DEWALT DWE4056-QS 115mm 800W Angle Grinder Instruction Manual

1. Introduction

Thank you for choosing the DEWALT DWE4056-QS 115mm 800W Angle Grinder. This manual provides essential information for the safe and efficient operation, maintenance, and troubleshooting of your tool. Please read these instructions carefully before use and keep them for future reference. Proper use and maintenance will ensure long-lasting performance and user safety.

2. General Safety Instructions

Always observe basic safety precautions to reduce the risk of fire, electric shock, and personal injury. Familiarize yourself with all safety warnings and instructions provided with the tool.

2.1 Work Area Safety

• Keep the work area clean and well-lit. Cluttered or 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 children and bystanders away while operating a power tool. Distractions can cause you to lose control.

2.2 Electrical Safety

• Power tool plugs must match the outlet. Never modify the plug in any way.
• 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.
• Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

2.3 Personal Safety

• Always wear appropriate personal protective equipment (PPE), including safety glasses, hearing protection, gloves, and a dust mask.
• Stay alert, watch what you are doing, and use common sense when operating a power tool.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts.

2.4 Angle Grinder Specific Safety

• Always ensure the guard is correctly positioned and securely fastened before operation.
• Use only cutting or grinding discs that are rated for the speed of your grinder and are in good condition.
• Never force the tool. Allow the disc to do the work.
• Be aware of kickback. Always maintain a firm grip on the tool.
• Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool.

3. Product Overview

The DEWALT DWE4056-QS is a compact and powerful 115mm angle grinder designed for various grinding and cutting applications. Key components include the main body, side handle, protective guard, spindle lock button, and power switch.

Figure 1: DEWALT DWE4056-QS Angle Grinder, showing the main body, side handle, and protective guard.

Figure 2: Side view of the angle grinder, highlighting its compact design.

3.1 Key Features

• Abrasion-Protected Motor: Engineered for enhanced durability and extended tool life, even in demanding work environments.
• No-Volt Release Switch: Prevents accidental restarts if power is interrupted while the switch is in the 'ON' position. The tool will not restart until the switch is manually reset.
• Epoxy-Coated Stator Windings: Provides an additional layer of protection against abrasive dust and debris, further increasing motor longevity.

4. Setup

Before operating the angle grinder, ensure it is properly assembled and configured for your task.

4.1 Attaching the Side Handle

The side handle can be attached to either side of the gear housing for optimal control and comfort, depending on your application and handedness. Screw the side handle firmly into one of the threaded holes on the gear housing.

4.2 Adjusting the Protective Guard

The protective guard must always be used and adjusted to provide maximum protection from sparks and debris. Loosen the guard clamping screw, rotate the guard to the desired position, and then securely tighten the screw.

4.3 Installing/Changing Grinding or Cutting Discs

1. Ensure the tool is unplugged from the power source.
2. Press and hold the spindle lock button to prevent the spindle from rotating.
3. Use the supplied wrench to loosen and remove the outer flange nut.
4. Place the desired grinding or cutting disc onto the inner flange, ensuring it is centered.
5. Re-attach the outer flange nut and tighten it securely with the wrench while holding the spindle lock button. Do not overtighten.

Figure 3: Detail of the grinder head, illustrating the spindle lock button and the area for disc attachment.

5. Operating Instructions

Follow these steps for safe and effective operation of your DEWALT DWE4056-QS angle grinder.

5.1 Pre-Operation Checks

• Verify that the correct disc is installed and securely fastened.
• Check that the protective guard is properly positioned and tightened.
• Inspect the power cord for any damage.
• Ensure your workpiece is securely clamped or held to prevent movement during operation.

5.2 Switching ON/OFF

• To turn ON: Slide the power switch forward until it locks into the 'ON' position.
• To turn OFF: Slide the power switch backward to the 'OFF' position. The No-Volt release feature will prevent accidental restarts after a power cut.

5.3 Grinding and Cutting Techniques

• Allow the tool to reach full speed before contacting the workpiece.
• For grinding, hold the tool at a slight angle (15-30 degrees) to the workpiece. Apply moderate pressure and move the tool smoothly across the surface.
• For cutting, hold the tool perpendicular (90 degrees) to the workpiece. Do not apply excessive side pressure, as this can damage the disc and cause kickback. Make shallow passes rather than attempting to cut through thick material in one go.
• Always direct sparks away from yourself and bystanders.

Figure 4: The angle grinder in operation, demonstrating typical use with sparks being generated.

6. Maintenance

Regular maintenance ensures the longevity and safe operation of your angle grinder.

6.1 Cleaning

• Always unplug the tool before cleaning.
• Clean the ventilation slots regularly to prevent overheating. Use compressed air if available.
• Wipe the tool housing with a damp cloth. Do not use harsh chemicals or solvents.

6.2 Carbon Brush Replacement

This tool is equipped with auto-stop carbon brushes. When the brushes wear down, the tool will automatically stop operating, indicating that brush replacement is necessary. Replacement should be performed by a qualified service technician to ensure proper installation and continued safety.

6.3 Cord Inspection

Regularly inspect the power cord for cuts, abrasions, or other damage. If the cord is damaged, have it replaced by an authorized service center to avoid electrical hazards.

6.4 Storage

Store the tool in a dry, secure location out of reach of children and unauthorized users. Ensure the tool is unplugged and any accessories are removed before storage.

7. Troubleshooting

This section addresses common issues you might encounter with your angle grinder.

7.1 Tool Does Not Start

• Check if the power cord is securely plugged into a working outlet.
• Ensure the power switch is fully engaged in the 'ON' position. If it was previously 'ON' during a power interruption, reset it to 'OFF' and then 'ON' again due to the No-Volt release feature.
• Inspect the power cord for damage.
• The carbon brushes may be worn out. If so, the tool will not operate. Refer to Section 6.2 for brush replacement.

7.2 Excessive Vibration

• Check if the grinding/cutting disc is properly installed and securely tightened.
• Inspect the disc for damage or imbalance. Replace if necessary.
• Ensure the side handle is firmly attached.

7.3 Poor Performance / Overheating

• Ensure the ventilation slots are clear of dust and debris. Clean as described in Section 6.1.
• Do not apply excessive pressure to the tool; let the disc do the work.
• Ensure you are using the correct type of disc for the material being worked on.

If problems persist, contact an authorized DEWALT service center.

8. Specifications

Technical data for the DEWALT DWE4056-QS Angle Grinder:

Figure 5: Dimensions of the DEWALT DWE4056-QS Angle Grinder.

9. Warranty and Support

DEWALT power tools are designed to the highest standards and are subject to rigorous quality control. Your DEWALT DWE4056-QS Angle Grinder comes with a standard warranty. Please refer to the warranty card included with your purchase for specific terms and conditions, including warranty period and registration details.

For technical assistance, service, or to locate an authorized service center, please visit the official DEWALT website or contact your local DEWALT dealer. Always use genuine DEWALT replacement parts to maintain tool performance and warranty validity.