DW411K - Sander DEWALT - Free user manual and instructions

USER MANUAL DW411K DEWALT

DeWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286

(JAN06) Form No. 158635-03 DW411, DW412 Copyright © 1998, 2001, 2004, 2005 DEWALT

The following are trademarks for one or more DeWALT power tools: the yellow and black color scheme; the "D" shaped air intake grill; the array of pyramids on the handgrip; the kit box configuration; and the array of lozenge-shaped humps on the surface of the tool.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS OR ANY DEWALT TOOL, CALL US FREE AT 1-800-4-DEWALT(1-800-433-9258).

General Safety Instructions

WARNING! Read and understand all instructions. Failure to follow all instructions listed below, may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.
• Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adaptor plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. Applicable only to Class I (grounded) tools.
• Double insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system. Applicable only to Class II (double insulated) tools.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.
• Don't 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 to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.
• When operating a power tool outside, use an outdoor extension cord marked "W-A" or "W." These cords are rated for outdoor use and reduce the risk of electric shock.

Minimum Gage for Cord Sets

Volts Total Length of Cord In Feet
120V 0-25 26-50 51-100 101-150
240V 0-50 51-100 101-200 201-300

Ampere Rating

More Not more AWG

ThanThan

0	-	6	18	16	16	14
6	-	10	18	16	14	12

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury,
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. Air vents often cover moving parts and should also be avoided.
• Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents.
• Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.

• Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

• Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

TOOL USE AND CARE

• 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.
• Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
• Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventative safety measures reduce the risk of starting the tool accidentally.
• Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control.
• Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.
• Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.

SERVICE

• Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.
• When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury.

Additional Safety Instructions for Sanders

ALWAYS WEAR EYE PROTECTION

• It is not advised to sandpaper painted surfaces that may contain lead. See page 2 for Precautions to Take When Sanding Paint.
  Clean your tool out periodically.
• Empty dust bag frequently. Especially when sanding resin coated surfaces such as polyurethane, varnish, shellac, etc. The accumulation of fine sanding dust particles may self ignite and cause fire.
• Do not operate this tool for long periods of time. Vibration caused by the operating action of this tool may cause permanent injury to fingers, hands, and arms. Use gloves to provide extra cushion, take frequent rest periods, and limit daily time of use.

WARNING: Some dust created by power sanding, sawing, grinding, drifting, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paints,
  crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber (CCA).

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

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disburse dust, which may cause serious and permanent respiratory or other injury. Always use NiOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

CAUTION: Wear appropriate hearing protection during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

The label on your tool may include the following symbols.

V.....volts
Hz...hertz
min.....minutes
----direct current
Class II Construction
A ......safety alert symbol

A .amperes
W.....watts
..alternating current
no load speed
...earthing terminal
../min....revolutions per minute

SAVE THESE INSTRUCTIONS

Motor

Your DeWALT tool is powered by a DeWALT built motor. Be sure your power supply agrees with the nameplate marking (Volts, 120 AC only). A Voltage decrease of more than 10% will cause loss of power and overheating. All tools DeWalt tools are factory tested; if this tool does not operate, check the power supply.

Attaching Abrasive Paper (Fig. 3)

Your sander is designed to use 1/4 sized sanding sheets. This size paper can be made by:

a. Cutting full sized (9" x 11") sandpaper into 1/4 sheets of 4-1/2" x 5-1/2".

b. Cutting 1/2 sheet sandpaper into two 4· 1 / 2^× 5· 1 / 2^ sheets. Pre-cut 4· 1 / 2^× 5· 1 / 2^ sandpaper is available at extra cost.

For normal operations, assemble the abrasive paper to your unit as follows.

1. Soften the stiff sandpaper by pulling it over the 90^ edge of a table or other straight edge, as shown in Figure 1. Concentrate on softening the edges to be clamped.
2. Release clamp by pulling up on clamp lever and disengaging it from the tab on the base plate. Fig. 2 (A).
3. Insert the 4 - 1 / 2^* edge of the abrasive paper under the front paper clamp, as shown in Figure 3 until it hits the paper limiting ribs shown in the figure. Close the front paper clamp and hook it into the lock position behind the tab on the base plate.
4. Stretch paper over sanding pad and insert under the opposite clamp in the same way.
5. If you are using the dust extraction feature, perforate the sand- paper with the provided paper punch as shown in Figure 5.

Switch (Fig. 4)

Paper Punch (Fig. 5)

Dust Collection Bag (Fig. 8)

To turn the unit on, depress the side of the dust protected switch that corresponds to the symbol "I". To turn the tool off, depress the side of the switch that corresponds to the symbol "O". See Figure 4.
A paper punch is provided with your sander to let you perforate regular sandpaper to make dust collection possible.
To perforate your sandpaper, install the sandpaper on the tool as instructed in this manual. With the sander turned off and unplugged, place the paper punch on the paper so that the tabs at the edges of the punch are against any two adjacent sides of the sanding pad, as shown. Press the punch against the pad so that the 8 points penetrate the paper, as shown in Figure 6. (Press the punch into the pad as far as it will go.) Remove the paper punch and the paper is ready. An alternate method of perforating the paper is to fasten the punch down to a suitable work surface and press the sander (with the paper attached) down on the punch. Two holes are provided in the punch for this purpose. Use #8 flat head screws.
DUST COLLECTION BAG: NEVER OPERATE THIS TOOL WITH PERFORATED PAPER UNLESS THE DUST COLLECTION BAG IS IN PLACE.
To use the dust collecting system, lower the plastic end of the collection bag over the flange and push it down as far as it will go, as shown.
To empty the dust collection bag, simply lift it up, off of the sander and empty over a trash receptacle.

Operation (Fig. 9)

To operate your sander, grasp it as shown in Figure 9 and turn it on. Move it in long, sweeping strokes along the surface being sanded, letting it do the work. Pushing down on the tool while sanding actually slows the removal rate and produces an inferior quality surface. Be sure to check your work often, this sander is capable of removing material rapidly, especially with coarse paper. Your sander is designed to sand flush on three sides (four sides without the dust collection bag) for sanding in corners, and its small size and light weight make it ideal for overhead work. The orbital action of your sander allows you to sand with the grain or at any angle across it for most sanding jobs. On the final sanding steps, as discussed below, a better finish will result if you sand only with the grain.

To produce the best finish possible, start with coarse grit sandpaper and change gradually to finer and finer paper. A final sanding with a piece of well worn fine sandpaper will produce a really professional looking finish that in many cases will need no hand sanding at all. The rate at which the dust collection bag will fill up will vary with the type of material being sanded and the coarseness of the sandpaper. For best results, empty the bag frequently and check the opening for clogging.

When sanding painted surfaces, you may find that the sandpaper loads up and clogs with paint. A heat gun will work much better to remove paint before sanding. FOLLOW ALL SAFETY INSTRUCTIONS IN HEAT GUN INSTRUCTION MANUAL.

Precautions To Take When Sanding Paint

1. Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling the contaminated dust. The greatest danger of lead poisoning is to children and pregnant women.
2. Since it is difficult to identify whether or not a paint contains lead without a chemical analysis, we recommend the following precautions when sanding any paint:

PERSONAL SAFETY

a. No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.
b. A dust mask or respirator should be worn by all persons entering the work area. The filter should be replaced daily or whenever the wearer has difficulty breathing. NOTE: Only those dust masks suitable for working with lead paint dust and fumes should be used. Ordinary painting masks do not offer this protection. See your local hardware dealer for the proper N.I.O.S.H. approved mask.
c. NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingesting contaminated paint particles. Workers should wash and clean up BEFORE eating, drinking or smoking. Articles of food, drink, or smoking should not be left in the work area where dust would settle on them.

ENVIRONMENTAL SAFETY

a. Paint should be removed in such a manner as to minimize the amount of dust generated.
b. Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils thickness.
c. Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

CLEANING AND DISPOSAL

a. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the duration of the sanding project. Vacuum filter bags should be changed frequently.
b. Plastic drop cloths should be gathered up and disposed of along with any dust chips or other removal debris. They should be placed in sealed refuse receptacles and disposed of through regular trash pick-up procedures.

During clean up, children and pregnant women should be kept away from the immediate work area.
c. All toys, washable furniture and utensils used by children should be washed thoroughly before being used again.

Tool Care

Keep your machine as clean as possible by wiping with a clean cloth and blowing through it with air after every 5 hours of use.
Don't use harsh chemicals or solvents to clean the tool. These chemicals could seriously damage the plastic.
Avoid overloading your sander. Overloading will result in a considerable reduction in speed and efficiency and the unit will become hot. In this event, run sander at a "no load" condition for a minute or two.

Brush Replacement (Fig 10 & 11)

TURN OFF AND UNPLUG THE SANDER

To replace the tool's brushes, remove the three screws located in the top cap, as shown in Figure 10.
Lift off the top cap. Observe the brush holders, as shown in Figure 11 and the wires leading from the brushes to the motor field.
Pull the wires from the motor field and then lift and hold out of the way one of the brush springs. Remove the old brush from the brush holder and discard the brush/wire assembly. Still holding the brush spring out of the way, insert the new brush, release the spring against the back of the brush and plug the wire into the motor field. Repeat the procedure for the second brush.
Replace the top cap and tighten the three screws that hold it in place. (Always replace both brushes.)

Accessories

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory for your tool, please contact DeWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-800-4-DeWALT (1-800-433-9258) or visit our website www.dewalt.com.
CAUTION: The use of any other accessory not recommended for use with this tool could be hazardous.

DUST EXTRACTION HOSE ADAPTOR (DW4111)

Slides over flange at rear of tool, as shown in Figure 12. Accepts a variety of vacuum hoses for dust extraction.

6" CIRCULAR PLATEN (DW4112)

Includes 6^th dia. round sanding pad for sanding irregular shapes where extra flexibility may be desired.

To install the circular platen, remove the four screws in the bottom of the sanding pad and remove the pad and the rectangular platen. Replace with the circular platen and the 6^ diameter sanding pad using the same four screws.
Accepts 6" dia. adhesive backed sanding discs only.
NOTE: Recommended accessories for this tool are listed in this manual. The use of any other accessories may be hazardous.

Lubrication

Self lubricating bearings are used in the tool and periodic relubrication is not required. However, it is recommended that, once a year, you take or send the tool to a service center for a thorough cleaning and inspection.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement) should be performed by a DeWALT factory service center, a DeWALT authorized service center or other qualified service personnel. Always use identical replacement parts.

Three Year Limited Warranty

DeWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DewALT (1-800-433-9258). This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

FIG.1

FIG. 2

FIG. 10

FIG. 12

In addition to the warranty, DeWALT tools are covered by our:

YEAR FREE SERVICE

DeWALT will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.

90 DAY MONEY BACK GUARANTEE

If you are not completely satisfied with the performance of your DrWALT Power Tool, Laser, or Nailer for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund - no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call the local company or see website for warranty information.
FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT for a free replacement.

POUR TOUT RENSEIGNEMENT SUPPLEMENTaire SUR CET OUTIL OU TOUT AUTRE OUTIL DE WALT, COMPOSER SANS FRAIS LE NUMERO SUIVANT : 1 800 4-DeWALT (1 800 433-9258)