Dewalt DW412, DW411 User Manual

INSTRUCTION MANUAL

GUIDE D'UTILISATION

MANUAL DE INSTRUCCIONES

DW411/DW412

1/4 Sheet Sanders

Ponceuses à 1/4 feuille

Lijadoras de 1/4 de hoja

INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA

DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES

DE USAR EL PRODUCTO.

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

(JUN04-CD-1) Form No. 158635-03 DW411,DW412 Copyright © 1998, 2001, 2004

The following are trademarks for one or more D

EWALT 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.

Questions? See us in the World Wide Web at www.dewalt.com

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL,
CALL US FREE AT 1-800-4-DEWALT (1-800-433-9258).

General Safety Instructions

WARNING! Read and understand all instructions. Failure to follow all instruc­tions listed below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.

• 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.

• 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 elec­trician if you are in doubt as to whether the outlet is properly grounded. If 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.

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
ThanThan
0-6 18 16 16 14

6 - 10 18 16 14 12

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 injury,

• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your
hair, clothing , and gloves away from moving parts. Loose clothes, 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 dan­gerous 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 tools 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

Maintenance Instructions may create a risk of electric shock or injury.

Additional Safety Instructions for Sanders

• ALWAYS WEAR EYE PROTECTION.

• It is not advised to sandpaper painted surfaces that may contain lead. See page 2 for

Precautions to Take When Sanding Paint.

• Clean your tool out periodically.

• Empty dust bag frequently. Especially when sanding resin coated surfaces such as
polyurethane, varnish, shellac, etc. The accumulation of fine sanding dust particles may self
ignite and cause fire.

• The label on your tool may include the following symbols.

V..........volts A ..........amperes

Hz........hertz W ..........watts

min ......minutes ........alternating current

....direct current no..........no load speed

........Class II Construction ..........earthing terminal

........safety alert symbol .../min....revolutions per minute

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 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 (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 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 pro-

mote 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.

CAUTION: Wear appropriate hearing protection during use. Under some conditions

and duration of use, noise from this product may contribute to hearing loss.

SAVE THESE INSTRUCTIONS

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). A Voltage decrease of more than 10% will cause
loss of power and overheating. All tools D

EWalt tools are factory tested; if this tool does not oper-

ate, check the power supply.

Attaching Abrasive Paper (fig. 3)

Your sander is designed to use 1/4 sized sanding sheets. This size paper can be made by:

a. Cutting full sized (9" x 11") sandpaper into 1/4 sheets of 4-1/2" x 5-1/2".
b. Cutting 1/2 sheet sandpaper into two 4-1/2" x 5 1/2" sheets. Pre-cut 4-1/2" x 5-1/2" sandpa-

per is available at extra cost.

For normal operations, assemble the abrasive paper to your unit as follows.

1. Soften the stiff sandpaper by pulling it over the 90° edge of a table or other straight edge, as
shown in Figure 1. Concentrate on softening the edges to be clamped.

2. Release clamp by pulling up on clamp lever and disengaging it from the tab on the base plate.
Fig. 2 (A).

3. Insert the 4-1/2" edge of the abrasive paper under the front paper clamp, as shown in Figure
3 until it hits the paper limiting ribs shown in the figure. Close the front paper clamp and hook
it into the lock position behind the tab on the base plate.

4. Stretch paper over sanding pad and insert under the opposite clamp in the same way.

5. If you are using the dust extraction feature, perforate the sand- paper with the provided paper
punch as shown in Figure 5.

Switch (Fig. 4)

To turn the unit on, depress the side of the dust protected switch that corresponds to the sym­bol “I”. To turn the tool off, depress the side of the switch that corresponds to the symbol “O”.
See Figure 4.

Paper Punch (Fig. 5)

A paper punch is provided with your sander to let you perforate regular sandpaper to make dust
collection possible.

To perforate your sandpaper, install the sandpaper on the tool as instructed in this manual. With
the sander turned off and unplugged, place the paper punch on the paper so that the tabs at the
edges of the punch are against any two adjacent sides of the sanding pad, as shown. Press the
punch against the pad so that the 8 points penetrate the paper, as shown in Figure 6. (Press the
punch into the pad as far as it will go.) Remove the paper punch and the paper is ready. An alter­nate method of perforating the paper is to fasten the punch down to a suitable work surface and
press the sander (with the paper attached) down on the punch. Two holes are provided in the
punch for this purpose. Use #8 flat head screws.

Dust Collection Bag (Fig. 8)

DUST COLLECTION BAG: NEVER OPERATE THIS TOOL WITH PERFORATED PAPER
UNLESS THE DUST COLLECTION BAG IS IN PLACE.

To use the dust collecting system, lower the plastic end of the collection bag over the flange and
push it down as far as it will go, as shown.

To empty the dust collection bag, simply lift it up, off of the sander and empty over a trash
receptacle.

Operation (Fig. 9)

To operate your sander, grasp it as shown in Figure 9 and turn it on. Move it in long, sweeping
strokes along the surface being sanded, letting it do the work. Pushing down on the tool while

O

I

ON

OFF

FIG. 4

FIG. 5

A

FIG. 6

A

FIG. 1

FIG. 2

FIG. 3

A

B

A

FIG. 8

A

B

FIG. 9

O

I

FIG. 10

FIG. 11

A

B

FIG. 12

I

sanding actually slows the removal rate and produces an inferior quality surface. Be sure to check
your work often, this sander is capable of removing material rapidly, especially with coarse paper.
Your sander is designed to sand flush on three sides (four sides without the dust collection bag)
for sanding in corners, and its small size and light weight make it ideal for overhead work.
The orbital action of your sander allows you to sand with the grain or at any angle across it for
most sanding jobs. On the final sanding steps, as discussed below, a better finish will result if
you sand only with the grain.
To produce the best finish possible, start with coarse grit sandpaper and change gradually to
finer and finer paper. A final sanding with a piece of well worn fine sandpaper will produce a real­ly professional looking finish that in many cases will need no hand sanding at all. The rate at
which the dust collection bag will fill up will vary with the type of material being sanded and the
coarseness of the sandpaper. For best results, empty the bag frequently and check the opening
for clogging.
When sanding painted surfaces, you may find that the sandpaper loads up and clogs with paint.
A heat gun will work much better to remove paint before sanding. FOLLOW ALL SAFETY
INSTRUCTIONS IN HEAT GUN INSTRUCTION MANUAL.

Precautions To Take When Sanding Paint

1. Sanding 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

a. No children or pregnant women should enter the work area where the paint sanding is

being done until all clean up is completed.

b. 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.

c. NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingest-

ing 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

a. Paint should be removed in such a manner as to minimize the amount of dust generated.
b. Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils

thickness.

c. Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

CLEANING AND DISPOSAL

a. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the dura-

tion of the sanding project. Vacuum filter bags should be changed frequently.

b. 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.

c. All toys, washable furniture and utensils used by children should be washed thoroughly

before being used again.

Tool Care

Keep your machine as clean as possible by wiping with a clean cloth and blowing through it with
air after every 5 hours of use.

Don’t use harsh chemicals or solvents to clean the tool. These chemicals could seriously dam­age the plastic.

Avoid overloading your sander. Overloading will result in a considerable reduction in speed and
efficiency and the unit will become hot. In this event, run sander at a “no load” condition for a
minute or two.

Brush Replacement (Fig 10 & 11)

TURN OFF AND UNPLUG THE SANDER

To replace the tool’s brushes, remove the three screws located in the top cap, as shown in
Figure 10.

Lift off the top cap. Observe the brush holders, as shown in Figure 11 and the wires leading from
the brushes to the motor field.

Pull the wires from the motor field and then lift and hold out of the way one of the brush springs.
Remove the old brush from the brush holder and discard the brush/wire assembly. Still holding
the brush spring out of the way, insert the new brush, release the spring against the back of the
brush and plug the wire into the motor field. Repeat the procedure for the second brush.

Replace the top cap and tighten the three screws that hold it in place. (Always replace both
brushes.)

Accessories

Recommended accessories for use with your tool are available at extra cost from your local
dealer or authorized service center. If you need assistance in locating any accessory for your
tool, contact: D

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

CAUTION: The use of any other accessory not recommended for use with this tool could be

hazardous.

DUST EXTRACTION HOSE ADAPTOR (DW4111)

Slides over flange at rear of tool, as shown in Figure 12. Accepts a variety of vacuum hoses for
dust extraction.

6" CIRCULAR PLATEN (DW4112)

Includes 6" dia. round sanding pad for sanding irregular shapes where extra flexibility may be
desired.

To install the circular platen, remove the four screws in the bottom of the sanding pad and
remove the pad and the rectangular platen. Replace with the circular platen and the 6" diame­ter sanding pad using the same four screws.

Accepts 6" dia. adhesive backed sanding discs only.
NOTE: Recommended accessories for this tool are listed in this manual. The use of any other

accessories may be hazardous.

Lubrication

Self lubricating bearings are used in the tool and periodic relubrication is not required. However,
it is recommended that, once a year, you take or send the tool to a service center for a thorough
cleaning and inspection.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including
brush inspection and replacement) should be performed by authorized service centers or other
qualified service personnel, always using identical replacement parts.

Three Year Limited Warranty

DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three
years from the date of purchase. This warranty does not cover part failure due to normal wear
or tool abuse. For further detail of warranty coverage and warranty repair information, visit
www.dewalt.com or call 1-800-4-D

EWALT (1-800-433-9258). This warranty does not apply to

accessories or damage caused where repairs have been made or attempted by others. This
warranty gives you specific legal rights and you may have other rights which vary in certain
states or provinces.

In addition to the warranty, D

EWALT tools are covered by our:

1 YEAR FREE SERVICE

DEWALT will maintain the tool and replace worn parts caused by normal use, for free, any time
during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your D

EWALT Power Tool, Laser, or

Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt
for a full refund – no questions asked.

FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are miss­ing, call 1-800-4-DEWALT for a free replacement.

POUR TOUT RENSEIGNEMENT SUPPLÉMENTAIRE SUR CET OUTIL OU TOUT AUTRE
OUTIL D

EWALT, COMPOSER SANS FRAIS LE NUMÉRO SUIVANT : 1 800 4-DEWALT

(1 800 433-9258)

Importantes mesures de sécurité

AVERTISSEMENT! Lire et comprendre toutes les directives. Le non-respect
de toutes les directives suivantes présente des risques de secousses élec­triques, d'incendie ou de blessures graves.

CONSERVER CES MESURES

ZONE DE TRAVAIL

• S'assurer que la zone de travail est propre et bien éclairée. Des établis encombrés et des

endroits sombres présentent des risques d'accidents.

• Ne pas utiliser des outils électriques en présence de vapeurs explosives (comme
celles dégagées par des liquides, des gaz ou des poussières inflammables). Les étin­celles générées par le moteur des outils électriques peuvent enflammer les poussières ou les
vapeurs.

• Éloigner les curieux, les enfants et les visiteurs de la zone de travail lorsqu'on utilise

un outil électrique. Une distraction peut entraîner la perte de maîtrise de l'outil.

MESURES DE SÉCURITÉ RELATIVES À L'ÉLECTRICITÉ

• Les outils mis à la terre doivent être branchés dans une prise bien installée et mise à
la terre conformément à tous les codes et règlements en vigueur. Ne jamais retirer la
broche de terre ni modifier la fiche. Ne pas utiliser d'adaptateur pour fiche. Vérifier
auprès d'un électricien certifié en cas de doute quant à la mise à la terre de la prise.

En cas de défaillance électrique ou de bris de l'outil, la mise à la terre procure un chemin de
faible résistance au courant qui autrement traverserait l'utilisateur. Valable seulement pour

les outils de classe I (mis à la terre).

• Les outils à double isolation comportent une fiche polarisée (une lame plus large
que l'autre). La fiche n'entre que d'une façon dans une prise polarisée. Lorsque la
fiche n'entre pas à fond dans la prise, essayer de nouveau après avoir inversé les
broches de la fiche. Si la fiche n'entre toujours pas dans la prise, communiquer avec
un électricien certifié afin de faire installer une prise polarisée. Ne modifier en aucune

façon la fiche. La double isolation élimine le besoin d'un cordon trifilaire mis à la terre et
d'un système d'alimentation mis à la terre. Valable seulement pour les outils de classe
II (à double isolation).