DWE491 - Grinder DEWALT - Free user manual and instructions

Product Type	Angle Grinder
Model	DWE491
Brand	DeWalt
Wheel Diameter	4-1/2 in (115 mm)
No-Load Speed	8000 RPM
Motor	11 Amp, AC only
Arbor Size	5/8 in (16 mm)
Switch Type	Paddle switch with lock-off
Weight	5.5 lbs (2.5 kg)
Length	12.5 in (317 mm)
Height	5.5 in (140 mm)
Power Source	120V AC, 60 Hz
Main Functions	Cutting, grinding, sanding, wire brushing
Guard	Adjustable, tool-free guard
Spindle Lock	Yes, for easy wheel changes
Overload Protection	Yes
Maintenance	Clean housing with dry cloth; inspect carbon brushes periodically
Safety Features	Two-finger trigger, lock-off button, guard, side handle
Spare Parts Availability	Service centers and authorized dealers; model-specific parts
Warranty	3-year limited warranty

Frequently Asked Questions - DWE491 DEWALT

How do I change the grinding wheel on the DWE491?

Always unplug the tool. Press the spindle lock to hold the shaft, then use the provided wrench to loosen the nut. Remove the old wheel, place the new wheel with the label facing the spindle, and tighten the nut securely.

What size wheels does the DWE491 accept?

The DWE491 accepts 4-1/2 inch (115 mm) wheels with a 5/8 inch (16 mm) arbor hole. Also compatible with 5 inch (125 mm) wheels using the appropriate backing pad.

Can I use the DWE491 for sanding?

Yes, attach a sanding backing pad and sandpaper disc. Ensure the pad is rated for the tool's speed.

Is the DWE491 suitable for cutting metal?

Yes, using a cutoff wheel rated for the tool's speed. Always use the guard and wear appropriate PPE.

How do I maintain the DWE491?

Keep air vents clean. Inspect carbon brushes after 50 hours of use; replace if worn below 1/4 inch. Wipe housing with a dry cloth.

Why does my grinder spark excessively?

Excessive sparking from the motor may indicate worn carbon brushes. Replace both brushes at the same time.

How do I install the side handle?

Thread the side handle into one of the three mounting holes on the gear case. Tighten firmly by hand. The handle reduces torque reaction.

Can I use the DWE491 for wire brushing?

Yes, attach a wire cup brush or wheel with a 5/8-11 threaded hub. Use at lower speeds if possible.

What is the proper way to hold the grinder?

Hold the grinder with both hands: one on the main handle with finger on the paddle switch, the other on the side handle. Keep the guard between you and the wheel.

How do I adjust the guard?

Unlock the guard lever, rotate the guard to the desired position, and release the lever to lock. Ensure the guard is secured before starting.

USER MANUAL DWE491 DEWALT

English (original instructions) 28

--- o DC.....corrientedirecta

Close-up of a mechanical grinding tool with a circular cutter and angular workpiece (no visible text or symbols)

Protectores

Technical illustration of mechanical components, one showing a curved bracket and the other a mechanical housing with a central screw (no text or symbols)

Cross-sectional diagram of a mechanical component with a central bore and textured base (no text or symbols)

DWE490-B3 DWE490-B2 DWE490-B2C DWE490-AR

Vatios de potencia: 2 200 W 2200 W 2 200 W 2 200 W

DWE491-B3 DWE491-B2 DWE491-B2C DWE491-AR

Vatios de potencia: 2200 W 2200 W 2200 W 2200 W

Mechanical tool diagram showing a grinding machine with a central blade and base (no text or symbols)

Protetores

3D rendered mechanical component with curved and straight sections, no visible text or symbols

Technical illustration of a mechanical assembly with a central shaft and mounting holes (no text or symbols)

ESPECIFICAÇÕES
DWE490-B3 DWE490-B2 DWE490-B2C DWE490-BR DWE490-AR

Definitions: Safety Alert Symbols and Words

This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.

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.
(### without word) Indicates a safety related message.

NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.

Fig. A

1 Trigger Switch
2 Lock On Button
3 Spindle Lock
4 Guard
5 Side Handle

WARNING! Read all safety warnings and all

instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

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

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GENERAL POWER TOOL SAFETY WARNINGS

WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

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 ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI 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 energizing power tools that have the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. 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 tool's operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits, etc. in accordance with these instructions, taking

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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) Service

a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

ADDITIONAL SPECIFIC SAFETY RULES

Safety Instructions for All Operations

a) This power tool is intended to function as a grinder, sander, wire brush or cut-off tool. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
b) Operations such as polishing are not recommended to be performed with this power tool. Operations for which the power tool was not designed may create a hazard and cause personal injury.
c) 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.
d) The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
e) The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories can not be adequately guarded or controlled.
f) 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.
9) 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.
h) 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.

i) 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.
j) 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 could give the operator an electric shock.
k) Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
1) Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.
m) Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
n) Regularly clean the power tool's air vents. The motor's fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
o) Do not operate the power tool near flammable materials. Sparks could ignite these materials.
p) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

FURTHER SAFETY INSTRUCTIONS FOR ALL OPERATIONS

Causes and Operator Prevention of Kickback

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory's rotation at the point of the binding.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction

of the wheel's movement at the point of pinching. Abrasive wheels may also break under these conditions.

Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

a) Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start up. The operator can control torque reaction or kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may kickback over your hand.
c) Do not position your body in the area where power tool will move if kickback occurs. Kickback will propel the tool in direction opposite to the wheel's movement at the point of snagging.
d) Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and Abrasive Cutting-Off Operations

a) Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel. Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.
b) The 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 the operator from broken wheel fragments and accidental contact with wheel and sparks that could ignite clothing.
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.

Additional Safety Warnings Specific for Abrasive Cutting-Off Operations

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

Safety Warnings Specific for Sanding Operations

a) Do not use excessively oversized sanding disc paper. Follow manufacturer's recommendations, when selecting sanding paper. Larger sanding paper extending beyond the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.

Safety Warnings Specific for Wire Brushing Operations

a) Be aware that wire bristles are thrown by the brush even during ordinary operation. Do not overstress the wires by applying excessive load to the brush. The wire bristles can easily penetrate light clothing and/or skin.
b) If the use of a guard is recommended for wire brushing, do not allow any interference of the wire wheel or brush with the guard. Wire wheel

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or brush may expand in diameter due to work and centrifugal forces.

Additional Safety Warnings for Grinders

• Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbour hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
• The grinding surface of the center depressed wheels must be mounted below the plane of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.

Additional Safety Information

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,
• NIOSH/OSHA/MSHA respiratory protection.

WARNING: Some dust created by power sanding, sanding, grinding, drilling, and other construction activities contains chemicals known to the State of California 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.

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.

- 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 disperse 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.

CAUTION: When not in use, place tool on its side can be stable surface where it will not cause a

tripping or falling hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.

• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.
- Do not operate this tool for long periods of time. Vibration caused by tool action may be harmful to your hands and arms. Use gloves to provide extra cushion and limit exposure by taking frequent rest periods.
- An extension cord must have adequate wire size 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. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The lower the gauge number, the heavier the cord.

Voltage (Volts)	Total length of cord in meters (m)
120-127V 0-	77-15 15-30	30-50
220-240V 0-	15 15-30 30-	60 60-100
Rated Ampere Range	Minimal cross-sectional area of the cord in meters ( mm^2 )
0-6A 1.0 1.5	1.5 2.5
6-10A 1.0 1.5	2.5 4.0
10-12A 1.5 1.5	2.5 4.0
12-16A 2.5 4.0 Not Recommended

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

V....volts Hz....hertz min....minutes \~ or AC....alternating current \~ or AC/DC....alternating or direct current
or DC.....direct current Class I Construction (grounded) Construction (double insulated)
.../min.....per minute n _o .....no load speed RPM heats per minute n .....rated speed
IPM....impacts per minute ⊕ ....earthing terminal
RPM....revolutions per minute ⚠️....safety alert symbol ⚠️....visible radiation
sfpm .... surface feet per minute .... wear respiratory protection
SPM....strokes per minute @....wear eye A amperes protection
W....walts O....wear hearing protection

SAVE THESE INSTRUCTIONS FOR FUTURE USE

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Motor

Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than 10% will cause loss of power and overheating. DeWALT tools are factory tested; if this tool does not operate, check power supply.

COMPONENTS (FIG. A)

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

Refer to Figure A at the beginning of this manual for a complete list of components.

INTENDED USE

Your angle grinder has been designed for professional grinding and cutting applications.

Do NoT use under wet conditions or in presence of flammable liquids or gases.

This heavy-duty angle grinder is a professional power tool.

Do NoT let children come into contact with the tool.

Supervision is required when inexperienced operators use this tool.

ASSEMBLY AND ADJUSTMENTS

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories.

An accidental start-up can cause injury.

Attaching the Side Handle (Fig. B)

To install the side handle, thread the handle into one of the two positions and tighten securely by turning clockwise.

Fig. B

Close-up of a mechanical tool with a grinding wheel and blade (no visible text or symbols)

Guards

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.

CAUTION: When using a grinding wheel with a type 2 or 29 guard, be sure that the bottom surface of the grinding wheel is inside the the guard lip.

Mounting and Removing Guard (Fig. C)

1. Align the lugs with slots on the gear case cover. Position the guard facing backward, as shown.

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

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

4. Secure the guard on the gear case cover. You 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, follow steps 1–4 of these instructions in reverse.

Fig. C

Technical illustration of mechanical components, one showing a curved bracket and the other a mechanical housing with a central screw (no text or symbols)

NoTE: The guard is preadjusted 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.

Flaring Cup Wheel Guard

WARNING: The flaring cup wheel guard is not in bed with this tool. Flaring cup wheels require proper flanges and guards. 4" (102 mm) flaring cup wheel guard and 6" (152 mm) flaring cup wheel guard are available as accessories and include proper flange. Failure to use the proper flange and guard can result in injury resulting from wheel breakage and wheel contact.

Flanges and Wheels

The grinder is equipped with a mount that should be used with all wheel types with the exception of flaring cup wheels. See the Accessories Chart for more information. The mount enabling easy wheel installation and removal.

Spindle Lock (Fig. D)

The spindle lock 2 is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock only when the tool is turned off, unplugged from the power supply, and has come to a complete stop.

NOTICE: To reduce the risk of damage to the tool, do not engage the spindle lock while the tool is operating. Damage to the tool will result and 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.

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Close-up of a mechanical power tool with a labeled component (3), no visible text or symbols beyond the label.

Mounting Non-Hubbed Wheels (Fig. E)

WARNING: Failure to properly seat the flanges or wheel could result in serious injury (or damage to the tool or wheel).

CAUTION: Accessory flanges must be used with a closed center Type 27 grinding wheels and Type 1 cutting wheels. See the Accessories Chart for more information.

WARNING: A closed, two-sided cutting wheel guard is required when using cutting wheels.

WARNING: Use of a damaged flange or guard or failure to use proper flange and guard can re suit in injury due to wheel breakage and wheel contact. See the

Accessories Chart for more information.

1. Place the tool on a table, guard up.
2. Install the backing flange 7 on spindle 6 against the mount.
3. Place wheel against the backing flange, centering the wheel on raised center (pilot) of the backing flange.

Fig. F

1. While depressing the spindle lock button, thread the outer flange 8 on spindle, piloting the raised hub on the flange in the center of grinding wheel.
2. Tighten the outer flange with a wrench.
3. Reverse the above procedure to remove the wheel.

Mounting Sanding Backing Pads (Fig. F)

Sanding pads and sanding discs must be rated above minimum accessory speed as shown on tool. Recommended sanding backing pads and sanding discs are available at extra cost from DeWALT service centers and DeWALT dealers.

NOTE : Guard may be removed for sanding applications with backing pads and sanding discs. Sanding flap discs are considered grinding wheels by ANSI standards and require the use of a guard. (See Guards).

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 rubber backing pad 9 down to mount.
2. Place the sanding disc 10 on the rubber backing pad 9.
3. While depressing spindle lock, thread clamp nut on spindle, piloting the raised hub on the clamp nut into the center of sanding disc and backing pad.
4. Tighten the clamp nut with the proper wrench.
5. To remove the wheel, reverse the above procedure. Fig. F

Mounting and Removing Hubbed Wheels (Fig. A)

Hubbed wheels install directly on the spindle. Thread of accessory must match thread of spindle.

1. Remove backing flange by pulling away from tool.
2. Thread the wheel on the spindle 1 by hand.
3. Depress the spindle lock button 2 and use a wrench to tighten the hub of the wheel.
4. Reverse the above procedure to remove the wheel.

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

Mounting Wire Cup Brushes and Wire Wheels (Fig. A)

WARNING: Failure to properly seat the flanges or wheel could result in serious injury (or damage to the tool or wheel).

CAUTION: To reduce the risk of personal injury, when 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

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

Wire cup brushes or wire wheels install directly on the threaded spindle without the use of flanges. Use only wire brushes or wheels provided with a threaded hub. These accessories are available at extra cost from your local dealer or authorised service center.

1. Place the tool on a table, guard up.
2. Thread the wheel on the spindle by hand.
3. Depress spindle lock button 2 and use a wrench on the hub of the wire wheel or brush to tighten the wheel.
4. To remove the wheel, reverse the above procedure.

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

Mounting Flaring Cup Wheel (Fig. G)

1. Remove the mount 12.
2. Install the flaring cup wheel backing flange, aligning the flats on spindle 11 with the flats on backing flange 7. Fig. G

1. Thread the flaring cup wheel on spindle by hand, seating wheel against backing flange.

2. Depress the spindle lock button and tighten the wheel by hand.

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

CAUTION: Failure to properly seat the wheel against bending flange before turning the tool on may result in damage to the tool or the wheel.

NoTE: Adjust the guard skirt so that only 1/8" (3 mm) of the wheel is exposed below the skirt.

Prior to Operation

• Install the guard and appropriate disc or wheel. Do not use excessively worn discs or wheels.

• Be sure the inner and outer flange are mounted correctly. Follow the instructions given in the Grinding and Cutting Accessory Chart.
• Make sure the disc or wheel rotates in the direction of the arrows on the accessory and the tool.
• Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If 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.

Removal of Lock-On Feature

The lock-on button can be permanently removed without compromising compliance with regulatory agencies shown on the tool's nameplate. Removal of the lock pin must be done by a DeWALT service center.

OPERATION

WARNING: Always observe the safety instructions and applicable regulations.

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start-up can cause injury.

Proper Hand Position

WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown.

WARNING: To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction.

Proper hand position requires one hand on the main handle.

Trigger Switch (Fig. I)

CAUTION: Before connecting the tool to a power source or after a power failure, depress and release the trigger switch 1 once without depressing the lock-on button 2 to ensure that the switch is in the off position. If the trigger switch is locked on, the tool will start unexpectedly when power is reconnected to the tool. Hold the side handle and rear handle firmly to maintain control of tool at start up and during use.

To turn the tool on, depress the trigger switch 1. The tool will remain running while the trigger is depressed. Turn the tool off by releasing the trigger.

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The lock-on button 2 and be engaged to lock the trigger in the depressed position providing increased comfort in extended use applications. To unlock the trigger and turn the tool off, depress and release trigger.

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

CAUTION: Make sure the wheel has come to a complete stop before setting the tool down.

Surface Grinding, Sanding and Wire Brushing

CAUTION: Always use the correct guard per the instructions in this manual.

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

To perform work on a the surface of a workpiece:

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. Material removal rate is greatest when the tool operates at high speed.

1. Maintain an appropriate angle between the tool and work surface. Refer to the chart according to particular function.

Grinding 20°-30°
Grinding with a Flaring Cup Wheel	5°-10°
Sanding with Flap Disc 5°-10°
Sanding with Backing Pad 5°-15°
Wire Brushing 5°-10°

1. Maintain contact between the edge of the wheel and the work surface.

2. If grinding, sanding with flap discs or wire brushing move the tool continuously in a forward and back motion to avoid creating gouges in the work surface.

3. If sanding with a backing pad, move the tool constantly in a straight line to prevent burning and swirling of work surface. Always use the appropriate grit sandpaper for your application

NOTE: Allowing the tool to rest on the work surface without moving will damage the work piece.

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

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

Precautions To Take When Working on a Painted Workpiece

1. Sanding or wire brushing 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 or wire brushing 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.

Edge Grinding and Cutting

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.

CAUTION: Wheels used for edge grinding and cutting may break or kick back if they bend or twist while the tool is being used. In all edge grinding/cutting operations, the open side of the guard must be positioned away from the operator.

NOTICE: Edge grinding/cutting with a Type 27 wheel must be limited to shallow cutting and notching—less than 13 mm in depth when the wheel is new. Reduce the depth of cutting/notching equal to the reduction of the wheel radius as it wears down. Refer to the Accessories Chart for more information. Edge grinding/cutting with a Type 1 wheel requires usage of a Type 1 guard. For deeper cutting with a type 1 wheel, use a closed, type 1 guard. Type 1 guards are available at extra cost from your local dealer or authorized service center.

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/cutting 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.

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories.

An accidental start-up can cause injury.

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

Your power tool requires no additional lubrication.

Motor Brushes

When brushes become worn, the tool will automatically stop, preventing damage to the motor. Brush replacement should be performed by D'WALT authorized service centers or other qualified service personnel. Qualified service personnel should follow the procedures below when replacing motor brushes.

1. Remove the brush doors located on the sides of motor housing.
2. To remove the brush, hold the female terminal, which is attached to the brush lead wire, and disconnect the female terminal from the male terminal.
3. Pull the brush straight up out of the brush holder.
4. Replace brushes, in pairs, with original D'WALT brushes available from D'WALT authorized service centers.
5. Ensure that the brushes slide freely in brush box.
6. Reconnect the brush lead wire to brush box terminal.
7. Reinstall the brush doors before using the tool. Torque screws to 10 in-lbs, maximum. Overtightening may cause screws to strip.

Cleaning

WARNING: Blow dirt and dust out of all air vents with dry air at least once a week. To minimize the risk of eye injury, always wear approved eye protection when performing this.

WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Accessories

WARNING: Since accessories, other than those identified 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

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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.

Repairs

The charger and battery pack are not serviceable.

WARNING: To assure product SAFETY and PABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by a DeWALT factory service center or a DeWALT authorized service center. Always use identical replacement parts.

Protecting the Environment

Separate collection. Products and batteries marked with this symbol must not be disposed of with normal household waste.

Products and batteries contain materials that can be recovered or recycled reducing the demand for raw materials. Please recycle electrical products and batteries according to local provisions.

SPECIFICATIONS

DWE490-B3 DWE490-B2 DWE490-B2C DWE490-AR

Power Output: 2 200 W 2200 W 2 200 W 2 200 W

Voltage: 120 V\~ 220 V\~ 220 V\~ 220 V\~

Frequency: 50–60 Hz 50–60 Hz 50 Hz 50 Hz

RPM: 6500/min 6500/min 6500/min 6500/min

DWE491-B3 DWE491-B2 DWE491-B2C DWE491-AR

Power Output: 2200 W 2200 W 2200 W 2200 W

Voltage: 120 V\~ 220 V\~ 220 V\~ 220 V\~

Frequency: 50–60 Hz 50–60 Hz 50 Hz 50 Hz

RPM: 8500/min 8500/min 8500/min 8500/min

ACCESSORIES CHART

Grinding Wheels

NOTE: Wheel size must match guard size; i.e., a new 7" (180 mm) wheel may not be used with a 9" (230 mm) guard. The bottom surface of wheel must be inside the bend of the guard lip.

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Buenos Aires (B1618FBQ)

CNPJ: 53.296.273/0001-91

Insc. Est.: 701.948.711.00-98

S.A.C.: 0800-703-4644

MAQUINAS Y HERRAMIENTAS BLACK & DECKER CHILE S.A.

Avda. Eduardo Frei M. #6001 Edificio 67

Conchalí - Santiago de Chile

TEL: [phone]

IMPORTADO POR:

BLACK & DECKER DEL PERÚ S.A.