Dremel 4000 User Manual

IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

For English Version Version française Versión en español See page 2 Voir page 41 Ver la página 81

Operating/Safety Instructions Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

1-800-4-DREMEL (1-800-437-3635) www.dremel.com

Call Toll Free for

Consumer Information

& Service Locations

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

P.O. Box 081126 Racine, WI 53408-1126

4000

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 1

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 adapt e r plugs wi t h e arthed (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.

IIf operating a power tool in a damp location 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 us e c o mmon sen se w hen ope r atin g 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.

Read all safety warnings and all 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 the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

General Power Tool Safety Warnings

Safety Symbols

The definitions below describe the level of severity for each signal word. Please read the manual

and pay attention to these symbols.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, will result in minor or moderate injury.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 2

Use personal protective equipment. Always wear eye protection. Protective equipment

uch 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- posi tion befo re connecting to power source and / or battery pa ck, pic king up or carryi ng the too l.

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 n trol of the powe r too l in unex p ected 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 for ce th e pow er to o l. Us e 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 n n o t be control l e d with the switc h is dangerous and must be repaired.

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 n y a c c i dents are caused by p oorly 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 re p a i r pe r s o n us i n g onl y iden t i c a l replacement parts. This will ensure that the

safety of the power tool is maintained.

Safety warnings common for

grinding, sanding, wire brushing,

polishing, carving or abrasive

cutting-off operations:

This power tool is intended to function as a gr inde r, san der, wi re br ush, polishe r, carving or cut-of f tool. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed

below may result in electric shock, fire and/or serious injury.

Do not use acc ess ories which a re not specifically designed and recommended by the tool manufacturer. Just because the

accessory can be attached to your power tool, it does not assure safe operation.

The RATED SPEE D of the accessories must be at least equal to the operating speed setting marked on the power tool.

Accessories running faster than their RATED SPEED can break and fly apart.

The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized

Safety Rules for Rotary Tools

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 3

accessories cannot be adequately guarded or controlled.

The arbor size of wheels, sanding drums or any other accessory must properly fit the sp i ndle or c o llet of t h e p o wer tool.

Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

Mandrel mounted wheels, sanding drums, cutters or other accessories must be fully inserted into the collet or chuck. If the

ma ndre l is ins uff icie n tly held a nd/or the overhang of the wheel is too long, the mounted wheel may become loose and be ejected at high velocity.

Do not use a damaged accessory. Before each use inspect the accessory such as abra sive wheels f or chips and cracks, sanding drum for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropp ed, inspect for damage or install an undamaged accessory. After inspecting and installing an acce ssory, posi tion yours elf and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute.

Damaged accessories will normally break apart during this test time.

Wear pe rsona l prot e ctiv e equi p ment . Depending on application, use face shield, sa fety goggl es or safety glass es. As ap prop riat e, wear dus t m ask, he aring protectors, gloves and workshop apron capable of stopping sma ll ab ras ive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust

mask or respirator must be capable of filtrating pa rtic les gener ated by y our oper atio n . Prolonged exposure to high intensity noise may cause hearing loss.

Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment.

Fr agme nts of wor kpie ce or of a bro ken accessory may fly away and cause injury beyond immediate area of operation.

Hold the power tool by insulated gripping su rfac es onl y, when perfo rming an operation where the cutting accessory may contact hidden wiring or its own cord.

Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

Always hold the tool firmly in your hand(s) during the start-up. The reaction torque of the

motor, as it accelerates to full speed, can cause the tool to twist.

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. Clamping a small workpiece

allows you to use your hand(s) to control the tool. Round material such as dowel rods, pipes or tubing have a tendency to roll while being cut, and may cause the bit to bind or jump toward you.

Position the cord clear of the spinning accessory. If you lose control, the cord may be

cut or snagged and your hand or arm may be pulled into the spinning accessory.

Never lay the power tool down until the accessory has come to a complete stop.

The spinning accessory may grab the surface and pull the power tool out of your control.

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

can unexpectedly shift, causing loss of control, loose rotating components will be violently thrown.

Do not run the power tool while carrying it at your side. Accidental contact with the

spinning accessory could snag your clothing, pulling the accessory into your body.

Regularly clean the power tool’s air vents.

The motor’s fan will draw the dust inside the ho usin g and exce ssiv e acc umul atio n of powdered metal may cause electrical hazards.

Do n ot o pera te the power tool n ear flammable materials. Sparks could ignite

these materials.

Do not use accessories that require liquid coolants. Using water or other liquid coolants

may result in electrocution or shock. Use only in well-ventilated area. Working in a

safe environment reduces risk of injury.

Allo w for suff icient space, at least 6”, between your hand and the spinning bit. Do not reach in the area of the spinning bit. The

proximity of the spinning bit to your hand may not always be obvious.

Safety Rules for Rotary Tools - (cont.)

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 4

Safety Rules for Rotary Tools - (cont.)

Do not touch the bit or collet after use. After

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

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 injury may result.

Kickback and Related Warnings

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory’s rotation.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kickout. The wheel may either jump toward or away from the operator, de pend ing on direc tion of the w heel ’s movement at the point of pinching. Abrasive wheels may also break under these conditions.

Kickback is the result of power tool misuse and/ or in cor rect ope rating procedures or conditions and can be avoided by taking proper precautions as given below.

Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. The operator can

control kickback forces, if proper precautions are taken.

Use special care when working corners, sh arp edg es etc. Avoi d b ounci ng and snagging the accessory. Corners, sharp

edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.

Do not attach a toothed saw blade. Such blades create frequent kickback and loss of control.

Always feed the bit into the material in the same direction as the cutting edge is exiting fr om th e mat eria l (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.

When using rotary files, cut-off wheels,

high-speed cutters or tungsten carbide cutters, always have the work securely clamped. These whe els will gr ab if they

become slightly canted in the groove, and can kickback. When a cut-off wheel grabs, the wheel itself usually breaks. When a rotary file, high-speed cutter or tungsten carbide cutter grabs, it may jump from the groove and you could lose control of the tool.

Safety warnings specific for

grinding and abrasive

cutting-off operations:

Us e on ly wheel typ es that are recommended for your power tool and only fo r rec omme nded a ppli cati ons. For example: do not grind with the side of a cutoff wheel. Abrasive cut-off wheels are intended

for peripheral grinding, side forces applied to these wheels may cause them to shatter.

For threaded abrasive cones and plugs use only undamaged wheel mandrels with an unrelie ved shoulder flange that ar e of correct size and length. Proper mandrels will

reduce the possibility of breakage.

Do not ′′jam′′ a c ut-off wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the

wheel increases the loading and susceptibility to twisting or snagging of the wheel in the cut an d th e po ssib ility of kickba ck or whe el breakage.

Do not position your hand in line with and behind the rotating wheel. When the wheel,

at the point of operation, is moving away from your hand, the possible kickback may propel the spinning wheel and the power tool directly at you.

When wheel is pinched, snagged or when interrupting a cut for any reason, switch off the power tool and hold the power tool motion less until the wheel comes to a complete stop. Never attempt to remove the cut-off wheel from the cut while the wheel is in motion otherwise kickback may occur.

Investigate and take corrective a ction to eliminate the cause of wheel pinching or snagging.

Do not restart the cutting operation in the workpiece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may

bind, walk up or kickback if the power tool is restarted in the workpiece.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 5

Additional Safety Warnings

Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under

their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

Use extra caution when making a ′′pocket cut′′ into existing walls or other blind areas.

The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

Safety warnings specific for wire

brushing operations:

Be aware that wire bristles are thrown by the brush even during ordinary operation.

Do not overstress the wires by applying excessive load to the brush. The wire bristles

can easily penetrate light clothing and/or skin.

Allow brushes to run at operating speed for at least one minute before using them. 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.

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 use of these brushes and may become imbedded in your skin.

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 t he 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 t ool. When cleani ng a tool be careful not to disassemble any portion of th e tool sin ce inter nal wire s may be misplaced or pinched or safety guard return sp ring s may be improp erly mount ed.

Certain cleaning agents such as gasoline, carbon tetrachloride, am mon ia, etc. may damage plastic parts.

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

Some dust creat ed by

power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to ca use ca n cer, b irth defects or ot h er 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 an d chromium from chemically-

treated lumber.

You r ris k from these exp o s u res vari e s , depending on how often you do this type of work. To r educ e your exposu re to thes e 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.

Safety Rules for Rotary Tools - (cont.)

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 6

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.

Symbols

Symbol Designation / Explanation

V Volts (voltage)

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.)

No load speed (rotational speed at no load)

n Rated speed (maximum attainable speed)

.../min

Revolutions or reciprocation per minute (revolutions, strokes, surface speed, orbits etc. per minute)

0 Off position (zero speed, zero torque...)

1, 2, 3, ...

I, II, III,

Selector settings (speed, torque or position settings. Higher number means greater speed)

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)

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 7

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.

Symbol Designation / Explanation

Designates Li-ion battery recycling program

Designates Ni-Cad battery recycling program

Alerts user to read manual

Alerts user to wear eye protection

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

This symbol designates that this component 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.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 8

Disconnect the plug fr om th e pow er so urce before maki ng any assembly, adjustments or changing accessories. Such preventive

safety measures reduce the risk of starting the tool accidentally.

Functional Description and Specifications

Model 4000 High Speed Rotary Tool

COLLET

WRENCH

ON/OFF

SWITCH

SHAFT LOCK

BUTTON

EZ TWIST™

INTEGRATED

WRENCH/NOSE CAP

CORD

BRUSH COVER

(one on each side)

VARIABLE SPEED

DIAL

VENTILATION

OPENINGS

VENTILATION

OPENINGS

HANGER

COLLET

NUT

COLLET

SHAFT

Model number 4000

Voltage rating 120V 60Hz

Amperage rating 1.6A

Rated speed n 5,000/35,000/min

Collet capacities 1/32, 1/16", 3/32", 1/8"

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 9

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.

Al ways use the col let

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.

Always unplug Rotary Tool before changing accessories, changing collets or servicing your Rotary Tool.

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 engages the output shaft in 8 separate locations on the shaft for easier operation.

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 is gripped by the collet. Avoid excessive tightening of the

collet nut when there is no bit inserted.

EZ TWIST™ INTEGRATED

WRENCH/NOSE CAP

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 counter-clockwise to loosen.

Assembly

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)

COLLET

NUT

IDENTIFICATION

RINGS

480

1/8"

COLLET

481

3/32"

COLLET

482

1/16"

COLLET

483

1/32"

COLLET

NUT

LOOSEN

TIGHTEN

COLLET

WRENCH

SHAFT LOCK

BUTTON

COLLET

NUT

LOOSEN

TIGHTEN

SHAFT LOCK

BUTTON

EZ TWIST™

INTEGRATED

WRENCH/NOSE CAP

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 10

Operating Instructions

Dremel 4000

Thank you for purchasing the Dremel 4000. This pro duct wa s d esig ned by th e m any Dremel users who passionately use their rotary tools daily. This tool was designed to give you the ultimate performance when working on projects.

The Dremel 4000 is the MOST versatile rotary tool available today. It has a wide speed range including a high p erformance m otor w ith 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 positi ons. The quic k col let l ock mechanism makes locking the output shaft easier for c hanging accessories. You w ill 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 accept a large variety of accessories including a brasive wheels, drill bits, w ire brushes, polishers, engraving cutters, router bi ts, cutt ing wheel s and att achme nts. Accessories come in a variety of shapes and permit you to do a number of different jobs. As yo u be c ome f amil iar w ith the ran ge 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 re volu tion s pe r m inut e . T he R otar y 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 yo u. To lea rn abo ut mor e uses and the ve rsat ilit y of D reme l acce ssor ies a nd 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 b e g ras ped mu ch like a pe n or pencil (Figure A).

BALANCING ACCESSORIES — For precision w

ork, 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. Re tighten 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 y

our tool w hile usin g the fle x-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.

FIXING STUCK COLLETS – It is possible for a collet to get stuck within the collet nut especially if a collet nut is tightened onto the tool without a bit in p lac e. If this ha ppe ns, the collet c an be removed from the collet nut by pushing the shank of an accessory into the hole in the collet nut. This should cause the collet to pop out of the collet nut.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 11

Always hold the tool a

way from your face. Ac cess orie s can be da mage d du ring handling, and can fly apart as they come up to speed. This is not

common, but it does happen.

Whenever you hold the

tool, be ca refu l n ot to cover the air vents with your hand. This blocks the air flow and causes the motor to overheat.

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 de pth. For mo st work, the gentle touch i s b est . With it, you have t he best control, are less likely to make errors, and will ge t t he most e ffi cie n t work out o f the accessory.

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

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.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 12

Needs for Slower Speeds

Certain materials, however, (some plastics and pr eciou s me t als, for ex a mple) re q uire 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 di sch arg e f rom 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 poi n t to reme m ber is th i s: Ma ny applications and accessories in our line will provide the best performance at full speed, but fo r ce rtain mat e rials , ap p licat i ons, and accessories, you need slower speeds, which is the reason our variable speed models are available.

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

NO T E: Spe e d is aff e cted b y voltag e changes. A reduced incoming voltage will slow the RPM of the tool.

SLIDE "ON/OFF" SWITCH

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.

HIGH PERFORMANCE MOTOR

Your tool is equipped with a high performance rotary tool motor. This motor expands the versatility of the rotary tool by driving additional 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. Th e sp eed may be ad just ed duri ng operation by presetting th e dial on or between any one of the settings.

You can refer to the charts on page 24, 25, 26 and 27 to determine the proper speed, based on the materi al being worked and t

he type of accessory being used. These ch a r t s ena b l e you to s e l e c t both t h e 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.

Operating Speeds

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 13

Service

Preventive maintenance

pe r formed by unaut hor ized pe r so n nel m ay resu lt in misplacing of in t e r n a l wi r e s and components which could cause serious hazard. We recommend that all tool service

be performed by a Dremel Service Facility.

To av o i d in j u r y f r o m

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 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 pow e r, ma k e s unusual noises or runs at a reduced speed, check the brushes.

To continue using the

tool i n this c o n d i t i o n

will permanently damage your tool.

Follo w th ese steps to check/ cha nge the rotary tool brushes:

1. With the power cord unplugged, place the tool on a clean surf ace . Use the tool wrench as a screwdriver to remove the brush ca p s i n a co u n t e r-clockwise direction (Figure C).

Maintenance Information

To aid you in de termi n ing the optim u m o

perational speed for differ ent materials and different accessories, we have construct ed a series of tables that appear on page 24, 25, 26 and 27. 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 t

ype of bristle brush must be do ne 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 al l oys an d tin may be cut at va r ious 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 sh o uld. Per haps y ou sh ould b e us i ng a di ffer e nt a ccess o ry, and perh a ps 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.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 14

2. Re move th e brush es from t he tool by p

ulling 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 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.

BEARINGS

Model 4000 has ball bearing construction. Under normal use no additional lubrication is required.

Cleaning

To a v o i d accidents

always dis connect the tool f r o m the p o w e r supply b efore cleaning or performing any main tenance.

The tool may be cleaned most effectively wi t h compres s e d dry a i r. Always w e a r

safety gog gles when cleaning tools with compressed air.

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.

Certain cleaning agents an d sol vent s damage

plastic parts. Some of these are: gasoline,

carbon tetrachlo ride, chlo rinated cleaning solvents, amm o n i a an d ho u se ho l d detergents that contain ammonia.

Extension Cords

If an extension cord is

necessary, a cord with adequate size conductors that is capable of carrying the current necessary for your to o l m u st be used. This will prev e n t

excessive v oltag e dro p, 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

higher the cord capacity.

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

FIG. C

BRUSH

BRUSH SPRING

BRUSH CAP

Curved end of brush must match curvature of commutator

FIG. D

Tool’s

Ampere

Rating

Cord Size in A.W.G. Wire Sizes in mm

Cord Length in Feet Cord Length in Meters

25 50 100 150

15 30 60 120

3-6 6-8

8-10 10-12 12-16

18 18 18 16 14

16 16 16 16 12

16 14 14 14

–

14 12 12 12

–

0.75

1.0 –

0.75

1.0

2.5 –

1.5

2.5

4.0 –

2.5

4.0

4.0 – –

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 15

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 he ad, which are re quir ed w hen you use polishing accessories, cutting wheels, sanding di scs, and po l ish i n g p o ints. The rea s on mandrels are used is tha t sandi ng discs, 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.

Screw Mandrel No 401

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

Small Screw Mandrel No 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 No 402

The D r e m e l EZ Lock m a k e s accessory changes easy as PULL - TWIST - RELEASE. The one-piece mandrel design simplifies the process of changing cutting wheels, buffs and d e t a il a b r a s i v e brushes ( E Z Lock compatible accessories).

EZ Drum™ Mandrel No EZ407SA

Th e Dre m el EZ Drum mak es ac c essor y changes easy as PULL - INSERT - PRESS DOWN. T h e one-piece mandrel d e s i g n simplifies the process of changing sanding bands.

High Speed Cutters

Available in many shapes, high speed cutters are used in carving, cutting and slotting in wo o d , pla s t ics an d soft met a l s su c h as aluminum, copper and brass. These are the accessories to use for freehand routing or carving in wood or plastic, and for precision cu ttin g. Made o f hi gh q ualit y st eel. 1/8" shank.

Tungsten Carbide Cutters

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

Dremel Accessories

Use only Dremel®, high-performance accessories. Other accessories are

not designed for this tool and may lead to personal injury or property damage.

Store accessories in a dry and temperate environment to avoid corrosion and deterioration.

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.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 16

Engraving Cutters

This group has a wide variety of sizes and shapes, and are made for intricate work on ceramics (greenw a r e ) , wo o d ca r v i n g s , jewelry and scrimshaw. They often are used in making complicat ed printed circuit boards. They should not be used on steel and other very hard materia ls but a re excel len t o n wood, plastic and soft metals. 1/8" shank.

Structured Tooth

Tungsten Carbide Cutters

Fast cutting, needle-sharp teeth for greater material removal with minimum loading. Use on fibe r glass, wood, plas t ic, e p oxy a n d rubber. 1/8" shank.

Aluminum Oxide Grinding Stones

(red/brown)

Round, pointed, flat — you name the shape and there is one available in this category. These are ma de of a luminum oxide and cover virtually every possible kind of grinding application. Use them for sharpening lawn mo wer b lade s , sc rewdr iver tips, k nive s , scissors, chisels and other cutting tools. Use to remove f l a s h fr o m me t a l cast i n g s , 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.

Silicon Carbide Grinding Stones

(blue/green)

Tougher than aluminum oxide points, these are m a d e es p e c i a l l y fo r us e on ha r d materials s u c h as gl a ss and ce ra m i c s . 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 cove red with diamond particl es. 1/8" shanks. (Not recommended for drilling)

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 s h a p es c o m e in th r e e di f f e r e n t materials: stainless steel, brass and carbon wire. The stainless steel pe rform well on pewter, aluminum, stainless steel, and other metals, without leaving "after-rust". Brass brushes are non sparking, and softer than stee l; makin g t hem go od for u se on soft me t a l like g o l d , cooper and b r a s s. The carbon wire brushes are good for general purpose cleaning.

Dremel Accessories (Continued)

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 17

Bristle Brushes

These are ex c e l l e n t cleaning to o l s on silverware, jew elry and antiques. The three shapes make it poss ible to get in to tight corners and othe r diffi cult places. Bristle brushes c a n be us e d wi t h po l i s h i n g 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.

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 resu lt in wi re breakage and shortened brush life.

Polishing Accessories

These in clud e an impre gnated polishing point and an impregnated polishing wheel 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 gr o u p is a p o l is hing compound (No. 421) for use with the felt and cloth polishers. Polishing p o i n t s m a k e a very smoot h 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 polis hing co mpo und is neede d 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.

Sanding Accessories

Sanding discs in fine, medium and coarse grades are made to fit mandrel No. 402 and EZ407. They can be used for nearly any sm all san ding job you migh t ha ve, fro m model making to fine furniture finish ing. In addition, there is the drum sander, a tiny drum wh ich fits in to the Rotary Tool and makes it possible to shape wood, smooth fiberglass, sand inside curves and other diffi -

Dremel Accessories (Continued)

INCORRECT:

Excessive pressure can cause wire breakage.

CORRECT: Wire tips doing the work.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 18

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 af t e r he a v i e r surf a c e sanding and material removal is completed. Flapwheels come in fine and coarse grades. Buffs are a great finishi ng accesso ry for cleaning and lig h t sanding. The y work effectively on metal, glass, wood, aluminum and plastics. Coarse and medium buffs are sold together. All buffs are sold individually.

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.

Cutting Wheels

These thin discs of emery or fiberglass are us e d for s l i c i n g , cutting off and s i m i l a r operations. Use them for cutting off frozen bolt heads and nuts, or to reslot a screw head which has become so damaged that the screwdr iver won’t wor k 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. Use wi t h Dreme l No 5 6 5 / 5 6 6 Cutting Guide attachment.

Tile Cutting Bit

Cuts ceramic wall tile, cement board, and plaster. Use with Dremel No 565/566 Cutting Guide attachment.

Spiral Cutting Bit

Cuts through all types of wood and wood composites. Use with Dremel No 565/566 Cutting Guide attachment.

High Speed Router Bits

For routing, inlaying, and mortising in wood and other soft materials. Use with Dremel No. 335 R outer atta chm ent and N o. 231 Shaper/Router table.

Brad Point Drill Bits

Titanium coated brad points stay on center and begin drilling immediately. For use on wood. Size 1/8”, 5/32”, 3/16”, ¼” . 1/8” shank.

HSS Drill Bits

HSS drill bit for use in metal and plastic. Size 1/8”, 7/64”, 3/32”, 5/64”, 1/16”, 3/64”, 1/32”. Shank si z e matc h e s the dr i l l bi t size. Diff e r e n t collet size ( 4 8 1 , 482, 4 8 3 ) or Dremel chuck (4486) required according to drill bit being used.

Dremel Accessories (Continued)

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 19

Dremel Accessories (Continued)

Glass Drill Bits

Diamond tipped drill bits for use on glass and ceramic wall tile. Lubricant included.

Collet Fan

Blows dust away for greater visibility to work piece. Great f or sanding, engraving a nd carving. Do not use dust blower to stop or slow down the tool. Do not contact dust blower with fingers or workpiece during use.

Dremel Chuck

This chuck allows you to quickly and easily change accessories on Dremel Rotary Tools without changi n g c o l l e t s . A c c e p ts accessories with 1/32” - 1/8” shank. Read in s tructi o n man u a l. In s ert a n d se c u rely tighten the shank of the accessory well within the jaws of the chuck.

Detail Nose Piece

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 comforta bly betwe en thumb an d forefinger. It provides an excellent line of sight for performing detailed etching, carving and engraving work.

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 20

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

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

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

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

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.

Before each use, check

to 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.

Replacing Screw Mandrel Accessories

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 21

EZ Lock™Operating Instructions

EZ Lock™ Mandrel No. EZ402 has a spring

loa d e d sleeve a n d is u s e d with cut t i n g wheels, abrasive buffs and polishing cloth.

Alwa ys make sure the

rotary tool is “OFF” and disconnect the plug fro m the powe r source or the battery pack from the tool before ch a n g i n g a cc essories. S u c h

preventative safety measures reduce the risk of starting the power tool accidentally.

Always make sure accessory is properly seated on mandrel before use. Incorrect

seating of accessory on mandrel may lead to personal injury or property damage.

To load accessory:

1. Place EZ Lock™ mandrel into collet as

deep as possible and tighten collet nut. Note: Th ere is a blue s pacer t hat will

bottom out on the collet nut, setting the mandrel to the correct depth. When using with Dremel chuck, back the mandrel out slightly before tightening.

2. Pull spring-loaded sleeve DOWN towards

to ol w ith one ha nd a n d hold. You can brace the tool on the body or work-bench for extra leverage (Fig. 1).

3. With the other hand, align bowtie shape on

cut-off wheel with mandrel and make sure metal insert is facing away from the tool (Fig. 2).

4. Place wheel on the mandrel to a point just

below the bowtie on the mandrel and twist 90 degrees until the bowtie shape on the wheel al igns wi th the sleeve. Release sleeve. Wheel should lock in place (Fig. 3).

5. When mounting sand ing an d p olishing

accessories, align bowtie with metal insert on bottom of accessory (Fig. 4 & 5).

To check for proper seating, hold shaft lock but t o n an d twist ac c e s s o r y. Accessory will not be able to rotate on mandrel.

To unload accessory:

1. Pull spring-loaded sleeve DOWN toward

tool with one hand (Fig. 1).

2. Hold sleeve down while twisting accessory

90 degrees.

3. Remove accessory.

During use

Avoid damage to EZ lock™ mandrel by not letting it contact the workpiece.

FIG. 4

FIG. 5

FIG. 2

FIG. 3

FIG. 1

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 22

EZ Drum™ Mandrel No. EZ407SA has a spring loade d sleeve an d is used wi t h sanding bands.

lway s make sure the

rotary tool is “OFF” and disconnect the plug fro m the powe r source or the battery pack from the tool before ch a n g i n g a cc essories. S u c h

preventative safety measures reduce the risk of starting the power tool accidentally.

Always make sure accessory is properly seated on mandrel before use. Incorrect

seating of accessory on mandrel may lead to personal injury or property damage.

To load accessory:

1. As indicated, place two fingers underneath

the mandrel and pull firmly up. This will place the EZ Drum™ in the "unlocked" position (Fig. 1).

2. Keeping two fingers beneath the mandrel,

slide the sandin g ba nd d own unt il t he entire blue mandrel is covered (Fig. 2).

3. To return to "locked" position, press firmly

down on the top of the mandrel (Fig. 3).

Removing the sanding band on

the mandrel:

1. Place two fingers underneath the mandrel

and pull firmly up. This will place the EZ Drum™ in the "unlocked" position (Fig. 1).

2. Sandin g b and will now e asily s lide off

mandrel (Fig. 2). Do not squeeze sanding band when r emov ing from EZ Dru m™ mandrel. This can lead to rubber band pulling off ma n d rel an d b e c o m in g inoperable.

FIG. 1

FIG. 2

FIG. 3

EZ Drum™Operating Instructions

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 23

Note: Each number settings listed in the speed charts = x 1,000 RPMs

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

• Depending on cutting direction relative to grain.

Speed Settings

High Speed Cutters

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

100, 121, 131 25-35 25-35 12-17 12-17 18-24 - - -

114,124, 134, 144 25-35 12-17 9-11 12-17 12-17 - - -

118, 190, 191, 192,

193, 194

25-35 25-35 9-11 12-17 25-35 - - -

116, 117, 125, 196 25-35 12-17 9-11 12-17 12-17 - - -

115 25-35 25-35 9-11 12-17 12-17 - - -

198, 199 25-35 18-24 9-11 12-17 12-17 - - -

Engraving Cutters

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

105, 108 25-35 25-35 18-24 9-11 12-17 - - -

106, 107, 109, 110 25-35 25-35 12-17 9-11 12-17 - - -

111 25-35* 25-35* 18-24* 9-11 12-17 - - -

112, 113 25-35* 25-35* 12-17* 9-11 12-17 - - -

Diamond Wheel Points

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

7103, 7105, 7117, 7120, 7122, 7123,

7134, 7144

25-35 18-24 - - - 25-35 25-35 25-35

Structured Tooth Tungsten Carbide Cutters

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

9931, 9932, 9933,

9934, 9935, 9936

25-35 18-24 9-11 - 12-17 - - -

1600A012FM.qxp_4000 1/30/17 10:01 AM Page 24

Speed Settings (Continued)

Note: Each number settings listed in the speed charts = x 1,000 RPMs

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

• Depending on cutting direction relative to grain.

Tungsten Carbide Cutters

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

9901, 9902, 9903, 9904, 9905, 9906,

9912

25-35 18-24 9-11 25-35 12-17 18-24 18-35 18-35

9909, 9910, 9911 - - - - - 18-24 18-35 18-35

High Speed Router Bits

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

612, 640 25-35* 18-24• - - - - - 615, 617, 618 25-35* 25-35• - - - - - 650, 652, 654 25-35* 18-24• - - - - - -

Silicon Carbide Grinding Stones (blue/green)

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

83142, 83322, 83702, 84922, 85422, 85602,

85622

- - 12-17 25-35 9-11 12-17 25-35 25-35

Abrasive Wheels / Points

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

516 4-6 4-6 - 18-24 12-17 - - 500 4-6 4-6 - 18-24 9-17 - - -

EZ541GR - - - 12-24 9-17 - - -

Aluminum oxide grinding stones (orange/brown)

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

541, 903, 911, 921, 932, 941, 945, 952, 953, 954, 971, 997,

8153, 8175, 8193,

8215

25-35 25-35 - 18-24 9-11 12-17 25-35 -

1600A012FM.qxp_4000 1/30/17 10:02 AM Page 25

Speed Settings (Continued)

Note: Each number settings listed in the speed charts = x 1,000 RPMs

Speed for light cuts, Caution - burning on deep grooves.

• Depending on cutting direction relative to grain.

Chain Saw Sharpening Stones

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

453, 454, 455 - - - 25-35 - - - -

Cutting Accessories

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

409, 420, 426, 540,

EZ409

- - 5-11 25-35 25-35 25-35 25-35 -

543, 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 Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

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

Wire Brushes

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

403, 404, 405 9-11 9-11 5-11 12-17 5-8 - - 428, 442, 443 9-11 9-11 5-8 9-11 9-11 - - 530, 531, 532 - 9-11 - 9-11 - - - 535, 536, 537 9-11 9-11 - 9-11 9-11 9-11 - -

Sanding Bands and Discs

Catalog

Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum, Brass, etc.

Shell/ Stone

Ceramic Glass

407, 408, 430, 431, 432, 438, 439, 440,

444

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 - - -

1600A012FM.qxp_4000 1/30/17 10:02 AM Page 26

Speed Settings (Continued)

Note: Each number settings listed in the speed charts = x 1,000 RPMs

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

• Depending on cutting direction relative to grain.

Flapwheels

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum,

Brass, etc.

Shell/ Stone

Ceramic Glass

502, 503, 504, 505 25-35 18-24 5-8 25-35 18-35 - - -

Finishing Abrasive Buffs

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum,

Brass, etc.

Shell/ Stone

Ceramic Glass

511E, 512E 12-17 12-17 9-11 12-17 12-17 - - -

Detail Abrasive Brushes

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum,

Brass, etc.

Shell/ Stone

Ceramic Glass

EZ471SA, EZ472SA, EZ473SA

5-17 5-17 5-17 5-17 5-17 - - -

Drill Bit

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum,

Brass, etc.

Shell/ Stone

Ceramic Glass

150 25-35 18-35 5-11 - 12-17 - - -

Glass Drilling Bits

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum,

Brass, etc.

Shell/ Stone

Ceramic Glass

662DR, 663DR - - - - - 5-17 5-17 5-17

Grout Removal Bits

Catalog Number

Soft

Wood

Hard

Wood

Laminates

/Plastics

Steel

Aluminum,

Brass, etc.

Shell/ Stone

Ceramic Glass

569, 570 For use on wall and floor grout - 12-24 -

1600A012FM.qxp_4000 1/30/17 10:02 AM Page 27

Flex Shaft Attachment Model 225

Safety Rules for Flex Shaft

Re a d the tool man u al

and these instructions

for the use of this accessory with your tool.

Failure to follow all instructions listed below may result in serious personal injury.

Wear ANSI compliant eye protection. The operation of an y power tool can result in foreign objects being thrown into the eyes.

Do not operate the flexible shaft with a sharp or multipl e bends. Ensure that there are no sharp residual bends or kinks in the flexible shaft before operation. Over bending the

shaft can generate excessive heat on the jacket or h and piec e and ma y cause the flexible shaft to disengage from tool. The minimum recommended bend radius is 6”

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.

No t for us e with ro u t e r bits or other large diameter (1” or larger) bits. Large

diameter bits can cause kickback and loss of control when used with the flexible shaft.

Do not remove end ferrule while tool is running. The cable will become loose from the

jacket and will uncontrollably whip or lash around.

Installation Instructions

It is extremely important to carefully read and follow the directions to assemble the flexible shaft to your rotary tool below to ensure the tool will function properly.

To pr operly attach th e Fl ex Shaft to the rotary tool, THREE items must be removed from the tool: the nose cap, Dremel Chuck or collet nut and collet.

1. Press the Shaft lock button 1, unscrew and remove the collet nut or Dremel Chuck 2 (Fig. A1).

RADIUS

FIG. A1 FIG. A2

FIG. A3

FIG. A4

FIG. A5

FIG. A6

FIG. A7

Dremel Attachments

The following attachments are not included with all kits.

1600A012FM.qxp_4000 1/30/17 10:02 AM Page 28

2. Unscrew the nose cap 3 from the tool (Fig. A

2).

3. Remove the collet 4 (Fig. A3).

Note: If t he collet nut a nd collet are n ot removed from the motor shaft, the tool will not function properly.

4. Install the driver cap 5 on the motor shaft 6

and tighten (Fig. A4).

To p reve nt dam age to

tool, do not overtighten

driver cap. Tighten the driver cap finger tight

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

5. Attach by screwing the collar of the Flex

Shaft 7 to the rotary tool. Make sure the square end of the center core engages the sq u are hol e sock e t in the dr i v e r cap (Fig. A5).

6. Re fer to “Drem el Chuc k” and “Colle ts” se ctio ns o f t he r otar y to ol m anua l f o r instructions on how to change accessories.

Do not pull out cent er

co r e to eng a ge into

driver cap. This 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.

Operating Instructions

Run-In before Operation

For optimum performance, allow your new flex shaft attachment to run at high speed on your rotary tool in a vertical position for 2 minutes before use (Fig. A7).

Disengagement of the Flex Shaft

he flexible shaft may become disengaged if the motor of your rotary tool is not elevated higher than the working end of the Flex Shaft.

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 2 and remove the old collet 4. Insert the unslotted end of the collet in the hole in the end of the Flex Shaft 8. Replace collet nut on the shaft (Fig. A5).

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.

To o muc h gre ase will cau se the uni t to overheat.

Reattach the Flex Shaft to the rotary tool.

FIG. A7

1600A012FM.qxp_4000 1/30/17 10:02 AM Page 29

Cutting Guide attachment Models 565 and 566

Re a d the tool man u al

and these instructions

for the use of this accessory with your tool.

Failure to follow all instructions listed below may result in serious personal injury.

Do n o t us e Dremel

chuck w i t h thi s attachment. Only use a collet and collet nut.

The c u t t i n g gu i d e co m e s com p l e t e l y assembled and ready to use on a variety of materials up to 3/4" (19 mm) thick. Always hold the tool fi rml y, using a slow steady pressure to guide the tool through your work. The speed of the tool will do the work.

IMPORTANT: Al w a y s cut in cl o c kw is e direction except when following a template , then cut in counter clockwise direction.

Cutting Guide Attachment Installation

Instruction

1. Press the Shaft lock button 1, unscrew and

remove the collet nut 2 (Fig. B1).

2. Unscrew the nose cap 3 from the tool (Fig.

B2).

3. Place the collet nut 2 loosely on the end of

the rotary tool and insert the cutting bit 4. Tighten collet nut 2 using the wrench or nose cap (Fig. B3).

When inserting the #560,

#561 and #562 Cutting Bit into your Dremel Rotary Tool, be sure that the bit is securely inserted into the collet. Always u s e t h e wrench o r n o s e cap t o

tighten the collet nut to prevent the bit from loosening within the collet.

4. Thread the Cutting Guide Attachment 5 onto the exposed housing threads on the rotary tool (Fig. B4).

5. Adjus t the a t tachmen t to t h e desir e d cutting depth (Fig. B5).

56 0 Drywall Cutting Bit – For use in drywall.

Use with 1/8" (3.2 mm) collet #480 and collet nut.

When inserting the #560 bit into your rotary tool, it is very important that at least 1/16” (1.6 mm) and no more than 1/8" (3.2 mm) of smooth shank remains visible above the collet. Leaving too much shank out of the tool can cause the bit to spin unevenly and make the tool difficult to control. The guide has a "0" depth marking on it, however, when inserted properly, the bit will stick out from the end of the guide by 1/16” (1.6 mm) – 1/8" (3.2 mm). The depth can be adjusted from that point on a continuous slide up to 3/4" (19 mm).

When making freehand cuts in drywall – e. g. Repairing a hole in drywall, you may use the #560 Drywall Cutting Bit (cutting in a counter clockwise direction) or the #561 Multipurpose Cutting Bit (cutting in a clockwise direction).

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

FIG. B1 FIG. B2

FIG. B3

FIG. B4

FIG. B5

1600A012FM.qxp_4000 1/30/17 10:02 AM Page 30

+ 94 hidden pages