DeWalt DW441, DW443, DW442, DW444 Instruction Manual
INSTRUCTION MANUAL
GUIDE D'UTILISATION
MANUAL DE INSTRUCCIONES
DW441, DW442, DW443, DW444
Right Angle Random Orbit Sanders
Ponceuses orbitales excentriques à angle droit
Lijadoras orbitales de movimiento múltiple de ángulo recto
INSTRUCTIVO DE OPERACIÓN, CENTROS DE SERVICIO Y PÓLIZA
DE GARANTÍA. ADVERTENCIA: LÉASE ESTE INSTRUCTIVO ANTES
DE USAR EL PRODUCTO.
If you have questions or comments, contact us.
Pour toute question ou tout commentaire, nous contacter.
Si tiene dudas o comentarios, contáctenos.
1-800-4-DEWALT • www.dewalt.com
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Important Safety Instructions
(For all tools)
WARNING: When using electric tools, basic safety precautions should always be followed to reduce risk of fire, electric
shock, and personal injury, including the following:
READ ALL INSTRUCTIONS
• KEEP WORK AREA CLEAN. Cluttered areas and benches invite
injuries.
• CONSIDER WORK AREA ENVIRONMENT. Don’t expose power
tools to rain. Don’t use power tools in damp or wet locations. Keep
work area well lit.
• GUARD AGAINST ELECTRIC SHOCK. Prevent body contact
with grounded surfaces; for example, pipes, radiators, ranges, and
refrigerator enclosures.
• KEEP CHILDREN AWAY. All visitors should be kept away from
work area. Do not let visitors contact tool or extension cord.
• STORE IDLE TOOLS. When not in use, tools should be stored in
dry, and high or locked-up place — out of reach of children.
• DON’T FORCE A TOOL. It will do the job better and safer at the
rate for which it was intended.
• USE RIGHT TOOL. Don’t force small tool or attachment to do the
job of a heavy duty tool. Don’t use tool for purpose not intended; for
example, don’t use circular saw for cutting tree limbs or logs.
• DRESS PROPERLY. Do not wear loose clothing or jewelry. They
can be caught in moving parts. Rubber gloves and non-skid
footwear are recommended when working outdoors. Wear protective hair covering to contain long hair.
Air vents often cover moving
parts and should also be avoided.
• USE SAFETY GLASSES. Also use face or dustmask if operation
is dusty.
• DON’T ABUSE CORD. Never carry tool by cord or yank it to dis-
connect from receptacle. Keep cord from heat, oil, and sharp
edges.
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IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR
ANY D
EWALT TOOL, CALL US TOLL FREE AT:
1-800-4-DEWALT (1-800-433-9258)
SANDING PAD
(HOOK AND LOOP - DW442 AND DW443)
(PSA- PRESSURE SENSITIVE ADHESIVE - DW441 AND DW444)
DUST BAG
SPEED CONTROL DIAL
(DW443 AND DW444)
ON/OFF SWITCH
SHROUD
• SECURE WORK. Use clamps or a vise to hold work. It’s safer than
using your hand and it frees both hands to operate tool.
• DON’T OVERREACH. Keep proper footing and balance at all
times.
• MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for
better and safe performance. Follow instructions for lubricating and
changing accessories. Inspect tool cords periodically and if damaged have repaired by authorized service facility. Inspect extension
cords periodically and replace if damaged. Keep handles dry,
clean, and free from oil and grease.
• DISCONNECT OR LOCK OFF TOOLS when not in use, before
servicing, and when changing accessories, such as blades, bits,
cutters.
• REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of
checking to see that keys and adjusting wrenches are removed
from tool before turning it on.
• AVOID UNINTENTIONAL STARTING. Don’t carry plugged-in tool
with finger on the switch. Be sure the switch is off when plugging
in.
• OUTDOOR USE EXTENSION CORDS. When tool is used out-
doors, use only extension cords intended for use outdoors and so
marked.
• STAY ALERT. Watch what you are doing. Use common sense. Do
not operate tool when you are tired.
• CHECK DAMAGED PARTS. Before further use of the tool, a guard
or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function.
Check for alignment of moving parts, binding of moving parts,
breakage of parts, mounting, and any other conditions that may
affect its operation. A guard or other part that is defective should be
properly repaired or replaced by an authorized service center
unless otherwise indicated elsewhere in this instruction manual.
Have defective switches replaced by authorized service center. Do
not use tool if switch does not turn it on and off.
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• DO NOT OPERATE portable electric tools near flammable liquids
or in gaseous or explosive atmospheres. Motors in these tools normally spark, and the sparks might ignite fumes.
Special Safety Instructions For Sanders
• Always wear eye protection and a respirator when sanding.
• Sanding of lead based paint is not recommended. See page 5 for
additional precautions when sanding paint.
• Do not operate the unit without the dust shroud.
• 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, hands, and arms. Use gloves to provide extra
cushion, take frequent rest periods, and limit daily time of use.
WARNING: Some dust created by power sanding, sawing, grinding,
drilling, and other construction 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, saw-
ing, 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.
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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.
Double Insulation
Double insulated tools are constructed throughout with two separate
layers of electrical insulation or one double thickness of insulation
between you and the tool’s electrical system. Tools built with this insulation system are not intended to be grounded. As a result, your tool
is equipped with a two prong plug which permits you to use extension
cords without concern for maintaining a ground connection.
NOTE: Double insulation does not take the place of normal safety precautions when operating this tool. The insulation system is for added
protection against injury resulting from a possible electrical insulation
failure within the tool.
CAUTION: When servicing all tools, USE IDENTICAL REPLACE-
MENT PARTS. Repair or replace damaged cords.
Polarized Plug
This product is supplied with a polarized plug (one blade is wider than
the other). This plug will fit into a polarized outlet (receptacle) only one
way. If the plug does not fit fully into your outlet, reverse the plug. If it
still does not fit, contact a qualified electrician to install a proper polarized outlet. Do not modify or change this plug in any way.
Extension Cords
Make sure your extension cord is in good condition. 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 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 number, 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
6 - 10 18 16 14 12
SAVE THESE INSTRUCTIONS
FOR FUTURE USE
Motor
Be sure your power supply agrees with nameplate marking.120 AC
means your tool may be operated only with alternating current and
never with direct current. Voltage decrease of more than 10% will
cause loss of power and overheating. All tools are factory tested; if this
tool does not operate, check the power supply.
Attaching Sanding Discs
Your sander is designed to use 6" sanding discs with the 6 hole dust
extraction pattern.
Hook and Loop
(DW442 and DW443)
PSA - Pressure Sensitive Adhesive
(DW441 and DW444)
To attach paper to the sanding pad:
1. Turn off and unplug tool.
2. Turn the sander over so that the sanding pad is facing upward.
3. (DW441 and DW444 only) Clean dust from vinyl pad face.
4. Hold the pad with one hand to keep it from rotating.
5. With the other hand, align the holes and place the disc directly on
top of the pad (see FIG. 1).
Switch
(See FIG. 2)To turn the unit on, slide the switch forward (the symbol
“I” will be visible.) To turn the unit off, slide the switch back (the symbol “O” will be visible). Before plugging in the unit, make sure the
switch is in the off position.
Speed Control Dial
(DW443 & DW444 Only)
The speed control dial (5 incremental settings) allows you to increase
or decrease speed from 4000 - 6800 Orbits Per Minute. The optimal
speed setting for each application is very much dependent on personal preference. You may want to experiment on a piece of scrap to
determine what gives you the best combination of finish quality and
material removal rate for your application. Generally, you will want to
use a higher setting on harder materials and a lower setting on softer
materials. Material removal rate increases as speed increases.
Dust Collection
Your sander comes equipped with a cloth filter bag to collect the dust
generated during sanding. To empty the dust bag, first turn off and
unplug tool. Firmly pull the bag off while holding the rubber boot
(FIG. 3). Empty the bag (you may want to turn it inside out.)
NOTE: Never operate this tool unless the dust collection bag is in
place.
Replacing Sanding Pad
When the pad becomes worn out, use the following procedure to
replace pad. (See FIG. 4)
1. Turn off and unplug tool.
2. Remove 4 torx head screws from the bottom of the tool and
remove the pad.
3. Replace the pad and screws, making sure the CFS disc is aligned
properly.
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FIG. 1
SANDING DISC
PAD
FIG. 2
ON
OFF
SPEED CONTROL DIAL
(SETTINGS 1 - 5)
FIG. 3
4
Operation
To operate your sander, grasp it as shown in FIG. 5 and turn it on.
Move the unit in long, sweeping strokes along the surface being sanded, letting the sander do the work.
NOTE: Excessive downward pressure on the tool while sanding actually slows the removal rate and produces an inferior quality surface.
A side handle has been provided with your unit and can be used if
desired. The side handle can be screwed into either side of tool by first
removing the plastic screw, as shown in FIG. 6.
NOTE: Be sure to check your work often, this sander is capable of
removing material rapidly, especially with coarse paper.
The random orbital action of your sander allows you to sand with the
grain or at any angle across it for most sanding jobs. To produce the
best finish possible, start with coarse grit sandpaper and change gradually to finer and finer paper. Vacuum and wipe surface with a tack
cloth between grit steps.
The rate at which the dust bag fills up will vary with the type of material being sanded and the coarseness of the sandpaper. For best
results, empty the bag frequently.
When sanding painted surfaces, (see page 5 for additional precautions when sanding paint) 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.
NOTE: (DW441 and DW444 only): When using PSA sanding discs, it
is necessary to remove the disc soon after operation. PSA papers, if
left on during tool storage, sometimes become difficult to remove. To
aid in the removal of old PSA paper, sand for a few minutes to soften
adhesive backing prior to changing disc.
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.
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FIG. 5
FIG. 6
FIG. 4
TORX HEAD
SCREWS
CFS DISC
PAD
ALIGN NOTCHES
TO THOSE IN
SHROUD
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 ingesting 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 thorough-
ly cleaned daily for the duration 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 particles 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.
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.
Cleaning
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 engineering polymers used to construct your
sander. If you typically wrap the cord around the tool when you store
it, leave a generous loop of cord such that the strain relief does not
bend. This helps prevent premature cord failure.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance
and adjustment (including brush inspection and replacement) should
be performed by a D
EWALT factory service center, a DEWALT autho-
rized service center or other qualified service personnel. Always use
identical replacement parts.
Application Notes
SANDPAPER - GRIT TYPES
Natural Abrasives
Flint is the softest (Mohs’ Scale 7)* of the common natural abrasives.
It has a tan color and is very inexpensive.
Garnet paper is harder than flint (Mohs’ Scale 7.5) and is easily identified by its bright orange color. Even though it is not the hardest, the
way the abrasive fractures gives you a good cutting edge for woodworking.
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Emery, even though harder than garnet (Mohs’ Scale 9), has blunt
edges making it a poor sanding abrasive. Its primary use is for polishing metal.
* Mohs’ Scale is the mineral hardness scale. It rates diamond at 15,
the hardest, and talc at 1.
Manufactured Abrasives
White Aluminum Oxide (AlO) is extremely hard (Mohs’ Scale 12) and
durable which makes it a great abrasive for use with the Random Orbit
Sander. “White” describes the particular way the abrasive is manufactured, not its color. This abrasive is widely available and comes in a
variety of colors due to the increasing use of dyes. Stearate lubricants
on the paper also enhance performance by reducing heat and the rate
at which the paper clogs.
Silicon Carbide (SiC) is the hardest abrasive (Mohs’ Scale 13) commonly available next to industrial diamond but is not as tough as
Aluminum Oxide abrasives. This abrasive easily fractures and provides sharp faces to the work throughout the life of the sanding paper.
This “self-sharpening” feature makes SiC an outstanding abrasive for
material removal but limits its life.
OPEN COAT VERSUS CLOSED COAT
Abrasives are applied to the paper with glue. When the grit is large
(say 60 or 80 grit) the percent of coverage is usually reduced to 60%
to 70% of the backing paper surface.This increases the life of the
paper by reducing the rate at which the paper clogs. This is called an
open coat and almost the only way you can buy sandpaper in heavier
grits. With finer grits the grit is applied at rates of 90% or more and
are labeled closed coat. Since the dust particle is much smaller the
tendency of the paper to load up and clog is greatly reduced.
GRIT SIZES
There are several grading systems used. The system most popular
today is sieve size. The number on the back of your sandpaper disc
refers to the screen size the particle can pass through. 120 grit paper
for example will sift through a screen with 120 holes per linear inch.
Every square inch of screen has 14,400 holes (120 x 120). The higher the number the finer the particle size. Common sizes are from 36
to 600 with the recent introduction of grit sizes up to 1200.
PAPER AND FILM: THE BACKING
Paper: The material most commonly used to carry the abrasive is
paper. Paper is graded by weight. “A” weight paper which is the most
prevalent is the lightest paper used and gives good durability and flexibility in most sanding applications. Other paper weights that are available are C, D, E, and F weight. The disadvantage of paper is its low
mechanical stiffness. Since the paper fiber gives during sanding, the
abrasive doesn’t stand up and some of the cutting edges do not
engage the work. The advantage is cost.
Film: Film backed sanding discs address the disadvantage of paper.
The film is mechanically stiffer than paper. Film is also more expensive but when all other things are held constant improves the cutting
performance of the abrasive.
Cloth and Vulcanized Fiber: These backings are typically hard to
find and are used in specialty applications. Most sandpaper you will
use will have the paper or film backing.
HOOK AND LOOP AND PSA: WHAT HOLDS THE SANDING
DISK TO THE PAD.
Hook & Loop
: The sanding disk as backed with a fabric nap (loops)
that interlocks with a grid of posts (hooks) on the sander’s pad. The
advantages are paper reusability and cooler interface between paper
and work.
PSA:
Pressure Sensitive Adhesive is applied to the back of the sanding disc and adheres to the sanding pad (Not the same pad that carries Hook & Loop paper). The advantage is cost. The major disadvantage is the tendency of PSA backed papers to adhere permanently to the pad if left on after sanding. Why does this happen? The main
culprit is heat. During sanding the pad and paper heat up. This causes the adhesive to flow into all the ridges on the vinyl pad and form a
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tight bond. If you remove the paper soon after you are finished sanding you don’t allow the adhesive to set. If you leave it on for a couple
of days the adhesive sets and has more strength than the paper carrier, causing the paper to tear and leaving you with a difficult clean up
job. One more disadvantage: If you do small sanding jobs and don’t
wear out the paper you cannot reuse it and tend to waste more paper.
SANDING
THE BASIC RULES: Which ones to break and which ones not to.
Always start with the coarsest grit first. Don’t break this rule. The
scratches get smaller as the grit number gets larger and the quality of
the finish generally improves. When you change grits be particular
about cleaning the surface that you are finishing. An 80 grit particle
floating on your work under your 220 grit paper will leave 80 grit
scratches. The best way to avoid this is to vacuum the work and then
carefully wipe down the work with a tack rag.
The random orbit sander action is equally applied across the grain and
with the grain. Since the scratch mark is small and random in all directions, the ability of the eye to see a scratch is greatly reduced.
Always wear a mask to avoid breathing the dust. NEVER BREAK
THIS RULE. We have engineered the tool to collect a majority of the
dust created in the sanding process but the tool does not capture it all.
To improve the capture rate use a vacuum but ALWAYS wear a dust
mask.
SOME OTHER HINTS FOR A BETTER FINISH
A random orbit sander is much more aggressive than other similarly
sized orbital tools so you may want to consider the next finer grit when
you start to sand your project.
Since the random orbit action makes a short scratch, you may find that
a project doesn’t require as many grit steps. A lot of professional cabinet makers only use 80, 120, and 150 grit on their work with satisfactory results. If in doubt about how the finish will take to your sanded
surface, wipe the surface with some paint thinner. Defects will show
up darker than the surrounding wood.
Careful inspection of the work prior to the finishing operation may
reveal dents. Try to correct these problems by raising the dent (a
hot iron and wet rag will do this) or carefully sand a large area
around the dent. If you vigorously sand the dent, you may create a
cupped surface.
When you are satisfied with the sanding job and you have finished
sanding with your finest grit, raise the grain by dampening the wood
with a wet rag. When the wood has dried and you are ready to apply
the finish, resand lightly to take off the wood fibers raised by the water.
Vac and tack the surfaces and immediately apply the first coat of finish before the wood gets dirty.
WOOD: Some important characteristics of wood
Hard grain and soft grain
Wood has hard grain and soft grain. Hard grain is typically the product of summer growth and soft grain the product of spring. All sanders
will remove more soft grain than hard grain and since the random
orbit sander is more aggressive, it will remove it that much more
quickly. Extended sanding on a piece of fir for example, will produce
a noticeably uneven finish. This is a good reason to correct flaws
before sanding.
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, please contact D
EWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD
21286, call 1-800-4-D
EWALT (1-800-433-9258) or visit our website
www.dewalt.com.
CAUTION: The use of any other accessory not recommended for
use with this tool could be hazardous.
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.
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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
D
EWALT will maintain the tool and replace worn parts caused by nor-
mal 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.
LATIN AMERICA: This warranty does not apply to products sold in
Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call the local
company or see website for warranty information.
FREE WARNING LABEL REPLACEMENT: If your warning labels
become illegible or are missing, call 1-800-4-D
EWALT for a free
replacement.
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