Dremel 4200 User Manual

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IMPORTANT: IMPORTANT : IMPORTANTE:

Read Before Using Lire avant usage Leer antes de usar

Operating/Safety Instructions Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

4200

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

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

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

For English Version Version française Versión en español

See page 2 Voir page 25 Ver la página 49

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General Power Tool Safety Warnings

WARNING

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.

Work area safety

Keep work area clean and well lit. Cluttered

or dark areas invite accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power

tools create sparks which may ignite the dust or fumes.

Keep children and bystanders away while operating a power tool. Distractions can

cause you to lose control.

Electrical safety

Power tool plugs must match the outlet. Never modify the plug in any way. Do not us e a ny adapter pl ug s with earthed (grounded) power tools. Unmodified plugs

and matching outlets will reduce risk of electric shock.

Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk

of electric shock if your body is earthed or grounded.

Do not expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled

cords increase the risk of electric shock.

When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use

reduces the risk of electric shock.

If operating 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 use co mmon sense when operating 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 switch is in the off- posit ion before connecting to power source and / or battery pack, picking up or carryi ng t he t ool.

Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.

Remove any adjusting key or wrench before turning the power tool on. A wrench or a key

left attached to a rotating part of the power tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times. This enables better

co ntrol of the power to ol in unexpe ct ed situations.

Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose

clothes, jewelry or long hair can be caught in moving parts.

If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-

related hazards.

Power tool use and care

Do not force the power tool. Use the correct power tool for your application. The correct

power tool will do the job better and safer at the rate for which it was designed.

Do not use the power tool if the switch does not turn it on and off. Any power tool that

ca nn ot be co nt ro lled with the swi tc h is dangerous and must be repaired.

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Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such

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

Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are

dangerous in the hands of untrained users.

Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use.

Ma ny acci de nt s a re ca us ed by poorly maintained power tools.

Safety Rules for Rotary Tools

Hold power tool by insulated gripping surfaces, because the cutter may contact its own cord. Cutting a ”live” wire may make

exposed metal parts of the power tool ”live” and shock the operator.

Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the work by your

hand or against the body leaves it unstable and may lead to loss of control.

Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running

over rated speed can fly apart and cause injury.

If cutting into existing walls or other blind areas where electrical wiring may exist is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

Do not operate the flexible shaft with a sharp bend. Over bending the shaft can

generate excessive heat on the jacket or hand piece. The recommended minimum is 5" radius.

Always disconnect the power cord from th e pow er source bef or e making an y adjustments or attaching any accessories.

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

Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the

power tool for operations different from those intended could result in a hazardous situation.

Service

Have your power tool serviced by a qualified re pa ir person using o nly id en tical replacement parts. This will ensure that the

safety of the power tool is maintained.

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.

Do not reach in the area of the spinning bit. The proximity of the spinning bit to your

hand may not always be obvious.

Allow brushes to run at opera ting speed for at least one minute before using wheel. During this time no one is to stand in front or in line with the brush. Loose bristles or

wires will be discharged during the run-in time.

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

particles and tiny wire fragments may be di sc ha rged at high ve lo ci ty during t he “cleaning” action with these brushes and may become imbedded in your skin. Bristles or wires will be discharged from the brush at high speeds.

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Safety Rules for Rotary Tools - (cont.)

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

“Heavy” pressure on bristles will cause the wi re or b ri stle t o become overstres se d, resulting in a wiping action and will cause the bristles/wire to be discharged.

Ca re fully handle both the tool and in di vidual gr in ding wh ee ls to avoid chipping or cracking. Install a new wheel if tool is dropped while grinding. Do not use a wheel that may be damaged. Fragments

from a wheel that bursts during operation will fly away at great velocity possibly striking you or bystanders.

Never use dull or damaged bits. Sharp bits must be handled with care. Damaged bits

can snap during use. Dull bits require more force to push the tool, possibly causing the bit to break.

Us e cl am ps to supp or t w or kpiece whenever practical. Never hold a small workpiece in one hand and the tool in the ot he r hand while in us e. A ll ow f or sufficient space, at least 6", between your hand and the spinning bit. Round material

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

Inspect your workpiece before cutting. Wh en cu tt ing i rregularly 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.

Ne ve r start the tool wh en 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 is it 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 by compressed air. Excessive accumulation of

powdered metal inside the motor housing may cause electrical failures.

Do not al lo w familiarity gai ne d from frequent use of your rotary tool to become commonplace. Always remember that a

careless fraction of a second is sufficient to inflict severe injury.

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

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

result.

When using the steel saws, cut off wheels, high speed cutters or tungsten carbide cutters, always have the work secure ly clamped. Never attempt to hold the work with one hand while using any of these accessories. The reason is that these wheels

will grab if they become slight ly canted in the groove, and can kick back causing loss of control resulting in serious in jury. Your second hand should be used to steady and guide the hand holding the tool. When a cutoff wheel

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Safety Rules for Rotary Tools - (cont.)

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.

Us e only Dre mel acces sories. Other accesso ries ar e not

designed for this tool and may lead to personal injury or property damage.

, high -performa nce

Additional Safety Warnings

GFCI and personal protection devices like electrician’s rubber gloves and footwear will further enhance your personal safety.

Do not use AC only rated tools with a DC power supply. While the tool may appear to

work, the electrical components of the AC rated tool are likely to fail and create a hazard to the operator.

Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely

control the power tool.

Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against

your body is unstable and may lead to loss of control.

Develop a periodic maintenance schedule for your tool. When cleaning a tool be careful not to disassemble any portion of the tool since inter nal wires may be misplaced or pinched or safety guard return springs ma y be improperly mo unted .

Certain cleaning agents such as gasoline,

Af te r c ha ng ing b it s o r ma ki ng an y adjustments, make sure the bit is properly secured by pulling the EZ Change™ levers forward. Loose adjustm ent devic es c an

unexpectedly shift, causing loss of control, loose rotating components may be ejected.

carbon tetrachloride, a mmo nia, etc. ma y damage plastic parts.

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

WARNING

drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints,

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

• Arsenic and chro mium fro m chemic allytreated lumber.

You r ris k from these exposu re s varies, depending on how often you do this type of work. To reduce your expos ure to t hese chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

Some dust created by power sanding, sawing, grinding,

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Symbols

IMPORTANT: Some of the following symbols may be used on your tool. Please study them

and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

n Rated speed Maximum attainable speed

.../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

Li-ion RBRC seal Designates Li-ion battery recycling

program

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

Read manual symbol Alerts user to read manual

Wear eye protection symbol Alerts user to wear eye protection

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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.

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.

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Functional Description and Specifications

WARNING

Di sconnect the plug fro m the pow er source bef ore maki ng any assembly, adjustments or changing accessories. Such preventive safety

measures reduce the risk of starting the tool accidentally.

Model 4200 High Speed Rotary Tool EZ Change™

FIG. 1

BRUSH COVER

(one on each side)

ON/OFF SWITCH

HOUSING

CAP

COLLET

VARIABLE SPEED

DIAL

CORD

HANGER

VENTILATION

OPENINGS

EZ CHANGE™

CHUCK

VENTILATION

OPENINGS

EZ CHANGE™

LEVERS

Model number 4200 Voltage rating 120V 50 - 60Hz Amperage rating 1.6A No load speed n

5,000-35,000/min

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

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Assembly

WARNING

changing collets or servicing your Rotary Tool.

WARNING

make sure the bit is properly secured by pulling the EZ Change™ levers forward.

Loose adjustment devices can unexpectedly shift, causing loss of control, loose rotating components may be ejected.

INSTALLING AND REMOVING

Your Dremel 4200 is equipped with the EZ Change™ mechanism which will allow you to quickly and easily change accessories without the use of a wrench.

1. To install a accessory, pull and hold the EZ Change™ levers in direction of arrows 1 as far as they will go (Fig. 2).

Always unplug Rotary Tool before changing accessories,

Af te r ch an gi ng bi ts or making any adjustments,

ACCESSORIES

FIG. 2

EZ CHANGE™

LEVERS

ACCESSORY

COLLET

2. Insert accessory into the collet as far as possible to minimize runout and unbalance, and then and release EZ Change™ levers.

3. Press EZ Change™ levers towards the nose of the tool to fully secure the bit. If slipping of the bit while in use occur, the tool needs service.

4. To remove accessories, pull and hold the EZ Change™ levers in direction of arrows 1 as far as they will go and simply remove accessory from the EZ Change™ chuck.

CAUTION

Rotary Tool is running as the bit may be

ejected.

Four different size collets to accommodate different shank sizes, are avail able for your Rotary Tool (Fig. 3).

CAUTION

Do not engage the EZ Change™ levers while the

COLLETS

Always use the collet which matches the shank size of

EZ CHANGE™

CHUCK

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

FIG. 3

1/8"

COLLET

IDENTIFICATION

RINGS

3/32"

COLLET

1/16"

COLLET

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. 1/8" is included

in the 4200 kit.

Note: Most rotary tool kits do not include all four

collets sizes. Other collets sizes can be ordered through the Dremel Service Center or on-line.

To install a different collet, remove collet from EZ Change™ chuck by using needle nose pliers (Fig. 4). Lightly depress the finger of the collet until it is clear of the detent feature (Fig. 5) and pull collet free from chuck. Insert

FIG. 4

NEEDLE

NOSE

PLIERS

CHANGING COLLETS

EZ CHANGE™

CHUCK

COLLET

FIG. 5

DETENT

FINGER

Push collet finger with needle nose pliers

until clear of detents and then pull it out

1/32"

COLLET

DETENT

WAR NING

Wear Eye Protection



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narrow end of the new collet completely into the EZ Change™ chuck. The fingers of the collet must be aligned with the detents of the EZ Change™ chuck to be fully inserted.

BALANCING ACCESSORIES — For precision work, 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 by pulling back on the EZ Change™ levers and give the accessory a 1/4 turn. Release EZ Change™

Operating Instructions

Dremel 4200

Thank you for purchasing the Dremel 4200. Th is prod uct was designed by the many Dremel users who passionately use their rotary tools daily. This tool was designed to give you an easy way to change accessories and the ultimate performance when working on projects.

The Dremel 4200 is the FIRST rotary tool that easily change accessories without using a wrench. It uses a fully integrated mechanism that clamps the accessory through a lever system. In addition, the Dremel 4200 is a high pe rform ance rotary too l with elect ronic 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 many po sitio ns. You will appreciate the many applications that the Dremel 4200 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 abrasive wheels, drill bits, wire brushes, polishers, engraving cutters, router bi ts, c uttin g wh eels and attachments. Accessories come in a variety of shapes and permit you to do a number of different jobs. As yo u be come familiar wi th 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 re volut ions per minu te. The Rotary Tool operates at speeds up to 35,000 revolutions per minute. The typical electric drill is a low-

levers and run the Rotary Tool. You should be able to tell by th e sound and fe el 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.

speed, 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 learn about more uses and the ve rsati lity o f Drem el acce ssori es and attachments refer to this Owner's Manual or check our website at www.Dremel.com.

Using the Rotary Tool

The first step in learning to use the Rotary Tool is to get the “feel” of it. Hold it in your hand and feel its weight and balance. Feel the taper of the housing.

Always hold the tool away from your face. Ac cesso ries ca n be da maged du ring handling, and can fly apart as they come up to speed. This is not

common, but it does happen.

CAUTION

Wh enever yo u hold th e

tool, be careful not to cover the air vents with your hand. This blocks th e air flow and ca uses the motor to overheat.

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For best control in close work, grip the Rotary Tool like a pencil between your thumb and forefinger (Figure 6).

FIG. 6

The “Golf Grip” method of holding the tool is used for more aggressive operations such as grinding a flat surface or using cutoff wheels (Figure 7).

FIG. 7

Questions or Problems? Call 1-800-437-3635

or check our website at www.Dremel.com

Practice on scrap materials first to see how the Rotary Tool's high speed action performs. Keep in mind that the work is done by the speed of the tool and by the accessory in the collet. You should not lean on or push the tool during use.

Instead, lower the spinning accessory lightly to the work and allow it to touch the point at which you want cutting (or sanding or etching, etc.) to begin. Con centrate on guiding the tool over the work using very little pressure from your hand. Allow the accessory to do the work.

Usually, it is best to make a series of passes with the tool rather than attempt to do all the work in one pass. To make a cut, for example, pass the tool back and forth over the work, much as you would a small paint brush. Cut a little material on each pass until you reach the desired depth. For most work, the gentle touch is best. With it, you have the best control, are less likely to make errors, and will get the most effi cient work out of the accessory.

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

Operating Speeds

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

NO TE: Spee d i s affect ed by volta ge changes. A reduced incoming voltage will slow the RPM of the tool.

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 Mini-Saw and Dremel Right Angle.

Your tool is equipped with an internal electronic

ELECTRONIC FEEDBACK

feedback system that provides a “soft start”, which will reduce the stresses that occur from a high torque start. The system also helps to keep the preselected speed virtually constant between no-load and load conditions.

VARIABLE SPEED DIAL

Your tool is equipped with a variable speed dial. The speed may be adjuste d du ring operati on b y presett in g the dial on or between any one of the settings.

You can refer to the charts on page 21, 22, 23 and 24 to determine the proper speed, based on the materi al being worked and the type of accessory being used. These charts enable you to select both the correct acces sory and the optimum speed at a glance.

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The speed of Rotary Tool is controlled by setting this dial on the housing (Fig. 8).

Settings for Approximate Revolutions.

VARIABLE SPEED

DIAL

FIG. 8

Switch Setting Speed Range

5 15,000-7,000 RPM

*10 17,000-10,000 RPM

15 13,000-17,000 RPM

20 18,000-23,000 RPM

25 23,000-27,000 RPM

30 28,000-32,000 RPM

35 33,000-35,000 RPM

* Wire Brush Setting.

Needs for Slower Speeds

Certain materials, however, (some plastics and pr ecious metals , fo r ex ample) requi re a relatively slow speed because at high speed the friction of the accessory generates heat and may cause damage to the material.

Slow speeds (15,000 RPM or less) usually are best for polishing operations employing the felt polishing ac ces sories. They may also be best for working on deli cate projects as “eggery” work, delicate wood carving and fragile model parts. All brushing applications require

lower speeds to avoid wire 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.

Many applications and accessories in our line will provide the best performance at full speed, but for certain materials, applications, and

accessories, you need slower speeds, which is the reason our variable speed models are available.

To aid you in det erminin g the optim um operational speed for differ ent materials and different accessories, we have construct ed a series of tables that appear on page 21, 22, 23 and 24. By referring to these tables, you can discover the recommended speeds for each type of accessory. Look these tables over and become familiar with them.

Ultimately, the best way to determine the correct speed for work on any material is to practice for a few minutes on a piece of scrap, even after referring to the chart. You can quickly learn that a slower or faster speed is more effective just by observing what hap pens as you make a pass or two at different speeds. When working with plastic, for example, start at a slow rate of speed and increase the speed until you observe that the plastic is melting at the point of contact. Then reduce the speed slight ly to get the optimum working speed.

Some rules of thumb in regard to speed:

1. Plastic and other materials that melt at low temperatures should be cut at low speeds.

2. Polishing, buffing and cleaning with any type of bristle brush must be done at speeds not greater than 15,000 RPM to prevent damage to th e bru sh from brist le s fly ing toward operator.

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 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 ould. Pe rhaps yo u sho uld be us ing a di ffere nt ac cessory, an d pe rhaps an adjustment in speed would solve the problem. Leaning on the tool does not help.

Let speed do the work!

Use only Dremel®, high-performance accessories.

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Maintenance Information

Service

WARNING

per so n nel may result in misplacing of internal wires and components which could cause serious hazard. We recommend that

all tool service be performed by a Dremel Service Facility.

WARNING

electrical shock, always remove plug from wall outlet before performing service or cleaning.

The brushes and commutator in your tool have be en engineer ed for many ho urs of dependable service.

In order to prepare your brushes for use, run your tool at full speed for 5 minutes under no load. This will properly “seat” your brushes, which extends the life of both your brushes and your tool.

To maintain peak efficiency of the motor, we recommend every 40 - 50 hours the brush es be examined. Only genuine Dremel replace ment brushes specially designed for your tool should be used.

MAINTENANCE OF REPLACEABLE

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.

permanently damage your tool.

Follow these steps to check/change the rotary tool brushes:

1. With the power cord unplugged, place the tool on a clean surface. Use a screwdriver to remove the brush caps in a counter-clockwise direction (Figure 9).

2. Remove the brushe s fr om the tool by pulling on the spring that is attached to the carbon brush. If the brush is less than 1/8" long and the end surface of the brush that contacts the commutator is rough and/or pitted, they should be replaced. Check both brushes (Figure 10).

BRUSHES ON MODEL 4200

CAUTION

Pr eventiv e mai ntenanc e pe r formed by unauthorized

To avoi d in ju ry fr om un ex pected s ta rting or

CARBON BRUSHES

To continue using the tool in this condition will

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 surfa ce will “wear ” longer.

FIG. 9

BRUSH CAP

BRUSH SPRING

BRUSH

CURVED END OF BRUSH MUST MATCH CURVATURE OF COMMUTATOR

FIG. 10

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Model 4200 has ball bearing construction.

BEARINGS

Under normal use no additional lubrication is required.

Cleaning

WARNING

th e power supp ly be fore cleanin g or performing any main tenance. The tool may

be cleaned most effectively with compressed dry air. Always wear safety gog gles when

cleaning tools with compressed air.

To avoid accidents always dis connect the tool from

Extension Cords

WARNING

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. 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.

If an extension cord is necessary, a co rd with

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

Certain cleaning agents an d sol vent s dama ge

plastic parts. Some of these are: gasoline,

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

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

Tool’s

Ampere

Rating

3-6 6-8

8-10 10-12 12-16

Cord Size in A.W.G.

Cord Length in Feet Cord Length in Meters

25 50 100 150 15 30 60 120

18 16 16 14 0.75 0.75 1.5 2.5 18 16 14 12 0.75 1.0 2.5 4.0 18 16 14 12 0.75 1.0 2.5 4.0 16 16 14 12 1.0 2.5 4.0 — 14 12 —— ————

Wire Sizes in mm

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Dremel Attachments

The Dremel 4200 will work with a variety of Dremel attachments including the attachments included in the kit. Before purchasin g an individual Dremel attachment, always check for the compatibility with the Dremel 4200. Please note that the PL400 and MS400 attachments, as well as some other older attachments, will NOT fit on this rotary tool. When in doubt, please contact customer service.

The adapter kit provided with your 4200 will allow you to use the optional 225, 575 and 670 Dremel attachment.

INSTALLING ADAPTER

1. Remove accessory from the EZ Change™ chuck (Fig. 2).

2. Unscrew housing cap and remove from tool (Fig. 11).

3. Insert drive coupling into the EZ Change™ chuck (Fig. 12).

4. Thread adapter onto the tool until tight (Fig. 12).

INSTALLING OPTIONAL ATTACHMENTS

Make sure the square end of the center core of desired attachment engages the square hole

Dremel Accessories

socket in the driver cou pling and t hread attachment onto end of adapter.

FIG. 11

HOUSING

CAP

Tighten

Loosen

FIG. 12

Tighten

ADAPTER

Loosen

DRIVE

COUPLING

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. 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.

The collets used in the Dremel 4200 are different from the ones used in any other

Use only Dremel®, high-performance accessories. Other accessories are not

designed for this tool and may lead to personal injury or property damage.

Collets

Dremel Rotary Tool. Collets 480, 481, 482, 483 and 4485 cannot be used in the 4200.

Mandrels

A mandrel is a shank with a threaded or screw he ad, which are requi red wh en y ou u se polishing accessories, cutting wheels, sanding di scs, a nd pol ish ing points. The rea son mandre ls ar e use d is that sandi ng di scs, cutting wheels and similar accesso ries must be replaced frequently. The mandrel is a per manent shank, allowing you to replace only the worn head when necessary, thus saving the expense of replacing the shaft each time.

Screw Mandrel N° 401

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

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This is a mandrel with a small screw at its tip,

Small Screw Mandrel N° 402

and is used with emery and fiberglass cutting wheels, sanding discs and polishing wheels. 1/8" shank.

EZ Lock™ Mandrel N° 402

Th e Dremel EZ Lock mak es acce ssory changes easy as PULL - TWIST - RELEASE. The one-piece mandrel design simplifies the

High Speed Cutters

Available in many shapes, high speed cutters are used in carving, cutting and slotting in wo od, plasti cs and soft me ta ls such as aluminum, copper and brass. These are the accessories to use for freehand routing or carving in wood or plastic, and for precision cutting. Made of high quality steel. 1/8" shank.

Tungsten Carbide Cutters

These are tough, long-lived cutters for use on hard ened steel, fired ceramics and other very ha rd ma teri al s. Th ey ca n be us ed fo r engraving on tools and garden equipment. 1/8" shanks.

process of changing cutting wheels, buffs and detail abrasive brushes (EZ Lock compatible accessories).

EZ Drum™ Mandrel N° EZ407SA

Th e Dremel EZ Drum mak es accesso ry changes easy as PULL - PLACE - SECURE. The one-piece mandrel design simplifies the process of changing sanding discs.

Aluminum Oxide Grinding Stones

(red/brown)

Round, pointed, flat — you name the shape and there is one available in this category. These are made of aluminum oxide and cover vi rtually every possibl e kind of gri nd ing application. Use them for sharpening lawn mo wer bl ades, screw dr iver tips, knives , scissors, chisels and other cutting tools. Use to remove flash from metal castings, deburring any metal after cutting, smoothing welded joints, grinding off rivets and re mov ing rust. These grinding stones can be resharped with a dressing stone. In machine shops, high speed drills and cut ters normally are ground with aluminum oxide wheels. 1/8" shank.

This group has a wide variety of sizes and

Engraving Cutters

shapes, and are made for intricate work on ceramics (greenware), wood carvings, jewelry and scrimshaw. They often are used in making compl icat ed printed circuit boards. They should not be used on steel and other very hard materials but are excellent on wood, plastic and soft metals. 3/32" shank.

Structured Tooth Tungsten Carbide Cutters

Fast cutting, needle-sharp teeth for greater material removal with minimum loading. Use on fiberglass, wood, plastic, epoxy and rubber. 1/8" shank.

Silicon Carbide Grinding Stones

(blue/green)

Tougher than aluminum oxide points, these are made es pecially for use on hard materials such as glass and ce ramics. Typical uses might be the removal of stilt marks and excess glaze on ceramics and engraving on glass. 1/8" shank.

Diamond Wheel Points

Excellent for fine detail work on wood, jade, ceramic, glass and other hard material. Bits are covered with diamond particles. 3/32" shanks. (Not recommended for drilling)

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Dremel Accessories (Cont.)

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

Three different shapes of wire brushes are

Wire Brushes

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

three shapes come in three different materials: stainless steel, brass and carbon wire. The st ainless steel pe rform wel l on pe wt er, aluminum, stainless steel, and other metals, without leaving "after-rust". Brass brushes are non sparking, and softer than steel; making them good for use on soft metal like gold, cooper and brass. The carbon wire brushes are good for general purpose cleaning.

Bristle Brushes

Th ese a re excellent cl ea ning tools on silverware, jew elry and antiques. The three shapes make it possible to get i nto tight corners and other difficult places. Bristle brushes can be used with polishing compound for faster cleaning or polishing.

Brushing Pressure

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

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

INCORRECT:

Excessive pressure can cause wire breakage.

breakage and shortened brush life.

Wire tips doing the work.

Polishing Accessories

These include an impregnated polishing point an d an impre gnate d polishing whe el for bringing metal sur faces to smooth finish; a felt polishing tip and felt polish ing wheel, and cloth polishing wheel, all used for polishing plastics, metals, jewelry and small parts. Also included in this group is a polishing compound (No. 421) for use with the felt and cloth polishers.

Polishing points make a very smooth surface, but a high luster is obtained using felt or cloth wheels and polishing compound. For best

results polishing accessories should be used at speeds not greater than 15,000 RPM.

No polishing compound is needed when using the 425 Polishing Wheel.

Aluminum Oxide Abrasive Wheels

Use to remove paint, deburr metal, polish stainless steel and other metals. Available in medium grit. 1/8" shank.

CORRECT:

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Dremel Accessories (Cont.)

operations. Use them for cutting off frozen bolt heads and nuts, or to reslot a screw head which has bec ome so d amaged that the

Sanding discs in fine, medium and coarse

Sanding Accessories

grades are made to fit on a mandrel. 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 wo rk effec tivel y 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.

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 us ed fo r slicing , cutting off and similar

For routing, inlaying, and mortising in wood

High Speed Router Bits

and other soft materials. Use with Dremel No. 33 5 R outer attach me nt a nd No. 231 Shaper/Router table.

Drill bits

The following drill bits (628, 660, 661) can only be used with the 4200 if the 1/8" collet that comes with the tool is changed with the collet that matches the drill bit shank size (1/32" or 1/16" or 3/32").

3 Jaw Chuck

The following chucks (4484, 4486) can not be used with the 4200 due to the absence of a th re ad ed c on e i n th e EZ Chan ge ™ mechanism.

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EZ Lock™and EZ Drum™Operating Instructions

™

EZ Lock

abrasive buffs and polishing cloth.

FIG. 1

Mandrel No. EZ402 has a spring loaded sleeve and is used with cutting wheels,

FIG. 2

WARNING

Incorrect seating of wheel on mandrel may lead to personal injury orproperty damage.

1. Pull EZ Change™ levers down towards unlock sign on the tool (Fig. 1). Place EZ Lock™ mandrel (1) into EZ Change™ chuck (2) as deep as possible (Fig. 2) and release EZ Change™ levers to tighten (Fig. 3). Note: there is a blue spacer (3) on the mandrel that will bottom out on the EZ Change™ chuck, setting the mandrel to the correct depth.

2. Pu ll spring- loaded sleev e (4) DOWN towards tool with one hand and hold. You can brace the tool on the body or work-bench for extra leverage (Fig. 4).

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. 5).

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 aligns with the sleeve. Release sleeve. Wheel should lock in place (Fig. 6).

5. When mounting s anding and polishing accessories, align bowtie with metal insert on bottom of accessory (Fig. 7a & 7b).

To check for proper seating, hold collet lock button and twist accessory. Accessory will not be able to rotate on mandrel.

1. Pull spring-loaded sleeve DOWN toward tool with one hand (Fig. 4).

2. Hold sleeve down while twisting accessory 90 degrees.

3. Remove accessory.

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

Al ways u nplug rotary tool before changing accessories.

To load accessory:

To unload accessory:

During use

FIG. 3

FIG. 4

FIG. 5

FIG. 6

90˚

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FIG. 7a FIG. 7b

90˚

EZ Drum™ Mandrel No. EZ407SA has a

spring loaded sleeve and is used with sanding bands.

1. Pull EZ Change™ levers down towards unlock sign on the tool (Fig. 1). Place EZ Drum™ mandrel (1) into EZ Change™ chuck (2) as deep as possible (Fig. 2) and release EZ Change™ levers to tighten (Fig. 3). Note: there is a blue spacer (3) on the mandrel that will bottom out on the EZ Change™ chuck, setting the mandrel to the correct depth.

WARNING

Incorrect seating of sanding band on mandrel may lead to personal injury orproperty damage.

2. As indicated, place two fingers underneath the mandrel and pull firmly up. This will place

Al ways u nplug rotary tool before changing accessories.

To load accessory:

FIG. 1

the EZ Drum™ in the "unlocked" position (Fig. 2).

3. Keeping two fingers beneath the mandrel, slide the sanding band down until the entire blue mandrel is covered (Fig. 3).

4. To return to "locked" position, press firmly down on the top of the mandrel (Fig. 4).

Removing the sanding band on

1. Place two fingers underneath the mandrel and pull firmly up. This will place the EZ Drum™ in the "unlocked" position (Fig. 2).

2. Sanding band will now easily slide off mandrel. (Do not squeeze sanding band when removing from EZ Drum ™ mandrel. This can lead to rubber band pulling off mandrel and becoming inoperable (Fig. 4).

the mandrel:

FIG. 2

FIG. 3

FIG. 4

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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 = x 1000 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 7150

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

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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 = x 1000 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

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 • -- - --655

Silicon Carbide Grinding Stones (blue/green)

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 Wheels/Points

Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass Number Wood Wood /Plastic Brass, etc. Stone

516 9-17 9-17 - 18-24 12-17 --500 9-17 9-17 - 18-24 9-17 EZ541GR -- -12-24 9-17 ---

Aluminum oxide grinding stones (orange/bown)

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

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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 = x 1000 RPM’s

Chain Saw Sharpening Stones

Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass Number Wood Wood /Plastic Brass, etc. Stone

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

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 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 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

Wire Brushes

Catalog Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass Number Wood Wood /Plastic Brass, etc. Stone

403, 404, 405 9-11 9-11 5-11 12-15 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 Wood Wood /Plastic

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 EZ407SA 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 EZ411SA, 12-17 12-17 5-8 - 5-8 EZ412SA, 12-17 12-17 5-8 - 5-8

EZ413SA

411, 412, 413 12-17 12-17 5-8 - 5-8

Soft Hard Laminates Steel Aluminum, Shell/ Ceramic Glass

12-17 12-17 5-8 - 5-8

Brass, etc. Stone

- - -

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