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

Read and understand all instructions. Failure to follow all instructions list-
! WARNING 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
long hair can be caught in moving parts.
Electrical Safety 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
change the plug in any way. Double Remove adjusting keys or wrenches
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
unavoidable, a Ground Fault Circuit Tool Use and Care
Interrupter must be used to supply the power Use clamps or other practical way to
to your tool. Electricians 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
to carry the tools or pull the plug from an designed.
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 Service
and other untrained persons. Tools are
Tool service must be performed only by
dangerous in the hands of untrained users.
qualified repair personnel. Service or
Maintain tools with care. Keep cutting maintenance performed by unqualified per-
tools sharp and clean. Properly main- sonnel could result in a risk of injury. For
tained tools, with sharp cutting edges are example: internal wires may be misplaced
less likely to bind and are easier to control. or pinched, safety guard return springs may
Any alteration or modification is a misuse be improperly mounted.
and may result in a dangerous condition.
When servicing a tool, use only identical
Check for misalignment or binding of replacement parts. Follow instructions in
moving parts, breakage of parts, and any the Maintenance section of this manual.
other condition that may affect the tools Use of unauthorized parts or failure to follow
operation. If damaged, have the tool Maintenance Instructions may create a risk
serviced before using. Many accidents of electric shock or injury. Certain cleaning
are caused by poorly maintained tools. agents such as gasoline, carbon tetrachlo-
Develop a periodic maintenance schedule ride, ammonia, etc. may damage plastic
for your tool. parts.
Use only accessories that are recom-
mended by the manufacturer for your
model. Accessories that may be suitable for
one tool, may become hazardous when
used on another tool.

SAFETY RULES FOR ROTARY TOOL

Accessories must be rated for at least the Always wear safety goggles and dust
speed recommended on the tool warning mask. Use only in well ventilated area.
label. Wheels and other accessories run- Using personal safety devices and working in
ning over rated speed can fly apart and safe environment reduces risk of injury.
cause injury.
After changing the bits or making any
Hold tool by insulated gripping surfaces adjustments, make sure the collet nut and
when performing an operation where the any other adjustment devices are secure-
cutting tool may contact hidden wiring or ly tightened. Loose adjustment device can
its own cord. Contact with a "live" wire will unexpectedly shift, causing loss of control,
make exposed metal parts of the tool "live" loose rotating components will be violently
and shock the operator. If cutting into existing thrown.
walls or other blind areas where electrical
Do not reach in the area of the spinning
wiring may exist is unavoidable, disconnect
bit. The proximity of the spinning bit to your
all fuses or circuit breakers feeding this work-
hand may not always be obvious.
site.
Allow brushes to run at operating speed
Do not operate the flexible shaft with a
for at least one minute before using
sharp bend. Over bending the shaft can
wheel. During this time no one is to stand
generate excessive heat on the jacket or
in front or in line with the brush. Loose
hand piece. The recommended minimum is
bristles or wires will be discharged during the
6" radius.
run-in time.
Always disconnect the power cord from
Wire and bristle brushes must never be
the power source before making any
operated at speeds greater than
adjustments or attaching any acces-
15,000/min. Direct the discharge of the
sories. You may unexpectedly cause the tool
spinning wire brush away from you.
to start leading to serious personal injury.
Small particles and tiny wire fragments may
Be aware of the switch location, when be discharged at high velocity during the
placing the tool down or when picking the cleaning action with these brushes and may
tool up. You may accidentally activate the become imbedded in your skin. Bristles or
switch. wires will be discharged from the brush at
Always hold the hand piece firmly in your high speeds.
hands during the start-up. The reaction Carefully handle both the tool and individ-
torque of the motor, as it accelerates to full ual grinding wheels to avoid chipping or
speed, can cause the shaft to twist. cracking. Install a new wheel if tool is

3
 SAFETY RULES FOR ROTARY TOOL (CONTINUED)

dropped while grinding. Do not use a complete stop it is safe to put it down.
wheel that may be damaged. Fragments Do not grind or sand near flammable
from a wheel that bursts during operation will materials. Sparks from the wheel could
fly away at great velocity possibly striking you ignite these materials.
or bystanders.
Do not touch the bit or collet after use.
Never use dull or damaged bits. Sharp After use the bit and collet are too hot to be
bits must be handled with care. Damaged touched by bare hands.
bits can snap during use. Dull bits require
more force to push the tool, possibly causing Regularly clean the tool's air vents with
the bit to break. compressed air. Excessive accumulation of
powdered metal inside the motor housing
Use clamps to support workpiece when- may cause electrical failures.
ever practical. Never hold a small work-
piece in one hand and the tool in the other Do not allow familiarity gained from fre-
hand while in use. Allow for sufficient quent use of your rotary tool to become
space, at least 6", between your hand and commonplace. Always remember that a
the spinning bit. Round material such as careless fraction of a second is sufficient to
dowel rods, pipes or tubing have a tendency inflict severe injury.
to roll while being cut, and may cause the bit Do not alter or misuse tool. Any alteration
to bite or jump toward you. Clamping a or modification is a misuse and may result in
small workpiece allows you to use both serious personal injury.
hands to control the tool. This product is not intended for use as a
Inspect your workpiece before cutting. dental drill, in human or veterinary med-
When cutting irregularly shaped work- ical applications. Serious injury may result.
pieces, plan your work so it will not slip When using the steel saws, cutoff wheels,
and pinch the bit and be torn from your high speed cutters or tungsten carbide
hand. For example, if carving wood, make cutters, always have the work securely
sure there are no nails or foreign objects in clamped. Never attempt to hold the work
the workpiece. Nails or foreign objects can with one hand while using any of these
cause the bit to jump. accessories. The reason is that these
Never start the tool when the bit is wheels will grab if they become slightly cant-
engaged in the material. The bit cutting ed in the groove, and can kickback causing
edge may grab the material causing loss of loss of control resulting in serious injury. Your
control of the cutter. second hand should be used to steady and
Avoid bouncing and snagging the wheel, guide the hand holding the tool. When a cut-
especially when working corners, sharp off wheel grabs, the wheel itself usually
edges etc. This can cause loss of control breaks. When the steel saw, high speed cut-
and kick-back. ters or tungsten carbide cutter grab, it may
jump from the groove and you could lose
The direction of feed with the bit into the control of the tool.
material when carving, routing or cutting
Some dust created by
is very important. Always feed the bit into ! WARNING power drilling and other
the material in the same direction as the
cutting edge is exiting from the material construction activities, contains chemi-
(which is the same direction as the chips cals known to cause cancer, birth defects
are thrown). Feeding the tool in the wrong or other reproductive harm. Some exam-
direction, causes the cutting edge of the bit to ples of these chemicals are:
climb out of the work and pull the tool in the Lead from lead-based paints,
direction of this feed. Crystalline silica from bricks and cement
If the workpiece or bit becomes jammed and other masonry products, and
or bogged down, turn the tool OFF by Arsenic and chromium from chemically
the switch. Wait for all moving parts to treated lumber.
stop and unplug the tool, then work to
free the jammed material. If the switch to Your risk from these exposures varies,
the tool is left ON the tool could restart depending on how often you do this type of
unexpectedly causing serious personal work. To reduce your exposure to these
injury. chemicals, work in a well ventilated area, and
work with approved safety equipment, such
Do not leave a running tool unattended, as those dust masks that are specially
turn power off. Only when tool comes to a designed to filter out microscopic particles.

4
 GETTING TO KNOW YOUR ROTARY TOOL

Unpacking & Checking Contents serve as a carver, grinder, polisher, sander,

To avoid injury from unex- cutter, power brush, drill, and more.
! WARNING pected starting or electri-
The tool utilizes a small, but effective DC
cal shock, always remove plug from wall
motor. The large variety of available
outlet when tool is not in use.
Dremel accessories includes abrasive
Separate all loose parts from packing materi- wheels, drill bits, wire and nylon brushes,
als and check each item with the contents engraving and carving cutters, router bits,
listed on the carton to make sure all items are polishing points and more. The ability to add
accounted for before discarding any packing different Dremel attachments adds to the
material. multi-faceted uses of the tool. The variety of
projects you can do with the tool is limitless.
IMPORTANT! If any parts are missing, or if
you require any assistance with these The 400 Series XPR Rotary Tool is a high-
instructions, please contact the Dremel speed tool and operates at speeds 5,000 to
Consumer Service at: 35,000 RPM. (A typical electric drill operates
only up to 2500 RPM!). When used with
1-800-437-3635 Dremel accessories and attachments, the
or check our website at www.Dremel.com. 400 Series XPR rotary tools high speed per-
formance allows you to work on even the
Description most demanding projects without having to
The 400 Series XPR Rotary Tool incorpo- exert undue pressure on the tool. The tool
rates both high-speed and performance to 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 Extension Cords

Voltage Rating . . . . . . . . . .120 V, 50-60 Hz If an extension cord is necessary, a cord
Amperage Rating . . . . . . . . . . . . . . . . .2.0 A with adequate size conductors that is
capable of carrying the current necessary
No Load Speed . . . . . . . . . .No 35,000/min for your tool must be used. This will pre-
Collet Capacity . . . .1/32", 1/16", 3/32", 1/8" vent excessive voltage drop, loss of power or
overheating.
Motor Specifications
RECOMMENDED SIZES
This Rotary Tool utilizes a variable high-
OF EXTENSION CORDS
speed RPM motor. It is wired for operation on
110-120 volts, 50-60 Hz. alternating current. 120 VOLT ALTERNATING CURRENT TOOLS
Before connecting the motor cord to wall out- NOTE: The smaller the gauge number, the
let, make certain the power switch is in the heavier the cord.
OFF position and be sure the electric current
is of the same characteristics as stamped on Cord Size in A.W.G. Wire Sizes in mm2
the Rotary Tool nameplate. Tools
Ampere
Connection To A Power Source
Cord Length in Feet Cord Length in Meters
Rating
25 50 100 150 15 30 60 120
To avoid electric shock,
! DANGER do not touch the metal 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
prongs on the plug when installing or 8-10 18 16 14 12 .75 1.0 2.5 4.0
removing the plug to or from the outlet. 10-12 16 16 14 12 1.0 2.5 4.0
If power cord is worn, cut
! DANGER or damaged in any way,
12-16 14 12

have it replaced immediately to avoid

shock or fire hazard.

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 This symbol designates

that this tool is listed by that this tool is listed to
Underwriters Laboratories. Canadian Standards by
Underwriters This symbol
This symbol designates Laboratories. designates
that this tool is listed by
that
the Canadian Standards This symbol designates that this tool com-
Association, and is listed this tool is listed by plies
to US Standards by CSA. Underwriters Laboratories, to NOM
and listed to Canadian Mexican
This symbol designates Standards by Underwriters Standards.
that this tool is listed by Laboratories.
the Canadian Standards
Association.
7
 ASSEMBLY
Always unplug rotary tool before changing accessories, changing
! WARNING 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.

Always use the collet which matches the shank size of the accessory you
! CAUTION 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. Shaft Lock Button
Do not engage the shaft
! WARNING lock button while rotary
tool is running. To
2. With the shaft lock button engaged, Tighten
loosen and remove the collet nut. Use Collet Nut
the collet wrench if necessary. Collet Wrench

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 To
finger tight. Do not fully tighten the nut Loosen
when there is no bit or accessory
installed.

Changing Accessories
1. Press the shaft lock button and rotate Shaft Lock Button
the shaft by hand until it engages the
shaft lock.
Do not engage the shaft
! WARNING lock button while rotary
tool is running.
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, fin- NOTE: Be sure to read the instructions
ger tighten the collet nut until the bit or supplied with your Dremel accessory for
accessory shank is gripped by the collet. further information on its use.

8
 ASSEMBLY (CONTINUED)

Keyless Chuck
The keyless chuck is used in place of the stan- Keyless Chuck
dard collet and collet nut to easily and quickly
remove and install some accessories.
The keyless chuck holds various accessories
with shank sizes 1/32" to 1/8" and is intended
for light duty accessories such as drill bits,
sanding drums, polishing accessories, wire
and bristle brushes and cut-off wheels.
1. See steps 13, Changing Collets on 3. Use the supplied wrench to complete-
page 7 to install the keyless chuck. ly tighten the keyless chuck if you are
2. Thread the keyless chuck onto the rotary unable to apply sufficient tightening
tool shank. pressure to hold the bit or accessory.

OPERATION
Learning To Use the Rotary Tool
Getting the most out of your rotary tool is a
matter of learning how to let the speed and

2
4

the feel of the tool in your hands work for you.

The first step in learn-
ing 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
For best control in close work, grip the rotary
housing. This taper permits the tool to be
tool like a pencil between your thumb and
grasped much like a pen or pencil. The
forefinger.
unique comfort grip on the nose allows for
added comfort and control during use.
Always hold the tool
! WARNING away from your face.
Accessories can be damaged during
handling and can fly apart as they come
up to speed. This is not common, but it
does happen.
When holding tool, do not
! CAUTION cover the air vents with
your hand. Blocking the air vents could
cause the motor to overheat.
IMPORTANT! Practice on scrap material first
2

to see how the tools high-speed action per-

4

forms. Keep in mind that your rotary tool will The golf grip method is used for more aggres-
perform best by allowing the speed, along sive operations such as grinding or cutting.
with the correct Dremel accessory and
attachment, do the work for you. Do not put Usually it is better to make a series of pass-
pressure on the tool during use, if possible. es with the tool rather than to do the entire
Instead, lower the spinning accessory lightly job with one pass. A gentle touch gives the
to the work surface and allow it to touch the best control and reduces the chance for
point at which you want to begin. error.
Concentrate on guiding the tool over the
work using very little pressure from your
hand. Allow the accessory to do the work.

9
 OPERATION (CONTINUED)

Operating Speeds
To achieve the best results when working Set the Speed Control to the desired setting.
with different materials, set the variable
speed control to suit the job. To select the
right speed for the accessory in use, practice
with scrap material first.
NOTE: Speed is affected by voltage changes. A
2

reduced incoming voltage will slow the RPM of the

tool, especially at the lowest setting. If your tool

4
appears to be running slowly, increase the speed
setting accordingly. The tool may not start at the
lowest switch setting in areas where outlet voltage
is less than 120 volts. Simply move the speed set-
ting to a higher position to begin operation.
The 400 Series XPR Rotary Tool switch set-
tings are marked on the speed control dial.
Refer to the Speed Settings chart on pages Some guidelines regarding tool speed:
11 thru 13 to help determine the proper There is no accessory for the Dremel
speed for the material being worked on and Rotary tool that will drill or cut glass.
the accessory to use.
Plastic and other materials that melt at low
Most jobs can be accomplished using the temperatures should be cut at low speeds.
tool at the highest setting. However, certain
materials (some plastics and metals) can be Polishing, buffing and cleaning with a wire
damaged by high-speed generated heat and brush must be done at speeds not greater
should be worked on at relatively slow than 15,000 RPM to prevent damage to the
speeds. brush and your material.
Slow speed operation (15,000 RPM or less) Wood should be cut at high speed.
is usually best for polishing operations Iron or steel should be cut at high speed.
employing the felt polishing accessories, del-
If a high speed steel cutter starts to vibrate,
icate wood carving and fragile model parts.
it usually indicates that it is running too
All brushing applications require lower
slow.
speeds to avoid wire discharge from the
holder. Let the performance of the tool do the Aluminum, copper alloys, lead alloys, zinc
work for you when using lower speed set- alloys and tin may be cut at various
tings. speeds, depending on the type of cutting
being done. Use a paraffin (not water) or
Higher speeds are better for drilling, carving,
other suitable lubricant on the cutter to pre-
cutting, routing, shaping, cutting dadoes or
vent the cut material from adhering to the
rabbets in wood. Hardwoods, metals and
cutter teeth.
glass require high speed operation also.
NOTE: Increasing pressure on the tool is not
The settings for approximate RPMs are:
the answer when it is not performing proper-
Switch Setting Speed Range RPM ly. Try a different accessory or speed setting
2 5,000-8,000 to achieve the desired result. Please refer to
the following Speed Setting charts or simply
4 9,000-11,000 contact Dremel Consumer Service at:
6 12,000-17,000 1-800-437-3635
8 18,000-24,000 or at www.Dremel.com.
10 25,000-35,000

10
 SPEED SETTINGS
Use only Dremel tested, high performance accessories.
* Speed for light cuts; Caution - burning on deep grooves.
Depending on cutting direction relative to grain.
High Speed Cutters
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
100, 121, 131 8 10 5 5 6 - - -
114, 124, 8 6 4 5 6 - - -
134, 144
190 8 10 4 7 8 - - -
118, 191, 192, 8 10 4 5 8 - - -
193, 194
116, 117, 8 6 4 5 6 - - -
125, 196
115 8 10 4 5 6 - - -
198 8 8 4 5 6 - - -
199 8 8 4 5 6 - - -
Engraving Cutters
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
105, 108 8 10 6 4 6 - - -
106, 109 8 10 5 4 6 - - -
107, 110 8 10 5 4 6 - - -
111 8* 10* 6* 4 6 - - -
112 8* 10* 5* 4 6 - - -
113 8* 10* 5* 4 6 - - -
Diamond Wheel Points
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
7103, 7105, 10 8 - - - 10 10 10
7117, 7120,
7122, 7123,
7134, 7144

Structured Tooth Tungsten Carbide Cutters

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
9931, 9932, 8 8 4 - 6 - - -
9933, 9934,
9935, 9936
Tungsten Carbide Cutters
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
9901, 9902, 8 8 4 8-10 6 8 8-10 8-10
9903, 9904,
9905, 9906,
9909, 9910,
9911, 9912

11
 SPEED SETTINGS (CONTINUED)
Use only Dremel tested, high performance accessories.
* Speed for light cuts; Caution - burning on deep grooves.
Depending on cutting direction relative to grain.
High Speed Router Bits
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
612, 640 10* 8 - - - - - -
615, 617, 618, 10* 8 - - - - - -
650, 652
654 10* 8 - - - - - -
Silicon Carbide Grinding Stones
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
83142, 83322, - - 6 10 4 6 10 10
83702, 84922,
85422, 85602,
85622

Abrasive Points
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
516, 517, 518, 4-6 4-6 - 8 6 - - -
500 4-6 4-6 - 8 6 - - -
Aluminum Oxide Grinding Stones
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
903, 911, 921, 10 10 - 8 4 6 10 -
932,941, 945,
952, 953, 954,
971, 997,
8153, 8175,
8193, 8215
541 10 10 - 8 4 6 10 -
Chain Saw Sharpening Stones
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
453, 454, 455 - - - 8 - - - -

12
 SPEED SETTINGS (CONTINUED)
Use only Dremel tested, high performance accessories.
* Speed for light cuts; Caution - burning on deep grooves. Depending on cutting direction relative to grain.
Cutting Accessories
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
409, 420, 426, - - 2-4 10 10 10 10 -
540
542 10 8-10 2-4 10 10 10 10 -
545 8-10 8 - - - - - -
560 For use on drywall. For best results, use at 35,000 rpm.
561 6-10 6-10 2-4 - 10 - - -
562 - - - - - - 10 -
Polishing Accessories
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
461, 462, 463 - - - 8 8 8 8 8
414, 422, 429 - - - 6 6 6 6 6
425, 427 - - - 8 8 - - -
423 - - - 6-8 6-8 6-8 6-8 6-8
403, 404, 405 4 4 2-4 6 6 - - -
530, 531, 532 - 4 - 4 - - - -
428, 442, 443 4 4 2 4 - - - -
535, 536, 537 4 4 - 4 4 4 - -
Sanding Bands and Discs
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
430, 431, 438 2-10 2-10 2-6 10 10 2-10 2-10 -
439, 440, 444 2-10 2-10 2-6 10 10 2-10 2-10 -
407, 408, 432 2-10 2-10 2-6 10 10 2-10 2-10 -
411, 412, 413 8 8 2-4 - 2-4 - - -
Flapwheels
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
502, 503, 504, 6-8 8 2 10 8-10 - - -
505
Finishing Abrasive Buffs
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
511 6 6 4 6 6 - - -
Drill Bit
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
150 10 8-10 2-4 - 6 - - -
Grout Removal Bits
Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic Glass
Number Wood Wood Plastic Brass, etc. Stone
569, 570 For use on wall and floor grout. 6-8 -

13
 MAINTENANCE

Preventative maintenance
! WARNING performed by unautho- A
rized personnel may result in misplacing
of internal wires and components which
could cause serious hazard. We recom-
mend that all tool service be performed
by a Dremel Service Facility.

2
To avoid injury from unex-
4

! WARNING pected starting or electri-

cal shock, always remove plug from wall
outlet before performing service or clean-
ing.
Carbon Brushes
The brushes in your tool have been engi- Removing Brush Cover
neered for many hours of dependable serv-
ice.
To prepare the brushes for use, run the tool B
at full speed for 5 minutes under no load.
This will properly seat the brushes, and
extend the life of the tool.
To maintain peak efficiency of the motor,
examine the brushes for wear every 40-50
hours.
Using the tool with worn
! CAUTION brushes will permanently
damage the motor.
Use only original Dremel replacement
brushes.
Inspect the rotary tool brushes after 40-50
hours of use. If the rotary tool runs erratical-
ly, loses power, or makes unusual noises
check the brushes for wear and possible
replacement. Remember: brushes in the
rotary tool are similar to oil in a car; the more Removing/Inspecting Brushes
you check/service, the better the perform-
ance.
Follow these steps to check/change the
rotary tool brushes. C
1. With the power cord unplugged, place
the tool on a clean surface. Use the tool
wrench to pry up and release the clip on
the brush cover (Figure A).
2. Remove the brushes from the tool by
pulling the shunt and brass clip which
are attached to the brush (Figure B).
NOTE: Be sure to note how the brass clip
slides out of the slot next to the brush pock-
et. Also, note how the detent on brass clip fits "V" Notch
into brush pocket slot, which secures the
brass clip into proper position.
3. Check each brush for wear. If brush is
less than 3/8" long, or if contact end is
rough or pitted, replace the brush.
Installing Brushes

14
 For questions or replacement brushes, Cleaning The Tool
please call Dremels Consumer Service Ventilation openings and switch levers must
at 1-800-437-3635 be kept clean and free of foreign matter. Do
or check our website at www.Dremel.com. not attempt to clean by inserting pointed
objects through openings.
4. Install existing or new brushes so the The tool may be
curved surface of the brush end match- cleaned with com-
es the curvature of the motor commuta- pressed air. Always
tor (as seen through the brush opening). wear safety goggles
NOTE: The detent on the brass clip must fit when cleaning tool
into the slot on the side of the brush pocket, with compressed air.
which secures the brass clip in the proper There is no need to lubricate the Dremel
position (Figure C). rotary tool.
5. Reinstall brush covers by angling the Certain cleaning agents
non-clip end into the opening. Make cer- ! CAUTION and solvents will damage
tain brush spring is centered in the V plastic parts. Some of these are: gasoline,
notch on the brush, then snap closed carbon tetrachloride, chlorinated clean-
the clip end of the brush cover. ing solvents, ammonia and household
6. Plug power cord into a wall outlet. Run detergents that contain ammonia.
the rotary tool at full speed for 5 minutes Clean the soft grip areas of the tool using a
under no load. This will properly seat the damp cloth. Tougher soiled areas may
brushes and extend the life of the tool. require more than one wipe application to get
clean.

15
 ACCESSORIES
For availability of all accessories and attachments, refer your local hardware, hobby or home
center. Or contact Dremel Consumer Service at:1-800-437-3635 or at www.Dremel.com.
Use only Dremel, high-performance accessories. Other accessories are
! WARNING not designed for this tool and may lead to personal injury or property
damage.

Drywall Cutting Bit Tile Cutting Bit

When using a template (outlet box) behind For use wall tile, cement board and plaster.
the drywall, cut in a counterclockwise direc- Start the bit into the material at a 45 angle
tion. and then slowly bring it to a 90 angle to
High Speed Router Bits begin the cut.
Multipurpose Cutting Bit

For use in wood, plastics, drywall, fiberglass,

vinyl or aluminum siding, acoustical tile and
For routing, inlaying and mortising in wood laminates.
and other soft materials. Use only with Start the bit into the material at a 45 angle
Dremel Router Attachment #330 or and then slowly bring it to a 90 angle to
Shape/Router Table #231. begin the cut.

Mandrels Small Screw Mandrel

A mandrel is a shank with a threaded or Mandrel has a small screw
screw head used with polishing accessories, at the tip and is used with 1/8" shank
cutting wheels, sanding discs and polishing emery and fiberglass cutting
points. The mandrel is a permanent shank, wheels, sanding discs and
allowing for replacement of the worn head polishing wheels.
when necessary.
Threaded Tip Mandrel
Screw Mandrel Mandrel has a threaded tip
For use with the felt polishing 1/8" shank which threads into the polish- 1/8" shank
tip and felt polishing wheels. ing point accessory #427.

Aluminum Oxide Grinding Silicon Carbide Grinding

Stones (red/brown) Stones (blue/green) 1/8" shank
These grinding stones Tougher than aluminum oxide
1/8" shank points, these are made especially for use on
come round, pointed or flat
and are made of aluminum hard materials such as glass and ceramics.
oxide. Use them for every possible grinding
operation: sharpening lawn mower blades,
screwdriver tips, knives, scissors, chisels and
other cutting tools. Use to remove flash from
metal castings, deburring any kind of metal.
These grinding stones can be resharpened Diamond Wheel Points
with a dressing stone. In machine shops,
Used for fine detail work on 3/32" shank
high speed drills and cutters are normally
wood, jade, ceramic, glass and
ground with aluminum oxide wheels.
other hard material. Bits are
covered with diamond parti-
cles.

16
 ACCESSORIES (continued)

High Speed Cutters Engraving Cutters

High speed cutters are Engraving cutters come in a 3/32" shank
used in carving, cutting 1/8" shank wide variety of sizes and
and slotting wood, plastics shapes and are used for intricate work on
and soft metals (such as aluminum, copper ceramics (greenware), wood carvings, jewel-
and brass). Made of high quality steel. ry and scrimshaw. They are often used in
making complicated printed circuit boards.
Structured Tooth Tungsten Carbide Cutters They should not be used on steel and very
hard materials, but are good for use on
wood, plastic and soft metals.

Tungsten Carbide Cutters

1/8" shank Tungsten carbide cutters 1/8" shank
are long-lived cutters for
These cutters feature fast cutting needle- use on hardened steel, fired
sharp teeth for greater material removal with ceramics and other very hard materials. They
minimum loading. Use on fiberglass, wood, can be used for engraving on tools and gar-
plastic, epoxy and rubber. den equipment.

Wire Brushes Brushing Pressure

Never use wire brushes at . The tips of a wire brush do the work.
! CAUTION speeds greater than Operate the brush with the lightest pres-
15,000 rpm. Refer to Speed Settings sure so only the tips of the wires come in
(pages 10-12) for proper tool and setting. contact with the work surface.
Three different shapes . If heavier pressure is used, the wires will
of wire brushes are become overstressed, resulting in a wip-
available in three differ- ing action. If this continues, the life of the
ent materials: stainless brush will be shortened by fatigue.
steel, brass and carbon 1/8" shank
. Apply the brush to the work surface so
wire. Stainless steel the majority of the brush face makes full
brushes perform well on pewter, aluminum, contact. Applying the edge or side of the
stainless steel and other metals, without brush to the work surface will result in
leaving rust. Brass brushes are non-sparking wire breakage and shortened brush life.
and softer than steel, making them good for
use on soft metals like gold, copper and
brass. Carbon wire brushes are good for
general purpose cleaning.

Bristle Brushes
Bristle brushes are 1/8" shank
used for cleaning tools on
silverware, jewelry and antiques. The three
shapes make it possible to get into tight cor-
ners and other difficult spaces. They can be
used with polishing compound for faster
cleaning or polishing.

Aluminum Oxide Abrasive Grinding Wheel

Wheels Used for deburring, removing
Used to remove paint, deburr rust, and general purpose grind-
metal, polish stainless steel ing. Use with Mandrel #402.
and other metals. Available in 1/8" shank
medium grit.

17
 ACCESSORIES (continued)

Sanding Accessories Flapwheels grind and polish flat or contoured

surfaces. They are used most effectively as a
Sanding discs in fine, finishing sander, after heavier surface sand-
medium and coarse 1/8" shank ing and material removal is completed.
grades are made to fit Flapwheels come in fine and coarse grades.
mandrel #402. They can be
used for nearly any small sanding job from Buffs are a great finishing accessory for
model making to fine furniture finishing. cleaning and light sanding. They work effec-
tively on metal, glass, wood, aluminum and
In addition, the drum sander makes it possi- plastics. Buffs are available in medium and
ble to shape wood, smooth fiberglass, sand coarse grades.
inside curves and other difficult places. Drum
bands are replaceable and come in fine and
coarse grades.

ATTACHMENTS
The following attachments are part of the Dremel Rotary Tool System; increasing the versatility
of your rotary tool.

XPR MultiSaw
The Dremel XPR MultiSaw turns your rotary tool into a multipur-
pose saw that will allow you to make straight and curved cuts in
a variety of materials. Scroll cutting patterns is now fast and easy.
Using standard jigsaw blades, you can cut soft & hard wood, ply-
wood, metal, PVC, plastic, and much more!

Use with model 400 Series XPR only.

XPR Planer
Convert your corded rotary tool into a planer.
The planer is designed for two types of planing: straight
planing and 45 planing, up to 2-1/8".
In addition, the straight planing technique can be used for
limited shaping and carving.
Ideal for fixing a warped or stuck door!
Use with model 400 Series XPR only.

Flex Light
The flex light uses Lithium Ion batteries (bat-
teries included).
LED lighting provides visibility in dimly lit
areas and increases light on detailed proj-
ects
Easy to attach, no confusing wires or con-
nections
Attaches to Workstation 220 and Plunge
Router 335

Use with model 400 Series XPR only.

18
 ATTACHMENTS (continued)
Flex Shaft
Ideal for hard-to-reach places and fine detail work.
Quick connect attach system
36" long cable with new 5" bend radius provides more flexibility
5" Radius
Comfort grip hand piece
Integrated shaft lock button
Holds up to 1/8" shank

Use with models: 275, 285, 395, 398, 780, 800, 400 Series XPR.

Plunge Router
Converts you corded rotary tool into a plunge router.
Clear base
Two depth stop
Includes edge guide and circle guide

1
3
4
5
Rout circles, parallel to edge, signs, inlay work, and

2
6
7
3
lettering template adapters

Use with models: 275, 285, 395, 398, 800, 400 Series XPR.

Grout Removal
Fast and easy way to regrout any room or replace a
broken tile!
Multiple side depth adjustment
30 angle for control cutting
Guides 180 apart to keep bit centered between
tiles
Easy screw mounting
Includes 1/16" grout removal bit

Use with models: 275, 285, 395, 398, 770, 780, 800, 400 Series XPR.

Cutting Guide
Provides controlled cutting in a variety of materials
Allows for sturdy controlled cuts with maximum visi-
4/3

2/1

4/1

bility
Easy depth adjustment. Set to the correct cutting
depth for the project material.
Use with models: 275, 285, 395, 398, 770, 780, 800, 400 Series XPR.

19
 ATTACHMENTS (continued)

Lawn / Garden Sharpener

The fastest, easiest, safest way to sharpen your lawn mower
blade and other garden tools.
Guide provides optimum sharpening angle
Sharpens most rotary lawn mower blades
Includes sharpening stone
Use with models: 275, 285, 395, 398, 770, 780, 800, 400 Series XPR.

Chain Saw Sharpener

Easily sharpen the dullest of chains
Contains: sharpening attachment, 3 sharpening stones,
30 o

o
30
gauge, 2 spacers, wrench, instruction manual

GA
GE
Use with models: 275, 285, 395, 398, 770, 780, 800, 400 Series XPR.

Right Angle
Enhances the versatility of the rotary tool by allowing you to
get into hard-to-reach places.
Ball bearings and spiral gears provide smooth and cool
operation
Coupling system allows you to orient the attachment on
your tool in 12 different directions
Quick disconnect system easily attaches to your rotary tool
in place of the housing cap, no wrenches required
Use with models: 275, 285, 395, 398, 780, 800, 400 Series XPR.

Dremelite
Provides visibility in dimly lit areas and increases light on
detailed projects
Two extremely long lasting and durable LED lights
Uses a magnet threaded onto the tools output shaft to pro-
vide a clever and simple power sourceno wires!

Use with models: 275, 285, 395, 398, 770, 780, 800, 400 Series XPR.

20
 ATTACHMENTS (continued)

Flex Shaft Tool Holder

Conveniently suspends any Dremel rotary tool above your work-
bench.
Perfect for use with the Flex-Shaft attachment
Clamps to workbenches up to 1-3/4" thick, and adjusts in height
from 12" to 42"
Store extra bits on base

Use with models: 275, 285, 395, 398, 400 Series XPR.

Tool Holder and Base

Firmly holds rotary tools in any position
Control workpiece (hands free) for better results

Use with models: 275, 285, 395, 398, 780, 400 Series XPR.

21
 SERVICE PARTS & DIAGRAM

24
1
25 23

24
25 5
28

10

16 1
10
20
2
22
27

17
3
25
19 25
18 4
30

Ref. Part No. Description Ref. Part No. Description

1 2610920980 Housing Set 18 2610922763 Collet Nut
2 2610920701 Field Assembly 19 2615110480 1/8" Collet (In Tool)
3 2610920702 Armature and 20 2610920710 Switch Assembly
Bearing Assembly 22 2610914379 Rubber Bearing
4 2615990962 Wrench Sleeve
5 2615294041 Cord 23 2610920718 Hanger
10 2610920705 Brush Spring (Pair) 24 2615294035 Screws (Individual)
16 261920709 Brush Holder 25 2610921563 Brush Door (Pair)
Assembly 27 2610920716 Glamour Cap
17 2610920972 Collet Lock & Spring 28 2640920711 Speed Control
30 2610920717 Housing Cap

22
 DREMEL LIMITED WARRANTY

Your Dremel product is warranted against defective material or workmanship for a period of five
years from date of purchase. In the event of a failure of a product to conform to this written warran-
ty, please take the following action:
1. DO NOT return your product to the place of purchase.
2. Carefully package the product by itself, with no other items, and return it, freight prepaid,
along with:
A. A copy of your dated proof of purchase (please keep a copy for yourself).
B. A written statement about the nature of the problem.
C. Your name, address and phone number to:
UNITED STATES
Dremel Service Center Dremel Service Center
4915 21st Street, Racine, WI 53406 OR
4631 E. Sunny Dune, Palm Springs, CA 92264
CANADA OUTSIDE
Giles Tool Agency CONTINENTAL UNITED STATES
6520 Lawrence Av. East See your local distributor or write to
Scarborough, Ont., Canada M1C 4A7 Dremel, 4915 21st Street, Racine, WI
53406

We recommend that the package be insured against loss or in transit damage for which we can-
not be responsible.
This warranty applies only to the original registered purchaser. DAMAGE TO THE PRODUCT
RESULTING FROM TAMPERING, ACCIDENT, ABUSE, NEGLIGENCE, UNAUTHORIZED
REPAIRS OR ALTERATIONS, UNAPPROVED ATTACHMENTS OR OTHER CAUSES UNRE-
LATED TO PROBLEMS WITH MATERIAL OR WORKMANSHIP ARE NOT COVERED BY THIS
WARRANTY.
No employee, agent, dealer or other person is authorized to give any warranties on behalf of
Dremel. If Dremel inspection shows that the problem was caused by problems with material or
workmanship within the limitations of the warranty, Dremel will repair or replace the product free
of charge and return product prepaid. Repairs made necessary by normal wear or abuse, or
repair for product outside the warranty period, if they can be made, will be charged at regular fac-
tory prices.
DREMEL MAKES NO OTHER WARRANTY OF ANY KIND WHATEVER, EXPRESSED OR
IMPLIED, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE WHICH EXCEED THE ABOVE MENTIONED OBLIGATION ARE HEREBY
DISCLAIMED BY DREMEL AND EXCLUDED FROM THIS LIMITED WARRANTY.
This warranty gives you specific legal rights and you may also have other rights which vary from state
to state. The obligation of the warrantor is solely to repair or replace the product. The warrantor is
not liable for any incidental or consequential damages due to any such alleged defect. Some states
do not allow the exclusion or limitation of incidental or consequential damages, so the above limita-
tions or exclusion may not apply to you.
For prices and warranty fulfillment in the continental United States, contact your local Dremel distrib-
utor.

23
NOTE

24