DEWALT FLEXVOLT 60V MAX* Angle Grinder User Manual

Important Safety Instructions

Always follow basic safety precautions when using electrical tools to reduce the risk of fire, electric shock, and personal injury.

• Read all instructions before operating the tool.
• Wear appropriate personal protective equipment (PPE), including eye protection, hearing protection, and gloves.
• Ensure the work area is 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.
• Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
• Disconnect the battery pack from the tool before making any adjustments, changing accessories, or storing the tool.
• Use the correct tool for your application. Do not force the tool to do a job for which it was not designed.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools are less likely to bind and are easier to control.
• Store idle tools out of reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool.

Product Overview

The DEWALT FLEXVOLT 60V MAX* Angle Grinder (DCG418B) is a powerful cordless tool designed for grinding and cutting applications. It features a brushless motor, Kickback Brake, and E-CLUTCH technology for enhanced safety and performance.

Figure 1: DEWALT FLEXVOLT 60V MAX* Angle Grinder with the side handle attached, showing the main body, grinding wheel, and battery connection area.

Figure 2: DEWALT FLEXVOLT 60V MAX* Angle Grinder without the side handle, providing a clear view of the tool's compact design and key components.

Included Components:

• (1) DCG418 60V MAX* Brushless 4-1/2 in. - 6 in. Cordless Grinder
• (1) Wrench
• (2) Flanges
• (1) Side Handle
• (1) 4-1/2 in. (115mm) Type 27 Guard
• (1) 6 in. (150mm) Type 27 Guard

Note: Batteries and charger are sold separately.

Setup

Attaching the Side Handle:

1. Ensure the tool is off and the battery pack is removed.
2. Thread the side handle into one of the threaded holes on the gear case. Tighten securely.

Installing/Removing Grinding Wheel and Guard:

1. Ensure the tool is off and the battery pack is removed.
2. Select the appropriate guard (4-1/2 inch or 6 inch) for your grinding wheel.
3. Align the guard with the tool's collar and rotate until it locks into place.
4. Place the inner flange onto the spindle.
5. Position the grinding wheel onto the spindle, ensuring it sits flush against the inner flange.
6. Place the outer flange onto the spindle, with the raised hub facing the wheel for depressed center wheels, or flat side facing the wheel for flat wheels.
7. Press the spindle lock button and use the provided wrench to tighten the outer flange securely.
8. To remove, reverse the steps.

Battery Installation:

1. Ensure the tool's switch is in the OFF position.
2. Align the battery pack with the tool's battery port.
3. Slide the battery pack into the tool until it clicks securely into place.
4. To remove, press the battery release button and pull the battery pack out.

Operating Instructions

General Operation:

1. Before starting, ensure the work piece is securely clamped or held.
2. Hold the grinder firmly with both hands, using the main handle and the side handle.
3. To start the tool, depress the trigger switch.
4. Allow the wheel to reach full speed before making contact with the workpiece.
5. Apply light, even pressure. Do not force the tool.
6. Move the grinder smoothly across the workpiece.
7. To stop the tool, release the trigger switch. The Kickback Brake will engage to quickly stop the wheel.

Grinding Techniques:

• For general grinding, hold the tool at a 15-30 degree angle to the workpiece.
• Use a back-and-forth motion to ensure even material removal and prevent overheating.
• Always direct sparks away from yourself and others.

Cutting Techniques:

• When cutting, hold the tool at a 90-degree angle to the workpiece.
• Ensure the cutting wheel is properly rated for the material being cut.
• Do not apply side pressure to the cutting wheel, as this can cause it to bind or shatter.

Figure 3: Operator demonstrating proper use of the angle grinder for material removal on a brick wall, connected to a dust extraction system for a cleaner work environment.

Figure 4: Close-up view of the angle grinder in action, highlighting the precision and control required for effective material removal on a brick surface.

Figure 5: Overhead perspective of the angle grinder being used, showing the operator's grip and the tool's position relative to the workpiece and dust extraction hose.

Maintenance

Cleaning:

• Regularly clean the ventilation slots of the tool to prevent overheating. Use a soft brush or compressed air.
• Wipe down the exterior of the tool with a damp cloth. Do not use harsh chemicals or abrasive cleaners.

Accessory Inspection:

• Inspect grinding and cutting wheels before each use for cracks, chips, or excessive wear. Replace damaged wheels immediately.
• Ensure the guard is securely attached and undamaged.

Storage:

• Store the tool in a dry, secure location out of reach of children.
• Remove the battery pack from the tool before storage.

Troubleshooting

Specifications

*Maximum initial battery voltage (measured without a workload) is 60 volts. Nominal voltage is 54.

Warranty and Support

DEWALT provides a limited warranty for its products. For specific warranty terms and conditions, please refer to the warranty card included with your product or visit the official DEWALT website.

For technical support, service, or to locate an authorized service center, please contact DEWALT customer service or visit their official website:

• DEWALT Official Website: www.dewalt.com
• Customer Service: Refer to your product documentation for regional contact information.

Always use genuine DEWALT replacement parts and accessories to ensure optimal performance and maintain product warranty.