Dremel 100, 200, 3000 User Manual

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IMPORTANT:	IMPORTANT :	IMPORTANTE:
Read Before Using	Lire avant usage	Leer antes de usar

Operating/Safety Instructions Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

100

200

3000

P.O. Box 1468 Racine, Wisconsin 53401

	Call Toll Free for	Pour obtenir des informations	Llame gratis para
Consumer Information		et les adresses de nos centres	obtener información
	& Service Locations	de service après-vente,	para el consumidor y
		appelez ce numéro gratuit	ubicaciones de servicio
	1-800-4-DREMEL (1-800-437-3635) www.dremel.com
For English Version		Version française	Versión en español
	See page 2	Voir page 23	Ver la página 45

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	General Power Tool Safety Warnings
	Read all safety warnings and all instructions. Failure to follow the warnings
! WARNING
	and instructions may result in electric shock, fire and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE

The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

Work area safety

Keep work area clean and well lit. Cluttered or 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 children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical safety

Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.

Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

Do not 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 for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.

When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

If operating the power tool in damp locations is unavoidable, use a Ground Fault Circuit Interrupter (GFCI) protected supply. Use of an GFCI reduces the risk of electric shock.

Personal safety

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

power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.

Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and / or battery pack, picking up or carrying the tool.

Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.

Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dustrelated hazards.

Power tool use and care

Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.

Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.

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Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.

Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use.

Many accidents are caused by poorly maintained power tools.

Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

Service

Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Rules for Rotary Tools

Hold power tool by insulated gripping surfaces, because the cutter may contact its own cord. Cutting a ”live” wire may make exposed metal parts of the power tool ”live” and shock the operator.

Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your hand or against the body leaves it unstable and may lead to loss of control.

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 injury.

If cutting into existing walls or other blind areas where electrical wiring may exist is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

Do not operate the flexible shaft with a sharp bend. Over bending the shaft can generate excessive heat on the jacket or hand piece. The recommended minimum is 5" radius.

Always disconnect the power cord from the power source before making any adjustments or attaching any accessories.

You may unexpectedly cause the tool to start leading to serious personal injury.

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

Always hold the hand piece firmly in your hands during the start-up. The reaction torque of the motor, as it accelerates to full speed, can cause the shaft to twist.

Always wear safety goggles and dust mask. Use only in well ventilated area.

Using personal safety devices and working in safe environment reduces risk of injury.

After changing the bits or making any adjustments, make sure the collet nut and the EZ TWIST™ integrated wrench/nose cap are both securely tightened. Loose adjustment devices can unexpectedly shift, causing loss of control, loose rotating components will be violently thrown.

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

Allow brushes to run at operating speed for at least one minute before using wheel. During this time no one is to stand in front or in line with the brush. Loose bristles or wires will be discharged during the run-in time.

Wire and bristle brushes must never be operated at speeds greater than 15,000/min. Direct the discharge of the

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Safety Rules for Rotary Tools - (cont.)

spinning wire brush away from you. Small particles and tiny wire fragments may be discharged at high velocity during the “cleaning” action with these brushes and may become imbedded in your skin. Bristles or wires will be discharged from the brush at high speeds.

Wear protective gloves and face shield with wire or bristle brushes. Apply wire or bristle brushes lightly to the work as only the tips of the wire/bristles do the work.

“Heavy” pressure on bristles will cause the wire or bristle to become overstressed, resulting in a wiping action and will cause the bristles/wire to be discharged.

Carefully handle both the tool and individual grinding wheels to avoid chipping or cracking. Install a new wheel if tool is dropped while grinding. Do not use a wheel that may be damaged. Fragments from a wheel that bursts during operation will fly away at great velocity possibly striking you or bystanders.

Never use dull or damaged bits. Sharp bits must be handled with care. Damaged bits can snap during use. Dull bits require more force to push the tool, possibly causing the bit to break.

Use clamps to support workpiece whenever practical. Never hold a small workpiece in one hand and the tool in the other hand while in use. Allow for sufficient space, at least 6", between your hand and the spinning bit. Round material such as dowel rods, pipes or tubing have a tendency to roll while being cut, and may cause the bit to “bite” or jump toward you. Clamping a small workpiece allows you to use both hands to control the tool.

Inspect your workpiece before cutting. When cutting irregularly shaped workpieces, plan your work so it will not slip and pinch the bit and be torn from your hand. For example, if carving wood, make sure there are no nails or foreign objects in the workpiece. Nails or foreign objects can cause the bit to jump.

Never start the tool when the bit is engaged in the material. The bit cutting

edge may grab the material causing loss of control of the cutter.

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

The direction of feed with the bit into the material when carving, routing or cutting is very important. Always feed the bit into the material in the same direction as the cutting edge is exiting from the material (which is the same direction as the chips are thrown). Feeding the tool in the wrong direction, causes the cutting edge of the bit to climb out of the work and pull the tool in the direction of this feed.

If the workpiece or bit becomes jammed or bogged down, turn the tool “OFF” by the switch. Wait for all moving parts to stop and unplug the tool, then work to free the jammed material. If the switch to the tool is left “ON” the tool could restart unexpectedly causing serious personal injury.

Do not leave a running tool unattended, turn power off. Only when tool comes to a complete stop is it safe to put it down.

Do not grind or sand near flammable materials. Sparks from the wheel could ignite these materials.

Do not touch the bit or collet after use.

After use the bit and collet are too hot to be touched by bare hands.

Regularly clean the tool's air vents by compressed air. Excessive accumulation of powdered metal inside the motor housing may cause electrical failures.

Do not allow familiarity gained from frequent use of your rotary tool to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict severe injury.

Do not alter or misuse tool. Any alteration or modification is a misuse and may result in serious personal injury.

This product is not intended for use as a dental drill, in human or veterinary medical applications. Serious personal injury may result.

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! WARNING

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When using the steel saws, cutoff wheels, high speed cutters or tungsten carbide cutters, always have the work securely clamped. Never attempt to hold the work with one hand while using any of these accessories. The reason is that these wheels will grab if they become slightly canted in the groove, and can kickback causing loss of

control resulting in serious injury. Your second hand should be used to steady and guide the hand holding the tool. When a cutoff wheel grabs, the wheel itself usually breaks. When the steel saw, high speed cutters or tungsten carbide cutter grab, it may jump from the groove and you could lose control of the tool.

Additional Safety Warnings

GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety.

Do not use AC only rated tools with a DC power supply. While the tool may appear to work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.

Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely control the power tool.

Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of the tool since internal wires may be misplaced or pinched or safety guard return springs may be improperly mounted.

Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

Risk of injury to user. The power cord must only be serviced by a Dremel Service Facility.

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 chemicallytreated lumber.

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.

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Symbols

IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate 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
				n					Rated speed		Maximum attainable speed
.../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
0									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
									Li-ion RBRC seal		Designates Li-ion battery recycling
											program
									Ni-Cad RBRC seal		Designates Ni-Cad battery recycling
											program
									Read manual symbol		Alerts user to read manual
									Wear eye protection symbol		Alerts user to wear eye protection

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Symbols (continued)

IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

This symbol designates that this tool is listed by Underwriters Laboratories.

This symbol designates that this tool is recognized by Underwriters Laboratories.

This symbol designates that this tool is listed by Underwriters Laboratories, to United States and Canadian Standards.

This symbol designates that this tool is listed by the Canadian Standards

Association.

This symbol designates that this tool is listed by the Canadian Standards

Association, to United States and Canadian Standards.

This symbol designates that this tool is listed by the Intertek Testing

Services, to United States and Canadian Standards.

This symbol designates that this tool complies to NOM Mexican Standards.

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! WARNING

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Functional Description and Specifications

Disconnect the plug from the power source before making any assembly, adjustments or changing accessories. Such preventive safety

measures reduce the risk of starting the tool accidentally.

Models 100 & 200

SWITCH

High Speed Rotary Tools (100 SINGLE SPEED)

(200 TWO SPEED)

HANGER

SHAFT LOCK

BUTTON

HOUSING CAP	CORD

COLLET

COLLET

NUT

VENTILATION

OPENINGS

VENTILATION	BRUSH COVER
OPENINGS	(one on each side)

COLLET

WRENCH

Model 3000				ON/OFF	HANGER
				SWITCH
High Speed Rotary Tool
EZ TWIST™		SHAFT LOCK
INTEGRATED		BUTTON
WRENCH/NOSE CAP						CORD
(Model 3000 only)
COLLET
COLLET
NUT						VENTILATION
						OPENINGS
		VENTILATION		BRUSH COVER
		OPENINGS		(one on each side)
Model number	100		200		3000
Voltage rating	120V	50 - 60Hz	120V	50 - 60Hz	120V	50 - 60Hz
Amperage rating	1,15A		HI 1,15A, LO 0,80A		1,2A
No load speed	n0 35,000/min		n0 15,000/35,000/min		n0 5,000-32,000/min
Collet capacities	1/32, 1/16", 3/32", 1/8"		1/32, 1/16", 3/32", 1/8"		1/32, 1/16", 3/32", 1/8"

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	Assembly
! WARNING	Always unplug Rotary Tool before changing accessories, changing collets
	or servicing your Rotary Tool.
	SHAFT	EZ TWIST™
		INTEGRATED
	LOCK
		WRENCH/NOSE
	BUTTON
		CAP

	COLLET	COLLET
	WRENCH
		NUT
	TO
		TO
	TIGHTEN	LOOSEN

COLLET NUT — To loosen, first press shaft lock button and rotate the shaft by hand until the lock engages the shaft preventing further rotation.

! CAUTION Do not engage lock while the Rotary Tool is running.

With the shaft lock engaged use the collet wrench to loosen the collet nut if necessary. The collet nut must be loosely threaded on when inserting an accessory. Change accessories by inserting the new one into the collet as far as possible to minimize runout and unbalance. With the shaft lock engaged, finger tighten the collet nut until the accessory shank

COLLET

NUT

TO	TO
TIGHTEN	LOOSEN

is gripped by the collet. Avoid excessive tightening of the collet nut when there is no bit inserted.

EZ TWIST™ INTEGRATED

WRENCH/NOSE CAP (Model 3000 only)

The nose cap of your tool has an integrated wrench allowing you to loosen and tighten the collet nut without the use of the standard collet wrench. Unscrew the nose cap from the tool, line-up steel insert on inside of cap with collet nut. With the shaft lock engaged twist nose cap clockwise to tighten, and counterclockwise to loosen.

COLLETS — Four different size collets (see illustration), to accommodate different shank sizes, are available for your Rotary Tool. To

	480
	1/8"
COLLET	COLLET
NUT
			IDENTIFICATION
			RINGS
	481
	3/32"	482	483
	COLLET
		1/16"	1/32"
		COLLET	COLLET

install a different collet, remove the collet nut and remove the old collet. Insert the unslotted end of the collet in the hole in the end of the tool shaft. Replace collet nut on the shaft.

Always use the collet which ! CAUTION matches the shank size of

the accessory you plan to use. Never force a larger diameter shank into a collet.

Note: Most rotary tool kits do not include all four collets sizes.

COLLET IDENTIFICATION CHART

Collet sizes can be identified by the rings on the back end of collet.

1/32" Collet has one (1) ring. 1/16" Collet has two (2) rings. 3/32" Collet has three (3) rings.

1/8" Collet has no rings. (Included in most tool kits on the tool)

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BALANCING ACCESSORIES — For precision work, it is important that all accessories be in good balance (much the same as the tires on your automobile). To true up or balance an accessory, slightly loosen collet nut and give the accessory or collet a 1/4 turn. Retighten collet nut and run the Rotary Tool. You should be able to tell by the sound and feel if your accessory is running in balance. Continue adjusting in this fashion until best balance is achieved. To maintain balance on abrasive wheel points,

before each use, with the wheel point secured in the collet, turn on the Rotary Tool and run the 415 Dressing Stone lightly against the revolving wheel point. This removes high spots and trues up the wheel point for good balance.

The hanger is provided for the use of hanging your tool while using the flex-shaft or for storage. If you do not use the hanger, remove it from the tool and snap it back into place underneath the cord so it will be out of the way while the tool is in use.

Operating Instructions

The Rotary Tool is a handful of high-speed power. It serves as a carver, grinder, polisher, sander, cutter, power brush, drill and more.

The Rotary Tool has a small, powerful electric universal motor, is comfortable in the hand, and is made to accept a large variety of accessories including abrasive wheels, drill bits, wire brushes, polishers, engraving cutters, router bits, cutting wheels and attachments. Accessories come in a variety of shapes and permit you to do a number of different jobs. As you become familiar with the range of accessories and their uses, you will learn just how versatile the Rotary Tool is. You’ll see dozens of uses you hadn’t thought of before.

The real secret of the Rotary Tool is its speed. To understand the advantages of its high speed, you have to know that the standard portable electric drill runs at speeds up to 2,800 revolutions per minute. The Rotary Tool operates at speeds up to 35,000 revolutions per minute. The typical electric drill is a lowspeed, high torque tool; the Rotary Tool is just the opposite – a high-speed, low torque tool. The major difference to the user is that in the high speed tools, the speed combined with the accessory mounted in the collet does the work. You don’t apply pressure to the tool, but simply hold and guide it. In the low speed tools, you not only guide the tool, but also apply pressure to it, as you do, for example, when drilling a hole.

It is this high speed, along with its compact size and wide variety of special accessories and attachments, that makes the Rotary Tool different from other tools. The speed enables it to do jobs low speed tools cannot do, such as cutting hardened steel, engraving glass, etc.

Getting the most out of your Rotary Tool is a matter of learning how to let this speed work for you. To learn about more uses and the versatility of Dremel accessories and

Sharpen Tools

Drilling

Shape Wood

Carve Wood

Deburr Metal

Cut Metal

attachments refer to this Owner's Manual or check our website at www.Dremel.com.

Using the Rotary Tool

The first step in learning to use the Rotary Tool is to get the “feel” of it. Hold it in your hand and feel its weight and balance. Feel the taper of the housing. This taper permits the Rotary Tool to be grasped much like a pen or pencil (Figure A).

Always hold the tool away from your face.

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Accessories can be damaged during handling, and can fly apart as they come up to speed. This is not common, but it does happen.

Practice on scrap materials first to see how the Rotary Tool's high speed action performs. Keep in mind that the work is done by the speed of the tool and by the accessory in the collet. You should not lean on or push the tool during use.

Instead, lower the spinning accessory lightly to the work and allow it to touch the point at which you want cutting (or sanding or etching,

FIG. A

For best control in close work, grip the Rotary Tool like a pencil between your thumb and forefinger.

etc.) to begin. Concentrate on guiding the tool over the work using very little pressure from your hand. Allow the accessory to do the work.

Usually, it is best to make a series of passes with the tool rather than attempt to do all the work in one pass. To make a cut, for example, pass the tool back and forth over the work, much as you would a small paint brush. Cut a little material on each pass until you reach the desired depth. For most work, the gentle touch is best. With it, you have the best control, are less likely to make errors, and will get the most

FIG. B

The “Golf Grip” method of holding the tool is used for more aggressive operations such as grinding a flat surface or using cutoff wheels.

WARNING

Wear Eye Protection

Whenever you hold the tool, be careful not to ! CAUTION cover the air vents with your hand. This

blocks the air flow and causes the motor to overheat.

Questions or Problems? Call 1-800-437-3635 or check our website at www.Dremel.com

Operating Speeds

To select the right speed for each job, use a practice piece of material.

NOTE: Speed is affected by voltage changes. A reduced incoming voltage will slow the RPM of the tool.

(MODEL 100)

On the single speed model, there is an ONOFF switch. When the switch is on, the tool runs at 35,000 RPM.

(MODEL 200)

On the two-speed model, there is a LO and HI switch. When the switch indicator is on the low

setting, the tool runs at about 15,000 RPM. When the switch indicator is on the high setting, the tool runs at about 35,000 RPM.

(MODEL 3000)

On the variable speed model, there are switch setting indicators marked with a line. Slide to the number on the housing to select the operating speed needed from 5,000 – 32,000 RPM. You can refer to the charts on page 19, 20, 21 and 22 to determine the proper speed, based on the material being worked and the type of accessory being used. These charts enable you to select

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both the correct accessory and the optimum speed at a glance.

The speed of Rotary Tool is controlled by setting this indicator on the housing.

The Settings for Approximate Revolutions Per Minute on Rotary Tool Variable Speed Model 3000.

Switch Setting	Speed Range
2	15,000 – 18,000 RPM
*4	19,000 – 15,000 RPM
6	16,000 – 21,000 RPM
8	22,000 – 27,000 RPM

1028,000 – 32,000 RPM

*3000 Wire Brush Setting.

Needs for Slower Speeds

Certain materials, however, (some plastics and precious metals, for example) require a relatively slow speed because at high speed the friction of the accessory generates heat and may cause damage to the material.

Slow speeds (15,000 RPM or less) usually are best for polishing operations employing the felt polishing accessories. They may also be best for working on delicate projects as “eggery” work, delicate wood carving and fragile model parts. (All brushing applications require lower speeds to avoid wire discharge from the holder.)

If you need it, single-speed models also can have speed control by using a Model 221 foot control unit.

Not for use with two speed ! CAUTION or variable speed models

200 or 3000. Use with external speed control will damage the variable/two speed electronics.

Higher speeds are better for carving, cutting, routing, shaping, cutting dadoes or rabbets in wood.

Hardwoods, metals and glass require high speed operation, and drilling should also be done at high speeds.

The point to remember is this: You can do the great majority of work with the single speed at its regular speed of 35,000 RPM. But for certain materials and types of work, you need slower speeds — which is the reason the variable speed models are available.

To aid you in determining the optimum operational speed for different materials and different accessories, we have constructed a series of tables that appear on page 19, 20, 21 and 22. By referring to these tables, you can discover the recommended speeds for each type of accessory. Look these tables over and become familiar with them.

Ultimately, the best way to determine the correct speed for work on any material is to practice for a few minutes on a piece of scrap, even after referring to the chart. You can quickly learn that a slower or faster speed is more effective just by observing what happens as you make a pass or two at different speeds. When working with plastic, for example, start at a slow rate of speed and increase the speed until you observe that the plastic is melting at the point of contact. Then reduce the speed slightly to get the optimum working speed.

Some rules of thumb in regard to speed:

1.Plastic and other materials that melt at low temperatures should be cut at low speeds.

2.Polishing, buffing and cleaning with any type of bristle brush must be done at speeds not greater than 15,000 RPM to prevent damage to the brush.

3.Wood should be cut at high speed.

4.Iron or steel should be cut at high speed. If a high speed steel cutter starts to chatter — this normally means it is running too slow.

5.Aluminum, copper alloys, lead alloys, zinc alloys and tin may be cut at various speeds, depending on the type of cutting being done. Use paraffin or other suitable lubricant on the cutter to prevent the cut material from adhering to the cutter teeth.

Increasing the pressure on the tool is not the answer when it is not performing as you think it should. Perhaps you should be using a different accessory, and perhaps an adjustment in speed would solve the problem. Leaning on the tool does not help.

Let speed do the work!

Use only Dremel®, high-performance accessories.

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Maintenance Information

Service

Preventive maintenance performed by unauthorized personnel may result in misplacing of

internal wires and components which could cause serious hazard. We recommend that all tool service be performed by a Dremel Service Facility.

	To avoid	injury from
! WARNING
	unexpected	starting or

electrical shock, always remove plug from wall outlet before performing service or cleaning.

CARBON BRUSHES

The brushes and commutator in your tool have been engineered for many hours of dependable service.

In order to prepare your brushes for use, run your tool at full speed for 5 minutes under no load. This will properly “seat” your brushes, which extends the life of both your brushes and your tool.

To maintain peak efficiency of the motor, we recommend every 40 - 50 hours the brushes be examined. Only genuine Dremel replacement brushes specially designed for your tool should be used.

MAINTENANCE OF REPLACEABLE BRUSHES ON MODELS 100, 200 & 3000

The brushes should be inspected frequently when tools are used continuously. If your tool runs sporadically, loses power, makes unusual noises or runs at a reduced speed, check the brushes.

FIG. C

! CAUTION To continue using the tool in this condition will

permanently damage your tool.

Follow these steps to check/change the rotary tool brushes:

1.With the power cord unplugged, place the tool on a clean surface. Use the tool wrench as a screwdriver to remove the brush caps in a counter-clockwise direction (Figure C).

2.Remove the brushes from the tool by pulling on the spring that is attached to the carbon brush. If the brush is less than 1/8" long and the end surface of the brush that contacts the commutator is rough and/or pitted, they should be replaced. Check both brushes (Figure D).

Usually the brushes will not wear out simultaneously. If one brush is worn out, replace both brushes. Make sure the brushes are installed as illustrated. The curved surface of the brush must match the curvature of the commutator.

3.After replacing brushes the tool should be run at no-load; place it on a clean surface and run it freely at full speed for 5 minutes before loading (or using) the tool. This will allow the brushes to “seat” properly and will give you more hours of life from each set of brushes. This will also extend the total life of your tool since the commutator surface will “wear” longer.

BRUSH

CAP

BRUSH	FIG. D
SPRING

BRUSH

CURVED END OF BRUSH MUST

MATCH CURVATURE OF HOUSING

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! WARNING

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BEARINGS

Models 100, 200 & 3000 have double ball bearing construction. Under normal use they will not require lubrication.

Cleaning

To avoid accidents always disconnect the tool from the power supply before cleaning or

performing any maintenance. The tool may be cleaned most effectively with compressed dry air. Always wear safety goggles when cleaning tools with compressed air.

Ventilation openings and switch levers must be kept clean and free of foreign matter. Do not attempt to clean by inserting pointed objects through openings.

Certain cleaning agents and ! CAUTION solvents damage plastic

parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and household detergents that contain ammonia.

Extension Cords

If an extension cord is ! WARNING necessary, a cord with

adequate size conductors that is capable of carrying the current necessary for your tool must be used. This will prevent excessive voltage drop, loss of power or overheating. Grounded tools must use 3-wire extension cords that have 3-prong plugs and receptacles.

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

RECOMMENDED SIZES OF EXTENSION CORDS 120 VOLT ALTERNATING CURRENT TOOLS

	Tool’s	Cord Size in A.W.G.				Wire Sizes in mm2
	Ampere	Cord Length in Feet				Cord Length in Meters
	Rating
		25	50	100	150	15	30	60	120
	3-6
		18	16	16	14	0.75	0.75	1.5	2.5
	6-8	18	16	14	12	0.75	1.0	2.5	4.0
	8-10	18	16	14	12	0.75	1.0	2.5	4.0
	10-12	16	16	14	12	1.0	2.5	4.0	—
	12-16	14	12	—	—	—	—	—	—

			Dremel Accessories
			Use only Dremel®, high-performance accessories. Other accessories are not
	!	WARNING
			designed for this tool and may lead to personal injury or property damage.

The number and variety of accessories for the Rotary Tool are almost limitless. There is a category suited to almost any job you might have to do — and a variety of sizes and shapes within each category which enables you to get the perfect accessory for every need.

Refer to the DREMEL ACCESSORY ORDER FORM for illustrations of the accessories available. These accessories may be found at your local hardware, hobby or home center dealers.

Collets

If you expect to use a variety of accessories, we recommend that in the beginning you purchase a complete set of four collets. Store

these so that you will have the proper size of collet for any accessory or drill bit you want to use. Currently, the 1/8", 3/32",1/32" and

1/16" collets accommodate all of the avail - able Dremel accessories. 1/8" collets are included in most rotary tool kits.

Mandrels

A mandrel is a shank with a threaded or screw head, which are required when you use polishing accessories, cutting wheels, sanding discs, and polishing points. The reason mandrels are used is that sanding discs, cutting wheels and similar accessories must be replaced frequently. The mandrel is a permanent shank, allowing you to replace only the worn head when necessary, thus saving the expense of replacing the shaft each time.

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Screw Mandrel N° 401

This is a screw mandrel used with the felt polishing tip and felt polishing wheels. 1/8" shank.

Small Screw Mandrel N° 402

This is a mandrel with a small screw at its tip, and is used with emery and fiberglass cutting

wheels, sanding discs and polishing wheels. 1/8" shank.

EZ Lock Mandrel N° 402

The Dremel EZ Lock makes accessory changes easy as PULL - TWIST - RELEASE. The one-piece mandrel design simplifies the process of changing cutting wheels and makes it easy to cut through plastic.

High Speed Cutters

Available in many shapes, high speed cutters are used in carving, cutting and slotting in wood, plastics and soft metals such as aluminum, copper and brass. These are the accessories to use for freehand routing or carving in wood or plastic, and for precision cutting. Made of high quality steel. 1/8" shank.

Tungsten Carbide Cutters

These are tough, long-lived cutters for use on hardened steel, fired ceramics and other very hard materials. They can be used for engraving on tools and garden equipment. 1/8" shanks.

Engraving Cutters

This group has a wide variety of sizes and shapes, and are made for intricate work on ceramics (greenware), wood carvings, jewelry and scrimshaw. They often are used in making complicated printed circuit boards. They should not be used on steel and other very hard materials but are excellent on wood, plastic and soft metals. 3/32" shank.

Structured Tooth Tungsten Carbide Cutters

Fast cutting, needle-sharp teeth for greater material removal with minimum loading. Use on fiberglass, wood, plastic, epoxy and rubber. 1/8" shank.

Aluminum Oxide Grinding Stones (orange/brown)

Round, pointed, flat — you name the shape and there is one available in this category. These are made of aluminum oxide and cover virtually every possible kind of grinding application. Use them for sharpening lawn mower blades, screwdriver tips, knives, scissors, chisels and other cutting tools. Use to remove flash from metal castings, deburring any metal after cutting, smoothing welded joints, grinding off rivets and removing rust. These grinding stones can be resharped with a dressing stone. In machine shops, high speed drills and cutters normally are ground with aluminum oxide wheels. 1/8" shank.

Silicon Carbide Grinding Stones (blue/green)

Tougher than aluminum oxide points, these are made especially for use on hard materials such as glass and ceramics. Typical uses might be the removal of stilt marks and excess glaze on ceramics and engraving on glass. 1/8" shank.

Diamond Wheel Points

Excellent for fine detail work on wood, jade, ceramic, glass and other hard material. Bits are covered with diamond particles. 3/32" shanks. (Not recommended for drilling)

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Dremel Accessories (Cont.)

Wire Brushes

Three different shapes of wire brushes are available. For best results wire brushes should be used at speeds not greater than 15,000 RPM. Refer to Operating Speeds section for proper tool speed setting. The three shapes come in three different materials: stainless steel, brass and carbon wire. The stainless steel perform well on pewter, aluminum, stainless steel, and other metals, without leaving "after-rust". Brass brushes are non sparking, and softer than steel; making them good for use on soft metal like gold, cooper and brass. The carbon wire brushes are good for general purpose cleaning.

Bristle Brushes

These are excellent cleaning tools on silverware, jewelry and antiques. The three shapes make it possible to get into tight corners and other difficult places. Bristle brushes can be used with polishing compound for faster cleaning or polishing.

Brushing Pressure

1.Remember, the tips of a wire brush do the work. Operate the brush with the lightest pressure so only the tips of the wire come in contact with the work.

2.If heavier pressures are used, the wires will be overstressed, resulting in a wiping action; and if this is continued, the life of the brush will be shortened due to wire fatigue.

INCORRECT:

Excessive pressure can cause wire breakage.

3. Apply the brush to the work in such a way that as much of the brush face as possible is in full contact with the work. Applying the side or edge of the brush to the work will result in wire breakage and shortened brush life.

CORRECT:

Wire tips doing the work.

Polishing Accessories

These include an impregnated polishing point and an impregnated polishing wheel for bringing metal surfaces to smooth finish; a felt polishing tip and felt polishing wheel, and cloth polishing wheel, all used for polishing plastics, metals, jewelry and small parts. Also included in this group is a polishing compound (No. 421) for use with the felt and cloth polishers.

Polishing points make a very smooth surface, but a high luster is obtained using felt or cloth wheels and polishing compound. For best results polishing accessories should be used at speeds not greater than 15,000 RPM.

No polishing compound is needed when using the 425 Polishing Wheel.

Aluminum Oxide Abrasive Wheels

Use to remove paint, deburr metal, polish stainless steel and other metals. Available in fine and medium grits. 1/8" shank.

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Dremel Accessories (Cont.)

Sanding Accessories

Sanding discs in fine, medium and coarse grades are made to fit mandrel No. 402. They can be used for nearly any small sanding job you might have, from model making to fine furniture finishing. In addition, there is the drum sander, a tiny drum which fits into the Rotary Tool and makes it possible to shape wood, smooth fiberglass, sand inside curves and other difficult places, and other sanding jobs. You replace the sanding bands on the drum as they become worn and lose their grit. Bands come in fine medium and coarse grades. Flapwheels grind and polish flat or contoured surfaces. They are used most effectively as a finishing sander after heavier surface sanding and material removal is completed. Flapwheels come in fine and coarse grades. Buffs are a great finishing accessory for cleaning and light sanding. They work effectively on metal, glass, wood, aluminum and plastics. Coarse and medium buffs are sold together. Do not exceed 15,000 RPM in speed. 1/8" shank.

Grinding Wheel

Use for deburring, removing rust, and general purpose grinding. Use with Mandrel #402.

operations. Use them for cutting off frozen bolt heads and nuts, or to reslot a screw head which has become so damaged that the screwdriver won’t work in it. Fine for cutting BX cable, small rods, tubing, cable and cutting rectangular holes in sheet metal.

Drywall Cutting Bit

Gives you fast, clean cuts in drywall.

Tile Cutting Bit

Cuts ceramic wall tile, cement board, and plaster.

Spiral Cutting Bit

Cuts through all types of wood and wood composites.

High Speed Router Bits

For routing, inlaying, and mortising in wood and other soft materials. Use with Dremel No. 335 Router attachment and No. 231 Shaper/Router table.

Cutting Wheels

These thin discs of emery or fiberglass are used for slicing, cutting off and similar

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Mandrel No. 401 is used with the felt polishing tip and wheels. Thread the tip on to the screw carefully. The felt tip must thread

Mandrel N° 402 has a small screw at its tip, and is used with emery cutting wheels and sanding discs. Higher speeds, usually

To replace a band on the Drum Sander, loosen the screw without removing it to contract the drum then slide the old band off. Slide the new sanding band on and then expand the drum by tightening the screw once again.

down straight on the screw Mandrel, and be turned all the way to the collar.

maximum, are best for most work, including cutting steel. Which is shown here.

Before each use, check to ! WARNING make certain that all

components are assembled to accessory shank and that the drum is sufficiently expanded to secure the band during use. If sanding band is loose on the drum during operation it may “fly” off and strike you or bystanders.

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Speed Settings

*Speed for light cuts; Caution - burning on deep grooves.

•Depending on cutting direction relative to grain.

Not all speed settings can be achieved on 100 and 200 series tool. For certain applications, a variable speed tool is required.

2 =	5,000 - 8,000 RPM's 4 = 9,000 - 15,000 RPM's
6 = 16,000 - 21,000	RPM’s 8 = 22,000 - 27,000 RPM’s 10 = 28,000 - 32,000 RPM’s

High Speed Cutters

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
100, 121, 131	10	10	6	6	8	-	-	-
114, 124,	10	6	4	6	6	-	-	-
134, 144
190	10	10	4	6	10	-	-	-
118, 191, 192,	10	10	4	6	10	-	-	-
193, 194
116, 117,	10	6	4	6	6	-	-	-
125, 196
115	10	10	4	6	6	-	-	-
198	10	8	4	6	6	-	-	-
199	10	8	4	6	6	-	-	-

Engraving Cutters

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
105, 108	10	10	8	4	6	-	-	-
106, 109,	10	10	6	4	6	-	-	-
107, 110	10	10	6	4	6	-	-	-
111	10*	10*	8*	4	6	-	-	-
112	10*	10*	6*	4	6	-	-	-
113	10*	10*	6*	4	6	-	-	-

Diamond Wheel Points

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
7103, 7105,	10	8	-	-	-	10	10	10
7117, 7120,
7122, 7123,
7134, 7144

Structured Tooth Tungsten Carbide Cutters

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
9931, 9932,	10	8	4	-	6	-	-	-
9933, 9934,
9935, 9936

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Speed Settings (Continued)

*Speed for light cuts; Caution - burning on deep grooves.

•Depending on cutting direction relative to grain.

Not all speed settings can be achieved on 100 and 200 series tool. For certain applications, a variable speed tool is required.

2 =	5,000 - 8,000 RPM's 4 = 9,000 - 15,000 RPM's
6 = 16,000 - 21,000	RPM’s 8 = 22,000 - 27,000 RPM’s 10 = 28,000 - 32,000 RPM’s

Tungsten Carbide Cutters

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
9901, 9902,	10	8	4	10	6	8	8-10	8-10
9903, 9904,
9905, 9906,
9912
9909, 9910						8	8-10	8-10
9911

High Speed Router Bits

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
612, 640	10*	8 •	-	-	-	-	-	-
615, 617, 618,	10*	10 •	-	-	-	-	-	-
650, 652, 654	10*	8 •	-	-	-	-	-	-

Silicon Carbide Grinding Stones (blue/green)

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
83142, 83322,	-	-	6	10	4	6	10	10
83702, 84922,
85422, 85602,
85622

Abrasive Wheels/Points

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
516	4-6	4-6	-	8	6	-	-	-
500	4-6	4-6	-	6-8	4-6	-	-	-
EZ541GR	-	-	-	6-8	4-6	-	-	-

Aluminum oxide grinding stones (orange/bown)

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
541,903, 911,	10	10	-	8	4	6	10	-
921, 932, 941,
945, 952, 953,
954, 971, 997,
8153, 8175,
8193, 8215

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Speed Settings (Continued)

*Speed for light cuts; Caution - burning on deep grooves.

•Depending on cutting direction relative to grain.

Not all speed settings can be achieved on 100 and 200 series tool. For certain applications, a variable speed tool is required.

2 =	5,000 - 8,000 RPM's 4 = 9,000 - 15,000 RPM's
6 = 16,000 - 21,000	RPM’s 8 = 22,000 - 27,000 RPM’s 10 = 28,000 - 32,000 RPM’s

Chain Saw Sharpening Stones

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
453, 454, 455	-	-	-	10	-	-	-	-

Cutting Accessories

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
409, 420, 426	-	-	2-4	10	10	10	10	-
540, EZ409
543, EZ544	10	8-10	2-4	-	-		-	-
545, EZ545	8-10	8	-	-	-	6-8	6-8	-
560	For use on drywall. For best results, use at 30,000 rpm.
561	6-10	6-10	2-4	-	10	-	-	-
562	-	-	-	-	-	-	10
EZ456	-	-	-	10	10	-	-	-
EZ476	-	-	2-4	-	-	-	-	-

Polishing Accessories

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
461, 462, 463	-	-	-	8	8	8	8	8
414, 422, 429	-	-	-	6	6	6	6	6
425, 427	-	-	-	8	8	-	-	-
423E	-	-	-	6-8	2	2	2	6-8

Wire Brushes

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
403, 404, 405	4	4	2-4	6	2	-	-	-
428, 442, 443	4	4	2	4	4	-	-	-
530, 531, 532	-	4	-	4	-	-	-	-
535, 536, 537	4	4	-	4	4	4	-	-

Sanding Bands and Discs

Catalog	Soft	Hard	Laminates	Steel	Aluminum,	Shell/	Ceramic	Glass
Number	Wood	Wood	/Plastic		Brass, etc.	Stone
430, 431, 438	2-10	2-10	2-6	10	10	2-10	2-10	-
439, 440, 444	2-10	2-10	2-6	10	10	2-10	2-10	-
407, 408, 432	2-10	2-10	2-6	10	10	2-10	2-10	-
411, 412, 413	6	6	2	-	2	-	-	-

21