Dremel 4000 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
4000
P.O. Box 1468 Racine, Wisconsin 53401
Call Toll Free for
Consumer Information
& Service Locations
1-800-4-DREMEL (1-800-437-3635) www.dremel.com
For English Version Version française Versión en español
See page 2 Voir page 21 Ver la página 41
Pour obtenir des informations
et les adresses de nos centres
de service après-vente,
appelez ce numéro gratuit
Llame gratis para
obtener información
para el consumidor y
ubicaciones de servicio
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General Power Tool Safety Warnings
WARNING
!
Read all safety warnings and instructions. Failure to follow the warnings
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 all of 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
us e a ny adapter pl ug s w ith 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 reduce the risk of electric shock.
Personal safety
Stay alert, watch what you are doing and
us e co mmon s ense when opera ting 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
sw itch is in the off- posit ion befo re
connecting to power source and / or battery
pa ck, picking up or carryi ng t he t ool.
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
co ntrol of the power to ol in unexpe ct ed
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 dust-
related 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
ca nn ot be co nt ro lled with the swi tc h 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.
Ma ny acci de nt s a re ca us ed by poorly
maintained power tools.
Additional Safety Warnings
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
re pa ir person using o nl y id en ti cal
replacement parts. This will ensure that the
safety of the power tool is maintained.
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.
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.
Develop a periodic maintenance schedule
for your tool. When cleani ng a tool be
careful not to disassemble any portion of
th e tool since inter nal wires may be
misplaced or pinched or safety guard return
sp rings ma y be impro perly mo unted .
Certain cleaning agents such as gasoline,
carbon tetrachloride, a mmo nia, etc. ma y
damage plastic parts.
Risk of injury to user. The power cord must only
be serviced by a Dremel Service Facility..
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 chro mium fro m chemic allytreated lumber.
You r ris k from these exposu re s varies,
depending on how often you do this type of
work. To reduce your expos ure to t hese
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.
3
Some dust created by power
sanding, sawing, grinding,
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Safety Rules for Rotary Tools
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.
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
th e pow er source bef or e making an y
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.
Al ways 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 o r 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 opera ting 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
op er at ed 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
di sc ha rged at high ve lo ci ty during t he
“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
wi re or b ri stle t o become overstres se d,
resulting in a wiping action and will cause the
bristles/wire to be discharged.
Ca re fu lly handle both the tool and
in di vi dual gr in di ng wh ee ls to a void
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.
Us e cl am ps to supp or t w or kp iece
whenever practical. Never hold a small
workpiece in one hand and the tool in the
ot he r h and while in us e. A ll ow f or
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.
Wh en cu tt in g i rr egularly 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.
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Safety Rules for Rotary Tools - (cont.)
Ne ve r start the tool wh en the bi t 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 gr ind or sand near fl ammable
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 t ool's air vents by
compressed air. Excessive accumulation of
powdered metal inside the motor housing may
cause electrical failures.
Do not al lo w familiarity gai ne d 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, cut off wheels,
high speed cutters or tungsten carbide
cutters, always have the work secure ly
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 slight ly canted in the
groove, and can kick back causing loss of
control resulting in serious in jury. 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.
5
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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.
n
0
.../min Revolutions or reciprocation per minute Revolutions, strokes, surface speed,
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
No load speed Rotational speed, at no load
orbits etc. per minute
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
This symbol designates
that this tool is listed by
Underwriters Laboratories.
This symbol designates
that this tool is listed by
the Canadian Standards
Association.
This symbol designates that this tool is listed by the Intertek Testing
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
Underwriters Laboratories, to
United States and Canadian
Standards.
This symbol
designates
that
this tool
complies
to NOM
Mexican
Standards.
Services, to United States and Canadian Standards.
6
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Functional Description and Specifications
WARNING
!
Di sc onnect the plug fro m the pow er source bef ore maki ng any
assembly, adjustments or changing accessories. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Model 4000 High Speed Rotary Tool
BRUSH COVER
(one on each side)
ON/OFF
SWITCH
SHAFT LOCK
BUTTON
VENTILATION
OPENINGS
VARIABLE SPEED
DIAL
CORD
HANGER
VENTILATION
OPENINGS
COLLET
COLLET
NUT
SHAFT
HOUSING
CAP
COLLET
WRENCH
Model number 4000
Voltage rating 120V 50 - 60Hz
Amperage rating 1.6A
No load speed n
5,000-35,000/min
0
Collet capacities 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.
COLLET
WRENCH
TO
TIGHTEN
SHAFT
LOCK
BUTTON
TO
LOOSEN
COLLET
NUT
COLLET NUT — To loosen, first press shaft
lock button and rotate the shaft by hand until
the lock engages the shaft preventing further
rotation. Your Dremel 4000 is equipped with a
quick collet lock mechanism. This mechanism
engag es the output sh aft in 12 sep arate
locations on the shaft for easier operation.
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
wh en i nsertin g a n access ory. Chan ge
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 when there is no
bit inserted.
COLLETS — Four different size collets (see
illus tration), to accommodate different shank
sizes, are avail able 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.
CAUTION
!
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.
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)
480
1/8"
COLLET
COLLET
NUT
IDENTIFICATION
RINGS
481
3/32"
COLLET
482
1/16"
COLLET
483
1/32"
COLLET
BA LANCING AC CE SSORIES — Fo r
pr ecision work , i t i s i mportan t t ha t a ll
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. Re tighten collet nut and run the Rotary
Tool. You should be able to tell by the sound
an d feel if your acc essory is run ning i n
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 us ing the flex-shaft or for
storage. If you do not use the hanger, snap it
back into place so it will be out of the way while
the tool is in use.
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Operating Instructions
Thank you for purchasing the Dremel 4000.
Dremel 4000
This prod uct was designed by the many
Dremel users who pass ionately use their
rotary tools daily. This tool was designed to
give you the ul timate performance when
working on projects.
The Dremel 4000 i s the MOST versati le
rotary tool available today. It has a wide speed
range including a high performance motor with
electronic feedback that allows the tool to
maintain its speed under load. The design of
the tool is symmetrical and contains plenty of
soft grip so the tool can be held comfortably in
ma ny positions. The qu ic k coll et lock
mechanism makes locking the output shaft
easier for changing accessories. You will
appreciate the many applications that the
Dremel 4000 can easily tackle.
Rotary Tool Introduction
The Rotary Tool has a small, powerful electric
universal motor, is comfort able in the hand,
and is made to ac cept a large variety of
accessories including abrasive wheels, drill
bi ts, wi re bru shes, polishe rs, en graving
cu tt er s, router bits, cuttin g wheels and
attachments. Accessories come in a variety of
shapes and permit you to do a number of
different jobs. As you be come 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
acces sory 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
differ ent from other tools. The speed enables
it to do jobs low speed tools cannot do, such
as cutting hardened steel, en graving 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
ve rs at ility of Dremel acce ss or ies and
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.
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,
etc.) to begin. Con centrate 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 effi cient work out of the accessory.
9
WAR NING
Wear Eye Protection
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Questions or Problems? Call 1-800-437-3635
or check our website at www.Dremel.com
FIG. A FIG. B
For best control in close work, grip the
Rotary Tool like a pencil between your
thumb and forefinger.
For performing precision tasks a separate nose piece is available in
some kits. It has a tapered shape which allows the user to pinch the
nose piece comfortably between thumb and forefinger. It provides an
excellent line of sight for performing detailed etching, carving and
engraving work.
!
CAUTION
Whenever you hold the tool, be careful not to
cover the air vents with your hand. This blocks the
air flow and causes the motor to overheat.
Operating Speeds
To select the right speed for each job, use a
practice piece of material.
NO TE: Spee d i s affect ed by volta ge
changes. A reduced incoming voltage will
slow the RPM of the tool.
The tool is switched "ON" by the slide switch
located on the topside of the motor housing.
TO TURN THE TOOL "ON", slide the switch
button forward.
TO TURN THE TOOL "OFF", slide the switch
button backward.
Your tool is equipped with a high performance
rotary tool motor. This motor expands the
versatility of the rotary tool by driving additional
SLIDE "ON/OFF" SWITCH
HIGH PERFORMANCE MOTOR
The “Golf Grip” method of holding the
to ol is u sed f or more aggressive
operations such as grinding a flat surface
or using cutoff wheels.
attachments such as the Dremel Multi-Saw
and Dremel Planer.
ELECTRONIC FEEDBACK
Your tool is equipped with an internal electronic
feedback system that provides a “soft start”,
which will reduce the stresses that occur from
a high torque start. The system also helps to
keep the preselected speed virtually constant
between no-load and load conditions.
VARIABLE SPEED DIAL
Your tool is equipped with a variable speed
dial. The speed may be adjuste d du ring
operati on b y presett in g the dial on or
between any one of the settings.
You can refer to the charts on page 17, 18,
19 and 20 to determine the proper speed,
based on the materi al being worked and
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the type of accessory being used. These
ch ar ts en ab le yo u to select both the
correct acces sory and the optimum speed
at a glance.
The speed of Rotary Tool is controlled by
setting this dial on the housing.
Settings for Approximate Revolutions.
Switch Setting Speed Range
5 15,000-7,000 RPM
*10 17,000-10,000 RPM
15 13,000-17,000 RPM
20 18,000-23,000 RPM
25 23,000-27,000 RPM
30 28,000-32,000 RPM
35 33,000-35,000 RPM
* Wire Brush Setting.
Needs for Slower Speeds
Certain materials, however, (some plastics and
pr ecious metals , fo r ex ample) requi re 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 ac ces sories. They may also be best
for working on deli cate projects as “eggery”
work, delicate wood carving and fragile model
parts. (All brushing applications require lower
speeds to avoid wire disch arg e from the
holder.)
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.
Th e p oint to reme mber is this: M an y
applications and accessories in our line will
provide the best performance at full speed, but
fo r ce rtain materia ls, applicati ons, and
accessories, you need slower speeds, which is
the reason our variable speed models are
available.
To aid you in det erminin g the optim um
operational speed for differ ent materials and
different accessories, we have construct ed a
series of tables that appear on page 17, 18, 19
and 20. 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 hap pens
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
slight ly 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 brus h 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
do ne. Use paraf fin or ot he r suitabl e
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
sh ould. Pe rhaps yo u sho uld be us ing a
di ffere nt ac cessory, an d pe rhaps 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.
11
R
R
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:38 PM Page 12
Maintenance Information
Service
!
WARNING
per so n nel may res ult 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.
WARNING
!
electrical shock, always remove plug from
wall outlet before performing service or
cleaning.
The brushes and commutator in your tool have
be en engineer ed for many ho urs 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 brush es
be examined. Only genuine Dremel replace ment brushes specially designed for your tool
should be used.
MAINTENANCE OF REPLACEABLE
BRUSHES ON MODEL 4000
The brushes should be inspected frequently
when tools are used continuously. If your tool
runs spo rad ically, loses power, makes unusual
noises or runs at a reduced speed, check the
brushes.
!
CAUTION
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 to ol
wrench as a screwdriver to remove the
brush caps in a counter-clockwise direction
(Figure C).
2. Remove t he b rushes fr om t he 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).
Pr event ive maintenance
pe r formed by unauthorized
To a void injury f ro m
un ex pe cted star ti ng or
CARBON BRUSHES
To continue using the tool
in this co ndition will
BRUSH CAP
BRUSH SPRING
CURVED END OF
BRUSH MUST
MATCH
BRUSH
CURVATURE OF
HOUSING
Usually the brushes will not wear out simul taneously. If one brush is worn out, replace
both brushes. Make sure the brushes are
installed as illus trated. The curved surface of
the brush must match the curvature of the
commutator. Also check that the brush caps sit
flush with the tool housing.
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 com mutator surface will
“wear” longer.
12
FIG. C
FIG. D
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:38 PM Page 13
Model 4000 has ball bearing construction.
BEARINGS
Under normal use no additional lubrication is
required.
Cleaning
!
WARNING
th e power supp ly be fore cleanin g or
performing any main tenance. The tool may
be cleaned most effectively with compressed
dry air. Always wear safety gog gles when
cleaning tools with compressed air.
To avoid accidents always
dis connect the tool from
Extension Cords
If an extension cord is necessary, a cord
with adequat e size conductors that is
capable of carrying the current necessary
for your tool must be used. This will prevent
excessive voltage drop, loss of p ower or
overheating. Grounded tools must use 3-wire
extension cords that have 3-prong plugs and
receptacles.
NOTE: The smaller the gauge number, the
heav i er the cord.
Ventilation openings and switch levers must be
kept clean and free of foreign matter. Do not
at tempt to clean by inserting pointed objects
through openings.
!
CAUTION
Ce rtain clean ing agents
an d sol v ents da mage
plastic parts. Some of these are: gasoline,
carbon tetrachlo ride, chlo rinated cleaning
solvents, ammonia and house hold detergents
that contain ammonia.
RECOMMENDED SIZES OF EXTENSION CORDS
120 VOLT ALTERNATING CURRENT TOOLS
Tool’s
Ampere
Rating
3-6
6-8
8-10
10-12
12-16
Cord Size in A.W.G.
Cord Length in Feet Cord Length in Meters
25 50 100 150 15 30 60 120
18 16 16 14 0.75 0.75 1.5 2.5
18 16 14 12 0.75 1.0 2.5 4.0
18 16 14 12 0.75 1.0 2.5 4.0
16 16 14 12 1.0 2.5 4.0 —
14 12 —— ————
Wire Sizes in mm
2
Dremel Accessories
!
WARNING
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 en ables you to get
the perfect accessory for every need.
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 only Dremel®, high-performance accessories. Other accessories are not
designed for this tool and may lead to personal injury or property damage.
Collets
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
he ad, which are requi red wh en y ou u se
polishing accessories, cutting wheels, sanding
di scs, a nd pol ish in g poin ts. Th e re as on
mandre ls ar e use d is that sandi ng di scs,
cutting wheels and similar accesso ries must be
replaced frequently. The mandrel is a per manent shank, allowing you to replace only the
worn head when necessary, thus saving the
expense of replacing the shaft each time.
13
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:38 PM Page 14
This is a screw mandrel used with the felt
Screw Mandrel N° 401
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.
High Speed Cutters
Available in many shapes, high speed cutters
are used in carving, cutting and slotting in
wo od, plasti cs and soft me ta ls 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
hard ened steel, fired ceramics and other very
ha rd ma teri al s. Th ey ca n be us ed fo r
engraving on tools and garden equipment. 1/8"
shanks.
Th e Dremel EZ Lock mak es acce ssory
EZ Lock Mandrel N° 402
changes easy as PULL - TWIST - RELEASE.
The one-piece mandrel design simplifies the
process of changing cutting wheels, buffs and
detail abrasive brushes (EZ Lock compatible
accessories).
Aluminum Oxide Grinding Stones
(red/brown)
Round, pointed, flat — you name the shape
and there is one available in this category.
These are made of aluminum oxide and cover
vi rtually every possibl e kind of gri nd ing
application. Use them for sharpening lawn
mo wer bl ades, screw dr iver 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 re mov ing rust.
These grinding stones can be resharped with a
dressing stone. In machine shops, high speed
drills and cut ters normally are ground with
aluminum oxide wheels. 1/8" shank.
This group has a wide variety of sizes and
Engraving Cutters
shapes, and are made for intricate work on
ceramics (greenware), wood carvings, jewelry
and scrimshaw. They often are used in making
compl icat ed printed circui t board s. 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.
Silicon Carbide Grinding Stones
(blue/green)
Tougher than aluminum oxide points, these are
made es pecially for use on hard materials
such as glass and ce ramics. 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)
14
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:38 PM Page 15
Dremel Accessories (Cont.)
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
Three different shapes of wire brushes are
Wire Brushes
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
st ainless steel pe rform wel l on pe wt er,
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
Th ese a re excellent cl ea ning tools on
silverware, jew elry and antiques. The three
shapes make it possible to get i nto 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.
breakage and shortened brush life.
Wire tips doing the work.
Polishing Accessories
These include an impregnated polishing point
an d an impre gnate d polishing whe el for
bringing metal sur faces to smooth finish; a felt
polishing tip and felt polish ing 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
medium grit. 1/8" shank.
CORRECT:
15
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:39 PM Page 16
Dremel Accessories (Cont.)
us ed fo r slicing , cutting off and similar
operations. Use them for cutting off frozen bolt
Sanding discs in fine, medium and coarse
Sanding Accessories
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 finish ing. 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 diffi cult 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. Fine buffs are
sold individually. Do not exceed 15,000 RPM in
speed. 1/8" shank.
heads and nuts, or to reslot a screw head
which has bec ome so d amaged 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.
Use for deburring, removing rust, and general
Grinding Wheel
purpose grinding. Use with Mandrel #402.
Cutting Wheels
These thin discs of emery or fiberglass are
For routing, inlaying, and mortising in wood
High Speed Router Bits
and other soft materials. Use with Dremel No.
33 5 R outer attach me nt a nd No. 231
Shaper/Router table.
16
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:39 PM Page 17
Speed Settings
* Speed for light cuts; Caution - burning on deep grooves.
• Depending on cutting direction relative to grain.
Note: Each number settings listed in the speed charts = 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 25-35 25-35 12-17 12-17 18-24 --114, 124, 25-35 12-17 9-11 12-17 12-17 --134, 144
190 25-35 25-35 9-11 12-17 25-35 --118, 191, 192, 25-35 25-35 9-11 12-17 25-35 --193, 194
116, 117, 25-35 12-17 9-11 12-17 12-17 --125, 196
115 25-35 25-35 9-11 12-17 12-17 --198 25-35 18-24 9-11 12-17 12-17 --199 25-35 18-24 9-11 12-17 12-17 ---
Engraving Cutters
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
105, 108 25-35 25-35 18-24 9-11 12-17 --106, 109, 25-35 25-35 12-17 9-11 12-17 --107, 110 25-35 25-35 12-17 9-11 12-17 --111 25-35* 25-35* 18-24* 9-11 12-17 --112 25-35* 25-35* 12-17* 9-11 12-17 --113 25-35* 25-35* 12-17* 9-11 12-17 ---
Diamond Wheel Points
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
7103, 7105, 25-35 18-24 -- -25-35 25-35 25-35
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, 25-35 18-24 9-11 - 12-17 --9933, 9934,
9935, 9936
17
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:39 PM Page 18
Speed Settings (Continued)
* Speed for light cuts; Caution - burning on deep grooves.
• Depending on cutting direction relative to grain.
Note: Each number settings listed in the speed charts = 000 RPM’s
Tungsten Carbide Cutters
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
9901, 9902, 25-35 18-24 9-11 25-35 12-17 18-24 18-35 18-35
9903, 9904,
9905, 9906,
9909, 9910,
9911, 9912
High Speed Router Bits
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
612, 640 25-35* 18-24 • -- - --615, 617, 618, 25-35* 25-35 • -- - ---
650, 652, 654 25-35* 18-24 • -- - ---
Silicon Carbide Grinding Stones
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
83142, 83322, --12-17 25-35 9-11 12-17 25-35 25-35
83702, 84922,
85422, 85602,
85622
Abrasive Points
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
516, 517, 9-17 9-17 - 18-24 12-17 --518
500 9-17 9-17 - 12-24 9-17 ---
Aluminum oxide grinding stones
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
541,903, 911, 25-35 25-35 - 18-24 9-11 12-17 25-35 921, 932, 941,
945, 952, 953,
954, 971, 997,
8153, 8175,
8193, 8215
18
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:39 PM Page 19
Speed Settings (Continued)
* Speed for light cuts; Caution - burning on deep grooves.
• Depending on cutting direction relative to grain.
Note: Each number settings listed in the speed charts = 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, -- -25-35 ---455
Cutting Accessories
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
409, 420, 426 -- 5-11 25-35 25-35 25-35 25-35 540, EZ409
542, EZ544 25-35 18-35 5-11 -- -545, EZ545 18-35 18-24 -- -12-24 12-24 560 For use on drywall. For best results, use at 30,000 rpm.
561 12-35 12-35 5-11 - 25-35 --562 -- - - - -25-35
EZ456 -- -25-35 25-35 --EZ476 - - 5-11 -- ---
Polishing Accessories
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
461, 462, 463 -- -18-24 18-24 18-24 18-24 18-24
414, 422, 429 -- -12-17 12-17 12-17 12-17 12-17
425, 427 -- -18-24 18-24 --423E -- -12-24 5-8 5-8 5-8 12-24
403, 404, 405 9-11 9-11 5-11 12-15 5-8 --530, 531, 532 - 9-11 - 9-11 ---428, 442, 443 9-11 9-11 5-8 9-11 9-11 --535, 536, 537 9-11 9-11 - 9-11 9-11 9-11 --
Sanding Bands and Discs
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
430, 431, 438 5-35 5-35 5-17 25-35 25-35 5-35 5-35 439, 440, 444 5-35 5-35 5-17 25-35 25-35 5-35 5-35 407, 408, 432 5-35 5-35 5-17 25-35 25-35 5-35 5-35 411, 412, 413 12-17 12-17 5-8 - 5-8 ---
19
DM 2610005595 05-09:DM 2610005595 05-09 5/27/09 2:39 PM Page 20
Speed Settings (Continued)
* Speed for light cuts; Caution - burning on deep grooves.
• Depending on cutting direction relative to grain.
Note: Each number settings listed in the speed charts = 000 RPM’s
Flapwheels
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
502, 503, 504, 25-35 18-24 5-8 25-35 18-35 --505
Finishing Abrasive Buffs
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
511E, 512E 12-15 12-15 9-11 12-15 12-15 ---
Drill Bit
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
150 25-35 18-35 5-11 - 12-17 ---
Grout Removal Bits
Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass
Number Wood Wood /Plastic Brass, etc. Stone
569,570 For Use on Wall and Floor Grout 12-24
20
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