Dremel 4000-4/34, 4000-2/30, 4000-6/50 User manual

IMPORTANT:

R

Read Before Using

Operating/Safety Instructions

4000

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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 any ada p ter plug s wi t h ea rthe d
(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 commo n sen se wh en op era 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 th e off-p ositi on befo re
connecting to power source and / or battery
pa ck, picking up or ca rry ing 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 ntr ol of th e pow er tool in un expecte d
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 nnot be contr oll e d w ith the switc h i s
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 acc iden ts ar e c aus ed by po orly
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 pair p erso n usin g only i dent ical
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. Wh en cleani ng a tool be
careful not to disassemble any portion of
th e too l since internal wires may be
misplaced or pinched or safety guard return
sp rings may be imprope rly mounted.

Certain cleaning agents such as gasoline,

carbon tetrachlo ride, am mo nia, etc . may
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 chromium fr om chemically ­treated lumber.

You r r isk from the s e e xpos ure s var ies ,
depending on how often you do this type of
work. To r educe you r expos ure to th ese
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 be nding the shaft can

generate excessive heat on the jacket or hand
piece. The recom mended mini mum is 5"
radius.

Always disconnect the power cord from
th e p ower s ourc e b efo re maki ng any
adjustments or attaching any accessories.

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

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

switch.

Always hold the hand piece firmly in your
hands during the start-up. The reaction

torque of the motor, as it accelerates to full
speed, can cause the shaft to twist.

Al ways we ar sa fety go ggles a nd dust
mask. Use only in well ventilated area.

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

After changing the bits or maki ng 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 erat ed at s peed s gre ater than
15,000/min. Direct the discharge of the
spinning wire brush away from you. Small

parti cles an d tiny wire fragments may be
di scha rged at high vel ocit y du rin g the
“cleaning” action with these brushes and may
become imbedded in your skin. Bristles or
wires will be discharged from the brush at high
speeds.

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

“Heavy” pressure on bristles will cause the
wi re or br istl e to bec ome o v ers tre ssed ,
resulting in a wiping action and will cause the
bristles/wire to be discharged.

Ca refu lly h andl e bot h the t ool a nd
in divi dual g r ind ing whe els to av oid
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 amp s to su ppo rt work piec e
whenever practical. Never hold a small
workpiece in one hand and the tool in the
ot her h and w hil e in u se. Allo w for
sufficient space, at least 6", between your
hand and the spinning bit. Round material

such as dowel rods, pipes or tubing have a
tendency to roll while being cut, and may
cause the bit to “bite” or jump toward you.
Clamping a small workpiece allows you to use
both hands to control the tool.

Inspect your workpiece before cutting.
Wh en cu ttin g irr egul arl y sha p ed
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 ver star t th e tool when th e 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 n ot gri nd or sa nd nea r fla mma ble
materials. Sparks from the wheel could ignite

these materials.

Do not touch the bit or collet after use.

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

Regularly clean the tool's air vents by
compressed air. Excessive accumulation of

powdered metal inside the motor housing may
cause electrical failures.

Do not all ow fa mili arit y gai ned fr om
frequent use of your rotary tool to become
commonplace. Alway s remember t ha t 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.

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Symbols

0

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
Services, to United States and Canadian Standards.

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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.

6

This symbol

designates
that
this tool
complies
to NOM
Mexican
Standards.

Functional Description and Specifications

R

WARNING

!

Di sconnec t the plug fro m t he pow er sou rce bef ore m akin g 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

!

changing collets or servicing your Rotary
Tool.

COLLET

WRENCH

TO

TIGHTEN

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
enga ges th e outp ut s haft i n 12 separ ate
locations on the shaft for easier operation.

CAUTION

!

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 an acc ess ory. 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.

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

!

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

Always unplug Rotary Tool
before changing accessories,

SHAFT

LOCK

BUTTON

TO

LOOSEN

Do not engage lock while
the Rotary Tool is running.

Always use the collet which
matches the shank size of

COLLET

NUT

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

BA LAN CIN G A CCE SSO RIE S — F or
pr eci sio n wor k, it i s import ant 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
an d feel i f you r acce sso ry is run nin g in
balance. Continue adjusting in this fashion until
best balance is achieved. To maintain balance
on abrasive wheel points, before each use,
with the wheel point secured in the collet, turn
on the Rotary Tool and run the 415 Dressing
Stone lightly against the revolving wheel point.
This removes high spots and trues up the
wheel point for good balance.

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

482

1/16"

COLLET

483

1/32"

COLLET

8

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Operating Instructions

Thank you for purchasing the Dremel 4000.

Dremel 4000

This p roduct was desig ned by the many
Dremel users w ho passionately use their
rotary tools daily. This tool was designed to
give you the ultim ate performan ce w hen
working on projects.

The Dremel 4000 is the MO ST ve rs atile
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 posi tion s. The qui ck col l et loc k
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 accept a larg e vari ety of
accessories including abrasive wheels, drill
bi ts, w ire b rus hes , pol ish ers , eng rav ing
cu tter s, r out er b its , cut tin g wh e els 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.

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
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.

Using the Rotary Tool

cutting (or sanding or etching,

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WARNING

Wear Eye Protection



R

R

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: Spe ed is aff ect ed b y voltage
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 used f or mor e aggr ess i ve
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 m ay be a djusted d uring
ope r a tion by pre s e tting th e di a l 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 a rts enab le you to sele c t b oth 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 eci ous m eta ls, f or ex a mpl e) re qui 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 discharge 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 point t o re member i s th is: M any
applications and accessories in our line will
provide the best performance at full speed, but
fo r cert ain ma ter ial s, app lic ati ons , and
accessories, you need slower speeds, which is
the reason our variable speed models are
available.

To aid you in dete rmi nin g the opti mum
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 br istle bru sh m ust be d one 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 par affin or othe r suit abl 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 oul d. Perhaps y ou sho uld be usi ng a
di fferen t acce sso ry, and pe rha 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.

11

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Maintenance Information

R

R

Service

!

WARNING

per so n nel may re su lt in m is pl acing 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 en gineered f or ma ny h our s 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 cl ean surface . Use the tool
wrench as a screwdriver to remove the
brush caps in a counter-clockwise direction
(Figure C).

2. Remov e the bru shes from the too l 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 eventive m aintenan ce
pe r formed by unauthorized

To avo id inju ry from
un expe cted st arti ng or

CARBON BRUSHES

To continue using the tool
in th is condition 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

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Model 4000 has ball bearing construction.

BEARINGS

Under normal use no additional lubrication is
required.

Cleaning

!

WARNING

th e po wer supp ly before cl ean ing 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

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 rta in cl eaning age nts
an d sol v ent s damage

plastic parts. Some of these are: gasoline,

carbon tetrachlo ride, chlo rinated cleaning
solvents, ammonia and house hold detergents
that contain ammonia.

Extension Cords

If an extension cord is necessary, a cord
with ade qu ate size cond uctors that is
capable of carrying the current necessary
for your tool must be used. This will prevent

excessive voltage dr op, 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

heav i er the cord.

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

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

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 req uir ed w hen y ou us e
polishing accessories, cutting wheels, sanding
di scs , and p ol ish i ng po int s. The reason
mandrels are u sed is that sanding 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.

13

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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.

Th e Dre mel EZ Lock make s acc essory

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).

Available in many shapes, high speed cutters

High Speed Cutters

are used in carving, cutting and slotting in
wo od, pla sti cs and soft me tal s s uch 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 te ria ls. They ca n be use d for
engraving on tools and garden equipment. 1/8"
shanks.

Engraving Cutters

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

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 rtu all y every pos sib le kin d of grindi ng
application. Use them for sharpening lawn
mo wer b lad es, scre wdr ive r tips, k niv es,
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.

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.

Excellent for fine detail work on wood, jade,

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.

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ceramic, glass and other hard material. Bits
are covered with diamond particles. 3/32"
shanks. (Not recommended for drilling)

14

Diamond Wheel Points

Dremel Accessories (Cont.)

Wire Brushes

Three different shapes of wire brushes are
available. For best results wire brushes

should be used at speeds not greater than
15,000 RPM. Refer to Operating Speeds
section for proper tool speed setting. The

three shapes come in three different materials:
stainless steel, brass and carbon wire. The
st ain les s ste el pe rfo rm we ll on pewt 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 ex cellent c lea nin g too ls on
silverware, jew elry and antiques. The three
shapes make it possible to get in to tig ht
corners and other difficult places. Br is tle
brushes can be used with polishing compound
for faster cleaning or polishing.

Brushing Pressure

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

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

INCORRECT:

Excessive pressure can cause wire breakage.

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

CORRECT:

Wire tips doing the work.

Polishing Accessories

These include an impregnated polishing point
an d an im pre gnate d pol ishin g whe el fo r
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.

15

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Dremel Accessories (Cont.)

Sanding Accessories

Sanding discs in fine, medium and coarse
grades are made to fit mandrel No. 402. They
can be used for nearly any small sanding job
you might have, from model making to fine
furniture 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.

us ed f or s lic ing, cut t ing off and sim ilar
operations. Use them for cutting off frozen bolt
heads and nuts, or to reslot a screw head
whic h has becom e so d amaged that th e
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 Ro uter att achm ent and No. 231
Shaper/Router table.

16

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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

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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

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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

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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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Dremel®Limited Warranty

Your Dremel product is warranted against defective material or workmanship for a period of five years from
date of purchase. In the event of a failure of a product to conform to this written warranty, please take the
following action:

1. DO NOT return your product to the place of purchase.

2. Carefully package the product by itself, with no other items, and return it, freight prepaid, along

with:

A. A copy of your dated proof of purchase (please keep a copy for yourself).
B. A written statement about the nature of the problem.

C. Your name, address and phone number

We recommend that the package be insured against loss or in transit damage for which we cannot be
res

ponsible.

This warranty applies only to the original registered purchaser. DAMAGE TO THE PRODUCT RESULTING
FROM TAMPERING, ACCIDENT, ABUSE, NEGLIGENCE, UNAUTHORIZED REPAIRS OR ALTERATIONS,
UNAPPROVED ATTACHMENTS OR OTHER CAUSES UNRELATED TO PROBLEMS WITH MATERIAL OR
WORKMANSHIP ARE NOT COVERED BY THIS WARRANTY.

No employee, agent, dealer or other person is authorized to give any warranties on behalf of Dremel. If
Dremel inspection shows that the problem was caused by problems with material or workman ship within the
limitations of the warranty, Dremel will repair or replace the product free of charge and return product
prepaid. Repairs made necessary by normal wear or abuse, or repair for product outside the warranty period,
if they can be made, will be charged at regular factory prices.

DREMEL MAKES NO OTHER WARRANTY OF ANY KIND WHATEVER, EXPRESSED OR IMPLIED, AND ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH
EXCEED THE ABOVE MENTIONED OBLIGATION ARE HEREBY DISCLAIMED BY DREMEL AND EXCLUDED
FROM THIS LIMITED WARRANTY.

This warranty gives you specific legal rights and you may also have other rights which vary from state to
state. The obligation of the warrantor is solely to repair or replace the product. The warrantor is not liable for
any incidental or consequential damages due to any such alleged defect. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above limitations or exclusion may not
apply to you.

For prices and warranty fulfillment in the continental United States, contact your local Dremel distributor.

2610005595 05/09 Printed in Mexico

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