DWE6401DS - Sander DEWALT - Free user manual and instructions
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USER MANUAL DWE6401DS DEWALT
Definitions: Safety Alert Symbols and Words
This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.
D. IGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
W: NING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAITON: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
(without word) Indicates a safety related message.
NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.
Fig. A
1 Main handle
2 Side handle
3 Dust shroud
4 Dust port
5 Speed control dial
6 Trigger switch
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.
WARNING: To reduce the risk of injury, read the instruction manual.
If you have any questions or comments about this or any DEWALT tool, call us toll free at: 1-800-4-DEWALT (1-800-433-9258).
English
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 WARNING 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.
1) Work Area Safety
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) 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.
c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.
2) Electrical Safety
a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
b) 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.
c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
d) 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.
e) 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.
f) If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.
3) Personal Safety
a) Stay alert, watch what you are doing and use common 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.
b) 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.
c) Prevent unintentional starting. Ensure the switch is in the off position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents.
d) 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.
e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
f) 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.
g) 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.
4) Power Tool Use and Care
a) 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.
b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.
c) 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.
d) 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.
e) 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. Many accidents are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
g) 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.
5) Service
a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
SAFETY INSTRUCTIONS FOR ALL OPERATIONS
SafetyWarnings Common for Grinding, Sanding, Wire Brushing,Polishing or Abrasive,Cutting-Off Operations
a) This power tool is intended to function as a sander. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
b) Operations such as grinding, wire brushing, polishing or cutting-off are not recommended to be performed with this power tool. Operations for which the power tool was not designed may create a hazard and cause personal injury.
c) Do not use accessories which are not specifically designed and recommended by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.
d) The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and fly apart.
e) The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories cannot be adequately guarded or controlled.
f) Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbor hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
g) Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum
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no-load speed for one minute. Damaged accessories will normally break apart during this test time.
h) Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.
i) Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken accessory may fly away and cause injury beyond immediate area of operation.
j) Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and shock the operator.
k) Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
1) Never lay the power tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.
m) Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.
n) Regularly clean the power tool's air vents. The motor's fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.
o) Do not operate the power tool near flammable materials. Sparks could ignite these materials.
p) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.
q) Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories can result in injury.
r) Always use side handle. Tighten the handle securely. The side handle should always be used to maintain control of the tool at all times.
Kickback and RelatedWarnings
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to
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be forced in the direction opposite of the accessory's rotation at the point of the binding.
For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel's movement at the point of pinching. Abrasive wheels may also break under these conditions.
Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:
a) Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start up. The operator can control torque reaction or kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may kickback over your hand.
c) Do not position your body in the area where power tool will move if kickback occurs. Kickback will propel the tool in direction opposite to the wheel's movement at the point of snagging.
d) Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.
SafetyWarnings Specific for Sanding Operations
a) Do not use excessively oversized sanding disc paper. Follow manufacturers recommendations, when selecting sanding paper. Larger sanding paper extending beyond the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback.
Additional Safety Information
WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:
ANSI Z87.1 eye protection (CAN/CSA Z94.3)
ANSI S12.6 (S3.19) hearing protection,
- NIOSH/OSHA/MSHA respiratory protection.
WARNING: Some dust created by power sanding, grinding,drilling,and other construction
activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
- lead from lead-based paints,
crystalline silica from bricks and cement and other masonry products, and - arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.
- 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 disperse 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.
WARNING: Always wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19)
during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.
CAUTION: When not in use, place tool on its side stable surface where it will not cause a tripping or falling hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.
- Never use this power tool for grinding, wire brushing, polishing or cutting-off operations.
Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts. - An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is, 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The lower the gauge number, the heavier the cord.
Minimum Gauge for Cord Sets
| Volts | Total Length of Cord in Feet(meters) | ||||
| 120 V 25 (7.6) | 50 (15.2) | 100 (30.5) | 150 (45.7) | ||
| 240 V 50 (15.2) | 100 (30.5) | 200 (61.0) | 300 (91.4) | ||
| Ampere Rating | American Wire Gauge | ||||
| More Than | Not More Than | ||||
| 0 6 18 16 16 14 | |||||
| 6 10 18 16 14 12 | |||||
| 10 12 16 16 14 12 | |||||
| 12 16 14 12 Not Recommended | |||||
The label on your tool may include the following symbols. The symbols and their definitions are as follows:
V. volts
Hz .........hertz
min.........minutes
=or DC....direct current
Class I Construction
(grounded)
..min..per minute
BPM... .beats per minute
IPM............impacts per minute
RPM.......revolutionsper minute
sfpm.....surface feet per minute
SPM......... strokes per minute
A. amperes
W... .watts
or AC....alternating current
or AC/DC...alternatingor
direct current
回............ClassII
Construction
(double insulated)
no load speed
n............rated speed
...earthing terminal
A. ... safety alert symbol
...visible radiation
...wearrespiratory
protection
weareye
protection
O............wearhearing
protection
readall
documentation
Additional Safety Rules for Paint Removal
- 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.
- 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
- No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.
- 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. See your local hardware store for the proper NIOSH approved dust mask.
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
- Paint should be removed in such a manner as to minimize the amount of dust generated.
- Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mil thickness.
- Sanding should be done in a manner to reduce tracking of paint dust outside the work area.
Cleaning and Disposal
- 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.
- 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.
- All toys, washable furniture and utensils used by children should be washed thoroughly before being used again.
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Motor
Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than 10% will cause loss of power and overheating. DeWALT tools are factory tested; if this tool does not operate, check power supply.
COMPONENTS (FIG. A)
WARNING: Never modify the power tool or any part of damage or personal injury could result.
Refer to Figure A at the beginning of this manual for a complete list of components.
INTENDED USE
This sander is designed for professional sanding of solid surface material such as wood, metal, fiberglass, plastics and paint.
DO NOT use under wet conditions or in presence of flammable liquids or gases.
These heavy-duty sanders are professional power tools.
DO NOT let children come into contact with the tool.
Supervision is required when inexperienced operators use this tool.
Switch (Fig. A)
The variable speed is controlled in two ways: speed control dial 5 and the trigger switch 6.
Speed Control Dial
By rotating the speed control dial 5 in either direction, the maximum speed or revolutions per minute at which the sander will perform is adjusted. The speed control dial adjusts the rotation speed of the pad from approx. 0 to 4100 rpm.
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Trigger Switch
As the trigger switch is pressed in, the rotation continues to increase, but will not exceed the maximum setting on the speed control dial. As the trigger is released, the sander head revolutions per minute are reduced.
ASSEMBLY AND ADJUSTMENTS
WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start-up can cause injury.
Attaching Side Handle (Fig. A)
The side handle 2 can be fitted to either side of the housing in the threaded holes. Before using the tool, check that the handle is tightened se cure ly.
This handle should be used at all times to maintain complete control of the tool.
Assemble Dust Shroud (Fig. B-D)
- Loosen screw 7 on dust shroud 3. Do not remove screw or nut.
Fig. B
- Slide dust shroud onto sander body.
- With the sander on a stable surface, hold the dust shroud 3 by the dust port 4 and push this side of shroud over the notches 8. Then work in a circular motion and push the shroud over the remaining notches.
- Ensure dust shroud 3 is seated against sander body and tighten screw 7 so shroud does not move while tool is running. Do not overtighten.
Assemble Sanding Pad (Fig. E)
-
Place supplied wrench 9 onto spindle. Rotate and align wrench with dust shroud baffles 10.
-
While holding the spindle with the wrench, place sanding pad 11 onto spindle and rotate clockwise until tight.
Fig. E
Attaching Abrasive Disc (Fig. F)
Use 5" (127 mm) sanding discs with an 8-hole dust extraction pattern which attach to the sander with hook and loop.
- Turn the sander over so that the sanding pad is facing upward.
- Clean the dust from the hook and loop pad face.
- Hold the pad with one hand to keep it from rotating.
- With the other hand, align the holes and place the disc directly on top of the pad.
nOTE: Do not use the sanding screen (the screen used for sanding drywall) directly on the hook and loop pad. The screen will not hold and will damage the hooks on the pad. The hooks will wear very rapidly if left in contact with the work surface while the tool is operating.
OPERATION
WARNING: To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start-up can cause injury.
Proper Hand Position (Fig. G)
WARNING: To reduce the risk of serious personal injury, AYs use proper hand position as shown.
WARNING: To reduce the risk of serious personal injury, AYs hold securely in anticipation of a sudden reaction.
Proper hand position requires one hand under the main handle 1 and the other hand on the side handle 2.
C
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In addition to the warranty, DeWALT tools are covered by our:
1 YEAR FREE sERVICE
DrWALT 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.
IATin AMERiCA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information.
FREE WARNING LABEL REPLACEMENTT: If your warning labels become illegible or are missing, call 1-800-4-DEWALT (1-800-433-9258) for a free replacement.
Dewalt Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286
(JUL16) Part No. N472642 DWE6401 Copyright © 2016 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.
