Dremel 400XPR User Manual

	400 Series XPR
Instructional Safety	High Performance Rotary Tool
Manual

1-800-437-3635 http://www.dremel.com

Dremel brand products are manufactured and sold by the Dremel Division of Robert Bosch Tool Corporation

Form No. 2610925455 10/04	Robert Bosch Tool Corporation © 2004
	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				Personal Safety
	Keep your work area clean and well lit.					Stay alert, watch what you are doing and
	Cluttered benches and dark areas invite acci-					use common sense when operating a
	dents.					power tool. Do not use tool while tired or
	Do not operate power tools in explosive					under the influence of drugs, alcohol, or
	atmospheres, such as in the presence of					medication. A moment of inattention while
	flammable liquids, gases, or dust. Power					operating power tools may result in serious
	tools create sparks which may ignite the dust					personal injury.
	or fumes.					Dress properly. Do not wear loose cloth-
	Keep bystanders, children, and visitors					ing or jewelry. Contain long hair. Keep
	away while operating a power tool.					your hair, clothing, and gloves away from
	Distractions can cause you to lose control.					moving parts. Loose clothes, jewelry, or
		Electrical Safety				long hair can be caught in moving parts.
						Keep handles dry, clean and free from oil and
	Double Insulated tools are equipped with					grease.
	a polarized plug (one blade is wider than					Avoid accidental starting. Be sure switch
	the other.)	This plug will fit in a polarized
						is “OFF” before plugging in. Carrying tools
	outlet only one way. If the plug does not
						with your finger on the switch or plugging in
	fit fully in the outlet, reverse the plug. If it
						tools that have the switch “ON” invites acci-
	still does not fit, contact a qualified elec-
						dents.
	trician to install a polarized outlet. Do not
						Remove adjusting keys or wrenches
	change the plug in any way. Double
	Insulation	eliminates the need for the three				before turning the tool ON. A wrench or a
	wire grounded power cord and grounded					key that is left attached to a rotating part of
	power supply system. Before plugging in the					the tool may result in personal injury.
	tool, be certain the outlet voltage supplied is					Do not overreach. Keep proper footing
	within the voltage marked on the nameplate.
						and balance at all times. Proper footing and
	Do not use “AC only” rated tools with a DC
						balance enables better control of the tool in
	power supply.
						unexpected situations.
	Avoid body contact with grounded sur-					Use safety equipment. Always wear eye
	faces such as			pipes, radiators, ranges
						protection. Dust mask, non-skid safety
	and refrigerators. There is an increased risk
						shoes, hard hat, or hearing protection must
	of electric shock if your body is grounded. If
						be used for appropriate conditions.
	operating the power tool in damp locations is
						Tool Use and Care
	unavoidable, a Ground Fault Circuit
	Interrupter must be used to supply the power					Use clamps or other practical way to
	to your tool. Electrician’s rubber gloves and					secure and support the workpiece to a
	footwear will further enhance your personal					stable platform. Holding the work by hand
	safety.					or against your body is unstable and may
	Don't expose power tools to rain or wet					lead to loss of control.
	conditions. Water entering a power tool will					Do not force tool. Use the correct tool for
	increase the risk of electric shock.					your application. The correct tool will do the
	Do not abuse the cord. Never use the cord					job better and safer at the rate for which it is
						designed.
	to carry the tools or pull the plug from an
	outlet. Keep cord away from heat, oil,					Do not use tool if switch does not turn it
	sharp edges or moving parts. Replace					ON or OFF. Any tool that cannot be con-
	damaged	cords		immediately.	Damaged	trolled with the switch is dangerous and must
	cords increase the risk of electric shock.					be repaired.
	When operating a power tool outside, use					Disconnect the plug from the power
	an outdoor extension cord marked "W-A"					source before making any adjustments,
	or "W." These cords are rated for outdoor					changing accessories, or storing the tool.
	use and reduce the risk of electric shock.					Such preventive safety measures reduce the
						risk of starting the tool accidentally.

2

Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

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

Service

Tool service must be performed only by qualified repair personnel. Service or 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.

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. Contact with a "live" wire will make exposed metal parts of the tool "live" and shock the operator. If cutting into existing walls or other blind areas where electrical wiring may exist is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

Do not operate the flexible shaft with a sharp bend. Over bending the shaft can generate excessive heat on the jacket or hand piece. The recommended minimum is 6" radius.

Always disconnect the power cord from the power source before making any adjustments or attaching any accessories. You may unexpectedly cause the tool to start leading to serious personal injury.

Be aware of the switch location, when placing the tool down or when picking the tool up. 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.

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

Do not reach in the area of the spinning bit. The proximity of the spinning bit to your hand may not always be obvious.

Allow brushes to run at operating speed for at least one minute before using wheel. During this time no one is to stand in front or in line with the brush. Loose bristles or wires will be discharged during the run-in time.

Wire and bristle brushes must never be operated at speeds greater than 15,000/min. Direct the discharge of the spinning wire brush away from you.

Small particles and tiny wire fragments may be discharged at high velocity during the “cleaning” action with these brushes and may become imbedded in your skin. Bristles or wires will be discharged from the brush at high speeds.

Carefully handle both the tool and individual grinding wheels to avoid chipping or cracking. Install a new wheel if tool is

3

SAFETY RULES FOR ROTARY TOOL (CONTINUED)

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.

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

Inspect your workpiece before cutting. When cutting irregularly shaped workpieces, plan your work so it will not slip and pinch the bit and be torn from your hand. For example, if carving wood, make sure there are no nails or foreign objects in the workpiece. Nails or foreign objects can cause the bit to jump.

Never start the tool when the bit is engaged in the material. The bit cutting edge may grab the material causing loss of control of the cutter.

Avoid bouncing and snagging the wheel, especially when working corners, sharp edges etc. 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 it is safe to put it down.

Do not grind or sand near flammable 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 with compressed air. Excessive accumulation of powdered metal inside the motor housing may cause electrical failures.

Do not allow familiarity gained from frequent use of your rotary tool to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict severe injury.

Do not alter or misuse tool. Any alteration or modification is a misuse and may result in serious personal injury.

This product is not intended for use as a dental drill, in human or veterinary medical applications. Serious injury may result.

When using the steel saws, cutoff wheels, high speed cutters or tungsten carbide cutters, always have the work securely clamped. Never attempt to hold the work with one hand while using any of these accessories. The reason is that these wheels will grab if they become slightly canted in the groove, and can kickback causing loss of control resulting in serious injury. Your second hand should be used to steady and guide the hand holding the tool. When a cutoff wheel grabs, the wheel itself usually breaks. When the steel saw, high speed cutters or tungsten carbide cutter grab, it may jump from the groove and you could lose control of the tool.

! WARNING Some dust created by power drilling and other construction activities, contains chemi-

cals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints,

• Crystalline silica from bricks and cement and other masonry products, and

• Arsenic and chromium from chemically treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals, work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

4

GETTING TO KNOW YOUR ROTARY TOOL

Unpacking & Checking Contents
! WARNING	To avoid injury from unex-
	pected starting or electri-

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:

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

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

	Collet Nut
	Collet
	Shaft Lock Button
Housing Cap	On/Off Switch

Variable Speed Dial

Ventilation Openings

Brush Cover (one each side)

Hanger	Power Cord

5

SPECIFICATIONS

General Specifications

Voltage Rating . . . . . . . . . .120 V, 50-60 Hz Amperage Rating . . . . . . . . . . . . . . . . .2.0 A No Load Speed . . . . . . . . . .No 35,000/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 To avoid electric shock, do not touch the metal prongs on the plug when installing or

removing the plug to or from the outlet. ! DANGER If power cord is worn, cut

or damaged in any way, have it replaced immediately to avoid shock or fire hazard.

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. This will prevent 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.

	Tool’s	Cord Size in A.W.G.				Wire Sizes in mm2
	Ampere	Cord Length in Feet				Cord Length in Meters
	Rating
		25	50	100	150	15	30	60	120
	2-6	18	16	16	14	.75	.75	1.5	2.5
	6-8	18	16	14	12	.75	1.0	2.5	4.0
	8-10	18	16	14	12	.75	1.0	2.5	4.0
	10-12	16	16	14	12	1.0	2.5	4.0	—
	12-16	14	12	—	—	—	—	—	—

6

SYMBOLS

IMPORTANT! Some of the following symbols may be used on your tool. Please study
them and learn their meaning. Proper interpretation of these symbols will allow you to
operate the tool better and safer.
Symbol								Name	Designation/Explanation
				V				Volts	Voltage (potential)
				A				Amperes	Current
			Hz					Hertz	Frequency (cycles per second)
				W				Watt	Power
			kg					Kilograms	Weight
		min						Minutes	Time
				s				Seconds	Time
								Diameter	Size of drill bits, grinding wheels,etc.
			n0					No load speed	Rotational speed, at no load
.../min								Revolutions or reciprocation	Revolutions, strokes, surface speed,
								per minute	orbits etc. per minute
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
0								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 Association.

	This symbol designates
	that this tool is listed to
	Canadian Standards by
	Underwriters	This symbol
	Laboratories.	designates
		that
	This symbol designates that this tool com-
	this tool is listed by	plies
	Underwriters Laboratories,
		to NOM
	and listed to Canadian	Mexican
	Standards by Underwriters
		Standards.
	Laboratories.

7

ASSEMBLY

! WARNING Always unplug rotary tool before changing accessories, changing collets, or servicing the tool.

		Collets
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 iden-
tified by the rings on the back of the collet:			1/8" Collet (480)
• 1/32" collet has 1 ring (No. 483)			3/32" Collet (481)
•	1/16" collet has 2 rings (No. 482) Collet Nut		1/16" Collet (482)
• 3/32" collet has 3 rings (No. 481)			1/32" Collet (483)
• 1/8" collet has no rings (No. 480)
NOTE: Some rotary tool kits may not include all
four collet sizes. Collets are available separately.
!	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

1. Press the shaft lock button, hold down and rotate the shaft by hand until it engages the shaft.

! WARNING Do not engage the shaft tool is running.lock button while rotary

2. With the shaft lock button engaged, loosen and remove the collet nut. Use the collet wrench if necessary.

3. Remove the collet by pulling it free from the shaft.

4. Install the appropriate size collet fully 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

1. Press the shaft lock button and rotate the shaft by hand until it engages the shaft lock.

! WARNING Do not engage the shaft tool is running.lock button while rotary

2. With the shaft lock button engaged, loosen (do not remove) the collet nut. Use the collet wrench if necessary.

3. Insert the bit or accessory shank fully into the collet.

4. With the shaft lock button engaged, finger tighten the collet nut until the bit or accessory shank is gripped by the collet.

Shaft Lock Button

To

Tighten

Collet Wrench	Collet Nut

To

Loosen

Shaft Lock Button

NOTE: Be sure to read the instructions supplied with your Dremel™ accessory for further information on its use.

8