What could be the reason for my DeWalt dwe4011 angle grinder to smoke when turned on? No disk and brushes appear to be in good shape

It should be on the sticker with the model number & other information, if not it's likely on your receipt or original box. I know if you're like me you have no clue where they are, check the area where the battery connects to it also, if no luck just call/email DeWalt or call your Local Lowe's and get a Tool SalesPerson on the line, they'll tell you! I just had the same issue with some Milwaukee Tools that needed warranty repair, I know this is frustrating.

if you are using thin cutting disk turn arbor nut over. It he shaft is rotating while tightening disc, use shaft lock button on side of gear box.
Page 10 of your instruction manual. Here is a link


DeWalt D28402 Instruction Manual Page 10

I can only surmise that its dirt on the motor brushes.

I'll bet the brushes wore out.

The brushes are shot and the armature is burned, you need to get the armature out, spin it in a lathe or something to clean it up, a piece of sandpaper, then replace the brushes, blow out all the dust. You might be able to save it. Hope this helps.

check inside for any loose connections plus check the brushes. if like you say it is smoking it could be a trip to the wheelie bin for that one.

Hi J,

Hopefully you just wore out the brushes. Replacement kits are available for a few bucks and the fix is pretty easy.

On the darker side, If it overheated enough that it burned the windings (insulation melts, shorts, badness), there isn't much you can do unless it's still under warranty.

You won't know until you get it apart. You'll know which it is at a glance.

Unplug it and dismantle the base of the grip where the cord is attached.

The brushes are small spring loaded graphite blocks that transfer electricity to what looks like a cylinder around the central drive shaft that has a lot of vertical copper strips on it. They are normally housed inside small copper tubes opposite each other.

If those tubes are empty but for the spring, it's brushes.

If the insides are full of ashy residue, it's not the brushes

Best regards and I hope it it's the brushes

Mike

Pull it apart and clean the armature, you will find something between the brush contacts getting larger and making contact thus shorting it out, so clean the armature with fine point object do not gouge the material out of the area between the copper plates. Also blow out any metal dust you may see.

you need new brushes. carbon is meant to be touching the armature not the contact from the spring. Its worn down

most likely the carbon brush is worn out and need to be replaced.