Dremel 398-49 User Manual

DM 2610934164 05-06 10/6/06 8:41 AM Page 1

400 Series Digital

High Speed Rotary Tool

Operating/Safety Instructions
Model 398-49

HONESTLY NOW … Have you read

this OWNER’S MANUAL?

• Safety

• Assembly

• Operation

• Maintenance

• Accessory Information

• Warranty

• Service Parts

03-5415317

http://www.dremel.com

Dremel brand products are manufactured and sold by the

Dremel Division of Robert Bosch T

2610934164 10/06 Printed in Mexico

ool Corporation

This symbol refers to

the EMC requirements
of the Australian
Standards

DM 2610934164 05-06 10/6/06 8:41 AM Page 2

Power Tool Safety Rules

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.

which may ignite the dust or fumes.

Keep by-standers, children, and visitors away while
operating a power tool. Distractions can cause you

to lose control.

Power tools create sparks

Electrical Safety

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.

the three wire grounded power cord and grounded
power supply system. Before plugging in the tool, be
certain the outlet voltage supplied is within the voltage
marked on the nameplate. Do not use “AC only” rated
tools with a DC power supply.

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. If operating the power tool in damp
locations is unavoidable, a Ground Fault Circuit
Interrupter must be used to supply the power to your
tool. Electrician’s rubber gloves and footwear will
further enhance your personal safety.

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 carr
the tools or pull the plug from an outlet. Keep cord
away from heat, oil, sharp edges or moving parts.
Replace damaged cords immediately.

cords increase the risk of electric shock.

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

cords are rated for outdoor use and reduce the risk of
electric shock. Refer to “Recommended sizes of
Extension Cords” in the Accessory section of this
manual.

Double Insulation eliminates the need for

Damaged

."

-A" or "W

These

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.

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.
Keep handles dry, clean and free from oil and grease.

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 balance 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.

A moment of inattention

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.

y

safer at the rate for which it is designed.

Do not use tool if switch does not turn it “ON” or
“OFF”.

switch is dangerous and must be repaired.

Disconnect the plug from the power source before
making any adjustments, changing accessories, or
storing the tool.

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.

Page 2

The correct tool will do the job better and

Any tool that cannot be controlled with the

Such preventive safety measures

DM 2610934164 05-06 10/6/06 8:41 AM Page 3

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

utting edges are less likely to bind and are easier to

c
control. Any alteration or modification is a misuse and
may result in a dangerous condition.

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.

poorly maintained tools. Develop a periodic
maintenance schedule for your tool.

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.

Many accidents are caused by

Safety Rules for Rotary Tools

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

and other accessories running over rated speed can
fly apart and cause injury.

Hold tool by insulated gripping surfaces when
performing an operation where the cutting tool may
contact hidden wiring or its own cord. Contact with

a "live" wire will make exposed metal parts of the tool
"live" and shock the operator. 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 13cm 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.

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.

devices and working in safe environment reduces risk
of injury.

Using personal safety

Wheels

You may

Service

Tool service must be performed only by qualified
repair personnel.

by unqualified personnel could result in a risk of
injury. For example: internal wires may be misplaced
or pinched, safety guard return springs may be
improperly mounted.

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

After changing the bits or making any adjustments,
make sure the collet nut and any other adjustment
devices are securely tightened. Loose adjustment

device 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 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

Service or maintenance performed

Page 3

DM 2610934164 05-06 10/6/06 8:41 AM Page 4

Safety Rules for Rotary Tools - (cont.)

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 15,2cm, 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.

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 it is

safe to put it down.

Do not grind or sand near flammable materials.

Sparks from the wheel could ignite these materials.

This can

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.

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.

WARNING

!

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.

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.

Some dust created by power
sanding, sawing, grinding,

Page 4

DM 2610934164 05-06 10/6/06 8:41 AM Page 5

Functional Description and Specifications

WARNING

!

tool accidentally.

COLLET NUT

COLLET

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

Rotary Tool

FIG. 1

SWITCH

SHAFT LOCK

BUTTON

VENTILATION

OPENINGS

Model number 398-49
Voltage rating 230-240 V , 50-60 Hz
Power rating 140W
No load speed n05.000-33.000/min
Collet capacities 0,8mm, 1,6mm, 2,4mm, 3,2mm

COLLET

SPEED
DOWN
BUTTON

FLEXIBLE

SHAFT

CORE

L.C.D.
DISPLAY

SPEED UP
BUTTON

HANGER

CORD

DRIVER

CAP

COLLET NUT

(NOT INCLUDED)

WRENCH

Page 5

DM 2610934164 05-06 10/6/06 8:41 AM Page 6

Assembly

!

WARNING

collets or servicing your Rotary Tool.

S

COLLET

WRENCH

Always unplug Rotary Tool before
changing accessories, changing

HAFT LOCK

BUTTON

TO TIGHTEN

TO LOOSEN

COLLET

NUT

COLLET

COLLET

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

!

CAUTION

With the shaft lock engaged use the collet wrench to
loosen the collet nut if necessary. 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 is gripped by the collet. Avoid
excessive tightening of the collet nut.

Do not engage lock while the
Rotary Tool is running.

COLLETS

Four different size collets (see illustration), to
accommodate different shank sizes, are available for
your Rotary Tool. To 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 matches the shank size of the accessory you
plan to use. Never force a larger diameter shank into a

collet.

BALANCING ACCESSORIES

For precision work, it is important that all accessories
be in good balance (much the same as the tires on your
automobile). T
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

o true up or balance an accessor

y, slightly

COLLET IDENTIFICATION CHART — Collet sizes can
be identified by the rings on the back end of collet.

0,8mm Collet has one (1) ring.
1,6mm Collet has two (2) rings.
2,4mm Collet has three (3) rings.
3,2mm Collet has no rings.

COLLET

NUT

IDENTIFICATION
RINGS

480

3,2mm

COLLET

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.

481

2,4mm

COLLET

482

1,6mm

COLLET

FLEX-SHAFT TO ROTARY TOOL INSTALLATION

To properly attach the flex-shaft to the rotary tool,
THREE items must be removed from the tool: the
housing cap, collet nut and collet.

Step 1. Press the Shaft lock button, unscrew and
remove the collet nut.

Step 2. Unscrew the housing cap from the tool.

Page 6

483

0,8mm

COLLET

DM 2610934164 05-06 10/6/06 8:41 AM Page 7

Assembly - (cont.)

OUSING

H

AP

C

OLLET

C

inside)

(

Step 3. Remove the collet.

Note: If the collet nut and collet are not removed from

the motor shaft, the tool will not function properly.

Step 4. Install the driver cap on the motor shaft and
tighten.

MOTOR

SHAFT

DRIVER

CAP

!

CAUTION

the driver cap finger tight and then tighten an
additional 1/3 turn with the wrench. (Wrench included
with your rotary tool kit)

Step 5. Attach by screwing the collar of the flex-shaft
to the rotary tool. Make sure the square end of the
center core engages the square hole socket in the
driver cap.

!

CAUTION

could cause disengagement of center core from
handpiece. If tool stops when shaft is bent, center
core may be lodged in driver cap. Loosen shaft and
remove core from driver cap. Then screw flexible
shaft onto rotary tool housing again.

To prevent damage to tool, do not
overtighten driver cap. Tighten

Do not pull out center core to
engage into driver cap. This

Disengagement of the Flex-Shaft

The flexible shaft may become disengaged if the
motor of your rotary tool is not elevated higher than
the working end of the flex-shaft. The #2222 Rotary
Tool Stand is recommended to hold the rotary tool at
the proper height.

Collet and Accessory Assembly

The collet assembly consists of a collet nut and collet.
Take the collet nut
and collet that
were removed
from your tool in
step 2 and 3 and
insert them into
the tip of the flex­shaft handpiece.

Insert an accessory or
bit as deeply as
possible to avoid
wobble during use.
With the shaft lock
button engaged on the
flex-shaft handpiece
retighten the collet nut.

Collet Removal and Replacement

Four different size collets to accommodate different
shank sizes, are sold separately for your flex-shaft. To
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 flex-shaft. Replace
collet nut on the shaft. Always use the collet which

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

Do not operate the
flexible shaft with a
sharp or multiple
bends. Over bending

the shaft can generate
excessive heat on the
jacket or hand piece
and may cause the flexible shaft to disengage from
tool. The minimum recommended bend radius is 13cm.

Flexible Shaft Lubrication

The flex-shaft should be lubricated after every 25-30
hours of use. To lubricate, unscrew the flex-shaft
assembly from the motor housing. Pull the center
core out of the flex-shaft assembly. Wipe a very thin
film automotive wheel bearing grease on to the center
core and reinsert it back into the shaft. To prevent
damage to tool do not over grease shaft. Too much
grease will cause the unit to overheat.

Reattach the flex-shaft to the rotary tool.
Contents of 225 Flex-Shaft Attachment

Qty. Description

1 Flex-Shaft Assembly (1,07m long)
1 Driver Cap

Page 7

13CM

RADIUS

SHAFT LOCK

BUTTON

3
/4

1
/2

1
/4

0

DM 2610934164 05-06 10/6/06 8:41 AM Page 8

utting Guide Installation

C

The cutting guide 565 (sold separately) comes
completely assembled and ready to use. For use in a
variety of materials up to 19,1mm thick. Match the bit

Important: When viewing the tool from the top, the
bit rotates clockwise. Feed direction of cutting must
be counter-clockwise.

type to material to be cut. Always hold the tool firmly,
using slow steady pressure to make cuts.

To attach, follow the four steps shown below.

FIG. 1 FIG. 2

FIG. 3

Operating Instructions for Cutting Guide

Attachment

#560

Drywall Cutting Bit

For use in drywall.

• When inserting the #560 bit into your MultiPro tool,
make sure that the bit has been inserted as far as
possible.

• When making freehand cuts in drywall, example
repairing a hole in drywall, use the Multipurpose bit
#561, cutting in a clockwise direction. When using a
template (outlet box) behind the drywall, use the
drywall bit #560, cutting in a counter-clockwise
direction.

#561

Multipurpose Cutting Bit

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

• When inserting the #561 bit into your MultiPro tool,
make sure that the bit has been inserted as far as
possible.

• When making freehand cuts in Drywall, example
repairing a hole in drywall, use the Multipurpose bit

FIG. 4

#561, cutting in a clockwise direction. When using a
template (outlet box) behind the drywall, use the
drywall bit #560, cutting in a counter-clockwise
direction.

• When using #561, Multipurpose Cutting Bit, and

#562, Tile Cutting Bit, start the bit into the material at
a 45 degree angle and then slowly bring it to a 90
degree angle to begin the cut.

#562

Tile Cutting Bit

For use on wall tile, cement board and plaster

• When inserting the #562 bit into your MultiPro tool,

it is very important that 1,6mm-3,2mm of smooth
shank remains visible above the collet.

• When using #561, Multipurpose Cutting Bit, and

#562, Tile Cutting Bit, start the bit into the material at
a 45 degree angle and then slowly bring it to a 90
degree angle to begin the cut.

• NOT FOR USE ON FLOOR TILE

Page 8