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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 power 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 operator from broken wheel fragments, 

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 operation, 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 reenter 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.

Summary of Contents for DWE4557-XE

Page 1: ...DWE4557 XE DWE4559 XE DWE4597N XE DWE4599N XE HEAVY DUTY LARGE ANGLE GRINDERS INSTRUCTION MANUAL ...

Page 2: ......

Page 3: ...inty LWA sound power dB A 107 108 108 108 107 107 107 105 KWA sound pressure dB A 3 3 3 3 uncertainty Vibration total values triax vector sum determined according to EN 60745 Vibration emission value ah surface grinding ah AG m s 8 5 7 0 7 0 4 5 Uncertainty K m s 1 5 1 5 1 5 1 5 Vibration emission value ah disc sanding ah DS m s 2 5 2 5 Uncertainty K m s 1 5 The vibration emission level given in t...

Page 4: ... 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 devic...

Page 5: ... range can cause loss of power and can result in overheating All DEWALT tools are factory tested if this tool does not operate check the power supply Your DEWALT tool is double insulated therefore no earth wire is required Young children and the infirm This appliance is not intended for use by young children or infirm persons without supervision This appliance is not intended for use by persons in...

Page 6: ...ardware of the power tool will run out of balance vibrate excessively and may cause loss of control g 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 inspec...

Page 7: ...ator from broken wheel fragments 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 an...

Page 8: ...ncing the wheel or giving it rough treatment If this occurs stop the tool and inspect the wheel for cracks or flaws Always handle and store wheels in a careful manner Never cut into area that may contain electrical wiring or piping Serious injury may result Do not operate this tool for long periods of time Vibration caused by the operating action of this tool may cause permanent injury to fingers ...

Page 9: ...jury Always use AS NZS1716 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 AS NZS1270 during use Under some conditions and duration of use noise from this product may contribute to hearing loss The label on your tool may include the following symbols The symbols and th...

Page 10: ... case in the threaded holes The side positions are designed for optimized balance in surface finishing and grinding applications The side handle must be used at all times to maintain proper control of the tool Before using the tool check that the handle is tightened securely IINTENDED USE This grinder is designed for professional grinding sanding wire brushing polishing or abrasive cutting off app...

Page 11: ...part and cause injury Threaded accessories must have a M14 hub Every unthreaded accessory must have a 22 2 mm 7 8 arbor hole If it does not it may have been designed for a circular saw Use only the accessories shown on pages 10 11 of this manual Accessory ratings must always be above tool speed as shown on tool nameplate OPERATION WARNING To reduce the risk of serious personal injury turn tool off...

Page 12: ...rd Type 28 hubbed wheel Type 28 guard backing flange Type 28 non hubbed wheel clamp nut Type 27 guard backing flange Type 27 non hubbed wheel clamp nut Type 27 guard wire cup brush Type 27 guard wire wheel Wire Wheels Alternative guards can be purchased at an additional cost Please call 1 800 654 155 for more information ...

Page 13: ... 27 guard backing flange diamond cutting wheel outer flange washer clamp nut Cutting Wheels Alternative guards can be purchased at an additional cost Please call 1 800 654 155 for more information Sanding Flap Discs Type 27 guard backing flange non hubbed sanding flap disc clamp nut Type 27 guard hubbed sanding flap disc ...

Page 14: ... the backing flange pilot FIG 10 Q E R 3 While depressing the spindle lock button thread the clamp nut R on spindle piloting the raised hub on clamp nut in the center of grinding wheel 4 Tighten the clamp nut with a wrench 5 Reverse the above procedure to remove the wheel SURFACE GRINDING WITH GRINDING WHEELS FIG 11 1 Allow the tool to reach full speed before touching the tool to the work surface ...

Page 15: ...WARNING Proper guard must be reinstalled for grinding wheel cutting wheel sanding flap disc wire brush or wire wheel applications after sanding applications are complete 1 Place or appropriately thread backing pad S on the FIG 14 S T R spindle 2 Place the sanding disc T on the backing pad S 3 While depressing the spindle lock button thread clamp nut R on spindle piloting the raised hub on the clam...

Page 16: ...ed 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 Va...

Page 17: ... use are available Diamond blades for concrete cutting can also be used WARNING A Type 27 cutting wheel guard is included with this tool and is required when using cutting wheels Failure to use proper flange and guard can result in injury resulting from wheel breakage and wheel contact See pages 10 11 for more information MOUNTING TYPE 27 OR TYPE 1 GUARD 1 Open the guard latch M and align the lugs...

Page 18: ...e of the cut Changing the angle will cause the wheel to bend and may cause wheel breakage 4 Remove the tool from work surface before turning tool off Allow the wheel to stop rotating before laying the tool down MAINTENANCE WARNING To reduce the risk of serious personal injury turn tool off and disconnect tool from power source before making any adjustments or removing installing attachments or acc...

Page 19: ... 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 Recommended accessories for use with your tool are available at extra cost from your local service center If you need any assistance in locating any accessory please con...

Page 20: ... Part No N175365 DWE4557 XE DWE4559 XE DWE4597N XE DWE4599N XE Copyright 2013 DEWALT The following are trademarks for one or more DEWALT power tools the yellow and black color scheme the D shaped air intake grill the array of pyramids on the handgrip the kit box configuration and the array of lozenge shaped humps on the surface of the tool ...

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