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-D

E

WALT • www.dewalt.com

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.

DC413 Heavy-Duty 28V Cordless Cut-Off Tool

DC415 Heavy-Duty 36V Cordless Cut-Off Tool

Outil de tronçonnage sans fil robuste de 28 V DC413

Outil de tronçonnage sans fil robuste de 36 V DC415

Herramienta de corte inalámbrica de 28 V para trabajo pesado DC413

Herramienta de corte inalámbrica de 36 V para trabajo pesado DC415

SAVE THESE INSTRUCTIONS

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.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS

OR ANY D E WALT TOOL, CALL US TOLL FREE AT 1-800-4-

D E WALT (1-800-433-9258)

General Safety Rules – For All Battery

Operated Tools

WARNING! Read and understand all instructions.

Failure to follow all instructions listed below may result in electric shock, fire and/or serious personal injury.

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.

• 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.

• Keep bystanders, children, and visitors away while operating

a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Do not abuse the cord. Never use the cord to carry the tool.

Keep cord away from heat, oil, sharp edges or moving parts.

Replace damaged cords immediately. Damaged cords may create a fire.

• A battery operated tool with integral batteries or a separate battery pack must be recharged only with the specified

charger for the battery. A charger that may be suitable for one type of battery may create a risk of fire when used with another battery.

• Use battery operated tool only with the specifically designed

battery pack. Use of any other batteries may create a risk of fire.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired

or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury,

• Dress properly. Do not wear loose clothing or jewelry.

Contain long hair. Keep your hair, clothing, and gloves away

from moving parts. Loose clothing, jewelry, or long hair can be

1

caught in moving parts. Air vents often cover moving parts and should also be avoided.

• Avoid accidental starting. Be sure switch is in the locked or

off position before inserting battery pack. Carrying tools with your finger on the switch or inserting the battery pack into a tool with the switch on invites accidents.

• Remove adjusting keys or wrenches before turning the tool

on. A wrench or key that is left attached to a rotating part of the tool may result in personal injury.

• Do not overreach. Keep proper footing and balance at all

times. Proper footing and balance enables better control of the tool in unexpected situations.

• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

TOOL USE AND CARE

• Use clamps or other practical way to secure and support the

workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to a loss of control.

• Do not force tool. Use the correct tool for your application.

The correct tool will do the job better and safer and the rate for which it is designed.

• Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired.

• Disconnect battery pack from tool or place the switch in the locked or off position before making any adjustments,

changing accessories, or storing the tool. Such preventative safety measures reduce the risk of starting the tool accidentally.

• Store idle tools out of reach of children and other untrained

persons. Tools are dangerous in the hands of untrained users.

• When battery pack is not in use, keep it away from other metal objects like: paper clips, coins, keys, nails, screws, or other small metal objects that can make a connection from

one terminal to another. Shorting the battery terminals together may cause sparks, burns, or a fire.

• Maintain tools with care. Keep cutting tools sharp and clean.

Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control.

• Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s

operation. If damaged, have the tool serviced before using.

Many accidents are caused by poorly maintained tools.

• Use only accessories that are recommended by the

manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.

SERVICE

• Tool service must be performed only by qualified repair

personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.

• When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of

this manual. Use of unauthorized parts or failure to follow

Maintenance Instructions may create a risk of electric shock or injury.

Additional Specifi c Safety Rules

• Check that the grinding wheel backing flange has a yellow rubber ring (K) installed, see Figure 3. Replace rubber ring if missing, damaged or worn. See page 10 for details regarding proper accessory installation.

2

WARNING: The grinding wheel or accessory may loosen during coast-down of the tool when shut off if rubber ring is missing or damaged. If grinding wheel or accessory loosens, it may dismount from the machine and may cause serious personal injury.

• Always use proper guard with grinding wheel. A guard protects operator from broken wheel fragments and wheel contact.

• Accessories must be rated for at least the speed recom-

mended on the tool warning label. Wheels and other accessories running over their rated speed can fly apart and cause injury. Accessory ratings must always be above tool speed as shown on tool nameplate.

• Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden

wiring. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

• Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories can result in injury.

• Before using, inspect recommended accessory for cracks or

flaws. If such a crack or flaw is evident, discard the accessory.

The accessory should also be inspected whenever you think

the tool may have been dropped. Flaws may cause wheel breakage.

• Do not use circular saw blades or any other toothed blades

with this tool. Serious injury may result.

• When starting the tool with a new or replacement wheel, or a new or replacement wire brush installed, hold the tool in a

well protected area and let it run for one minute. If the wheel has an undetected crack or flaw, it should burst in less than one minute. If the wire brush has loose wires, they will be detected.

Never start the tool with a person in line with the wheel. This includes the operator.

• Avoid bouncing the wheel or giving it rough treatment. If this occurs, stop the tool and inspect the wheel for cracks or flaws.

• Direct sparks away from operator, bystanders or flammable

materials. Sparks may be produced while using a sander or grinder. Sparks may cause burns or start fires.

• Always use side handle. Tighten the handle securely. The side handle should always be used to maintain control of the tool at all times.

• Clean out your tool often, especially after heavy use. Dust and grit containing metal particles often accumulate on interior surfaces and could create a hazard.

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,

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known 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 (CCA).

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.

3

• 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 disburse 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.

WARNING: Always use eye protection. All users and bystanders must wear eye protection that conforms to ANSI Z87.1.

WARNING: When not in use, place grinder on a stable surface where it will not move inadvertantly, roll or cause a tripping or

falling hazard. The grinder may stand upright on the battery pack but may be easily knocked over. Serious personal injury may result.

CAUTION: To reduce the risk of personal injury, use extra care when working into a corner or edge because a sudden, sharp movement of the tool may be experienced when the wheel or other accessory contacts a secondary surface or a surface edge.

• The label on your tool may include the following symbols. The symbols and their definitions are as follows: min ........minutes

......direct current

..............alternating current no ..............no load speed

..........Class I Construction ...............earthing terminal

..............

(grounded) ..............safety alert symbol

...........Class II Construction …/min ........revolutions or

..............

(double insulated) ...................

reciprocation per

BPM ......beats per minute ...................

minute

Causes and Operator Prevention of Kickback

• Kickback is a sudden reaction to a pinched, bound or misaligned wheel, wire brush or flap disc causing an uncontrolled cut-off tool to lift up and out of the workpiece toward the operator.

• When the wheel is pinched or bound tightly by the workpiece, the wheel stalls and the motor reaction drives the unit rapidly back toward or away from the operator.

• 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:

• Maintain a firm grip with both hands on the unit and position your body and arm to allow you to resist kickback forces.

Kickback forces can be controlled by the operator, if proper precautions are taken.

• When wheel is binding, or when interrupting a cut for any reason, release the trigger and hold the unit motionless in the material until the wheel comes to a complete stop.

Never attempt to remove the unit from the work or pull the unit backward while the wheel is in motion or kickback may

occur. Investigate and take corrective actions to eliminate the cause of wheel binding.

• When restarting a cut-off tool in the workpiece, check that

the wheel is not engaged into the material. If wheel is binding, it may walk up or kickback from the workpiece as the tool is restarted.

4

• Support large panels to minimize the risk of wheel pinching

and kickback. Large panels tend to sag under their own weight.

Support must be placed under the panel on both sides, near the line of cut and near the edge of the panel.

Important Safety Instruction for Battery Packs

WARNING: For safe operation, read this manual and manuals originally supplied with tool before using the charger.

When ordering replacement battery packs, be sure to include catalog number and voltage. Consult the chart on the last page of this manual for compatibility of chargers and battery packs.

The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions below.

Then follow charging procedures outlined.

READ ALL INSTRUCTIONS

• Do not incinerate the battery pack even if it is severely

damaged or is completely worn out. The battery pack can explode in a fire. Toxic fumes and materials are created when lithium ion battery packs are burned.

• Do not charge or use battery in explosive atmospheres,

such as in the presence of flammable liquids, gases or dust.

Inserting or removing the battery from the charger may ignite the dust or fumes.

• If battery contents come into contact with the skin,

immediately wash area with mild soap and water. If battery liquid gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts.

• Contents of opened battery cells may cause respiratory

irritation. Provide fresh air. If symptoms persists, seek medical attention.

WARNING: Burn hazard. Battery liquid may be flammable if exposed to spark or flame.

• Charge the battery packs only in D E WALT chargers.

• DO NOT splash or immerse in water or other liquids.

• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 105°F (40˚)

(such as outside sheds or metal buildings in summer).

WARNING: Never attempt to open the battery pack for any reason. If battery pack case is cracked or damaged, do not insert into charger. Do not crush, drop or damage battery pack. Do not use a battery pack or charger that has received a sharp blow, been dropped, run over or damaged in any way (i.e., pierced with a nail, hit with a hammer, stepped on). Damaged battery packs should be returned to service center for recycling.

WARNING: Fire hazard. Do not store or carry battery so that

metal objects can contact exposed battery terminals. For example, do not place battery in aprons, pockets, tool boxes, product kit boxes, drawers, etc., with loose nails, screws, keys, etc.

Transporting batteries can possibly cause fires if the battery terminals inadvertently come in contact with conductive

materials such as keys, coins, hand tools and the like. The US

Department of Transportation Hazardous Material Regulations

(HMR) actually prohibit transporting batteries in commerce or on airplanes (i.e., packed in suitcases and carry-on luggage) UNLESS they are properly protected from short circuits. So when transporting individual batteries, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit.

5

The RBRC™ Seal

The RBRC™ (Rechargeable Battery Recycling

Corporation) Seal on the lithium ion battery (or battery pack) indicates that the costs to recycle the battery (or battery pack) at the end of its useful life have already been paid by D E WALT.

RBRC™ in cooperation with D E WALT and other battery users, has established programs in the United States to facilitate the collection of spent lithium ion batteries. Help protect our environment and conserve natural resources by returning the spent lithium ion battery to an authorized D E WALT service center or to your local retailer for recycling. You may also contact your local recycling center for information on where to drop off the spent battery.

RBRC™ is a registered trademark of the Rechargeable Battery Recycling

Corporation.

Storage Recommendations

1. The best storage place is one that is cool and dry away from direct sunlight and excess heat or cold.

2. Long storage will not harm the battery pack or charger. Under proper conditions, they can be stored for 5 years or more.

Important Safety Instructions for

Battery Chargers

SAVE THESE INSTRUCTIONS: This manual contains important safety instructions for battery chargers.

• Before using charger, read all instructions and cautionary markings on charger, battery pack, and product using battery pack.

WARNING: Shock hazard. Do not allow any liquid to get inside charger.

CAUTION: Burn hazard. To reduce the risk of injury, charge only

D E WALT batteries. Other types of batteries may burst causing personal injury and damage.

CAUTION: Under certain conditions, with the charger plugged in to the power supply, the charger can be shorted by foreign material.

Foreign materials of a conductive nature such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities.

Always unplug the charger from the power supply when there is no battery pack in the cavity. Unplug charger before attempting to clean.

• DO NOT attempt to charge the battery pack with any chargers

other than the ones in this manual. The charger and battery pack are specifically designed to work together.

• These chargers are not intended for any uses other than charging D E WALT rechargeable batteries. Any other uses may result in risk of fire, electric shock or electrocution.

• Do not expose charger to rain or snow.

• Pull by plug rather than cord when disconnecting charger.

This will reduce risk of damage to electric plug and cord.

• Make sure that cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.

• Do not use an extension cord unless it is absolutely

necessary. Use of improper extension cord could result in risk of fire, electric shock, or electrocution.

• 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. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size.

• Do not place any object on top of charger or place the charger on a soft surface that might block the ventilation

slots and result in excessive internal heat. Place the charger

6

in a position away from any heat source. The charger is ventilated through slots in the top and the bottom of the housing.

• Do not mount charger on wall or permanently affix charger

to any surface. The charger is intended to use on a flat, stable surface (i.e., table top, bench top).

• Do not operate charger with damaged cord or plug — have them replaced immediately.

• Do not operate charger if it has received a sharp blow, been

dropped, or otherwise damaged in any way. Take it to an authorized service center.

• Do not disassemble charger; take it to an authorized service

center when service or repair is required. Incorrect reassembly may result in a risk of electric shock, electrocution or fire.

• Disconnect the charger from the outlet before attempting

any cleaning. This will reduce the risk of electric shock.

Removing the battery pack will not reduce this risk.

• NEVER attempt to connect 2 chargers together.

• The charger is designed to operate on standard household electrical power (120 Volts). Do not attempt to use it on any

other voltage.

SAVE THESE INSTRUCTIONS

Charger

Your battery pack requires a 1 hour D E WALT charger. Be sure to read all safety instructions before using your charger. Consult the chart on the back of this manual for compatibility of chargers and battery packs.

Charging Procedure

1. Plug the charger into an appropriate outlet before inserting the battery pack.

2. Insert the battery pack into the charger. The charger is equipped with a three-light fuel gauge that will blink according to the state of charge of the battery pack.

3. The completion of charge is indicated by the three red lights remaining ON continuously. The pack is fully charged and may be used at this time or left on the charger.

0% - 33% 1 st light blinks

33% - 66% 1 st light on, 2 nd light blinks

66% - 99% 1 st , 2 nd lights on, 3 rd light blinks

100% 1 st , 2 nd , 3 rd lights on

Charger Diagnostics

This charger is designed to detect certain problems that can arise with the battery packs or the charger. Problems are indicated by the three red lights flashing together in different patterns.

PROBLEM POWER LINE

When the charger is used with some portable power sources such as generators or sources that convert DC to AC, the charger may temporarily suspend operation. The three red lights will flash together with two fast blinks followed by a pause. This indicates that the power source is out of limits.

BAD BATTERY

The charger can detect a weak or damaged battery. The three red lights will flash together with rapid blinking. The battery will no longer charge and should be returned to a service center or a collection site for recycling.

BAD CHARGER

The charger will detect if it is not functioning properly. The three red lights will flash together with one fast blink followed by a long

7

blink. The charger will no longer work and should be returned to an authorized service center or replaced.

LEAVING THE BATTERY IN THE CHARGER

The charger and battery pack can be left connected with the red lights glowing indefinitely. The charger will keep the battery pack fresh and fully charged. This charger features an automatic tune-up mode which equals or balances the individual cells in the battery pack to allow it to function at peak capacity. Battery packs should be tuned up weekly or whenever the battery no longer delivers the same amount of work. To use the automatic tune-up mode, place the battery pack in the charger and leave it for at least 8 hours.

Important Charging Notes

1. Longest life and best performance can be obtained if the battery pack is charged when the air temperature is between 65°F and

75°F (18°- 24°C). DO NOT charge the battery pack in an air temperature below +40°F (+4.5°C), or above +105°F (+40.5°C).

This is important and will prevent serious damage to the battery pack.

2. The charger and battery pack may become warm to touch while charging. This is a normal condition, and does not indicate a problem. To facilitate the cooling of the battery pack after use, avoid placing the charger or battery pack in a warm environment such as in a metal shed, or an uninsulated trailer.

3. If the battery pack does not charge properly: appliance turns power off when you turn out the lights. surrounding air temperature is approximately 65°F - 75°F

(18° - 24°C). charger to your local service center.

4. The battery pack should be recharged when it fails to produce sufficient power on jobs which were easily done previously. DO

NOT CONTINUE to use under these conditions. Follow the charging procedure. You may also charge a partially used pack whenever you desire with no adverse affect on the battery pack.

5. Foreign materials of a conductive nature such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil, or any buildup of metallic particles should be kept away from charger cavities. Always unplug the charger from the power supply when there is no battery pack in the cavity. Unplug charger before attempting to clean.

6. Do not freeze or immerse charger in water or any other liquid.

WARNING: Shock hazard. Do not allow any liquid to get inside charger.

CAUTION: To reduce the risk of personal injury, NEVER attempt to open the battery pack for any reason. If the plastic housing of the battery pack breaks or cracks, return to a service center for recycling.

Installing and Removing the Battery

Pack (Fig. 1)

NOTE: Make sure your battery pack is fully charged.

WARNING: To reduce the risk of serious personal injury, make certain the lock-off button (B), as shown on page 13, is engaged to prevent switch actuation before removing or installing battery.

To install the battery pack into the tool handle, align the base of the tool with the rails inside the tool’s handle and slide the battery pack firmly into the handle until you hear the lock snap into place.

To remove the battery pack from the tool, press the release button

(J) and firmly pull the battery pack out of the tool handle. Insert it into the charger as described in the charger section of this manual.

8

FIG. 1

FIG. 3

J

COMPONENTS (Fig. 2, 3)

A. Trigger switch G. Threaded clamp nut

H. Guard (Type 1, Type 27)

J. Battery release button

FIG. 2

E

C

H

B

D

A

DC415 SHOWN

J

I

9

F

G

F

K

ASSEMBLY AND ADJUSTMENTS

Attaching Side Handle

The side handle (D) can be fitted to either side of the gear case in the threaded holes.

Before using the tool, check that the handle is tightened se cure ly.

To improve user comfort, the gear case will rotate 90˚ for cutting operations.

Rotating the Gear Case

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

D screws attaching the gear case to motor housing.

2. Without separating the gear case from motor housing, rotate the gear case head to desired position.

NOTE: If the gear case and motor housing become separated by more than 1/4" (6.35 mm), the tool must be serviced and reassembled by a D E WALT service center. Failure to have the tool serviced may cause brush, motor and bearing failure.

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

Tighten screws to 18 in-lbs. (2.08 Nm) torque. Overtightening could cause screws to strip.

Accessories

It is important to choose the correct guards, backing pads and flanges to use with grinder accessories. See pages 11 and 12 for information on choosing 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 their rated accessory speed may fly apart and cause injury. Threaded accessories must have a 5/8"-11 hub.

Every unthreaded accessory must have a 7/8" (22.2 mm) arbor hole.

If it does not, it may have been designed for a circular saw. Use only the accessories shown on pages 11 and 12 of this manual.

Accessory ratings must always be above tool speed as shown on tool nameplate.

Mounting Guard

MOUNTING AND REMOVING GUARD

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

CAUTION: Guards must be used with all grinding wheels, cutting wheels, sanding flap discs, wire brushes, and wire

wheels. The tool may be used without a guard only when sanding with conventional sanding discs. D E WALT models DC413 and DC415 are provided with guards 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 (Type 27 and 29) and wire cup brushes. Grinding and cutting with wheels other than

Type 27 and 29 require different accessory guards included with tool.

A Type 1 guard is provided for use with a Type 1 wheel. Mounting instructions for these accessory guards are included in the accessory package.

M

1. Open the guard latch (L), and align the lugs (M) on the guard with the slots (N) on the gear case.

2. Push the guard down until the guard lugs engage and rotate freely in the groove on the gear case hub.

N

3. With the guard latch open, rotate the guard (H) into the desired working position. The guard body should be positioned between the spindle and the operator to provide maximum operator protection.

L

4. Close the guard latch to secure the guard on the gear case. You should not be able to rotate the guard by hand when the latch is closed. Do not operate the grinder with a loose guard or the clamp lever in open position.

H

5. To remove the guard, open the guard latch, rotate the guard so that the lugs are aligned with the slots and pull up on the guard.

O

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 (O) with clamp lever in the closed position with guard installed on the tool.

10

4-1/2" Grinding Wheels

Type 27 guard unthreaded backing flange

Type 27 guard

Type 27 hubbed wheel

Type 27 depressed center wheel threaded clamp nut

Type 27 guard

3" wire cup brush

Wire Wheels

Type 27 guard

4" wire wheel

11

Sanding Discs

rubber backing pad sanding disc threaded clamp nut

4-1/2" Sanding Flap Discs 4-1/2" Cutting Wheels

Type 27 guard hubbed sanding flap disc

Type 27 guard unthreaded backing flange

Type 1 guard backing flange

Type 1 guard backing flange non-hubbed sanding flap disc threaded clamp nut abrasive cutting wheel diamond cutting wheel clamp nut clamp nut

12

CAUTION: If the guard cannot be tightened by the adjusting clamp, 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.

CAUTION: To reduce the risk of damage to the tool, do not tighten the adjusting screw with the clamp lever in the open position.

Undetectable damage to the guard or the mounting hub may result.

NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose; 1/4" (6.35 mm) thick wheels are designed for surface grinding while 1/8" (3.17 mm) wheels are designed for edge grinding. Cutting can also be performed by using a Type 1 wheel and a Type 1 guard.

OPERATION

Switch

UNLOCKED

LOCK-OFF BUTTON AND

TRIGGER SWITCH

Your cut-off tool is equipped with a lock-off button (B).

To lock the trigger switch, press the lock-off button as shown. When the lock-off button is depressed to the lock icon, the unit is locked.

B

LOCKED

Always lock the trigger switch when carrying or storing the tool to eliminate unintentional starting.

A

To unlock the trigger switch, press the lock-off button. When the lock-off button is depressed to the unlock icon, the unit is unlocked.

The lock-off button is colored red to indicate when the switch is in its

unlocked position.

Pull the trigger switch (A) to turn the tool ON. Releasing the trigger switch turns the tool OFF.

NOTE: This tool has no provision to lock the switch in the ON position, and should never be locked ON by any other means.

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 be fore laying the tool down.

CAUTION: Allow the tool to reach full speed before touching tool to the work surface. Lift the tool from the work surface before turning the tool off.

SPINDLE LOCK

The spindle lock pin is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock pin only when the tool is turned off, the battery is removed, and the wheel has come to a complete stop.

CAUTION: To reduce the risk of damage to the tool, do not engage the spindle lock while the tool is operating. Damage to the tool will result and attached accessory may spin off possibly resulting in injury.

To engage the lock, depress the spindle lock button and rotate the spindle until you are unable to rotate the spindle further.

Mounting and Using Depressed Center

Grinding Wheels and Sanding Flap Discs

MOUNTING AND REMOVING HUBBED WHEELS

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

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

1. Thread the wheel on the spindle by hand.

13

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

MOUNTING NON-HUBBED WHEELS

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

Depressed center Type 27 grinding wheels must be used with included flanges. See pages 11 and 12 of this manual for more information.

F

1. Install the anti-lockup backing flange (F) on spindle (P) with the raised section

(pilot) against the wheel. Be sure the backing flange recess is seated onto the flats of the spindle by pushing and twisting the flange before placing the wheel.

2. Place wheel against the backing flange, centering the wheel on the raised section

(pilot) of the backing flange.

P button, thread the clamp nut (G) on spindle. If the wheel you are installing is

G more than 1/8" (3.17 mm) thick, place the threaded clamp nut on the spindle so that the raised section

(pilot) fits into the center of the wheel. If the wheel you are installing is 1/8" (3.17 mm) thick or less, place the threaded clamp nut on the spindle so that the raised section (pilot) is not against the wheel.

4. While depressing the spindle lock button, tighten the clamp nut with a wrench.

5. To remove the wheel, depress the spindle lock button and loosen the threaded clamp nut with a wrench.

NOTE: If the wheel spins after the clamp nut is tightened, check the orientation of the threaded clamp nut. If a thin wheel is installed with the pilot on the clamp nut against the wheel, it will spin because the height of the pilot prevents the clamp nut from holding the wheel.

1/4" WHEELS

Clamp Nut

Backing Flange

1/8" WHEELS

Clamp Nut

SURFACE GRINDING WITH

GRINDING WHEELS

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

Backing Flange

2. Apply minimum pressure to the work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool operates at high speed.

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

4. Continuously move the tool in a forward and back motion to avoid creating gouges in the work surface.

20˚-30˚

5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

EDGE GRINDING WITH

GRINDING WHEELS

WARNING: Wheels used for cutting and edge grinding may break or 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,

14

limit the use of these wheels with a standard Type 27 guard to shallow cutting and notching (less than 1/2" in depth). The open side of the guard must be positioned away from the operator. For deeper cutting with a Type 1 cut-off wheel, use a closed Type 1 guard. See pages 11 and 12 for more information.

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

2. Apply minimum pressure to the work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool operates at high speed.

3. Position yourself so that the open-underside of the wheel is facing away from you.

4. Once a cut is begun and a notch is established in the workpiece, do not change the angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel breakage. Edge grinding wheels are not designed to withstand side pressures caused by bending.

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

Allow the tool to stop rotating before laying it down.

WARNING: Do not use edge grinding/ cutting wheels for surface grinding applications because these wheels are not designed for side pressures encountered with surface grinding.

Wheel breakage and serious personal injury may result.

SURFACE FINISHING WITH SANDING FLAP DISCS

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

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Sanding rate is greatest when the tool operates 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˚-10˚

5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

MOUNTING SANDING BACKING PADS

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

NOTE: Guard may be removed when using sanding backing pads

CAUTION: Proper guard must be reinstalled for grinding wheel, sanding flap disc, wire brush or wire wheel applications after sanding applications are complete.

1. Place or appropriately thread backing pad (Q) on the spindle.

2. Place the sanding disc (R) on the backing pad (Q).

3. While depressing spindle lock, thread clamp nut (S) on spindle, piloting the raised hub on the clamp nut into the pad.

4. Tighten the clamp nut by hand. Then depress the spindle lock button while turning the sanding disc until the sanding disc and clamp nut are snug.

S

R

Q

15

5. To remove the wheel, grasp and turn the backing pad and sanding pad while depressing the spindle lock button.

USING SANDING BACKING PADS

Choose the proper grit sanding discs for your application. Sanding discs are available in various grits. Coarse grits yield faster material removal rates and a rougher finish. Finer grits yield slower material removal and a smoother finish.

Begin with coarse grit discs for fast, rough material removal. Move to a medium grit paper and finish with a fine grit disc for optimal finish.

Coarse

Medium

Fine Finishing

16 - 30 grit

36 - 80 grit

100 - 120 grit

Very Fine Finishing 150 - 180 grit

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

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Sanding rate is greatest when the tool operates at high speed.

3. Maintain a 5˚ to 15˚ angle between the tool and work surface. The san ding disc should contact approximately 1"

(25.4 mm) of work surface.

5˚-15˚

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 work surface before turning tool off. Allow the tool to stop rotating before laying it down.

Precautions To Take When Sanding Paint

1. Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling the contaminated dust. The greatest danger of lead poisoning is to children and pregnant women.

2. Since it is difficult to identify whether or not a paint contains lead without a chemical analysis, we recommend the following precautions when sanding any paint:

PERSONAL SAFETY

1. No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.

2. A dust mask or respirator should be worn by all persons entering the work area. The filter should be replaced daily or whenever the wearer has difficulty breathing.

NOTE: Only those dust masks suitable for working with lead paint dust and fumes should be used. Ordinary painting masks do not offer this protection. See your local hardware dealer for the proper N.I.O.S.H. approved mask.

3. NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingesting contaminated paint particles.

Workers should wash and clean up BEFORE eating, drinking or smoking. Articles of food, drink, or smoking should not be left in the work area where dust would settle on them.

ENVIRONMENTAL SAFETY

1. Paint should be removed in such a manner as to minimize the amount of dust generated.

2. Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils thickness.

3. Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

16

CLEANING AND DISPOSAL

1. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the duration of the sanding project.

Vacuum filter bags should be changed frequently.

2. Plastic drop cloths should be gathered up and disposed of along with any dust chips or other removal debris. They should be placed in sealed refuse receptacles and disposed of through regular trash pick-up procedures.

During clean up, children and pregnant women should be kept away from the immediate work area.

3. All toys, washable furniture and utensils used by children should be washed thoroughly before being used again.

Mounting and Using 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 5/8"-11 threaded hub. A Type 27 guard is required when using wire brushes and wheels.

CAUTION: To reduce the risk of personal injury, wear work

gloves when handling wire brushes and wheels. They can become sharp.

CAUTION: To reduce the risk of damage to the tool, wheel or brush must not touch guard when mounted or while in use.

Undetectable damage could occur to the accessory, causing wires to fragment from accessory wheel or cup.

MOUNTING WIRE CUP BRUSHES AND WIRE WHEELS

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

1. Thread the wheel on the spindle by hand.

2. Depress spindle lock button and use a wrench on the hub of the wire wheel or brush to tighten the wheel.

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

CAUTION: To reduce the risk of damage to the tool, properly seat the wheel hub before turning the tool on.

USING WIRE CUP BRUSHES AND WIRE WHEELS

Wire wheels and brushes can be used for removing rust, scale and paint, and for smoothing irregular surfaces.

NOTE: The same precautions should be taken when wire brushng paint as when sanding paint (see page 16).

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

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Material removal rate is greatest when the tool operates at high speed.

3. Maintain a 5˚ to 10˚ angle between the tool and work surface for wire cup brushes.

4. Maintain contact between the edge of the wheel and the work surface with wire wheels.

5˚-10˚

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.

CAUTION: Use extra care when working over an edge, as a sudden sharp movement of grinder may be experienced.

17

Mounting and Using Cutting

(Type 1) Wheels

Cutting wheels include diamond wheels and abrasive discs. Abrasive cutting wheels for metal and concrete use are available. Diamond blades for concrete cutting can also be used.

WARNING: A closed, 2-sided cutting wheel guard is included with this tool and is re quired when using cutting wheels. Fail ure to use breakage and wheel contact. See pages 11 and 12 for more information.

MOUNTING CLOSED (TYPE 1) GUARD

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

U 1. Open the guard latch (L), and align the lugs (T) on the guard with the slots on the hub (U).

2. Push the guard down until the guard lug engages and rotates freely in the groove on the gear case hub.

3. Rotate guard (H) into desired working position. The guard body should be positioned between the spindle and the operator to provide maximum operator protection.

T

L

4. Close the guard latch to secure the on guard the gear case cover. You

H 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 clamp lever in open position.

5. To remove the guard, open the guard latch, rotate the guard so that the lugs and slots are aligned and pull up on the guard.

NOTE: The guard is pre-adjusted to the dia met er of the gear case hub at the factory.

If, after a period of time, the guard becomes loose, tighten the adjusting screw (O) with the clamp lever in the closed position with guard installed on the tool.

O

CAUTION: To reduce the risk of damage

to the tool, do not tighten adjusting screw with clamp lever in open position. Undetectable damage to guard or mounting hub may result.

MOUNTING CUTTING WHEELS

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

CAUTION: Matching diameter threaded backing flange and clamp nut (included with tool) must be used for cutting wheels.

1. Place the unthreaded backing flange on spindle with the raised section (pilot) facing up. The raised section (pilot) on the backing flange will be against the wheel when the wheel is installed. Be sure the backing flange recess is seated onto the flats of the spindle by pushing and twisting the flange before placing the wheel.

2. Place the wheel on the backing flange, centering the wheel on the raised section (pilot).

3. Install the threaded clamp nut with the raised section (pilot) facing away from the wheel.

4. Depress the spindle lock button and tighten clamp nut with a wrench.

18

5. To remove the wheel, grasp and turn while depressing the spindle lock button.

USING CUTTING WHEELS

WARNING: Do not use edge grinding/cutting wheels for surface grinding applications because these wheels are not designed for side pressures encountered with surface grinding. Wheel breakage and injury may result.

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

2. Apply minimum pressure to work surface, allowing tool to operate at high speed. Cutting rate is greatest when the tool operates at high speed.

3. Once a cut is begun and a notch is established in the workpiece, do not change the angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel breakage.

4. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before setting it down.

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn tool off and and remove battery pack before making any adjustments or removing/installing attachments or accessories.

Cleaning

WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when performing this. Exterior plastic parts may be cleaned with a damp cloth and mild detergent. Although these parts are highly solvent resistant, NEVER use solvents.

CHARGER CLEANING INSTRUCTIONS

WARNING: Shock hazard. Disconnect the charger from the AC outlet before cleaning. Dirt and grease may be removed from the exterior of the charger using a cloth or soft non-metallic brush. Do not use water or any cleaning solutions.

Lubrication

D E WALT tools are properly lubricated at the factory and are ready for use.

Repairs

The charger is not user serviceable. There are no user serviceable parts inside the charger. Servicing at an authorized service center is required to avoid damage to static sensitive internal components.

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustments (including brush inspection and replacement) should be performed by a D E WALT factory service center, a D E WALT authorized service center or other qualified service personnel. Always use identical replacement parts.

Purchasing Accessories

WARNING: Since accessories, other than those offered by

D E WALT, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only D E WALT, recommended accessories should be used with this product.

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact D E WALT

Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-D E WALT (1-800-433-9258) or visit our website www.

dewalt.com.

19

Three Year Limited Warranty

D E WALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase.

This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-D E WALT (1-800-

433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

In addition to the warranty, D E WALT tools are covered by our:

1 YEAR FREE SERVICE

D E WALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

2 YEARS FREE SERVICE ON D E WALT BATTERY PACKS

DC9096, DC9091, DC9071, DC9360 and DC9280

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your

D E WALT Power Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call the local company or see website for warranty information.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-D E WALT for a free replacement.

20

Patent Notifi cation

Manufactured under one or more of the following U.S. patents:

6859013

6329788

6175211

6133713

6057608

6653815

D540638

Other patents pending.

D

E

WALT Battery and Charger Systems

Systèmes de batterie et de chargeur de D

E

WALT • Sistemas de la batería y del cargador de D

E

WALT

Battery Output

Batterie Production

Batería Producción

Chargeurs/Durée de charge (Minutes)

Cargadores de baterías/Tempo de carga (Minutos)

Cat Number Voltage

Modèle Tension

120 Volts/Voltios 12 Volts/Voltios

Modelo Tensión DW9106 DW9118 DW9107 DW9108 DW9116 DW9216 DW9117 DW911 DC011 DC9000 DW0246 DW0249 DW9109

DW0242 24 X X X X X X X X X X 60 X 60

DC9091 14.4 90 115 60 60 60 60 20 60 60 X X 60 X

DW9091 14.4 45 90 45 45 45 45 15 45 45 X X 45 X

DW9094 14.4 60 60 30 30 30 30 12 30 30 X X 30 X

DW9050 12 40 X X X X X X X X X X X X

DW9061 9.6 60 90 45 45 45 45 15 45 45 X X 45 X

DW9062 9.6 45 60 30 30 30 30 12 30 30 X X 30 X

DW9048 9.6 40 X X X X X X X X X X X X

DW9057 7.2 45 60 30 30 30 30 12 30 30 X X 30 X

DC9360 36 X X X X X X X X X 60 X X X

DC9280 28 X X X X X X X X X 60 X X X

X Indicates that the battery pack is not compatible with that specific charger.

X indique que le bloc-piles n’est pas compatible avec ce chargeur.

Una “X” indica que el paquete de baterías no es compatible con ese determinado cargador.

All charge times are approximate. Actual charge time may vary.

Read the instruction manual for more specific information.

Les durées de charge sont approximatives; la durée de charge rélle peut varier.

Lire le manuel d’utilisation pour obtenir des renseignements plus précis.

El tiempo de duración de carga es aproximado; la duración de carga real puede variar.

Lea el manual de instrucciones para obtener información más precisa.

D E WALT Industrial Tool Co., 701 Joppa Road, Baltimore, MD 21286

(JUN07) Form No. 653787-00 DC413, DC415 Copyright © 2006, 2007 D E WALT

The following are trademarks for one or more D E WALT power tools: the yellow and black color scheme; the “D” shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool.