARNING: Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over rated accessory speed may burst and cause injury. Threaded accessories must have an M14 hub. Every unthreaded accessory must have a 22 mm arbor hole. If it does not, it may have been designed
for a circular saw and should not be used. Use only the accessories shown in the chart at the end of this section.
Accessory ratings must be above the listed minimum wheel speed as shown on the tool nameplate.

Mounting Guards
WARNING: To reduce the risk of serious personal injury, turn the tool off and disconnect the tool from the power source before making any adjustments or removing/installing attachments or accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off.
CAUTION : Guards must be used with this grinder.
When using the DWE4056, DWE4057, DWE4120, DWE4156, or the DWE4157 grinder for cutting metal or masonry, a Type 1 guard MUST be used. Type 1 guards are available at extra cost from DeWALT distributors.
NOTE: Please refer to the Grinding and Cutting Accessory Chart at the end of this section to see other accessories that can be used with these grinders.

MOUNTING AND REMOVING (TYPE 27)
ONE-TOUCH GUARD (FIG. 2A)
NOTE: If your grinder is supplied with a keyless One-Touch guard, ensure the screw, lever, and spring are fitted correctly before mounting the guard.

Press the guard release lever (J).
While holding the guard release lever open, align the lugs (K) on the guard with the slots (L) on the gear case.
Keeping the guard release lever open, push the guard down until the lugs engage then rotate them into the groove on the gear case hub. Release the guard release lever.
With the spindle facing the operator, rotate the guard clockwise into the desired working position. The guard body should be positioned between the spindle and the operator to provide maximum operator protection.
For easy adjustment, the guard can be rotated in the clockwise direction. NOTE: The guard release lever should snap into one of the alignment holes (M) on the guard collar. This ensures that the guard is secure. The guard can be repositioned in the opposite direction by depressing the guard release lever.
To remove the guard, follow steps 1–3 of these instructions in reverse.

GUARD WITH FIXING SCREW (FIG. 2B)

Place the angle grinder on a table, spindle (B) up.
Align the lugs (K) with the notches (L).
Press the guard (F) down and rotate it to the equired position.)
Securely tighten the screw (N).
To remove the guard, slacken the screw.

CAUTION: If the guard cannot be tightened by the adjusting screw, do not use the tool. To reduce the risk of personal injury, take the tool and guard to a service center to repair or replace the guard.

MOUNTING CLOSED (TYPE 1) GUARD

WARNING: If present, the One-Touch guard screw, lever, and spring must be removed before attempting to mount the closed (Type 1) guard. The removed parts must be retained and reinstalled to use the One-Touch guard. Noting the position of these parts before disassembly will aid in reassembly.

Open the guard latch. Align the lugs (K) on the guard with the slots (L) on the gear case.
Push the guard down until the guard lug engages and rotates freely in the groove on the gear case hub.
Rotate guard into desired working position.
The guard body should be positioned between the spindle and the operator to provide maximum operator protection.
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 the closed position. If rotation is possible, tighten the adjusting screw with the clamp lever in the closed position. Do not operate grinder with a loose guard or clamp lever in the open position.
To remove the guard, open the guard latch, rotate the guard so that the arrows are aligned, and pull up on the guard.

NOTE: If, after a period of time the closed (Type 1) guard becomes loose, tighten the adjusting screw with the clamp lever in the closed position.
CAUTION: If the guard cannot be tightened by the adjusting screw, do not use the tool. To reduce the risk of personal injury, take the tool and guard to an authorized repair agent to repair or replace the guard.
NOTICE: Do not tighten the adjusting screw with the clamp lever in the open position.
Undetectable damage to the guard or mounting hub may result.

Fitting and Removing a Grinding or Cutting Disc (fig. 1, 4, 5)

WARNING: Do not use a damaged disc.

Place the tool on a table, and guard up.
Fit the backing flange (D) correctly onto the spindle (B) (fig. 4).
Place the disc (P) on the backing flange (D).
When fitting a disc with a raised center, make sure that the raised center (O) is facing the backing flange (D).
Screw the threaded clamp nut (E) onto the spindle (B) (fig. 5):
a. The ring on the threaded clamp nut (E) must face towards the disc when fitting a grinding disc (fig. 5A);
b. The ring on the threaded clamp nut (E) must face away from the disc when fitting a cutting disc (fig. 5B).
Press the spindle lock button (A) and rotate the spindle (B) until it locks in position.
Tighten the threaded clamp nut (E) with the hex key provided or a two-pin spanner.
Release the spindle lock.
To remove the disc, loosen the threaded clamp nut (E) with the hex key provided or a two-pin spanner.

NOTE: Edge grinding can be performed with Type 27 wheels designed and specified for this purpose; 6 mm thick wheels are designed for surface grinding while 3 mm wheels are designed for edge grinding. Cutting can be performed by using a cutting wheel and a Type 1 guard.
Mounting Wire Brushes and Wire Wheels
Wire cup brushes or wire wheels screw directly on the grinder spindle without the use of flanges. Use only wire brushes or wheels provided with a M14 threaded hub. A Type 27 guard is required when using wire brushes and wheels.
CAUTION: Wear work gloves when handling wire brushes and wheels.
They can become sharp.
CAUTION : Wheel or brush must not touch guard when mounted or while in use. Undetectable damage could occur to the accessory, causing wires to fragment from the accessory wheel or cup.

Thread the wheel on the spindle by hand.
Depress the spindle lock button and use a wrench on the hub of the wire wheel or brush to tighten the wheel.
3. To remove the wheel, reverse the above procedure.

NOTICE: Failure to properly seat the wheel hub before turning the tool on may result in damage to the tool or wheel.

Fitting and Removing a
Backing Pad/Sanding Sheet (fig. 1)

Place the tool on a table or flat surface, with the guard facing up.
Remove the backing flange (D).
Place the rubber backing pad correctly onto the spindle (B).
Place the sanding sheet on the rubber backing pad.
Screw the threaded clamp nut (E) onto the spindle. The ring on the threaded clamp nut must face towards the rubber backing pad.
Press the spindle lock button (A) and rotate the spindle (B) until it locks in position.
Tighten the threaded clamp nut (E) with the hex key provided or a two-pin spanner.
Release the spindle lock.
To remove the rubber backing pad, loosen the threaded clamp nut (E) with the hex key provided or a two-pin spanner.

Fitting a Wire Cup Brush

Screw the wire cup brush directly onto the spindle without the use of the spacer and threaded flange.
Prior to Operation

Install the guard and appropriate disc or wheel.
Do not use excessively worn discs or wheels.
Be sure the inner and outer flange is mounted correctly. Follow the instructions given in the Grinding and Cutting Accessory Chart.
Make sure the disc or wheel rotates in the direction of the arrows on the accessory and the tool.
Do not use a damaged accessory. Before each use inspects 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 a power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute.
Damaged accessories will normally break apart during this test time.

OPERATION

WARNING: Always observe the safety instructions and applicable regulations.
WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect tool from power source before making any adjustments or removing/installing attachments or accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off.
WARNING:

Ensure all materials to be ground or cut are secured in place.
Secure and support the workpiece. Use clamps or a vice to hold and support the workpiece to a stable platform. It is important to clamp and support the workpiece securely to prevent movement of the workpiece and loss of control. Movement of the workpiece or loss of control may create a hazard and cause personal injury.
Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback.
Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.
Always wear regular working gloves while operating this tool.
The gear becomes very hot during use.
Apply only gentle pressure to the tool. Do not exert side pressure on the disc.
Avoid overloading. Should the tool become hot, let it run for a few minutes under no load conditions.
Avoid overloading. Should the tool become hot, let it run for a few minutes under no load conditions to cool the accessory. Do not touch accessories before they have cooled. The discs become very hot during use.
Never work with the grinding cup without a suitable protection guard in place.
Do not use the power tool with a cutoff stand.
Never use blotters together with bonded abrasive products.
Be aware, that the wheel continues to rotate after the tools is switched off.

Proper Hand Position (fig. 1, 6)

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 side handle (C), with the other hand on the body of the tool, as shown in Figure 1.

Switches

CAUTION: Hold the side handle and body of the tool firmly to maintain control of the tool at start-up and during use and until the wheel or accessory stops rotating. Make sure the wheel has come to a complete stop before laying the tool down.
NOTE: To reduce unexpected tool movement, do not switch the tool on or off while under load conditions. Allow the grinder to run up to full speed before touching the work surface. Lift the tool from the surface before turning the tool off. Allow the tool to stop rotating before putting it down.

SLIDER SWITCH (FIG. 3)
(DWE4056, DWE4057, DWE4156, DWE4157)

WARNING: Before connecting the tool to a power supply, be sure the slider switch is in the off position by pressing the rear part of the switch and releasing it.
Ensure the slider switch is in the off position as described above after any interruption in power supply to the tool, such as the activation of a ground fault interrupter, throwing of a circuit breaker, accidental unplugging, or power failure.
If the slider switch is locked on when the power is connected, the tool will start unexpectedly.
To start the tool, slide the ON/OFF slider switch (G) toward the front of the tool. To stop the tool, release the ON/OFF slider switch.
For continuous operation, slide the switch toward the front of the tool and press the forward part of the switch inward. To stop the tool while operating in continuous mode, press the rear part of the slider switch and release.

Instructions for Use

WARNING: Always observe the safety instructions and applicable regulations.
WARNING: To reduce the risk of serious personal injury, turn the tool off and disconnect the tool from the power source before making any adjustments or removing/installing attachments or accessories. Before reconnecting the tool, depress and release the trigger switch to ensure that the tool is off.
WARNING:

Ensure all materials to be ground or cut secured in place.
Secure and support the workpiece.
Use clamps or a vice to hold and support the workpiece to a stable platform. It is important to clamp and support the workpiece securely to prevent movement of the workpiece and loss of control. Movement of the workpiece or loss of control may createa hazards and cause personal injury.
Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback.
Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.
Always wear regular working gloves while operating this tool.
The gear becomes very hot during use.
Apply only gentle pressure to the tool. Do not exert side pressure on the disc.
Avoid overloading. Should the tool become hot, let it run for a few minutes under no load conditions.
Avoid overloading. Should the tool become hot, let it run for a few minutes under no load conditions to cool the accessory. Do not touch accessories before they have cooled. The discs become very hot during use.
Never work with the grinding cup without a suitable protection guard in place.
Do not use the power tool with a cutoff stand.
Never use blotters together with bonded abrasive products.
Be aware, that the wheel continues to rotate after the tools are switched off.

Proper Hand Position (fig. 1, 6)

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 side handle (C), with the other hand on the body of the tool, as shown in Figure 1.
Switches
CAUTION: Hold the side handle and body of the tool firmly to maintain control of the tool at start-up and during use and until the wheel or accessory stops rotating. Make sure the wheel has come to a complete stop before laying the tool down.
NOTE: To reduce unexpected tool movement,
do not switch the tool on or off while under load conditions. Allow the grinder to run up to full speed before touching the work surface. Lift the tool from the surface before turning the tool off. Allow the tool to stop rotating before putting it down.
SLIDER SWITCH (FIG. 3)
(DWE4056, DWE4057, DWE4156, DWE4157)
WARNING: Before connecting the tool to a power supply, be sure the slider switch is in the off position by pressing the rear part of the switch and releasing it.
Ensure the slider switch is in the off position as described above after any interruption in power supply to the tool, such as the activation of a ground fault interrupter, throwing of a circuit breaker, accidental unplugging, or power failure.
If the slider switch is locked on when the power is connected, the tool will start unexpectedly.
To start the tool, slide the ON/OFF slider switch (G) toward the front of the tool. To stop the tool, release the ON/OFF slider switch.
For continuous operation, slide the switch toward the front of the tool and press the forward part of the switch inward. To stop the tool while operating in continuous mode, press the rear part of the slider switch and release.

PADDLE SWITCH (FIG. 3) (DWE4120)

To turn the tool on, push the lock-off lever (I) toward the back of the tool, then depress the paddle switch (H). The tool will run while the switch is depressed.
Turn the tool off by releasing the paddle switch.

Spindle Lock (fig. 1)
The spindle lock (A) is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock only when the tool is turned off, unplugged from the power supply, and has come to a complete stop.
NOTICE: To reduce the risk of damage to the tool, do not engage the spindle lock while the tool is operating. Damage to the tool will result and the 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.

Metal Applications

When using the tool in metal applications, make sure that a residual current device (RCD) has been inserted to avoid residual risks caused by the metal swarf.
If the power supply is shut off by the RCD, take the tool to an authorized DeWALT repair agent.
WARNING: In extreme working conditions, conductive dust can accumulate inside the machine housing when working with metal. This can result in the protective insulation in the machine becoming degraded with a potential risk of an electrical shock.
To avoid the build-up of metal swarf inside the machine, we recommend to clear the ventilation slots on a daily basis. Refer to Maintenance.
Cutting Metal
When cutting, work with moderate feed, adapted to the material being cut. Do not exert pressure on the cutting disc, tilt or oscillate the machine.
Do not reduce the speed of running down cutting discs by applying sideward pressure.
The machine must always work in an upgrading motion. Otherwise, the danger exists of it being pushed uncontrolled out of the cut.
When cutting profiles and square bars, it is best to start at the smallest cross-section.

Rough Grinding

Never use a cutting disc for roughing.
Always use the guard type 27.
The best roughing results are achieved when setting the machine at an angle of 30° to 40°. Move the machine back and forth with moderate pressure. In this manner, the workpiece will not become too hot, does not discolor and no grooves are formed.
Cutting Stone
The machine shall be used only for dry cutting.
For cutting stone, it is best to use a diamond cutting disc. Operate the machine only with an additional dust protection mask.
Working Advice
Exercise caution when cutting slots in structural walls. Slots in structural walls are subject to country-specific regulations. These regulations are to be observed under all
circumstances. Before beginning work, consult the responsible structural engineer, architect or construction supervisor.

Using Flap Discs

WARNING: Metal dust build-up.
Extensive use of flap discs in metal applications can result in an increased potential for electric shock. To reduce this risk, insert an RCD before use and clean the ventilation slots daily by blowing dry compressed air into the ventilation slots in accordance with the below maintenance instructions.

MAINTENANCE

Your DeWALT power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

WARNING: To reduce the risk of serious personal injury, turn the tool off and disconnect the tool from the power source before making any adjustments or removing/installing attachments or accessories. Bewfore reconnecting the tool, depress and release the trigger switch to ensure that the tool is off.

Pop-off Brushes
The motor will be automatically shut off indicating that the carbon brushes are nearly worn out and that the tool needs servicing. The carbon brushes are not user-serviceable. Take the tool to an authorized DeWALT repair agent.

Lubrication
Your power tool requires no additional lubrication.

Cleaning

** WARNING: Blow dirt and dust out of the main housing with dry air as often as dirt is seen collecting in and around the air vents. Wear approved eye protection and approved dust masks 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.

Optional Accessories

WARNING: Since accessories, other than those offered by DeWALT, have not been tested with this product, the use of such accessories with this tool could be hazardous. To reduce the risk of injury, only DeWALT recommended accessories should be used with this product.
Consult your dealer for further information on the appropriate accessories.

| Max. [mm]| 1 [mm]| Min. Rotation [min:1]| Peripheral speed [m/s]| Threaded hole length [mm]
---|---|---|---|---|---
D| b| d
| 115
125| 6
6| 2223
2223| 11,800
11,800| 80
80|
| 115
125| –
–| | 11,800
11,800| 80
80|
| 75| 30| M14| 11,800| 45|
| 115
125| 12
12| M14
M14| 11,800
11,800| 80
80| 16.0
16.0

Protecting the Environment
Separate 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.

GRINDING AND CUTTING ACCESSORY CHART

Guard Type| Accessory| Description| How to Fit Grinder
TYPE 27 GUARD| | Depressed
center grinding
disc|
| Flap wheel
| Wire wheels
| Wire wheels
with threaded
nut|
| Wire cup with
threaded nut|
| Backing pad/
sanding sheet|
| | Masonry
cutting disc,
bonded|
---|---|---|---
| Metal
cutting disc,
bonded
| | Diamond
cutting wheels

DeWALT, 210 Bath Road;
Slough, Berks SL1 3YD
Tel: 01753-567055
Fax: 01753-572112
www.dewalt.co.uk
emeaservice@sbdinc.com
N586913