DeWalt D26453 TYPE 1, D26451 TYPE 1 Owner’s Manual

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DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286

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 con- figuration; and the array of lozenge-shaped humps on the surface of the tool.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,

CALL US TOLL FREE AT: 1-800-4-DEWALT (1-800-433-9258)

General Safety Instructions

A ARNING! Read and understand all instructions. Failure to follow all instructions listed

below may result in electric shock, fire and/or serious personal injui_.

SLAVE THESE INSTRUCTIONS

WORK AREA

* Keep your work area clean and well fit. Cluttered benches and dark areas invite accidents. * Do not operate power tools in explosive atmospheres, such as in the presence of flam-

mable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.

* Keep bystanders, children, and visitors away while operating a power tool Distractions

can cause you to lose control.

ELECTRICAL SAFETY

* Grounded tools must be plugged into an outlet properly installed and grounded in

accordance with all codes and ordinances. Never remove the grounding prong or

modify the plug in any way. Do not use any adaptor plugs. Check with a qualified elec- trician if you are in doubt as to whether the outlet is properly grounded, ff the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. Applicable only to Class I (grounded) tools.

* Double insulated tools are equipped with a polarized plug (one blade is wider than the

other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation [] elim- inates the need for the three wire grounded power cord and grounded power supply system.

Applicable only to Class II (double insulated) tools.

* Avoid body contact with grounded surfaces such as pipes, radiators, ranges and

refrigerators. There is an increased risk of electric shock if your body is grounded.

* Don't expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

* Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an

outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.

* When operating a power tool outside, use an outdoor extension cord marked "W-A"

or "W." These cords are rated for outdoor use and reduce the risk of electric shock. When using an extension cord, be sure to use one heavy enough to carry the current your product

will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage num-

ber, the heavier the cord.

Minimum Gage for Cord Sets

Volts Total Length of Cord in Feet 120V 0-25 26-50 51-100 101-150

240V 0-50 51-100 101-200 201-300 Ampere Rating

More Not more AWG

Than Than

0 6 18 16 16 14

PERSONAL SAFETY

* Stay alert, watch what you are doing and use common sense when operating a power

tool Do not use tool while tired or under the influence of drugs, alcohol, or medication.

A moment of inattention while operating power tools may result in serious personal injui_.

* Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair,

clothing, and gloves away from moving parts. Loose clothing, jewelry, or long hair can be caught in moving parts. Air vents often cover moving parts and should also be avoided.

* Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with

your finger on the switch or plugging in tools that have the switch on invites accidents.

* Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that

is left attached to a rotating part of the tool may result in personal injury.

* Do not overreach. Keep proper footing and balance at all times. Proper footing and bal-

ance enables better control of the tool in unexpected situations.

* Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes,

hard hat, or hearing protection must be used for appropriate conditions.

TOOL USE AND CARE

* Use clamps or other practical way to secure and support the workpiece to a stable

platform. Holding the work by hand or against your body is unstable and may lead to loss of

control.

* Do not force tool Use the correct tool for your application. The correct tool will do the

job better and safer at the rate for which it is designed.

* Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with

the switch is dangerous and must be repaired.

* Disconnect the plug from the power source before making any adjustments, changing

accessories, or storing the tool Such preventative safety measures reduce the risk of

starting the tool accidentally.

* Store idle tools out of reach of children and other untrained persons. Tools are dan-

gerous in the hands of untrained users.

. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools,

with sharp cutting edges are less likely to bind and are easier to control.

* Check for misalignment or binding of moving parts, breakage of parts, and any other

condition that may affect the tool's operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.

* Use only accessories that are recommended by the manufacturer for your model

Accessories that may be suitable for one tool, may become hazardous when used on

another tool.

SERVICE

* Tool service must be performed only by qualified repair personnel Service or mainte-

nance performed by unqualified personnel could result in a risk of injury

* When servicing a tool, use only identical replacement parts. Follow instructions in the

Maintenance section of this manual Use of unauthorized parts or failure to follow mainte- nance instructions may create a risk of electric shock or injury.

Additional Safety Instructions for Sanders

. Accessories must be rated for at least the speed recommended on the tool warning

label Wheels and other accessories running over rated speed can fly apart and cause inju_

Accessory ratings must be above listed minimum wheel speed as shown on tool nameplate.

, Hold tool by insulated gripping surfaces when performing an operation where the cut-

ting tool may contact hidden wiring or its own cord. Contact with a 'five" wire will make exposed metal parts of the tool 'five" and shock the operator.

, Always wear eye protection and a respirator when sanding. , Sanding of lead-based paint is not recommended. See Precautions To Take When

Sanding Paint for additional information before sanding paint.

, Do not operate the unit without the dust collection bag. , Clean your tool out periodically. , Empty dust bag frequently, especially when sanding resin coated surfaces such as

polyurethane, varnish, shellac, etc. Dispose of coated dust particles according to the finish

manufacturer's guidelines, or place in a metal can with a tight-fitting metal lid. Remove coated dust particles from the premises daily. The accumulation of fine sanding dust particles may serf ignite and cause fire.

, Replace worn CFS disc when it causes high tool rpm. High tool rpm caused by a worn

out CFS disc may result in separation of sanding pad from the sander, possibly causing per- sonal injui_. For instructions on replacing the CFS disc, see Tool Care.

_ WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other con-

struction activities contains chemicals known to cause cancer, birth defects or other reproduc- tive 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 (CCA).

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 weft 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 disburse 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. J_,CAUTION: Wear appropriate hearing protection 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 their definitions

are as follows:

V .............. volts

Hz ............ hertz

min............ minutes

.... ..........direct current

[] .............. Class II Construction

.............. safety alert symbol

A................ amperes

W .............. watts

............ alternating current

no .............. no load speed

.............. earthing terminal

.../min ........revolutions per minute

COMPONENTS (Fig. 1)

A. On/Off switch

B. Speed control dial (D26453)

C. Sanding pad

D. Dust collection bag E. Vac-adapter

R CFS disc (Fig. 6)

Motor

Your DEWALT tool is powered by a DEWALT built motor. Be sure your power supply agrees with the nameplate marking. (Volts, 120 AC only). Voltage decrease of more than 10% will cause loss

of power and overheating. All DEWALT tools are factory tested; if this tool does not operate, check the power supply.

REQUIRED SANDPAPERS

Model Disc Attachment Hole

Sander Size Method Pattern

D26450 5" PSA 8 Holes D26451 5" Hook & Loop 8 Holes D26453 5" Hook & Loop 8 Holes

Attaching Sanding Discs

Your sander is designed to use 5" (127mm) sanding discs with an 8-hole dust extraction pattern. Sanding discs for the D26451 and D26453 attach with hook and loop. Sanding discs for the

D26450 attach using pressure sensitive adhesive (PSA).

TO ATTACH PAPER TO THE SANDING PAD (FIG. 2)

_,CAUTION: Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Be sure the switch is in the OFF position.

1. Turn the sander over so that the sanding pad is facing upward.

2. Clean the dust from the vinyl pad face.

3. Hold the pad with one hand to keep it from rotating.

4. With the other hand, align the holes and place the disc directly on top of the pad.

NOTE: Do not use sanding screen (e.g,, screen used for -_adiag a_'v2_tl_+CJiP_lT¢+55+tW_:'ff_k

and loop pad, The screen wiI nat held and wtt dan;age the books on t-_e pod. The hooks On the pad Wil weal very rapidly t lelt is contact with the work sudace whte the tool is epe+'ating.

Switch (Fig, 31

To lure the unil on, depress lie side at the dust-protected switch (A) thai corresponds to lhe sym_ot"F. To turn the toe! off depress the side d he sw_!ch thai corresponds [o the symbe "O",

- .... , .:_

Speed Control Dial (D26453)

The epeed control dial (B). shown in Figure 1, alows you to increase or decrease speed from

7.000-12,000 Orbits Per Minute, The optmaI speed setting tot each app]icalian is very mt;ch dependent ee persana_ preference. Generuty, you wtf want to use a higher setting on harder _'natedalu end a lowel poling on molter materials. Matedat removal rate increases as speed

increases.

Dust Extraction (Fig, 41

_CAUTION: Turn off and unplug the too! before making any adjustments or removing or installing attachments or accessories, Be sure the switch is in the OFF position,

Year sander has two dust eclectics methods: a twist-on dast colecton bag (D) and a bull-in

sac-adapter (E) which can be hooked directly to a shop vaccum syeIem. TO EMPTY OUST BAG

1. Whle holding the sandal', grasp the dust colecton bag (b) at the end neatesl the sunder and twist off el the vae-arJepIer (E).

2. Gettly shake or tap the dust cotesdon bag to ernpbi.

3, Tw'ist dast colesgon bag back onto the sac-adapter.

Yo# may notice [hat ul the deal will oct come free from the bag. This _,.4[Ino[ a_ect sanding per-

"_o_mance but wl] ,'educe the sunder+s dust colection eftdency, To restore your sander's dust selection efficiency, depress the spring inside the dust bag whee you are _mptying it and tap it

on the side ot the trash can or dust receptacle. ,&CAUTION: Never opelate these too& untees the dust coflector _s in place. Sanding duet

exhaust may create a bteathing hazard,

OPERATION (Fig. 5)

To operate you+" sander, grasp it as st:own in Eigures 5A or 5B and lure [t on, Move the unt in

long, uwueping sh'okes along the sudaca being sanded, letting the sander do the wsrk. Pushing do',*,,;} on the roD1 v.,hite sanding actaaly slows Ire removal rate and prodaues an

inferior quafty sudace. Be sure to aheck your work often, [his sander ie capab, te oI _'ernoving malaria+ rapidly, especially with coarse paper.

The random olt_,ital acton ol your sander alews you to sand witr Ire grain or ai any ang_. across

il for mosf sanding jobs, To produce the best finish possible, sial1 wth coarse grit sandpaper and change gradua£y _o flour and fleer paper, Vacuum and wipe sudase with a tack cloth between grit steps.Your sanc_r is designed to sand inlo stoat or centined areas, Its small size and light

we{phi make i[ idea_ far overhead work. The rate at which t_e dual coteolion bug rills up will vary wth the type of matefiaf being sanded

and the coarsenesu of the sandpaper. For best resulta, empty the bag frequently. When sand- ing painted sudases, (see the folaa,ing tot additional precealians when sanding paint) you may lind that the sandpaper Ioads up and cogs with paint. A heat gun will work much belier to remove paint before sanding, FOLLOW ALL SAFETY iNSTRUCTIONS IN HEAT GUN

INSTRUCTION MANUAL. NOTE (D26458 only): When u£ing PSA sanding discs, remove Ibe disc soon after oparalon.

PSA paper, I the disc [s left on during tool storage, sometimes becc_rnes difficull to remsve. To aid in the _emoval or old PSA paper, sand for a few minutes to sotten the adhesive backing pdor to changing disc.

Precautions To Take When Sanding Past

1. Sanding of lead based paint is NOT RECOMMENDED due to the dtiiculy el sonlroling the contaminated dust, The greatest danger ol lead _oisoning is Io chtdren old pregnant wo_ea.

2, Since it is di#icuf Io identi_ whelrer or nol a painl contr_ins lead withoal a ehemicet analysis,

we recommend the fotowing precautions when sandhg any paint:

PERSONAL SAFETY

3. No children or pregnanl women should enter tl_e work area where the paint sanding is

being done until all clean ap imcompleted.

2. A dust mask or respirator shooed be worn by all persons entering the WOrk area. The liar

should be repIeced daily or whenever the weare_ has difflculy breathing. Sea your Ioca_ hardwale store for the proper N t.O S H, approved dust mask.

3. NO EATING, DRINKING or SMOKING sheuid be dane in the work area to prevent ingest-

ing contaminated paint particles. Workers should wash and clean up BEFORE ealing, ddnki]g o_ smoking A+li¢ieu et iood, drink, or smoking should not be left in the work area

where dual would settIe on tllem.

ENVIRONMENTAL SAFETY i, PAint ShoUld be Temoved in such a manner as to minimizo ths amount of dust generated.

2. Areas whore painl removai is occurbng should be sealed with ptautic sheeting of 4 mitu

Ihickness.

3, Sandiug shaold he done in a manna+- !o reduce tracking ot paint dust outside fhe work

area.

CLEANING AND DISPOSAL

1. AI surfaces [n tire work area should be vacuumed and ll_oroughiy cleaned daily lot the

duration r_f Ihu sanding project, Vaeaat'a filer bags sboi]id be changed frequen y

2. Pleslic drop cloths should be galhe+ed up and disposed at along with any dust chips or

other removal debris. I_ley should be pl_ced in sealed refLtse mceplacles a_td dispoued o[ through regular trash pick-t_p procedures During clean up, chtdren and pregnant women should be kept away from the immediate work area.

3. At Ioys, washable lurnlure and utensils used by chidden should be washed thoroughly

be[ole t_eing used aoain

Tool Care

_+ Keep your uander as dean as _s£ibie by wiping wth a cban cloth _nd blowing a[_ fl3rough

it e_let every 5 hours of use,

2. As part o| CFS (Controlled Finishing System®}, your sander is eqaipped wiih a replac_ able disc (F) whk:h is Iocaled between the p_d (C} and the sander body (G). t Js designud

to increase the dust eoleclion efficiency and control the pad speed while the unil is oft the work surface. The disc is designed to be a consumable pa_ and wit occasionalb+ need to be

replaced. Rep[acemen! is necessary when the pad speed kqcreases very dramaficuly when

lhe Qnit ]s lifted from the work sudace TO REPLACE YOUR CFS DISC (FIG. 6)

_, CAUTION: Turn off and unplug the tool before making any adjustments or removing _r installing attachments or acseesotiee. Be a_re the switch is in the OFF position.

a. Remove the three screws [ram |he 5ol_m or the pad.

b, Remove the pad (C). ¢. Remove worn CFS disc (F). d, To instal the new CFS disc, p_ace Ihe spring aide of the disc toward the sonde+r, e. Align lhe notches (H) on lhe CFS disc wilh the seams il'_ the sander body. L Replace Ihe pad and the lhree screws. Be carelul not to aver4ighten screws,

3. Don't use harsh chem+eals or solvenls to clee.rl +,he tool The_e chemicals could seriously damage lhe plastic oemponentu of you[ sander,

4. Avoid overloading your sandal Overloading wJl resatt in a considerable reduction in speed and Inish quaIily of your work. The unil may also be-come hot, In this event run sander at a

no Iced condilien tar a minute or two.

5. if you wrap the co+'d around the tool when you store iL leave a generous loop ol ¢o_d such

lhat the strain ruler does not bend, This helps prevent prema_tee cold lature.

Brush Replacement (Fig. 8, 9)

jLCAUTION: Turn off end unplug the tool before making any adjustments or removing or installing attachments or aecesaeries. Be sure the switch is in the OFF position.

PIG 1 D26450, D26451 D26453

FIG. 2

PiG 4

FIG. s

F_G 3

PIG. 5B

,/): :$

_+:5:1 ::r'

FIG B

FIG 9

+ +,+

TO REPLACE BRUSHES

1. Remove Ihe three screws I[om tl_e top cap and lit off to]_ cap, as shown in Figure 8,

2, Pull the bruuh spring 0) back [be eare[ul no; IO pull completely off) and stda oul the old

brush.

3. Pul! Ihe brush wi_e {J) which is connected to tire brush, oat o[ the motol field (K).

4. Plug the new brush w#e beck into the motor field. & Stil balding the btusb spdng back, slide in the new bn._sh wth thu wire coming out the top

of' the brush and release Ihe brush spring.

& Repeat steps 1_5 |Or the uecond brush.

7. Replace gie tap cap and tighter+ the three screws. Be careluf not to over tighten scre_,,,s,

8. Ah*.,ays reptace both brushes.

Lubrication

Sell lubricating bearings ate used in the tool and periodic retabfieatioa is nol required. However, it iU recommended that, once a year, you lake or send the tool Io a service cenler for a thorough

cleaning and inspection.

ACCESSORIES

Recommended accessodes for use w_h your tool are available at extra COSt from yon+ local

denies or authorized ser,,]ce center. 11 you need assistance in locating any accessory _or year

tool, son_ast: DEWALT Industrial Tool Co., 70t East Joppa Road. Batimore, MD 21286 or col I -SO04-0EWALT {t-800-433-9258).

_CAUTION: The use of any other accessory act recommended lot use with this toot could be

hazardous.

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