DBF 457 - Sander METABO - Free user manual and instructions

USER MANUAL DBF 457 METABO

Original instructions Under our sole responsibility, we hereby declare that these compressed air band files, identified by type and serial number *1), meet all relevant requirements of directives *2) and standards *3). Technical documents for *4) - see Page 3. For UK only: We as manufacturer and authorized person to compile the technical file, see *4) on page 3, hereby declare under sole responsibility that these compressed air band files, identified by type and serial number *1) on page 3, fulfill all relevant provisions of following UK Regulations S.I. 2008/ 1597 and Designated Standards EN ISO

12100:2010, EN ISO 11148-8:2011

The band file is used for dry sanding, deburring and polishing metals, wood, materials similar to wood, plastics and construction materials in professional applications. The tool must only ever be operated with a com- pressed air supply. The maximum supply pressure specified on the air tool must never be exceeded. The air tool must not be operated using explosive, inflammable or hazardous gases. It must not be used as a lever, crushing tool or striking tool. Any other use does not comply with the intended purpose. Unspecified use, modification of the air tool or use of parts that have not been tested and approved by the manufacturer can cause unfore- seeable damage. The user bears sole responsibility for any damage caused by improper use. Generally accepted accident prevention regula- tions and the enclosed safety information must be observed. For your own protection and for the protection of your air tool, pay attention to all parts of the text that are marked with this symbol! WARNING – Reading the operating instruc- tions will reduce the risk of injury. WARNING Read all safety warnings and instructions. Failure to follow all safety warn- ings and instructions may result in electric shock, fire and/or serious injury. Keep all safety instructions and information for future reference. Pass on your air tool only together with these docu- ments. - The user or user's employer must evaluate the specific risks associated with each application of the tool. - The safety instructions must be read and under- stood before installing, operating, repairing or maintaining the tool, and also before replacing any accessory parts or carrying out any work in the vicinity of the air tool. Failure to read and follow the instructions may lead to serious injury. - Only qualified, trained operators are authorised to install, adjust or use the air tool. - The air tool must not be modified. Any modifica- tions may reduce the efficiency of the safety measures and increase risks for the operator. - Never use air tools that have been damaged. Look after your air tools carefully. Regularly check that all moving parts are functioning correctly and do not jam. Also ensure that no parts are broken or damaged to an extent that they affect the opera- tion of the air tool. Check that all signs and labels are legible and intelligible. Have damaged parts repaired or replaced before using the device. Many accidents are caused by poorly maintained air tools.

4.1 Risks associated with ejected parts

Disconnect the air tool from the compressed air supply before replacing the mounted tool or acces- sory parts, and also before carrying out repairs or settings. If either the workpiece, accessory parts or the air tool breaks, parts may be ejected at high speed. While operating, maintaining or repairing the air tool, or replacing accessory parts, you must always wear impact-resistant safety goggles. The degree of protection required for each individual task must be evaluated separately in each case. Wear a safety helmet if carrying out work above your head. Also ensure that no other people are placed at risk. Ensure that the workpiece is securely attached.

4.2 Risks associated with items catching/

getting entwined Wear suitable clothing. Do not wear loose clothing or jewellery. Keep hair, clothing and gloves at a safe distance from the air tool and moving parts. Loose clothing, jewellery or long hair could catch in moving parts. There is a risk of injury in this case.

4.3 Risks during operation

When using the air tool, the operator's hands may be exposed to potential risk of cuts, abrasions and heat damage. To protect your hands, wear suitable gloves. The operator and maintenance staff must be physi- cally capable of handling the size, weight and power output of the air tool. Make sure you hold the air tool correctly: since you must be prepared to counter any standard or unex- pected movements, keep both hands ready.

1. Declaration of Conformity

3. General Safety Instructions

Ensure you stand in a safe position and keep your balance at all times. Avoid accidental operation. If the air supply is inter- rupted, switch off the air tool using the On/Off switch. Only use lubricants that have been recommended by the manufacturer. Wear personal protective equipment and always wear safety glasses. By wearing personal protec- tive equipment such as gloves, protective clothing, a dust mask, non-skid safety shoes, a safety helmet or ear protectors, to suit the type of device and its use, you reduce the risk of injury. Wearing this equipment is recommended. Check the sanding head before each use. Do not use if cracked or broken, or if it has been dropped. Avoid direct contact with the sanding head to prevent crushing or cutting your hands or other body parts. To protect your hands, wear suitable gloves. Never operate the machine when no abrasive (grinding medium) is installed. There is a risk of electrostatic discharge if the machine is used on plastic and other non-conduc- tive materials. Explosive or flammable dust or vapours may be generated while you work on workpieces. There is therefore a risk of explosion or fire. Always use a dust extraction or dust suppression system that is suitable for the material being processed.

4.4 Risks associated with recurring move-

ments When working with the air tool, you may experience an uncomfortable sensation in your hands, arms, shoulders, neck or other body parts. Make sure you are in a comfortable position to carry out work with the air tool, check that the tool is held securely, and avoid any awkward positions that make it difficult, for example, to keep your balance. If carrying out work over an extended period, you/ the operator should change position occasionally. This should help to avoid fatigue and any unpleasant sensation. If the operator experiences persistent symptoms such as feeling unwell, aches, pains or throbbing, a prickling or burning sensation, loss of hearing, or joint stiffening, these warning signs must not be ignored. The operator should advise the employer of these symptoms and consult a qualified doctor.

4.5 Risks associated with accessory parts

Disconnect the air tool from the air supply before the mounted tool or accessory part is secured or replaced. Only use accessories that are designed for this device and that fulfil the requirements and the spec- ifications listed in these operating instructions. Avoid any direct contact with the mounted tool both during and after use because it may be hot or have sharp edges. The rated speed of the mounted tool must be at least equal to the maximum speed marked on the air tool. Accessories running faster than their rated speed can break and fly apart.

4.6 Risks in the workplace

Slipping, tripping and falling are the main reasons for accidents in the workplace. Pay attention to surfaces that may have become slippery as a result of using the air tool, and also watch that the air hose does not cause someone to trip. The air tool is not designed for use in explosive envi- ronments and is not insulated against contact with sources of electric power. Ensure that the area where you wish to work is free of power cables, gas lines or water pipes (e.g. using a metal detector).

4.7 Risks associated with dust and vapours

The dust and vapours generated when the air tool is used may carry health risks (e.g. cancer, birth defects, asthma and/or dermatitis); it is therefore imperative that a risk assessment is carried out in relation to these risks and that suitable controls are then implemented. The risk assessment should take into account both the dust generated while the air tool is used and any existing dust that may be raised during operation. The air tool must be operated in accordance with the recommendations set forth in these instructions and must be maintained in order to minimise the release of dust and vapours. The extracted air must be discharged in such a way that, in a dust-filled environment, the minimum of dust is raised. If dust or vapours are generated, the main priority is to control these at the location where they are released. All integral or accessory parts on the air tool that are designed to collect, extract or prevent airborne dust or vapours must be used and maintained in accord- ance with the manufacturer's instructions. To avoid increasing the amount of dust or vapours generated unnecessarily, consumables and the mounted tool must be selected, maintained and replaced in accordance with these instructions. Use protective breathing apparatus in accordance with your employer instructions or in accordance with health and safety regulations.

4.8 Risks associated with noise

Failure to use adequate ear protectors when the noise level is high can result in lasting damage to hearing, hearing loss and other problems, such as tinnitus (ringing, whistling or buzzing in the ear). It is vital to carry out a risk assessment in relation to these risks and to implement appropriate control measures that take the risks into account. Appropriate risk control measures may include, for example, the use of sound-insulating materials to prevent the knocking sounds that occur on the workpieces.ENGLISHen

Use ear protection in accordance with your employer instructions or in accordance with health and safety regulations. The air tool must be operated in accordance with the recommendations provided in these instruc- tions and must be maintained in order to avoid unnecessarily raising the noise level. To avoid increasing the noise level unnecessarily, consumables and the mounted tool must be selected, maintained and replaced in accordance with these instructions. The integrated sound absorber must not be removed. You must ensure the sound absorber is in good working order.

4.9 Risks associated with vibration

The effects of vibrations can damage nerves and impair blood circulation in the hands and arms. When working in cold environments, you must wear warm clothing and keep your hands warm and dry. If you notice that the skin on your fingers or hands is numb, prickling or turning white, stop working with the air tool immediately, notify your employer and consult a doctor. The air tool must be operated in accordance with the recommendations provided in these instruc- tions and must be maintained in order to avoid unnecessarily raising the level of vibration. Hold the air tool firmly but not too tightly using the required manual torque reaction: the risk of vibra- tion is increased when the grip force is higher.

4.10 Additional safety instructions

Compressed air can cause serious injury. When the air tool is not in use, and before replacing accessory parts or when carrying out repairs, you must ensure that air supply is shut off, that the air hose is depressurised and that the air tool is discon- nected from the compressed air supply. Never direct the air jet at yourself or other people. Whiplashing hoses can cause serious injury. There- fore always check that the hoses and their fixtures are in good condition and that they have not become loose. If universal swivel couplings (claw couplings) are being used, locking pins must also be used. You should also use whip check hose restraints in case there is a problem with the connection between the hose and air tool or between the hoses themselves. Ensure that the maximum pressure specified on the air tool is not exceeded. Never carry air tools by the hose.

4.11 Additional safety instructions

- If applicable, observe any particular health and safety or accident prevention regulations governing the use of compressors and compressed air tools. - Ensure that the maximum supply pressure speci- fied in the Technical Specifications is not exceeded. - Do not overload the tool – use it only within the performance range for which it was designed (see “Technical Specifications”). - Use non-hazardous lubricants. Ensure the work- place is adequately ventilated. If there is a large amount of discharge: check the air tool and have it repaired if necessary. - Do not operate the tool unless you are completely focused. You must be alert, pay attention to what you are doing and proceed cautiously when working with an air tool. Never use a tool when you are tired or under the influence of drugs, alcohol or medication. Just one moment's carelessness when using the tool can cause serious injury. - Make sure your workplace is clean and well lit. Untidy or poorly lit workplaces can cause acci- dents. - Keep air tools away from children. - Do not store the tool outdoors or in damp condi- tions without protection. - Protect the air tool, especially the compressed air connection and the control elements from dust and dirt. - Dust from material such as paint containing lead, some wood species, minerals and metal may be harmful. Contact with or inhalation of the dust may cause allergic reactions and/or respiratory diseases to the operator or bystanders. Certain kinds of dust are classified as carcino- genic, such as oak and beech dust, especially in conjunction with additives for wood conditioning (chromate, wood preservative). Material containing asbestos must only be treated by specialists. - Use a dust extraction device where possible. - For efficient dust collection, use a suitable Metabo vacuum cleaner together with this air tool. - The workplace must be well ventilated. - The use of a dust mask of filter class P2 is recommended. - Follow national requirements for the materials you want to work with. - Materials emitting dusts or vapours that may be harmful to health (e.g. asbestos) must not be processed. - Secure the workpiece against slipping, e.g. with the help of clamping devices. - Flying sparks are created when sanding metal. Ensure that no persons are in danger. Due to the risk of fire, all combustible materials must be removed from the work area (area affected by flying sparks). - Use of a fixed extractor system is recommended. - Always guide the machine with both hands on the handles provided. Loss of control can cause personal injury. - Never place your hand near rotating parts of the device or near the rotating sanding belt. - Remove sanding dust and similar material only when the machine is not in operation. - The rated speed of the sanding belt must be at least equal to the specified belt speed in idling. A sanding belt running faster than its rated speed can break and fly apart. - Check prior to each use that the sanding belt is correctly attached and is completely on the rollers. Carry out a trial run: allow the machine to run atENGLISH en

idling speed for 30 seconds in a safe location. Stop immediately if significant vibrations occur or if other defects are noted. If such a situation occurs, check the machine to determine the cause. Information in these operating instructions is cate- gorised as shown below: Danger! Risk of personal injury or environ- mental damage. Caution. Risk of material damage

4.12 Symbols on the air tool

Read the operating instructions before starting to use the machine. Wear safety goggles. Wear ear protectors. Direction of rotation See page 2. 1 Sanding head

Clamp screw for adjusting sanding head 3 Auxiliary handle 4 Switch (on/off) 5Switch-on lock 6Air outlet 7 Compressed air connection with filter 8 Plug-in nipple 1/4" 9 Adjusting screw for setting the speed 10 Rotary knob for securing the sanding attachment and adjusting the belt run 11 Tensioner arm for replacing the sanding belt 12 Sanding attachment 13 Sanding belt* 14 Screw for securing the cover 15 Arrow (direction of rotation of drive shaft

• depending on features/not in scope of delivery

6.1 Before using the tool for the first time

Insert plug-in nipple (8).

6.2 Attaching the additional handle

Always work with the auxiliary handle attached (3)! Screw in the auxiliary handle firmly.

6.3 Turning the sanding head (1) to operat-

ing position Loosen the clamp screw (2) using the hexagon spanner and, if necessary and depending on the task at hand, turn the sanding head (1). The sanding head must be positioned in the permitted working area as shown (see illustration A, page 2). Firmly tighten the clamp screw (2). Before you start work, always verify that the clamp screw (2) is sufficiently tightened to ensure that the sanding head (1) does not move. Otherwise, the sanding belt (13) may come in contact with the user. Loss of control can cause personal injury.

6.4 Sanding belt replacement

See illustration B, page 2. - Manually loosen screw (14) and remove cover (16). - Pull tensioner arm (11) backwards and remove sanding belt (13). - Place the new sanding belt on the rollers such that its direction of circulation (arrows on the inside of the sanding belt) matches the arrows (15) on the cover. Place the sanding belt first on the drive shaft and then on the roller on the sanding attach- ment (12). - Replace the cover (16) and tighten the screw (14) by hand. - Check the belt run and adjust if necessary (see

6.5 Adjusting belt run

Disconnect the air tool from the compressed air supply. Using the screw (10), adjust the sanding belt - while the machine is not in operation - so that the belt runs along the centre of the sanding belt roller.

6.6 Sanding procedure

Switch the machine on first before mounting it on the workpiece. Place the machine on the material such that the sanding belt is parallel to the surface of the work- piece. Keep the machine in constant motion: otherwise indentations could be produced in the material.

6.7 Replacing the sanding attachment

See illustration C, page 2. - Removing the sanding belt (see Section 6.4). - Remove screw (10), and remove sanding attach- ment (12). - Attach the other sanding attachment as shown (ensure that the nose at the end of the sanding attachment is pointing in the direction of the tensioning arm; see illustration C). - Secure with screw (10). - Attaching the sanding belt (see Section 6.4). - Adjusting the belt run (see Section 6.5).

Always guide the machine with both hands. Switch the machine on first before mounting it on the workpiece. After switching off the machine, only set it down when the motor has come to a standstill. To benefit from the air tool's full performance, always use compressed air hoses with an inner diameter of at least 10mm. Tool performance can be significantly impaired if the inner diameter is too small. Caution. The compressed air line must not contain any water condensation. Caution. To preserve and extend the service life of this tool, you must ensure that it is regu- larly maintained with pneumatic oil lubricator. You can do this as follows: –Use oiled compressed air by fitting an oil-fog lu- bricator. – Without an oil-fog lubricator: manually apply oil every day via the compressed air connection. Use approx. 3-5 drops of pneumatic oil lubricator for each 15 minutes of continuous operation. If the tool has not been in use for several days, you should manually apply about 5 drops of pneumatic oil lubricator into the compressed air connection. Caution. Only allow the tool to run at idle speed for a brief period.

1. Fit a suitable sanding belt (13) (see Section

2. Adjust the supply pressure (this is measured at

the air outlet while the air tool is switched on). For details of the maximum permissible supply pressure, see the section on "Technical Specifi- cations".

3. Connect the air tool to the compressed air sup-

Set the rotational speed on the adjusting screw (9). (The best way to determine the ideal setting is through a practical trial). To switch off: release switch (4).

5. Do not press the device too firmly against the

surface being sanded. This does not improve, but rather impairs, the sanding performance.

6. For optimum operation: sand on the side on

which the sanding belt moves towards the ma- chine.

Danger! Disconnect the compressed air con- nection before carrying out any work. Danger! Repair and maintenance work other than described in this section should only be carried out by qualified specialists. - Carry out regular maintenance to ensure the safety of the air tool. - Check that all screw fittings are seated securely, and tighten if necessary. - Clean the filter in the compressed air connection at least once a week. - It is recommended that you install a pressure reducer with an air-water separator and lubricator upstream of the air tool. - If a large amount of air or oil is escaping, check the air tool and have it maintained if necessary. (see

- Check the rotational speed regularly and after every use. Also carry out a simple check on vibra- tion emission. - Avoid contact with dangerous substances that have collected on the tool. Wear suitable personal protective equipment and take appropriate meas- ures to remove any dangerous substances before maintenance.

Use only genuine Metabo accessories. Only use accessories that are designed for this air tool and that fulfil the requirements and the specifi- cations listed in these operating instructions. For a complete range of accessories, see www.metabo.com or the catalogue. Danger! Repairs to air tools must only be carried out by qualified specialists, using orig- inal Metabo spare parts! If you have Metabo air tools that require repairs, please contact your Metabo service centre. For addresses see www.metabo.com. You can download spare parts lists from www.metabo.com. Observe national regulations on environmentally compatible disposal and on the recycling of disused air tools, packaging and accessories. You must not cause risks to people or the environment. Explanatory notes on the specifications on page 3. Subject to change in line with technological advances.

max. = Maximum permissible supply pressure

=Sanding belt length

=Belt speed in idling

=Hose diameter (inner) C =Connecting thread A =Dimensions: Length x Width x Height m=Weight The technical specifications quoted are subject to tolerances (in compliance with the relevant valid standards). Emission values

7. Care and Maintenance

10. Environmental Protection

Using these values, you can estimate the emissions from this tool and compare these with the values emitted by other tools. The actual values may be higher or lower, depending on the particular appli- cation and the condition of the tool or mounted tools. In estimating the values, you should also include work breaks and periods of low use. Based on the estimated emission values, specify protec- tive measures for the user - for example, any organ- isational steps that must be put in place. Vibration (acceleration value, frequency-weighted according to EN 28927):

=Vibration emission level

=Sound pressure level

=Acoustic power level

4.3 Farer under drift