DeWalt DC415 Owner's manual

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ENGLISH

30

Congratulations!

You have chosen a DEWALT tool. Years of

experience, thorough product development and

innovation make D

EWALT one of the most reliable

partners for professional power tool users.

Technical data

DC413 DC415

Voltage V

DC

28 36

Power W 630 815

No-load min

-1

6,500 6,500

Wheel diameter mm 125 125

Spindle diameter M14 M14

Weight (without

battery pack) kg 2.3* 2.3*

* weight includes side handle and guard

Battery pack DE9280 DE9360

Voltage V

DC

28 36

Capacity Ah 2.2 2.2

Weight kg .92 1.0

Charger DE9000

Mains voltage V

AC

230

Battery type 28 V, 36 V Li-Ion

Approx. charging time min 60

Weight kg 0.9

Fuses

Europe 230 V tools

10 Amperes, mains

U.K. & Ireland 230 V tools

13 Amperes, in plugs

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.

Denotes risk of electric shock.

EC-Declaration of conformity

DC413/DC415

D E WALT declares that these power tools have been

designed in compliance with:

98/37/EC, 89/226/EEC, 86/188/EEC, 2006/95/EC,

EN 60745-1, EN 60745-2-3, EN 55014-1,

EN 55014-2.

DE9000

D E WALT declares that this charger has been

designed in compliance with:

89/336/EEC, 2002/95/EC, 2006/95/EC,

EN 60335-1, EN 60335-2-29, EN 55014-1,

EN 60745-2-3, EN 61000-2-3,

EN 61000-3-3.

For more information, please contact D

EWALT at the

address below, or refer to the back of the manual.

DC413 DC415

L

pA

(sound pressure) dB(A) 77 79

K

pA

(sound pressure uncertainty) dB(A) 3 3

L

WA

(acoustic power) dB(A) 88 90

K

WA

(acoustic power uncertainty) dB(A) 3 3

Vibration total values (triax vector sum) determined according

to EN 60745:

Weighted RMS

acceleration value m/s

2

5.7 5.8

Uncertainty K

m/s

2

5.3 5.3

HEAVY-DUTY CORDLESS GRINDER

DC413/DC415

ENGLISH

31

The declared vibration emission value has been

measured in accordance with a standard test

method and may be used for comparing one tool

with another.

The declared vibration emission value may also be

used in a preliminary assessment of exposure.

WARNING: The vibration emission

value during actual use of the power

tool can differ from the declared value

depending on the ways in which the tool

is used. This could lead to a significant

underestimate of exposure when the

tool is used regularly in such a way.

An estimation of the level of exposure to vibration

experienced during a given period of work should

also take into account the times when the tool is

switched off and when it is running idle in addition to

the trigger time.

This may significantly reduce the exposure level over

the total working period.

Director Engineering and Product Development

Horst Grossmann

DEWALT, Richard-Klinger-Strase 11D-65510,

Idstein, Germany

04/2007

WARNING: To reduce the risk of injury,

read the instruction manual.

General Safety Rules

WARNING! Read all instructions. Failure

to follow all instructions listed below

may result in electric shock, fire and/or

serious injury.

The term “power tool” in all of the warnings listed

below refers to your mains-operated (corded) power

tool or battery-operated (cordless) power tool.

SAVE ALL WARNINGS AND INSTRUCTIONS

FOR FUTURE REFERENCE.

1) WORK AREA SAFETY

a) Keep work area clean and well lit.

Cluttered or dark areas invite accidents.

b) Do not operate power tools in explosive

atmospheres, such as in the presence of

flammable liquids, gases or dust. Power

tools create sparks which may ignite the dust

or fumes.

c) Keep children and bystanders away while

operating a power tool. Distractions can

cause you to lose control.

2) ELECTRICAL SAFETY

a) Power tool plugs must match the outlet.

Never modify the plug in any way. Do

not use any adapter plugs with earthed

(grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of

electric shock.

b) Avoid body contact with earthed or

grounded surfaces such as pipes,

radiators, ranges and refrigerators. There

is an increased risk of electric shock if your

body is earthed or grounded.

c) Do not expose power tools to rain or wet

conditions. Water entering a power tool will

increase the risk of electric shock.

d) Do not abuse the cord. Never use the

cord for carrying, pulling or unplugging

the power tool. Keep cord away from

heat, oil, sharp edges or moving parts.

Damaged or entangled cords increase the

risk of electric shock.

e) When operating a power tool outdoors,

use an extension cord suitable for outdoor

use. Use of a cord suitable for outdoor use

reduces the risk of electric shock.

f) If operating a power tool in a damp

location is unavoidable, use a residual

current device (RCD) protected supply.

Use of an RCD reduces the risk of electric

shock.

3) PERSONAL SAFETY

a) Stay alert, watch what you are doing and

use common sense when operating a

power tool. Do not use a power tool while

you are tired or under the influence of

drugs, alcohol or medication. A moment of

inattention while operating power tools may

result in serious personal injury.

b) Use personal protective equipment.

Always wear eye protection. Protective

equipment such as dust mask, non-skid

safety shoes, hard hat, or hearing protection

used for appropriate conditions will reduce

personal injuries.

c) Prevent unintentional starting. Ensure

the switch is in the off-position before

connecting to power source and/or

battery pack, picking up or carrying the

tool. Carrying power tools with your finger

on the switch or energising power tools that

have the switch on invites accidents.

ENGLISH

32

d) Remove any adjusting key or wrench

before turning the power tool on. A

wrench or a key left attached to a rotating

part of the power tool may result in personal

injury.

e) Do not overreach. Keep proper

footing and balance at all times. This

enables better control of the power tool in

unexpected situations.

f) Dress properly. Do not wear loose

clothing or jewellery. Keep your hair,

clothing and gloves away from moving

parts. Loose clothes, jewellery or long hair

can be caught in moving parts.

g) If devices are provided for the connection

of dust extraction and collection facilities,

ensure these are connected and properly

used. Use of dust collection can reduce

dust-related hazards

4) POWER TOOL USE AND CARE

a) Do not force the power tool. Use the

correct power tool for your application.

The correct power tool will do the job

better and safer at the rate for which it

was designed.

b) Do not use the power tool if the switch

does not turn it on and off. Any power

tool that cannot be controlled with the switch

is dangerous and must be repaired.

c) Disconnect the plug from the power

source and/or the battery pack from

the power tool before making any

adjustments, changing accessories, or

storing power tools. Such preventive safety

measures reduce the risk of starting the

power tool accidentally.

d) Store idle power tools out of the reach

of children and do not allow persons

unfamiliar with the power tool or these

instructions to operate the power tool.

Power tools are dangerous in the hands of

untrained users.

e) Maintain power tools. Check for

misalignment or binding of moving parts,

breakage of parts and any other condition

that may affect the power tools 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.

5) BATTERY TOOL USE AND CARE

a) Ensure the switch is in the off position

before inserting battery pack. Inserting the

battery pack into power tools that have the

switch on invites accidents.

b) Recharge only with the charger specified

by the manufacturer. A charger that is

suitable for one type of battery pack may

create a risk of fire when used with another

battery pack.

c) Use power tools only with specifically

designated battery packs. Use of any other

battery packs may create a risk of

injury and fire.

d) When battery pack is not in use, keep it

away from other metal objects like paper

clips, coins, keys, nails, screws, or other

small metal objects that can make a

connection from one terminal to another.

Shorting the battery terminals together may

cause burns or a fire.

e) Under abusive conditions, liquid may be

ejected from the battery, avoid contact.

If contact accidentally occurs, flush with

water. If liquid contacts eyes, additionally

seek medical help. Liquid ejected from the

battery may cause irritation or burns.

6) SERVICE

a) Have your power tool serviced by a

qualified repair person using only identical

replacement parts. This will ensure that the

safety of the power tool is maintained.

Additional safety instructions for

battery packs and chargers

• Make sure that the battery pack is dry and

clean before inserting it into the charger.

• Use only chargers labelled with “Li-Ion” to

charge D

EWALT Lithium Ion battery packs.

• Never carry the charger by its cord. Never pull

the cord to disconnect from the socket. Keep

the cord away from heat, oil and sharp edges.

• Have any damaged or defective cords replaced

by an authorised DEWALT repair agent. Never

attempt any repairs yourself.

• Do not expose the charger to damp or wet

conditions.

• Do not attempt to charge wet battery packs.

ENGLISH

33

• Never attempt to open a battery pack for any

reason.

• Charge only battery packs with the ratings as

specified in this manual. Do not attempt to

charge non-rechargeable batteries.

• Always follow the instructions in the back of this

manual for battery pack disposal.

• When not in use, chargers and battery packs

must be stored in a dry place and locked up

securely, out of reach of children.

Transporting

DEWALT Li-Ion battery packs comply with the

necessary testing requirements under the UN

Manual of Tests and Criteria (ST/SG/AC.10/11/Rev.3

Part III, Subsection 38.3) as referenced in the UN

Recommendations on the Transport of Dangerous

Goods.

• The battery packs have effective protection

against internal overpressure and short-

circuiting.

• Appropriate measures have been provided for

prevention of forced rupture and dangerous

reverse current.

• The equivalent lithium content is below the

relevant limit value.

DEWALT Li-Ion battery packs are exempted from

national and international regulations applicable

to dangerous goods. However, these regulations

become relevant when transporting several battery

packs together.

• Make sure that battery packs are packed

according to the dangerous goods regulations

as mentioned above to prevent short-circuiting.

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.

LABELS ON CHARGER AND BATTERY PACK

In addition to the pictographs used in this manual,

the labels on the charger and the battery pack show

the following pictographs:

Read instruction manual

before use.

Do not expose to water.

Do not probe with conductive objects.

Do not charge damaged battery packs

Do not use damaged chargers

Charge only between 4 °C and 40 °C.

Have defective cords replaced

immediately.

Charger problem

Battery problem

Discard the battery pack with due care for

the environment.

Do not incinerate the battery pack.

Charge only with dedicated DEWALT

chargers.

See technical data for charging time.

Additional Speciﬁ c Safety Rules

a) This power tool is intended to function

as a grinder, sander, wire brush, polisher

or cut-off tool. Read all safety warnings,

instructions, illustrations and specifications

provided with this power tool. Failure to follow

all instructions listed below may result in electric

shock, fire and/or serious injury.

b) Do not use accessories which are not

specifically designed and recommended

by the tool manufacturer. Just because the

accessory can be attached to your power tool,

it does not assure safe operation.

c) The rated speed of the accessory must be at

least equal to the maximum speed marked

on the power tool. Accessories running faster

than their rated speed can break and fly apart.

d) The outside diameter and the thickness of

your accessory must be within the capacity

rating of your power tool. Incorrectly sized

accessories cannon be adequately guarded or

controlled.

ENGLISH

34

e) The arbour size of wheels, flanges, backing

pads or any other accessory must properly

fit the spindle of the power tool. Accessories

with arbour holes that do not match the

mounting hardware of the power tool will run

out of balance, vibrate excessively and may

cause loss of control.

f) Do not use a damaged accessory. Before

each use inspect the accessory such as

abrasive wheel for chips and cracks, backing

pad for cracks, tear or excess wear, wire

brush for loose or cracked wires. If power

tool or accessory is dropped, inspect for

damage or install an undamaged accessory.

After inspecting and installing an accessory,

position yourself and bystanders away from

the plane of the rotating accessory and run

the power tool at maximum no-load speed

for one minute. Damaged accessories will

normally break apart during this test time.

g) Wear personal protective equipment.

Depending on application, use face

shield, safety goggles or safety glasses.

As appropriate, wear dust mask, hearing

protectors, gloves and workshop apron

capable of stopping small abrasive or

workpiece fragments. The eye protection must

be capable of stopping flying debris generated

by various operations. The dust mask or

respirator must be capable of filtrating particles

generated by your operation. Prolonged

exposure to high intensity noise may cause

hearing loss.

h) Keep bystanders a safe distance away from

work area. Anyone entering the work area

must wear personal protective equipment.

Fragments of workpiece or of a broken

accessory may fly away and cause injury

beyond immediate area of operation.

i) Hold power tool by insulated gripping

surfaces only, when performing an operation

where the cutting accessory may contact

hidden wiring or its own cord. Cutting

accessory contacting a “live” wire may make

exposed metal parts of the power tool “live” and

shock the operator.

j) Position the cord clear of the spinning

accessory. If you lose control, the cord may be

cut or snagged and your hand or arm may be

pulled into the spinning accessory.

k) Never lay the power tool down until the

accessory has come to a complete stop. The

spinning accessory may grab the surface and

pull the power tool out of your control.

l) Do not run the power tool while carrying

it at your side. Accidental contact with the

spinning accessory could snag your clothing,

pulling the accessory into your body.

m) Regularly clean the power tool’s air vents.

The motor’s fan will draw the dust inside

the housing and excessive accumulation of

powered metal may cause electrical hazards.

n) Do not operate the power tool near

flammable materials. Sparks could ignite these

materials.

o) Do not use accessories that require liquid

coolants. Using water or other liquid coolants

may result in electrocution or shock.

Safety Warnings Speciﬁ c for

Grinding and Abrasive Cutting-off

Operations

a) Use only wheel types that are recommended

for your power tool and the specific guard

designed for the selected wheel. Wheels for

which the power tool was not designed cannot

be adequately guarded and are unsafe.

b) The guard must be securely attached

to the power tool and positioned for

maximum safety, so the least amount of

wheel is exposed towards the operator. The

guard helps to protect operator from broken

wheel fragments and accidental contact with

wheel.

c) Wheels must be used only for recommended

applications. For example: do not grind with

the side of cut-off wheel. Abrasive cut-off

wheels are intended for peripheral grinding, side

forces applied to these wheels may cause them

to shatter.

d) Always use undamaged wheel flanges

that are of correct size and shape for your

selected wheel. Proper wheel flanges support

the wheel thus reducing the possibility of wheel

breakage. Flanges for cut-off wheels may be

different from grinding wheel flanges.

e) Do not use worn down wheels from larger

power tools. Wheel intended for larger power

tool is not suitable for the higher speed of a

smaller tool and may burst.

Causes and Operator Prevention

of Kickback

• Kickback is a sudden reaction to a pinched,

bound or misaligned wheel, wire brush or flap

ENGLISH

35

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.

• 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.

Package contents

The package contains:

1 Angle grinder

1 Type 27 guard

1 Anti vibration side handle

1 Flange set

1 Two-pin spanner

2 Battery packs (DC413KL/DC415KL)

1 Battery charger (DC413KL/DC415KL)

1 Kit box (DC413KL/DC415KL)

1 Instruction manual

1 Exploded drawing

• 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 (ﬁ g. 1)

WARNING: Never modify the power

tool or any part of it. Damage or

personal injury could result.

INTENDED USE

Your DC413/DC415 grinders are designed for

professional applications. DO NOT use under humid

conditions or in presence of flammable liquids or

gases.

DO NOT use grinding wheels other than center

depressed wheels and flap-disc.

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.

a. Trigger switch

b. Lock-Off Button

c. Spindle lock button

d. Side handle

e. Abrasive wheel

f. Anti-lockup backing flange

g. Threaded clamp nut

h. Type 27 guard

i. Battery pack

j. Battery release button

Charger

Your DE9000 charger accepts DEWALT

Li-Ion battery packs of 36 V (DE9360) and

28 V (DE9280) at 2.2 Ah.

Electrical safety

The electric motor has been designed for one

voltage only. Always check that the battery pack

voltage corresponds to the voltage on the rating

plate. Also make sure that the voltage of your

charger corresponds to that of your mains.

Your DEWALT charger is double insulated

in accordance with EN 60335.

ENGLISH

36

Mains plug replacement

(U.K. & Ireland only)

DANGER:

• Should your mains plug need replacing

and you are competent to do this,

proceed as instructed below. If you are

in doubt, contact an authorized D

EWALT

repair agent or a qualified electrician.

• Disconnect the plug from the supply.

• Cut off the plug and dispose of it safely;

a plug with bared copper conductors

is dangerous if engaged in a live socket

outlet.

• Only fit 13 Amperes BS1363A approved

plugs fitted with the correctly rated fuse

(1).

• The cable wire colours, or a letter, will be

marked at the connection points of most

good quality plugs. Attach the wires to

their respective points in the plug (see

below). Brown is for Live (L) (2) and Blue

is for Neutral (N) (4).

• Before replacing the top cover of the

mains plug ensure that the cable restraint

(3) is holding the outer sheath of the cable

firmly and that the two leads are correctly

fixed at the terminals crews.

1

2

4

3

WARNING: NEVER use a light socket.

NEVER connect the live (L) or

neutral (N) wires to the earth

pin marked E or .

Using an extension cable

An extension cord should not be used unless

absolutely necessary. Use an approved extension

cable suitable for the power input of your charger

(see technical data). The minimum conductor size is

1 mm

2

; the maximum length is 30 m.

Assembly and adjustment

WARNING: Prior to assembly and

adjustment, always remove the battery

pack. Always switch off the tool before

inserting or removing the battery pack.

WARNING: Use only DEWALT battery

packs and chargers.

Battery pack (ﬁ g. 1)

BATTERY TYPE

The DC413 operates on 28 V lithium ion battery

packs and the DC415 operates on 36 volt lithium

ion battery packs.

Charging the Battery Pack

Always check the mains prior to charging the battery

pack. If the mains is functioning but the battery pack

does not charge, take your charger to an authorised

DEWALT repair agent. Whilst charging, the charger

and the battery pack may become warm to touch.

This is a normal condition and does not indicate a

problem.

CAUTION: Do not charge the battery

pack at ambient temperatures < 4 °C

or > 40 °C. Recommended charging

temperature: approx. 24 °C.

To charge the battery pack (i), insert it into the

charger (l) as shown and plug in the charger. Be sure

that the battery pack is fully seated in the charger.

The red charging indicator (m) will blink according to

the state of charge of the battery pack.

When finished charging, the indicators are all on.

The charger automatically switches to equalise

mode.

The battery pack can be removed at any time or left

in the connected charger indefinitely.

The red charging indicators flash rapidly to indicate

a charging problem. Reinsert the battery pack or try

a new one. If the new pack also refuses to charge,

have your charger tested by an authorized DEWALT

repair agent.

The red charging indicators flash rapidly with one

short blink followed by a long blink to indicate a

problem with the charger. Return the charger to an

authorized DEWALT repair agent.

When plugged into power sources such as

generators or sources that convert DC to AC, the

red charging indicators (m) may flash together with

two fast blinks followed by a pause. This indicates

a temporary problem of the power source. The

charger will automatically switch back to normal

operation.

ENGLISH

37

After approx. 1 hour all three indicators will remain

constant.

Charging process (ﬁ g. 2)

Refer the table below for the state of charge of the

battery pack.

State of charge

1 light blinking < 33%

1 light blinking, 1 light on 33-66%

1 light blinking, 2 lights on 66-99%

3 lights on 100%

Automatic refresh

The automatic refresh mode will equalise or balance

the individual cells in the battery pack at its peak

capacity. Battery packs should be refreshed weekly

or whenever the pack no longer delivers the same

amount of work.

To refresh your battery pack, place the battery in the

charger as usual. Leave the battery pack for at least

8 hours in the charger.

Hot/Cold Pack Delay

When the charger detects a battery that is too hot

or too cold, it automatically starts a Hot/Cold Pack

Delay, suspending charging until the battery has

reached an appropriate temperature. The charger

then automatically switches to the pack charging

mode. This feature ensures maximum battery life.

DEEP DISCHARGE PROTECTION

The battery pack is protected against deep

discharging when it is used in the tool.

Inserting and removing the

battery pack into the tool (ﬁ g. 2)

WARNING: To reduce the risk

of serious personal injury, make

certain the lock-off button (b)

is engaged to prevent switch

actuation before removing or

installing battery.

1. To fit the battery pack (i), line it up with the

receptacle on the tool. Slide the battery pack

into the receptacle and push until the battery

snaps into place.

2. To remove the battery pack, push the battery

release button (j) while at the same time pulling

the battery pack out of the receptacle.

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 (ﬁ g. 3)

WARNING: To reduce the risk of

serious personal injury, turn tool off and

remove battery pack before making

any adjustments or removing/installing

attachments or accessories.

1. Remove the four corner screws attaching the

gear case to motor housing.

2. Without separating the gear case from motor

housing, rotate the gear case head to desired

position.

NOTE: If the gear case and motor housing become

separated by more than 6.35 mm (1/4"), the tool

must be serviced and re-assembled by a DEWALT

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 2.08 Nm

(18 in-lbs.) torque. Overtightening could cause

screws to strip.

Mounting Guard

MOUNTING AND REMOVING GUARD (FIG. 4)

WARNING: To reduce the risk of

serious personal injury, turn tool off 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. The DC413/DC415 is

provided with a guard intended for use

with depressed center wheels (Type 27)

and hubbed grinding wheels (Type 27).

The same guard is designed for use

with sanding flap discs (Type 27 and 29)

and wire cup brushes.

ENGLISH

38

1. Open the guard latch (n), and align the lugs (p)

on the guard with the slots (o) on the gear case.

2. Push the guard down until the guard lugs

engage and rotate freely in the groove on the

gear case hub.

3. With the guard latch open, rotate the guard (h)

into the desired working position. The guard

body should be positioned between the spindle

and the operator to provide maximum operator

protection.

4. Close the guard latch to secure the guard on

the gear case. You should not be able to rotate

the guard by hand when the latch is closed. Do

not operate the grinder with a loose guard or

the clamp lever in open position.

5. To remove the guard, open the guard latch,

rotate the guard so that the lugs are aligned

with the slots and pull up on the guard.

NOTE: The guard is pre-adjusted to the diameter of

the gear case hub at the factory. If, after a period of

time, the guard becomes loose, tighten the adjusting

screw (q) with clamp lever in the closed position with

guard installed on the tool.

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; 6.35 mm (1/4") thick wheels are designed

for surface grinding while 3.17 mm (1/8") wheels are

designed for edge grinding.

OPERATION

Switch

LOCK-OFF BUTTON AND TRIGGER SWITCH (FIG. 5)

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.

Always lock the trigger switch when carrying or

storing the tool to eliminate unintentional starting.

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 (FIG. 6)

WARNING: To reduce the risk of

serious personal injury, turn tool off and

remove battery pack before making

any adjustments or removing/installing

attachments or accessories.

Hubbed wheels install directly on the M14 threaded

spindle.

1. Thread the wheel on the spindle by hand.

ENGLISH

39

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 (FIG. 7)

WARNING: To reduce the risk of

serious personal injury, turn tool off 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.

1. Install the anti-lockup backing flange (f) on

spindle (r) with the raised centre 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 (s).

2. Place wheel against the backing flange,

centering the wheel on the raised centre of the

backing flange.

3. While depressing the spindle lock button, thread

the clamp nut (g) on spindle. If the wheel you

are installing is more than 3.17 mm (1/8") thick,

place the threaded clamp nut on the spindle so

that the raised centre fits into the center of the

wheel (Fig. 7A). If the wheel you are installing is

3.17 mm (1/8") thick or less, place the threaded

clamp nut on the spindle so that the raised

centre is not against the wheel (Fig. 7B).

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.

SURFACE GRINDING WITH GRINDING WHEELS

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. Maintain a 20˚ to 30˚ angle between the

tool and work surface.

4. Continuously move the tool in a forward and

back motion to avoid creating gouges in the

work surface.

5. Remove the tool from work surface before

turning tool off. Allow the tool to stop rotating

before 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, limit the use of these wheels with

a standard Type 27 guard to shallow

cutting and notching [less than 13 mm

(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.

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.

ENGLISH

40

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.

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.

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.

Lubrication

This tool requires no lubrication.

CAUTION: Do not lubricate the tool as

it will damage the internal parts.

Cleaning

WARNING:

• Unplug the charger before cleaning the

housing with a soft cloth.

• Remove the battery pack before cleaning

your power tool.

• Keep the ventilation slots clear and

regularly clean the housing with a soft

cloth.

Optional accessories

WARNING: Since accessories, other

than those offered by DEWALT, have

not been tested with this product, use

of such accessories with this tool could

be hazardous. To reduce the risk of

injury, only DEWALT, recommended

accessories should be used with this

product.

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 M14 hub. Every

unthreaded accessory must have a

ENGLISH

41

22.2 mm (7/8") arbor hole. If it does not,

it may have been designed for a circular

saw. Accessory ratings must always

be above tool speed as shown on tool

nameplate.

It is important to choose the correct guards, backing

pads and flanges to use with grinder accessories.

Consult your dealer for further information on the

appropriate accessories.

Protecting the environment

Separate collection. This product must

not be disposed of with normal

household waste.

Should you ﬁnd one day that your DEWALT product

needs replacement, or if it is of no further use to you,

do not dispose of it with household waste. Make this

product available for separate collection.

Separate collection of used products

and packaging allows materials to be

recycled and used again. Re-use of

recycled materials helps prevent

environmental pollution and reduces

the demand for raw materials.

Local regulations may provide for separate collection

of electrical products from the household, at

municipal waste sites or by the retailer when you

purchase a new product.

DEWALT provides a facility for the collection and

recycling of DEWALT products once they have

reached the end of their working life. To take

advantage of this service please return your product

to any authorised repair agent who will collect them

on our behalf.

You can check the location of your nearest

authorised repair agent by contacting your local

DEWALT office at the address indicated in this

manual. Alternatively, a list of authorised DEWALT

repair agents and full details of our after-sales

service and contacts are available on the Internet at:

www.2helpU.com.

Rechargeable Battery Pack

This long life battery pack must be recharged when

it fails to produce sufficient power on jobs which

were easily done before. At the end of its technical

life, discard it with due care for our environment:

• Run the battery pack down completely, then

remove it from the tool.

• Li-Ion, NiCd and NiMH cells are recyclable. Take

them to your dealer or a local recycling station.

The collected battery packs will be recycled or

disposed of properly.

ENGLISH

42

GUARANTEE

• 30 DAY NO RISK

SATISFACTION GUARANTEE •

If you are not completely satisfied with

the performance of your D

EWALT tool,

simply return it within 30 days, complete as

purchased, to the point of purchase, for a full

refund or exchange. Proof of purchase must

be produced.

• ONE YEAR FREE SERVICE CONTRACT •

If you need maintenance or service for your

DEWALT tool, in the 12 months following

purchase, it will be undertaken free of charge

at an authorized DEWALT repair agent. Proof

of purchase must be produced. Includes

labour and spare parts for Power Tools.

Excludes accessories.

• ONE YEAR FULL WARRANTY •

If your DEWALT product becomes defective

due to faulty materials or workmanship within

12 months from the date of purchase, we

guarantee to replace all defective parts free of

charge or, at our discretion, replace the unit

free of charge provided that:

• The product has not been misused.

• Repairs have not been attempted by

unauthorized persons.

• Proof of purchase date is produced. This

guarantee is offered as an extra benefit

and is additional to consumers statutory

rights.

For the location of your nearest authorized

DEWALT repair agent, please use the

appropriate telephone number on the back of

this manual. Alternatively, a list of authorized

DEWALT repair agents and full details on our

after-sales service are available on the Internet

at www.2helpU.com.

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Belgique et Luxembourg Black & Decker - DEWALT Tel: +32 (0)015 - 15 47 9211

België en Luxemburg Nieuwlandlaan 7, IZ Aarschot B156 Fax: +32 (0)015 - 15 47 9210

B-3200 Aarschot www.dewalt.com

Danmark D

EWALT Tlf: 70 20 15 10

Sluseholmen 2-4 Fax: 36 94 49 01

2450 København SV www.dewalt-nordic.com

Deutschland D

EWALT Tel: 06126-21-1

Richard-Klinger-Straße Fax: 06126-21-2770

65510 Idstein www.dewalt.de

 Black & Decker (Hellas) S.A. Τηλ: (01) 8981-616

Στράβωνος 7 & Βουλιαγμένης 159 Φαξ: (01) 8983-570

Γλυφάδα 16674, Αθήνα Service: (01) 8982-630

España D

EWALT Tel: 934 797 400

Parque de Negocios “Mas Blau” Fax: 934 797 439

Edificio Muntadas, c/Bergadá, 1, Of. A6

08820 El Prat de Llobregat (Barcelona)

France D

EWALT Tel: 472 20 39 72

Le Paisy Fax: 472 20 39 02

BP 21, 69571 Dardilly Cedex www.dewalt.fr

Schweiz D

EWALT Tel: 01 - 730 67 47

Suisse In der Luberzen 40 Fax: 01 - 730 70 67

Svizzera 8902 Urdorf www.dewalt.ch

Ireland D

EWALT Tel: 00353-2781800

Calpe House Rock Hill Fax: 00353-2781811

Black Rock, Co. Dublin www.dewalt.ie

Italia D

EWALT Tel: 800-014353

Viale Elvezia 2 Fax: 039-2387592

20052 Monza (Mi) www.dewalt.it

Nederlands Black & Decker - D

EWALT Tel: 0164 283000

Joulehof 12 Fax: 0164 283100

4600 AB Bergen Op Zoom www.dewalt.com

Norge D

EWALT Tel: 22 90 99 00

Postboks 4814, Nydalen Fax: 22 90 99 01

0422 Oslo www.dewalt-nordic.com

Österreich D

EWALT Tel: 01 - 66116 - 0

Werkzeugevertriebs GmbH Fax: 01 - 66116 - 14

Erlaaerstraße 165, Postfach 320,1231 Wien www.dewalt.at

Portugal D

EWALT Tel: 214 66 75 00

Rua Egas Moniz 173 Fax: 214 66 75 75

João do Estoril, 2766-651 Estoril

Suomi D

EWALT Puh: 010 400 430

Keilasatama 3 Faksi: (09) 2510 7100

02150 Espoo www.dewalt-nordic.com

D

EWALT Tel: 010 400 430

Kägelhamnen 3 Fax: (09) 2510 7100

02150 Esbo www.dewalt-nordic.com

Sverige D

EWALT, c/o Regus Tel: 031 68 61 00

Fabriksgatan 7 Fax: 031 68 60 08

412 50 Göteborg www.dewalt-nordic.com

Türkiye

Merkez Servis

Tel:

0212 361 60 20

Tersane Cad.

Faks:

0212 361 60 19

Nafe Sokak 1-3/4 Karaköy - İstanbul

United Kingdom D

EWALT Tel: 01753-56 70 55

210 Bath Road Fax: 01753-57 21 12

Slough, Berks SL1 3YD www.dewalt.co.uk

653786-00 08/07

DeWalt DC415 Owner's manual

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