Dremel 400XPR User Manual
400 Series XPR
Instructional Safety
Manual
High Performance Rotary Tool
Dremel brand products are manufactured and sold by the
Dremel Division of Robert Bosch
Form No. 2610925455 10/04
1-800-437-3635
http://www.dremel.com
ool Corporation
T
Robert Bosch
ool Corporation © 2004
T
All Rights Reserved
POWER TOOL SAFETY RULES
WARNING
!
Read and understand all instructions. Failure to follow all instructions list-
ed below, may result in electric shock, fire and/or serious personal injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit.
Cluttered benches and dark areas invite accidents.
Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases, or dust.
tools create sparks which may ignite the dust
or fumes.
Keep bystanders, children, and visitors
away while operating a power tool.
Distractions can cause you to lose control.
Power
Electrical Safety
Double Insulated tools are equipped with
a polarized plug (one blade is wider than
the other.) This plug will fit in a polarized
outlet only one way. If the plug does not
fit fully in the outlet, reverse the plug. If it
still does not fit, contact a qualified electrician to install a polarized outlet. Do not
change the plug in any way.
Insulation eliminates the need for the three
wire grounded power cord and grounded
power supply system. Before plugging in the
tool, be certain the outlet voltage supplied is
within the voltage marked on the nameplate.
Do not use “AC only” rated tools with a DC
power supply.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges
and refrigerators.
of electric shock if your body is grounded. If
operating the power tool in damp locations is
unavoidable, a Ground Fault Circuit
Interrupter must be used to supply the power
to your tool. Electrician’s rubber gloves and
footwear will further enhance your personal
safety.
Don't expose power tools to rain or wet
conditions.
increase the risk of electric shock.
Do not abuse the cord. Never use the cord
to carry the tools or pull the plug from an
outlet. Keep cord away from heat, oil,
sharp edges or moving parts.
damaged cords immediately
cords increase the risk of electric shock.
When operating a power tool outside, use
an outdoor extension cord marked "W-A"
or "W."
use and reduce the risk of electric shock.
These cords are rated for outdoor
There is an increased risk
Water entering a power tool will
Double
Replace
. Damaged
Personal Safety
Stay alert, watch what you are doing and
use common sense when operating a
power tool. Do not use tool while tired or
under the influence of drugs, alcohol, or
medication.
operating power tools may result in serious
personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep
your hair, clothing, and gloves away from
moving parts.
long hair can be caught in moving parts.
Keep handles dry, clean and free from oil and
grease.
Avoid accidental starting. Be sure switch
is “OFF” before plugging in.
with your finger on the switch or plugging in
tools that have the switch “ON” invites accidents.
Remove adjusting keys or wrenches
before turning the tool ON.
key that is left attached to a rotating part of
the tool may result in personal injury.
Do not overreach. Keep proper footing
and balance at all times.
balance enables better control of the tool in
unexpected situations.
Use safety equipment. Always wear eye
protection.
shoes, hard hat, or hearing protection must
be used for appropriate conditions.
A moment of inattention while
Loose clothes, jewelry, or
Carrying tools
A wrench or a
Proper footing and
Dust mask, non-skid safety
Tool Use and Care
Use clamps or other practical way to
secure and support the workpiece to a
stable platform.
or against your body is unstable and may
lead to loss of control.
Do not force tool. Use the correct tool for
your application.
job better and safer at the rate for which it is
designed.
Do not use tool if switch does not turn it
ON or OFF.
trolled with the switch is dangerous and must
be repaired.
Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing the tool.
Such preventive safety measures reduce the
risk of starting the tool accidentally.
2
Holding the work by hand
The correct tool will do the
Any tool that cannot be con-
Store idle tools out of reach of children
and other untrained persons.
dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting
tools sharp and clean.
tained tools, with sharp cutting edges are
less likely to bind and are easier to control.
Any alteration or modification is a misuse
and may result in a dangerous condition.
Check for misalignment or binding of
moving parts, breakage of parts, and any
other condition that may affect the tools
operation. If damaged, have the tool
serviced before using.
are caused by poorly maintained tools.
Develop a periodic maintenance schedule
for your tool.
Use only accessories that are recommended by the manufacturer for your
model.
Accessories that may be suitable for
one tool, may become hazardous when
used on another tool.
Tools are
Properly main-
Many accidents
SAFETY RULES FOR ROTARY TOOL
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.
Hold tool by insulated gripping surfaces
when performing an operation where the
cutting tool may contact hidden wiring or
its own cord.
make exposed metal parts of the tool "live"
and shock the operator. If cutting into existing
walls or other blind areas where electrical
wiring may exist is unavoidable, disconnect
all fuses or circuit breakers feeding this worksite.
Do not operate the flexible shaft with a
sharp bend.
generate excessive heat on the jacket or
hand piece. The recommended minimum is
6" radius.
Always disconnect the power cord from
the power source before making any
adjustments or attaching any accessories.
to start leading to serious personal injury.
Be aware of the switch location, when
placing the tool down or when picking the
tool up.
switch.
Always hold the hand piece firmly in your
hands during the start-up.
torque of the motor, as it accelerates to full
speed, can cause the shaft to twist.
Contact with a "live" wire will
Over bending the shaft can
You may unexpectedly cause the tool
You may accidentally activate the
The reaction
Service
Tool service must be performed only by
qualified repair personnel.
maintenance performed by unqualified personnel could result in a risk of injury. For
example: internal wires may be misplaced
or pinched, safety guard return springs may
be improperly mounted.
When servicing a tool, use only identical
replacement parts. Follow instructions in
the Maintenance section of this manual.
Use of unauthorized parts or failure to follow
Maintenance Instructions may create a risk
of electric shock or injury. Certain cleaning
agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic
parts.
Always wear safety goggles and dust
mask. Use only in well ventilated area.
Using personal safety devices and working in
safe environment reduces risk of injury.
After changing the bits or making any
adjustments, make sure the collet nut and
any other adjustment devices are securely tightened.
unexpectedly shift, causing loss of control,
loose rotating components will be violently
thrown.
Do not reach in the area of the spinning
bit.
The proximity of the spinning bit to your
hand may not always be obvious.
Allow brushes to run at operating speed
for at least one minute before using
wheel. During this time no one is to stand
in front or in line with the brush.
bristles or wires will be discharged during the
run-in time.
Wire and bristle brushes must never be
operated at speeds greater than
15,000/min. Direct the discharge of the
spinning wire brush away from you.
Small particles and tiny wire fragments may
be discharged at high velocity during the
“cleaning” action with these brushes and may
become imbedded in your skin. Bristles or
wires will be discharged from the brush at
high speeds.
Carefully handle both the tool and individual grinding wheels to avoid chipping or
cracking. Install a new wheel if tool is
Loose adjustment device can
Service or
Loose
3
SAFETY RULES FOR ROTARY TOOL (CONTINUED)
dropped while grinding. Do not use a
wheel that may be damaged.
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.
bits can snap during use. Dull bits require
more force to push the tool, possibly causing
the bit to break.
Use clamps to support workpiece whenever practical. Never hold a small workpiece in one hand and the tool in the other
hand while in use. Allow for sufficient
space, at least 6", between your hand and
the spinning bit.
dowel rods, pipes or tubing have a tendency
to roll while being cut, and may cause the bit
to “bite” or jump toward you. Clamping a
small workpiece allows you to use both
hands to control the tool.
Inspect your workpiece before cutting.
When cutting irregularly shaped workpieces, plan your work so it will not slip
and pinch the bit and be torn from your
hand.
For example, if carving wood, make
sure there are no nails or foreign objects in
the workpiece. Nails or foreign objects can
cause the bit to jump.
Never start the tool when the bit is
engaged in the material.
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.
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).
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.
the tool is left “ON” the tool could restart
unexpectedly causing serious personal
injury.
Do not leave a running tool unattended,
turn power off.
Round material such as
This can cause loss of control
Feeding the tool in the wrong
Only when tool comes to a
Fragments
Damaged
The bit cutting
If the switch to
complete stop it is safe to put it down.
Do not grind or sand near flammable
materials.
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 with
compressed air.
powdered metal inside the motor housing
may cause electrical failures.
Do not allow familiarity gained from frequent use of your rotary tool to become
commonplace.
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.
When using the steel saws, cutoff wheels,
high speed cutters or tungsten carbide
cutters, always have the work securely
clamped. Never attempt to hold the work
with one hand while using any of these
accessories.
wheels will grab if they become slightly canted in the groove, and can kickback causing
loss of control resulting in serious injury. Your
second hand should be used to steady and
guide the hand holding the tool. When a cutoff wheel grabs, the wheel itself usually
breaks. When the steel saw, high speed cutters or tungsten carbide cutter grab, it may
jump from the groove and you could lose
control of the tool.
!
construction activities, contains chemicals known to cause cancer, birth defects
or other reproductive harm. Some examples of these chemicals are:
• Lead from lead-based paints,
• Crystalline silica from bricks and cement
and other masonry products, and
• Arsenic and chromium from chemically
treated lumber.
our risk from these exposures varies,
Y
depending on how often you do this type of
work. To reduce your exposure to these
chemicals, work in a well ventilated area, and
work with approved safety equipment, such
as those dust masks that are specially
designed to filter out microscopic particles.
Sparks from the wheel could
Excessive accumulation of
Always remember that a
Serious injury may result.
The reason is that these
WARNING
Some dust created by
power drilling and other
4
GETTING TO KNOW YOUR ROTARY TOOL
Unpacking & Checking Contents
WARNING
!
cal shock, always remove plug from wall
outlet when tool is not in use.
Separate all loose parts from packing materials and check each item with the contents
listed on the carton to make sure all items are
accounted for before discarding any packing
material.
IMPORTANT! If any parts are missing, or if
you require any assistance with these
instructions, please contact the Dremel™
Consumer Service at:
To avoid injury from unexpected starting or electri-
1-800-437-3635
or check our website at www.Dremel.com.
Description
The 400 Series XPR™ Rotary Tool incorporates both high-speed and performance to
Collet Nut
Collet
serve as a carver
, grinder, polisher, sander,
cutter, power brush, drill, and more.
The tool utilizes a small, but effective DC
motor. The large variety of available
Dremel™ accessories includes abrasive
wheels, drill bits, wire and nylon brushes,
engraving and carving cutters, router bits,
polishing points and more. The ability to add
different Dremel™ attachments adds to the
multi-faceted uses of the tool. The variety of
projects you can do with the tool is limitless.
The 400 Series XPR Rotary Tool is a highspeed tool and operates at speeds 5,000 to
35,000 RPM. (A typical electric drill operates
only up to 2500 RPM!). When used with
Dremel™ accessories and attachments, the
400 Series XPR rotary tool’s high speed performance allows you to work on even the
most demanding projects without having to
exert undue pressure on the tool. The tool
does the work for you.
Collet Wrench
Housing Cap
Ventilation Openings
Brush Cover
(one each side)
Shaft Lock Button
5
On/Off Switch
Hanger
Variable Speed Dial
Power Cord
SPECIFICATIONS
General Specifications
Voltage Rating . . . . . . . . . .120 V, 50-60 Hz
Amperage Rating . . . . . . . . . . . . . . . . .2.0 A
No Load Speed . . . . . . . . . .No35,000/min
Collet Capacity . . . .1/32", 1/16", 3/32", 1/8"
Motor Specifications
This Rotary Tool utilizes a variable highspeed RPM motor. It is wired for operation on
110-120 volts, 50-60 Hz. alternating current.
Before connecting the motor cord to wall outlet, make certain the power switch is in the
OFF position and be sure the electric current
is of the same characteristics as stamped on
the Rotary Tool nameplate.
Connection To A Power Source
DANGER
!
prongs on the plug when installing or
removing the plug to or from the outlet.
DANGER
!
have it replaced immediately to avoid
shock or fire hazard.
To avoid electric shock,
do not touch the metal
If power cord is worn, cut
or damaged in any way,
Extension Cords
If an extension cord is necessary, a cord
with adequate size conductors that is
capable of carrying the current necessary
for your tool must be used.
vent excessive voltage drop, loss of power or
overheating.
RECOMMENDED SIZES
OF EXTENSION CORDS
120 VOLT ALTERNATING CURRENT TOOLS
NOTE: The smaller the gauge number, the
heavier the cord.
ool’
T
Ampere
Rating
2-6
6-8
8-10
10-12
12-16
Cord Size in A.W.G.
s
Cord Length in Feet Cord Length in Meters
25 50 100 150 15 30 60 120
18 16 16 14 .75 .75 1.5 2.5
18 16 14 12 .75 1.0 2.5 4.0
18 16 14 12 .75 1.0 2.5 4.0
16 16 14 12 1.0 2.5 4.0 —
14 12 — —————
This will pre-
Wire Sizes in mm
2
6
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 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
per minute 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
Ni-Cad RBRC seal Designates Ni-Cad 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, and is listed
to US Standards by CSA.
This symbol designates
that this tool is listed by
the Canadian Standards
This symbol designates
that this tool is listed to
Canadian Standards by
Underwriters
Laboratories.
This symbol designates that
this tool is listed by
Underwriters Laboratories,
and listed to Canadian
Standards by Underwriters
Laboratories.
This symbol
designates
that
this tool complies
to NOM
Mexican
Standards.
Association.
7
Shaft Lock Button
Collet Wrench
To
Tighten
To
Loosen
Collet Nut
1/8" Collet (480)
3/32" Collet (481)
1/16" Collet (482)
1/32" Collet (483)
Collet Nut
ASSEMBLY
WARNING
!
The Dremel™ accessories available for the
rotary tool come with various shank sizes.
Four size collets are available to accommodate
the different shank sizes. Collet sizes are identified by the rings on the back of the collet:
• 1/32" collet has 1 ring (No. 483)
• 1/16" collet has 2 rings (No. 482)
• 3/32" collet has 3 rings (No. 481)
• 1/8" collet has no rings (No. 480)
NOTE: Some rotary tool kits may not include all
four collet sizes. Collets are available separately.
Always unplug rotary tool before changing accessories, changing
collets, or servicing the tool.
Collets
1. Press the shaft lock button, hold down
tool is running.
2. With the shaft lock button engaged,
3. Remove the collet by pulling it free from
4. Install the appropriate size collet fully
1. Press the shaft lock button and rotate
tool is running.
2. With the shaft lock button engaged,
3. Insert the bit or accessory shank fully
4. With the shaft lock button engaged, fin-
CAUTION
!
Always use the collet which matches the shank size of the accessory you
plan to use. Do not force a larger diameter shank into a smaller collet.
Changing Collets
and rotate the shaft by hand until it
engages the shaft.
WARNING
!
Do not engage the shaft
lock button while rotary
loosen and remove the collet nut. Use
the collet wrench if necessary.
the shaft.
into the shaft and reinstall the collet nut
finger tight. Do not fully tighten the nut
when there is no bit or accessory
installed.
Changing Accessories
the shaft by hand until it engages the
shaft lock.
WARNING
!
loosen (do not remove) the collet nut.
Use the collet wrench if necessary.
into the collet.
ger tighten the collet nut until the bit or
accessory shank is gripped by the collet.
Do not engage the shaft
lock button while rotary
Shaft Lock Button
NOTE: Be sure to read the instructions
supplied with your Dremel™ accessory for
further information on its use.
8
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