400 Series XPR -...

Instructional SafetyManual

400 Series XPRHigh Performance Rotary Tool

Form No. 2610925455 10/04 Robert Bosch Tool Corporation © 2004All Rights Reserved

1-800-437-3635http://www.dremel.com

Dremel brand products are manufactured and sold by the Dremel Division of Robert Bosch Tool Corporation

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Read and understand all instructions. Failure to follow all instructions list-ed below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREAKeep your work area clean and well lit.Cluttered benches and dark areas invite acci-dents.

Do not operate power tools in explosiveatmospheres, such as in the presence offlammable liquids, gases, or dust. Powertools create sparks which may ignite the dustor fumes.

Keep bystanders, children, and visitorsaway while operating a power tool.Distractions can cause you to lose control.

Electrical SafetyDouble Insulated tools are equipped witha polarized plug (one blade is wider thanthe other.) This plug will fit in a polarizedoutlet only one way. If the plug does notfit fully in the outlet, reverse the plug. If itstill does not fit, contact a qualified elec-trician to install a polarized outlet. Do notchange the plug in any way. DoubleInsulation eliminates the need for the threewire grounded power cord and groundedpower supply system. Before plugging in thetool, be certain the outlet voltage supplied iswithin the voltage marked on the nameplate.Do not use “AC only” rated tools with a DCpower supply.

Avoid body contact with grounded sur-faces such as pipes, radiators, rangesand refrigerators. There is an increased riskof electric shock if your body is grounded. Ifoperating the power tool in damp locations isunavoidable, a Ground Fault CircuitInterrupter must be used to supply the powerto your tool. Electrician’s rubber gloves andfootwear will further enhance your personalsafety.

Don't expose power tools to rain or wetconditions. Water entering a power tool willincrease the risk of electric shock.

Do not abuse the cord. Never use the cordto carry the tools or pull the plug from anoutlet. Keep cord away from heat, oil,sharp edges or moving parts. Replacedamaged cords immediately. Damagedcords increase the risk of electric shock.

When operating a power tool outside, usean outdoor extension cord marked "W-A"or "W." These cords are rated for outdooruse and reduce the risk of electric shock.

Personal SafetyStay alert, watch what you are doing anduse common sense when operating apower tool. Do not use tool while tired orunder the influence of drugs, alcohol, ormedication. A moment of inattention whileoperating power tools may result in seriouspersonal injury.

Dress properly. Do not wear loose cloth-ing or jewelry. Contain long hair. Keepyour hair, clothing, and gloves away frommoving parts. Loose clothes, jewelry, orlong hair can be caught in moving parts.Keep handles dry, clean and free from oil andgrease.

Avoid accidental starting. Be sure switchis “OFF” before plugging in. Carrying toolswith your finger on the switch or plugging intools that have the switch “ON” invites acci-dents.

Remove adjusting keys or wrenchesbefore turning the tool ON. A wrench or akey that is left attached to a rotating part ofthe tool may result in personal injury.

Do not overreach. Keep proper footingand balance at all times. Proper footing andbalance enables better control of the tool inunexpected situations.

Use safety equipment. Always wear eyeprotection. Dust mask, non-skid safetyshoes, hard hat, or hearing protection mustbe used for appropriate conditions.

Tool Use and CareUse clamps or other practical way tosecure and support the workpiece to astable platform. Holding the work by handor against your body is unstable and maylead to loss of control.

Do not force tool. Use the correct tool foryour application. The correct tool will do thejob better and safer at the rate for which it isdesigned.

Do not use tool if switch does not turn itON or OFF. Any tool that cannot be con-trolled with the switch is dangerous and mustbe repaired.

Disconnect the plug from the powersource before making any adjustments,changing accessories, or storing the tool.Such preventive safety measures reduce therisk of starting the tool accidentally.

WARNING!

POWER TOOL SAFETY RULES

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Store idle tools out of reach of childrenand other untrained persons. Tools aredangerous in the hands of untrained users.

Maintain tools with care. Keep cuttingtools sharp and clean. Properly main-tained tools, with sharp cutting edges areless likely to bind and are easier to control.Any alteration or modification is a misuseand may result in a dangerous condition.

Check for misalignment or binding ofmoving parts, breakage of parts, and anyother condition that may affect the toolsoperation. If damaged, have the toolserviced before using. Many accidentsare caused by poorly maintained tools.Develop a periodic maintenance schedulefor your tool.

Use only accessories that are recom-mended by the manufacturer for yourmodel. Accessories that may be suitable forone tool, may become hazardous whenused on another tool.

ServiceTool service must be performed only byqualified repair personnel. Service ormaintenance performed by unqualified per-sonnel could result in a risk of injury. Forexample: internal wires may be misplacedor pinched, safety guard return springs maybe improperly mounted.

When servicing a tool, use only identicalreplacement parts. Follow instructions inthe Maintenance section of this manual.Use of unauthorized parts or failure to followMaintenance Instructions may create a riskof electric shock or injury. Certain cleaningagents such as gasoline, carbon tetrachlo-ride, ammonia, etc. may damage plasticparts.

SAFETY RULES FOR ROTARY TOOL

Accessories must be rated for at least thespeed recommended on the tool warninglabel. Wheels and other accessories run-ning over rated speed can fly apart andcause injury.

Hold tool by insulated gripping surfaceswhen performing an operation where thecutting tool may contact hidden wiring orits own cord. Contact with a "live" wire willmake exposed metal parts of the tool "live"and shock the operator. If cutting into existingwalls or other blind areas where electricalwiring may exist is unavoidable, disconnectall fuses or circuit breakers feeding this work-site.

Do not operate the flexible shaft with asharp bend. Over bending the shaft cangenerate excessive heat on the jacket orhand piece. The recommended minimum is6" radius.

Always disconnect the power cord fromthe power source before making anyadjustments or attaching any acces-sories. You may unexpectedly cause the toolto start leading to serious personal injury.

Be aware of the switch location, whenplacing the tool down or when picking thetool up. You may accidentally activate theswitch.

Always hold the hand piece firmly in yourhands during the start-up. The reactiontorque of the motor, as it accelerates to fullspeed, can cause the shaft to twist.

Always wear safety goggles and dustmask. Use only in well ventilated area.Using personal safety devices and working insafe environment reduces risk of injury.

After changing the bits or making anyadjustments, make sure the collet nut andany other adjustment devices are secure-ly tightened. Loose adjustment device canunexpectedly shift, causing loss of control,loose rotating components will be violentlythrown.

Do not reach in the area of the spinningbit. The proximity of the spinning bit to yourhand may not always be obvious.

Allow brushes to run at operating speedfor at least one minute before usingwheel. During this time no one is to standin front or in line with the brush. Loosebristles or wires will be discharged during therun-in time.

Wire and bristle brushes must never beoperated at speeds greater than15,000/min. Direct the discharge of thespinning wire brush away from you.Small particles and tiny wire fragments maybe discharged at high velocity during the“cleaning” action with these brushes and maybecome imbedded in your skin. Bristles orwires will be discharged from the brush athigh speeds.

Carefully handle both the tool and individ-ual grinding wheels to avoid chipping orcracking. Install a new wheel if tool is

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SAFETY RULES FOR ROTARY TOOL (CONTINUED)

dropped while grinding. Do not use awheel that may be damaged. Fragmentsfrom a wheel that bursts during operation willfly away at great velocity possibly striking youor bystanders.

Never use dull or damaged bits. Sharpbits must be handled with care. Damagedbits can snap during use. Dull bits requiremore force to push the tool, possibly causingthe bit to break.

Use clamps to support workpiece when-ever practical. Never hold a small work-piece in one hand and the tool in the otherhand while in use. Allow for sufficientspace, at least 6", between your hand andthe spinning bit. Round material such asdowel rods, pipes or tubing have a tendencyto roll while being cut, and may cause the bitto “bite” or jump toward you. Clamping asmall workpiece allows you to use bothhands to control the tool.

Inspect your workpiece before cutting.When cutting irregularly shaped work-pieces, plan your work so it will not slipand pinch the bit and be torn from yourhand. For example, if carving wood, makesure there are no nails or foreign objects inthe workpiece. Nails or foreign objects cancause the bit to jump.

Never start the tool when the bit isengaged in the material. The bit cuttingedge may grab the material causing loss ofcontrol of the cutter.

Avoid bouncing and snagging the wheel,especially when working corners, sharpedges etc. This can cause loss of controland kick-back.

The direction of feed with the bit into thematerial when carving, routing or cuttingis very important. Always feed the bit intothe material in the same direction as thecutting edge is exiting from the material(which is the same direction as the chipsare thrown). Feeding the tool in the wrongdirection, causes the cutting edge of the bit toclimb out of the work and pull the tool in thedirection of this feed.

If the workpiece or bit becomes jammedor bogged down, turn the tool “OFF” bythe switch. Wait for all moving parts tostop and unplug the tool, then work tofree the jammed material. If the switch tothe tool is left “ON” the tool could restartunexpectedly causing serious personalinjury.

Do not leave a running tool unattended,turn power off. Only when tool comes to a

complete stop it is safe to put it down.

Do not grind or sand near flammablematerials. Sparks from the wheel couldignite these materials.

Do not touch the bit or collet after use.After use the bit and collet are too hot to betouched by bare hands.

Regularly clean the tool's air vents withcompressed air. Excessive accumulation ofpowdered metal inside the motor housingmay cause electrical failures.

Do not allow familiarity gained from fre-quent use of your rotary tool to becomecommonplace. Always remember that acareless fraction of a second is sufficient toinflict severe injury.

Do not alter or misuse tool. Any alterationor modification is a misuse and may result inserious personal injury.

This product is not intended for use as adental drill, in human or veterinary med-ical applications. Serious injury may result.

When using the steel saws, cutoff wheels,high speed cutters or tungsten carbidecutters, always have the work securelyclamped. Never attempt to hold the workwith one hand while using any of theseaccessories. The reason is that thesewheels will grab if they become slightly cant-ed in the groove, and can kickback causingloss of control resulting in serious injury. Yoursecond hand should be used to steady andguide the hand holding the tool. When a cut-off wheel grabs, the wheel itself usuallybreaks. When the steel saw, high speed cut-ters or tungsten carbide cutter grab, it mayjump from the groove and you could losecontrol of the tool.

Some dust created bypower drilling and other

construction activities, contains chemi-cals known to cause cancer, birth defectsor other reproductive harm. Some exam-ples of these chemicals are:

• Lead from lead-based paints,

• Crystalline silica from bricks and cementand other masonry products, and

• Arsenic and chromium from chemicallytreated lumber.

Your risk from these exposures varies,depending on how often you do this type ofwork. To reduce your exposure to thesechemicals, work in a well ventilated area, andwork with approved safety equipment, suchas those dust masks that are speciallydesigned to filter out microscopic particles.

WARNING!

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GETTING TO KNOW YOUR ROTARY TOOL

Shaft Lock Button

On/Off Switch

Collet Wrench

Collet Nut

Collet

Brush Cover(one each side)

Housing Cap

Ventilation Openings

Hanger Power Cord

Variable Speed Dial

Unpacking & Checking ContentsTo avoid injury from unex-pected starting or electri-

cal shock, always remove plug from walloutlet when tool is not in use.

Separate all loose parts from packing materi-als and check each item with the contentslisted on the carton to make sure all items areaccounted for before discarding any packingmaterial.

DescriptionThe 400 Series XPR™ Rotary Tool incorpo-rates both high-speed and performance to

serve as a carver, grinder, polisher, sander,cutter, power brush, drill, and more.

The tool utilizes a small, but effective DCmotor. The large variety of availableDremel™ accessories includes abrasivewheels, drill bits, wire and nylon brushes,engraving and carving cutters, router bits,polishing points and more. The ability to adddifferent Dremel™ attachments adds to themulti-faceted uses of the tool. The variety ofprojects you can do with the tool is limitless.

The 400 Series XPR Rotary Tool is a high-speed tool and operates at speeds 5,000 to35,000 RPM. (A typical electric drill operatesonly up to 2500 RPM!). When used withDremel™ accessories and attachments, the400 Series XPR rotary tool’s high speed per-formance allows you to work on even themost demanding projects without having toexert undue pressure on the tool. The tooldoes the work for you.

WARNING!

IMPORTANT! If any parts are missing, or ifyou require any assistance with theseinstructions, please contact the Dremel™Consumer Service at:

1-800-437-3635or check our website at www.Dremel.com.

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SPECIFICATIONS

General SpecificationsVoltage Rating . . . . . . . . . .120 V, 50-60 Hz

Amperage Rating . . . . . . . . . . . . . . . . .2.0 A

No Load Speed . . . . . . . . . .No 35,000/min

Collet Capacity . . . .1/32", 1/16", 3/32", 1/8"

Motor SpecificationsThis Rotary Tool utilizes a variable high-speed RPM motor. It is wired for operation on110-120 volts, 50-60 Hz. alternating current.Before connecting the motor cord to wall out-let, make certain the power switch is in theOFF position and be sure the electric currentis of the same characteristics as stamped onthe Rotary Tool nameplate.

Connection To A Power SourceTo avoid electric shock,do not touch the metal

prongs on the plug when installing orremoving the plug to or from the outlet.

If power cord is worn, cutor damaged in any way,

have it replaced immediately to avoidshock or fire hazard.

DANGER!

DANGER!

Extension CordsIf an extension cord is necessary, a cordwith adequate size conductors that iscapable of carrying the current necessaryfor your tool must be used. This will pre-vent excessive voltage drop, loss of power oroverheating.

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

NOTE: The smaller the gauge number, theheavier the cord.

Tool’s Ampere Rating

Cord Size in A.W.G. Wire Sizes in mm2

2-66-88-1010-1212-16

18 16 16 14 .75 .75 1.5 2.518 16 14 12 .75 1.0 2.5 4.018 16 14 12 .75 1.0 2.5 4.016 16 14 12 1.0 2.5 4.0 —14 12 — — — — — —

25 50 100 150 15 30 60 120

Cord Length in Feet Cord Length in Meters

IMPORTANT! Some of the following symbols may be used on your tool. Please studythem and learn their meaning. Proper interpretation of these symbols will allow you tooperate the tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels,etc.

n0 No load speed Rotational speed, at no load

.../min Revolutions or reciprocation Revolutions, strokes, surface speed,per minute orbits etc. per minute

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque or position settings.I, II, III, Higher number means greater speed

Infinitely variable selector with off Speed is increasing from 0 setting

Arrow Action in the direction of arrow

Alternating current Type or a characteristic of current

Direct current Type or a characteristic of current

Alternating or direct current Type or a characteristic of current

Class II construction Designates Double Insulated Construction tools.

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Ni-Cad RBRC seal Designates Ni-Cad battery recyclingprogram

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SYMBOLS

0

This symbol designatesthat this tool is listed byUnderwriters Laboratories.

This symbol designatesthat this tool is listed bythe Canadian StandardsAssociation.

This symbol designatesthat this tool is listed bythe Canadian StandardsAssociation, and is listedto US Standards by CSA.

This symbol designatesthat this tool is listed toCanadian Standards byUnderwritersLaboratories.

This symboldesignatesthatthis tool com-pliesto NOMMexicanStandards.

This symbol designates thatthis tool is listed byUnderwriters Laboratories,and listed to CanadianStandards by UnderwritersLaboratories.

Shaft Lock Button

Collet Wrench

ToTighten

ToLoosen

Collet Nut

1/8" Collet (480)

3/32" Collet (481)

1/16" Collet (482)

1/32" Collet (483)

Collet Nut

Always use the collet which matches the shank size of the accessory youplan to use. Do not force a larger diameter shank into a smaller collet.

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ASSEMBLYAlways unplug rotary tool before changing accessories, changing collets, or servicing the tool.WARNING!

ColletsThe Dremel™ accessories available for therotary tool come with various shank sizes.

Four size collets are available to accommodatethe different shank sizes. Collet sizes are iden-tified by the rings on the back of the collet:

• 1/32" collet has 1 ring (No. 483)

• 1/16" collet has 2 rings (No. 482)

• 3/32" collet has 3 rings (No. 481)

• 1/8" collet has no rings (No. 480)

NOTE: Some rotary tool kits may not include allfour collet sizes. Collets are available separately.

Changing Collets1. Press the shaft lock button, hold down

and rotate the shaft by hand until itengages the shaft.

Do not engage the shaftlock button while rotary

tool is running.

2. With the shaft lock button engaged,loosen and remove the collet nut. Usethe collet wrench if necessary.

3. Remove the collet by pulling it free fromthe shaft.

4. Install the appropriate size collet fullyinto the shaft and reinstall the collet nutfinger tight. Do not fully tighten the nutwhen there is no bit or accessoryinstalled.

CAUTION!

WARNING!

Changing Accessories1. Press the shaft lock button and rotate

the shaft by hand until it engages theshaft lock.

Do not engage the shaftlock button while rotary

tool is running.

2. With the shaft lock button engaged,loosen (do not remove) the collet nut.Use the collet wrench if necessary.

3. Insert the bit or accessory shank fullyinto the collet.

4. With the shaft lock button engaged, fin-ger tighten the collet nut until the bit oraccessory shank is gripped by the collet.

WARNING!

NOTE: Be sure to read the instructionssupplied with your Dremel™ accessory forfurther information on its use.

Shaft Lock Button

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OPERATION

ASSEMBLY (CONTINUED)

Learning To Use the Rotary ToolGetting the most out of your rotary tool is amatter of learning how to let the speed andthe feel of the tool in your hands work for you.

The first step in learn-ing to use the rotarytool is to get the “feel”of it. Hold it in yourhand and feel itsweight and balance.Feel the taper of the

housing. This taper permits the tool to begrasped much like a pen or pencil. Theunique comfort grip on the nose allows foradded comfort and control during use.

Always hold the toolaway from your face.

Accessories can be damaged duringhandling and can fly apart as they comeup to speed. This is not common, but itdoes happen.

When holding tool, do notcover the air vents with

your hand. Blocking the air vents couldcause the motor to overheat.

IMPORTANT! Practice on scrap material firstto see how the tool’s high-speed action per-forms. Keep in mind that your rotary tool willperform best by allowing the speed, alongwith the correct Dremel™ accessory andattachment, do the work for you. Do not putpressure on the tool during use, if possible.

Instead, lower the spinning accessory lightlyto the work surface and allow it to touch thepoint at which you want to begin.Concentrate on guiding the tool over thework using very little pressure from yourhand. Allow the accessory to do the work.

WARNING!

CAUTION!

Usually it is better to make a series of pass-es with the tool rather than to do the entirejob with one pass. A gentle touch gives thebest control and reduces the chance forerror.

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2

4

For best control in close work, grip the rotarytool like a pencil between your thumb andforefinger.

The “golf” grip method is used for more aggres-sive operations such as grinding or cutting.

Keyless ChuckThe keyless chuck is used in place of the stan-dard collet and collet nut to easily and quicklyremove and install some accessories.

The keyless chuck holds various accessorieswith shank sizes 1/32" to 1/8" and is intendedfor light duty accessories such as drill bits,sanding drums, polishing accessories, wireand bristle brushes and cut-off wheels.

1. See steps 1—3, Changing Collets onpage 7 to install the keyless chuck.

2. Thread the keyless chuck onto the rotarytool shank.

3. Use the supplied wrench to complete-ly tighten the keyless chuck if you areunable to apply sufficient tighteningpressure to hold the bit or accessory.

Keyless Chuck

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2

4

OPERATION (CONTINUED)

Operating SpeedsTo achieve the best results when workingwith different materials, set the variablespeed control to suit the job. To select theright speed for the accessory in use, practicewith scrap material first.

NOTE: Speed is affected by voltage changes. Areduced incoming voltage will slow the RPM of thetool, especially at the lowest setting. If your toolappears to be running slowly, increase the speedsetting accordingly. The tool may not start at thelowest switch setting in areas where outlet voltageis less than 120 volts. Simply move the speed set-ting to a higher position to begin operation.

The 400 Series XPR Rotary Tool switch set-tings are marked on the speed control dial.Refer to the Speed Settings chart on pages11 thru 13 to help determine the properspeed for the material being worked on andthe accessory to use.

Most jobs can be accomplished using thetool at the highest setting. However, certainmaterials (some plastics and metals) can bedamaged by high-speed generated heat andshould be worked on at relatively slowspeeds.

Slow speed operation (15,000 RPM or less)is usually best for polishing operationsemploying the felt polishing accessories, del-icate wood carving and fragile model parts.All brushing applications require lowerspeeds to avoid wire discharge from theholder. Let the performance of the tool do thework for you when using lower speed set-tings.

Higher speeds are better for drilling, carving,cutting, routing, shaping, cutting dadoes orrabbets in wood. Hardwoods, metals andglass require high speed operation also.

The settings for approximate RPM’s are:

Switch Setting Speed Range RPM

2 5,000-8,000

4 9,000-11,000

6 12,000-17,000

8 18,000-24,000

10 25,000-35,000

Some guidelines regarding tool speed:

• There is no accessory for the DremelRotary tool that will drill or cut glass.

• Plastic and other materials that melt at lowtemperatures should be cut at low speeds.

• Polishing, buffing and cleaning with a wirebrush must be done at speeds not greaterthan 15,000 RPM to prevent damage to thebrush and your material.

• Wood should be cut at high speed.

• Iron or steel should be cut at high speed.

• If a high speed steel cutter starts to vibrate,it usually indicates that it is running tooslow.

• Aluminum, copper alloys, lead alloys, zincalloys and tin may be cut at variousspeeds, depending on the type of cuttingbeing done. Use a paraffin (not water) orother suitable lubricant on the cutter to pre-vent the cut material from adhering to thecutter teeth.

NOTE: Increasing pressure on the tool is notthe answer when it is not performing proper-ly. Try a different accessory or speed settingto achieve the desired result. Please refer tothe following Speed Setting charts or simplycontact Dremel Consumer Service at:

1-800-437-3635or at www.Dremel.com.

Set the Speed Control to the desired setting.

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SPEED SETTINGS

CatalogNumber100, 121, 131114, 124,134, 144190118, 191, 192,193, 194116, 117,125, 196115198199

Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassWood Wood Plastic Brass, etc. Stone

8 10 5 5 6 - - -8 6 4 5 6 - - -

8 10 4 7 8 - - -8 10 4 5 8 - - -

8 6 4 5 6 - - -

8 10 4 5 6 - - -8 8 4 5 6 - - -8 8 4 5 6 - - -

High Speed Cutters

CatalogNumber105, 108106, 109107, 110111112113


8 10 6 4 6 - - -8 10 5 4 6 - - -8 10 5 4 6 - - -8* 10* 6* 4 6 - - -8* 10* 5* 4 6 - - -8* 10* 5* 4 6 - - -

Engraving Cutters

CatalogNumber7103, 7105,7117, 7120,7122, 7123,7134, 7144


10 8 - - - 10 10 10

Diamond Wheel Points

CatalogNumber9931, 9932,9933, 9934,9935, 9936


8 8 4 - 6 - - -

Structured Tooth Tungsten Carbide Cutters

CatalogNumber9901, 9902,9903, 9904,9905, 9906, 9909, 9910,9911, 9912


8 8 4 8-10 6 8 8-10 8-10

Tungsten Carbide Cutters

Use only Dremel™ tested, high performance accessories.* Speed for light cuts; Caution - burning on deep grooves.• Depending on cutting direction relative to grain.

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SPEED SETTINGS (CONTINUED)

CatalogNumber516, 517, 518,500


4-6 4-6 - 8 6 - - -4-6 4-6 - 8 6 - - -

Abrasive Points

CatalogNumber903, 911, 921,932,941, 945,952, 953, 954,971, 997,8153, 8175,8193, 8215541


10 10 - 8 4 6 10 -

10 10 - 8 4 6 10 -

Aluminum Oxide Grinding Stones

CatalogNumber453, 454, 455


- - - 8 - - - -

Chain Saw Sharpening Stones

Use only Dremel™ tested, high performance accessories.* Speed for light cuts; Caution - burning on deep grooves.• Depending on cutting direction relative to grain.

CatalogNumber612, 640615, 617, 618,650, 652654


10* 8• - - - - - -10* 8• - - - - - -

10* 8• - - - - - -

High Speed Router Bits

CatalogNumber83142, 83322,83702, 84922,85422, 85602,85622


- - 6 10 4 6 10 10

Silicon Carbide Grinding Stones


- - - 8 8 8 8 8- - - 6 6 6 6 6- - - 8 8 - - -- - - 6-8 6-8 6-8 6-8 6-84 4 2-4 6 6 - - -- 4 - 4 - - - -4 4 2 4 - - - -4 4 - 4 4 4 - -

CatalogNumber461, 462, 463414, 422, 429425, 427423403, 404, 405530, 531, 532428, 442, 443535, 536, 537

13

Polishing Accessories

CatalogNumber409, 420, 426,540542545560561562


- - 2-4 10 10 10 10 -

10 8-10 2-4 10 10 10 10 -8-10 8 - - - - - -

For use on drywall. For best results, use at 35,000 rpm.6-10 6-10 2-4 - 10 - - -

- - - - - - 10 -

Cutting Accessories

CatalogNumber430, 431, 438439, 440, 444407, 408, 432411, 412, 413

Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassWood Wood Plastic Brass, etc. Stone2-10 2-10 2-6 10 10 2-10 2-10 -2-10 2-10 2-6 10 10 2-10 2-10 -2-10 2-10 2-6 10 10 2-10 2-10 -

8 8 2-4 - 2-4 - - -

Sanding Bands and Discs

CatalogNumber502, 503, 504,505


6-8 8 2 10 8-10 - - -

Flapwheels

CatalogNumber511


6 6 4 6 6 - - -

Finishing Abrasive Buffs

CatalogNumber150


10 8-10 2-4 - 6 - - -

Drill Bit

CatalogNumber569, 570


For use on wall and floor grout. 6-8 -

Grout Removal Bits

SPEED SETTINGS (CONTINUED)Use only Dremel™ tested, high performance accessories.* Speed for light cuts; Caution - burning on deep grooves. • Depending on cutting direction relative to grain.

14

"V" Notch

MAINTENANCE

Preventative maintenanceperformed by unautho-

rized personnel may result in misplacingof internal wires and components whichcould cause serious hazard. We recom-mend that all tool service be performedby a Dremel™ Service Facility.

To avoid injury from unex-pected starting or electri-

cal shock, always remove plug from walloutlet before performing service or clean-ing.

Carbon BrushesThe brushes in your tool have been engi-neered for many hours of dependable serv-ice.

To prepare the brushes for use, run the toolat full speed for 5 minutes under no load.This will properly “seat” the brushes, andextend the life of the tool.

To maintain peak efficiency of the motor,examine the brushes for wear every 40-50hours.

Using the tool with wornbrushes will permanently

damage the motor.

Use only original Dremel™ replacementbrushes.’

Inspect the rotary tool brushes after 40-50hours of use. If the rotary tool runs erratical-ly, loses power, or makes unusual noisescheck the brushes for wear and possiblereplacement. Remember: brushes in therotary tool are similar to oil in a car; the moreyou check/service, the better the perform-ance.

Follow these steps to check/change therotary tool brushes.

1. With the power cord unplugged, placethe tool on a clean surface. Use the toolwrench to pry up and release the clip onthe brush cover (Figure A).

2. Remove the brushes from the tool bypulling the shunt and brass clip whichare attached to the brush (Figure B).

NOTE: Be sure to note how the brass clipslides out of the slot next to the brush pock-et. Also, note how the detent on brass clip fitsinto brush pocket slot, which secures thebrass clip into proper position.

3. Check each brush for wear. If brush isless than 3/8" long, or if contact end isrough or pitted, replace the brush.

WARNING!

WARNING!

2

4

Removing Brush Cover

Removing/Inspecting Brushes

Installing Brushes

CAUTION!

A

B

C

15

4. Install existing or new brushes so thecurved surface of the brush end match-es the curvature of the motor commuta-tor (as seen through the brush opening).

NOTE: The detent on the brass clip must fitinto the slot on the side of the brush pocket,which secures the brass clip in the properposition (Figure C).

5. Reinstall brush covers by angling thenon-clip end into the opening. Make cer-tain brush spring is centered in the “V”notch on the brush, then snap closedthe clip end of the brush cover.

6. Plug power cord into a wall outlet. Runthe rotary tool at full speed for 5 minutesunder no load. This will properly seat thebrushes and extend the life of the tool.

For questions or replacement brushes,please call Dremel’s Consumer Service

at 1-800-437-3635or check our website at www.Dremel.com.

Cleaning The ToolVentilation openings and switch levers mustbe kept clean and free of foreign matter. Donot attempt to clean by inserting pointedobjects through openings.

The tool may becleaned with com-pressed air. Alwayswear safety goggleswhen cleaning toolwith compressed air.

There is no need to lubricate the Dremel™rotary tool.

Certain cleaning agentsand solvents will damage

plastic parts. Some of these are: gasoline,carbon tetrachloride, chlorinated clean-ing solvents, ammonia and householddetergents that contain ammonia.

Clean the “soft grip” areas of the tool using adamp cloth. Tougher soiled areas mayrequire more than one wipe application to getclean.

CAUTION!

For availability of all accessories and attachments, refer your local hardware, hobby or homecenter. Or contact Dremel Consumer Service at:1-800-437-3635 or at www.Dremel.com.

Use only Dremel™, high-performance accessories. Other accessories arenot designed for this tool and may lead to personal injury or property

damage.

Screw MandrelFor use with the felt polishingtip and felt polishing wheels.

MandrelsA mandrel is a shank with a threaded orscrew head used with polishing accessories,cutting wheels, sanding discs and polishingpoints. The mandrel is a permanent shank,allowing for replacement of the worn headwhen necessary.

Drywall Cutting Bit

When using a template (outlet box) behindthe drywall, cut in a counterclockwise direc-tion.

16

ACCESSORIES

Multipurpose Cutting Bit

For use in wood, plastics, drywall, fiberglass,vinyl or aluminum siding, acoustical tile andlaminates.

Start the bit into the material at a 45° angleand then slowly bring it to a 90° angle tobegin the cut.

High Speed Router Bits

For routing, inlaying and mortising in woodand other soft materials. Use only withDremel™ Router Attachment #330 orShape/Router Table #231.

WARNING!

Tile Cutting Bit

For use wall tile, cement board and plaster.

Start the bit into the material at a 45° angleand then slowly bring it to a 90° angle tobegin the cut.

Small Screw MandrelMandrel has a small screwat the tip and is used withemery and fiberglass cuttingwheels, sanding discs andpolishing wheels.

Threaded Tip Mandrel Mandrel has a threaded tipwhich threads into the polish-ing point accessory #427.

Diamond Wheel PointsUsed for fine detail work onwood, jade, ceramic, glass andother hard material. Bits arecovered with diamond parti-cles.

Aluminum Oxide GrindingStones (red/brown)These grinding stonescome round, pointed or flatand are made of aluminumoxide. Use them for every possible grindingoperation: sharpening lawn mower blades,screwdriver tips, knives, scissors, chisels andother cutting tools. Use to remove flash frommetal castings, deburring any kind of metal.These grinding stones can be resharpenedwith a dressing stone. In machine shops,high speed drills and cutters are normallyground with aluminum oxide wheels.

Silicon Carbide GrindingStones (blue/green)Tougher than aluminum oxidepoints, these are made especially for use onhard materials such as glass and ceramics.

1/8" shank

1/8" shank

1/8" shank

1/8" shank

1/8" shank

3/32" shank

Wire BrushesNever use wire brushes atspeeds greater than

15,000 rpm. Refer to Speed Settings(pages 10-12) for proper tool and setting.

Three different shapesof wire brushes areavailable in three differ-ent materials: stainlesssteel, brass and carbonwire. Stainless steelbrushes perform well on pewter, aluminum,stainless steel and other metals, withoutleaving rust. Brass brushes are non-sparkingand softer than steel, making them good foruse on soft metals like gold, copper andbrass. Carbon wire brushes are good forgeneral purpose cleaning.

17

Tungsten Carbide CuttersTungsten carbide cuttersare long-lived cutters foruse on hardened steel, firedceramics and other very hard materials. Theycan be used for engraving on tools and gar-den equipment.

High Speed CuttersHigh speed cutters areused in carving, cuttingand slotting wood, plasticsand soft metals (such as aluminum, copperand brass). Made of high quality steel.

Engraving CuttersEngraving cutters come in awide variety of sizes andshapes and are used for intricate work onceramics (greenware), wood carvings, jewel-ry and scrimshaw. They are often used inmaking complicated printed circuit boards.They should not be used on steel and veryhard materials, but are good for use onwood, plastic and soft metals.

Structured Tooth Tungsten Carbide Cutters

These cutters feature fast cutting needle-sharp teeth for greater material removal withminimum loading. Use on fiberglass, wood,plastic, epoxy and rubber.

Bristle BrushesBristle brushes areused for cleaning tools onsilverware, jewelry and antiques. The threeshapes make it possible to get into tight cor-ners and other difficult spaces. They can beused with polishing compound for fastercleaning or polishing.

CAUTION!

Brushing Pressure•. The tips of a wire brush do the work.

Operate the brush with the lightest pres-sure so only the tips of the wires come incontact with the work surface.

•. If heavier pressure is used, the wires willbecome overstressed, resulting in a wip-ing action. If this continues, the life of thebrush will be shortened by fatigue.

•. Apply the brush to the work surface sothe majority of the brush face makes fullcontact. Applying the edge or side of thebrush to the work surface will result inwire breakage and shortened brush life.

Aluminum Oxide AbrasiveWheelsUsed to remove paint, deburrmetal, polish stainless steeland other metals. Available inmedium grit.

Grinding WheelUsed for deburring, removingrust, and general purpose grind-ing. Use with Mandrel #402.

ACCESSORIES (continued)

1/8" shank

1/8" shank

1/8" shank

1/8" shank

1/8" shank

3/32" shank

1/8" shank

Sanding AccessoriesSanding discs in fine,medium and coarsegrades are made to fitmandrel #402. They can beused for nearly any small sanding job frommodel making to fine furniture finishing.

In addition, the drum sander makes it possi-ble to shape wood, smooth fiberglass, sandinside curves and other difficult places. Drumbands are replaceable and come in fine andcoarse grades.

18

ACCESSORIES (continued)

ATTACHMENTSThe following attachments are part of the Dremel Rotary Tool System; increasing the versatility

of your rotary tool.

Flapwheels grind and polish flat or contouredsurfaces. They are used most effectively as afinishing sander, after heavier surface sand-ing and material removal is completed.Flapwheels come in fine and coarse grades.

Buffs are a great finishing accessory forcleaning and light sanding. They work effec-tively on metal, glass, wood, aluminum andplastics. Buffs are available in medium andcoarse grades.

XPR MultiSawThe Dremel XPR MultiSaw turns your rotary tool into a multipur-pose saw that will allow you to make straight and curved cuts ina variety of materials. Scroll cutting patterns is now fast and easy.Using standard jigsaw blades, you can cut soft & hard wood, ply-wood, metal, PVC, plastic, and much more!

1/8" shank

XPR PlanerConvert your corded rotary tool into a planer.

• The planer is designed for two types of planing: straightplaning and 45° planing, up to 2-1/8".

• In addition, the straight planing technique can be used forlimited shaping and carving.

• Ideal for fixing a warped or stuck door!

Flex LightThe flex light uses Lithium Ion batteries (bat-teries included).

• LED lighting provides visibility in dimly litareas and increases light on detailed proj-ects

• Easy to attach, no confusing wires or con-nections

• Attaches to Workstation 220 and PlungeRouter 335

Use with model 400 Series XPR only.



19

Flex Shaft Ideal for hard-to-reach places and fine detail work.

• Quick connect attach system

• 36" long cable with new 5" bend radius provides more flexibility

• Comfort grip hand piece

• Integrated shaft lock button

• Holds up to 1/8" shank

ATTACHMENTS (continued)

76

54

33

21

Plunge RouterConverts you corded rotary tool into a plunge router.

• Clear base

• Two depth stop

• Includes edge guide and circle guide

• Rout circles, parallel to edge, signs, inlay work, andlettering template adapters

Use with models: 275, 285, 395, 398, 780, 800, 400 Series XPR.

Use with models: 275, 285, 395, 398, 800, 400 Series XPR.

Use with models: 275, 285, 395, 398, 770, 780, 800, 400 Series XPR.

5" Radius

Grout RemovalFast and easy way to regrout any room or replace abroken tile!

• Multiple side depth adjustment

• 30° angle for control cutting

• Guides 180° apart to keep bit centered betweentiles

• Easy screw mounting

• Includes 1/16" grout removal bit

3/4

1/2

1/4

0

Cutting GuideProvides controlled cutting in a variety of materials

• Allows for sturdy controlled cuts with maximum visi-bility

• Easy depth adjustment. Set to the correct cuttingdepth for the project material.


20


Dremelite• Provides visibility in dimly lit areas and increases light on

detailed projects

• Two extremely long lasting and durable LED lights

• Uses a magnet threaded onto the tool’s output shaft to pro-vide a clever and simple power source—no wires!

Lawn / Garden SharpenerThe fastest, easiest, safest way to sharpen your lawn mowerblade and other garden tools.

• Guide provides optimum sharpening angle

• Sharpens most rotary lawn mower blades

• Includes sharpening stone

30o

30o

GAGE

Chain Saw Sharpener• Easily sharpen the dullest of chains

• Contains: sharpening attachment, 3 sharpening stones,gauge, 2 spacers, wrench, instruction manual

Right AngleEnhances the versatility of the rotary tool by allowing you toget into hard-to-reach places.

• Ball bearings and spiral gears provide smooth and cooloperation

• Coupling system allows you to orient the attachment onyour tool in 12 different directions

• Quick disconnect system easily attaches to your rotary toolin place of the housing cap, no wrenches required

Use with models: 275, 285, 395, 398, 780, 800, 400 Series XPR.




21


Tool Holder and Base• Firmly holds rotary tools in any position

• Control workpiece (hands free) for better results

Use with models: 275, 285, 395, 398, 400 Series XPR.

Use with models: 275, 285, 395, 398, 780, 400 Series XPR.

Flex Shaft Tool HolderConveniently suspends any Dremel rotary tool above your work-bench.

• Perfect for use with the Flex-Shaft attachment

• Clamps to workbenches up to 1-3/4" thick, and adjusts in heightfrom 12" to 42"

• Store extra bits on base

22

1

1

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3

10

10

16

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4

SERVICE PARTS & DIAGRAM

Ref. Part No. Description1 2610920980 Housing Set2 2610920701 Field Assembly3 2610920702 Armature and

Bearing Assembly4 2615990962 Wrench5 2615294041 Cord10 2610920705 Brush Spring (Pair)16 261920709 Brush Holder

Assembly17 2610920972 Collet Lock & Spring

Ref. Part No. Description18 2610922763 Collet Nut19 2615110480 1/8" Collet (In Tool)20 2610920710 Switch Assembly22 2610914379 Rubber Bearing

Sleeve23 2610920718 Hanger24 2615294035 Screws (Individual)25 2610921563 Brush Door (Pair)27 2610920716 Glamour Cap28 2640920711 Speed Control30 2610920717 Housing Cap

23

Your Dremel™ product is warranted against defective material or workmanship for a period of fiveyears from date of purchase. In the event of a failure of a product to conform to this written warran-ty, please take the following action:

1. DO NOT return your product to the place of purchase.

2. Carefully package the product by itself, with no other items, and return it, freight prepaid,along with:

A. A copy of your dated proof of purchase (please keep a copy for yourself).

B. A written statement about the nature of the problem.

C. Your name, address and phone number to:

UNITED STATESDremel Service Center Dremel Service Center4915 21st Street, Racine, WI 53406 OR

4631 E. Sunny Dune, Palm Springs, CA 92264CANADA OUTSIDEGiles Tool Agency CONTINENTAL UNITED STATES6520 Lawrence Av. East See your local distributor or write toScarborough, Ont., Canada M1C 4A7 Dremel, 4915 21st Street, Racine, WI

53406

We recommend that the package be insured against loss or in transit damage for which we can-not be responsible.

This warranty applies only to the original registered purchaser. DAMAGE TO THE PRODUCTRESULTING FROM TAMPERING, ACCIDENT, ABUSE, NEGLIGENCE, UNAUTHORIZEDREPAIRS OR ALTERATIONS, UNAPPROVED ATTACHMENTS OR OTHER CAUSES UNRE-LATED TO PROBLEMS WITH MATERIAL OR WORKMANSHIP ARE NOT COVERED BY THISWARRANTY.

No employee, agent, dealer or other person is authorized to give any warranties on behalf ofDremel. If Dremel inspection shows that the problem was caused by problems with material orworkmanship within the limitations of the warranty, Dremel will repair or replace the product freeof charge and return product prepaid. Repairs made necessary by normal wear or abuse, orrepair for product outside the warranty period, if they can be made, will be charged at regular fac-tory prices.

DREMEL MAKES NO OTHER WARRANTY OF ANY KIND WHATEVER, EXPRESSED ORIMPLIED, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE WHICH EXCEED THE ABOVE MENTIONED OBLIGATION ARE HEREBYDISCLAIMED BY DREMEL AND EXCLUDED FROM THIS LIMITED WARRANTY.

This warranty gives you specific legal rights and you may also have other rights which vary from stateto state. The obligation of the warrantor is solely to repair or replace the product. The warrantor isnot liable for any incidental or consequential damages due to any such alleged defect. Some statesdo not allow the exclusion or limitation of incidental or consequential damages, so the above limita-tions or exclusion may not apply to you.

For prices and warranty fulfillment in the continental United States, contact your local Dremel distrib-utor.

DREMEL™ LIMITED WARRANTY

24

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