IMPORTANT: Read Before Using

Operating/Safety Instructions

www.dremel.com

800-49

This symbol refers to theEMC requirements of theAustralian Standards

Australia 1300 30 70 44

New Zealand 0800 54 33 53

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Work AreaKeep your work area clean and well lit.Cluttered benches and dark areas inviteaccidents.

Do not operate power tools in explosiveatmospheres, such as in the presence offlammable liquids, gases, or dust. Powertools create sparks which may ignite the dust orfumes.

Keep bystanders, children, and visitorsaway while operating a power tool.Distractions can cause you to lose control.

Electrical SafetyA battery operated tool with integralbatteries or a separate battery pack must berecharged only with the specified chargerfor the battery. A charger that may be suitablefor one type of battery may create a risk of firewhen used with another battery.

Use battery operated tool only withspecifically designated battery pack. Use ofany other batteries may create a risk of fire.

Personal SafetyStay alert, watch what you are doing, anduse common sense when operating apower tool. Do not use tool while tired orunder the influence of drugs, alcohol, ormedication. A moment of inattention whileoperating power tools may result in seriouspersonal injury.

Dress properly. Do not wear loose clothingor jewelry. Contain long hair. Keep yourhair, clothing, and gloves away frommoving parts. Loose clothes, jewelry, or longhair can be caught in moving parts.

Avoid accidental starting. Be sure switch isin the locked or off position before insertingbattery pack. Carrying tools with your finger onthe switch or inserting the battery pack into atool with the switch on invites accidents.

Remove adjusting keys or wrenches beforeturning the tool on. A wrench or a key that isleft attached to a rotating part of the tool mayresult in personal injury.

Do not overreach. Keep proper footing andbalance at all times. Proper footing and

balance enable better control of the tool inunexpected situations.

Use safety equipment. Always wear eyeprotection. Dust mask, non-skid safety shoes,hard hat, or hearing protection must be used forappropriate conditions.

Tool Use and CareUse clamps or other practical way to secureand support the workpiece to a stableplatform. Holding the work by hand or againstyour body is unstable and may lead to loss ofcontrol.

Do not force tool. Use the correct tool foryour application. The correct tool will do thejob better and safer at the rate for which it isdesigned.

Do not use tool if switch does not turn it onor off. A tool that cannot be controlled with theswitch is dangerous and must be repaired.

Disconnect battery pack from tool or placethe switch in the locked or off positionbefore making any adjustments, changingaccessories, or storing the tool. Suchpreventive safety measures reduce the risk ofstarting the tool accidentally.

Store idle tools out of reach of children andother untrained persons. Tools aredangerous in the hands of untrained users.

When battery pack is not in use, keep itaway from other metal objects like: paperclips, coins, keys, nails, screws, or othersmall metal objects that can make aconnection from one terminal to another.Shorting the battery terminals together maycause sparks, burns, or a fire.

Maintain tools with care. Keep cutting toolssharp and clean. Properly maintained toolswith sharp cutting edge are less likely to bindand are easier to control.

Check for misalignment or binding ofmoving parts, breakage of parts, and anyother condition that may affect the tool'soperation. If damaged, have the toolserviced before using. Many accidents arecaused by poorly maintained tools.

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

SAVE THESE INSTRUCTIONS

! WARNING

General Safety Rules for All Battery Operated Tools

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Use only accessories that arerecommended by the manufacturer for yourmodel. Accessories that may be suitable forone tool may create a risk of injury when usedon another tool.

ServiceTool service must be performed only byqualified repair personnel. Service or

maintenance performed by unqualifiedpersonnel may result in a risk of injury.

When servicing a tool, use only identicalreplacement parts. Follow instructions inthe Maintenance section of this manual. Useof unauthorized parts or failure to followMaintenance Instructions may create a risk ofshock or injury.

Safety Rules for Cordless Rotary Tools

Accessories must be rated for at least thespeed recommended on the tool warninglabel. Wheels and other accessories runningover rated speed can fly apart and cause injury.

Hold tool by insulated gripping surfaceswhen performing an operation where thecutting tool may contact hidden wiring.Contact with a "live" wire will make exposedmetal parts of the tool "live" and shock theoperator. If cutting into existing walls or otherblind areas where electrical wiring may exist isunavoidable, disconnect all fuses or circuitbreakers feeding this worksite.

Do not operate the flexible shaft with asharp bend. Over bending the shaft cangenerate excessive heat on the jacket or handpiece. The recommended minimum is 6"radius.

Disconnect battery pack from tool or placethe switch in the locked or off positionbefore making any assembly, adjustmentsor changing accessories. Such preventivesafety measures reduce the risk of starting thetool accidentally.

Be aware of the switch location, whenplacing the tool down or when picking thetool up. You may accidentally activate theswitch.

Always hold the hand piece firmly in yourhands during the start-up. The reactiontorque of the motor, as it accelerates to fullspeed, can cause the shaft to twist.

Always wear safety goggles and dustmask. Use only in well ventilated area.Using personal safety devices and working insafe environment reduces risk of injury.

After changing the bits or making anyadjustments, make sure the collet nut andany other adjustment devices are securelytightened. Loose adjustment device canunexpectedly shift, causing loss of control,

loose rotating components will be violentlythrown.

Do not reach in the area of the spinning bit.The proximity of the spinning bit to your handmay not always be obvious.

Allow brushes to run at operating speed forat least one minute before using wheel.During this time no one is to stand in frontor in line with the brush. Loose bristles orwires will be discharged during the run-in time.

Wire and bristle brushes must never beoperated at speeds greater than15,000/min. Direct the discharge of thespinning wire brush away from you. Smallparticles and tiny wire fragments may bedischarged at high velocity during the“cleaning” action with these brushes and maybecome imbedded in your skin. Bristles orwires will be discharged from the brush at highspeeds.

Wear protective gloves and face shield withwire or bristle brushes. Apply wire orbristle brushes lightly to the work as onlythe tips of the wire/bristles do the work.“Heavy” pressure on bristles will cause thewire or bristle to become overstressed,resulting in a wiping action and will cause thebristles/wire to be discharged.

Carefully handle both the tool andindividual grinding wheels to avoidchipping or cracking. Install a new wheel iftool is dropped while grinding. Do not usea wheel that may be damaged. Fragmentsfrom a wheel that bursts during operation willfly away at great velocity possibly striking youor bystanders.

Never use dull or damaged bits. Sharp bitsmust be handled with care. Damaged bitscan snap during use. Dull bits require moreforce to push the tool, possibly causing the bitto break.

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Use clamps to support workpiecewhenever practical. Never hold a smallworkpiece in one hand and the tool in theother hand while in use. Allow for sufficientspace, at least 6", between your hand andthe spinning bit. Round material such asdowel rods, pipes or tubing have a tendency toroll while being cut, and may cause the bit to“bite” or jump toward you. Clamping a smallworkpiece allows you to use both hands tocontrol the tool.

Inspect your workpiece before cutting. Whencutting irregularly shaped workpieces, planyour work so it will not slip and pinch the bitand be torn from your hand. For example, ifcarving wood, make sure there are no nails orforeign objects in the workpiece. Nails orforeign objects can cause the bit to jump.

Never start the tool when the bit is engagedin the material. The bit cutting edge may grabthe material causing loss of control of the cutter.

Avoid bouncing and snagging the wheel,especially when working corners, sharpedges etc. This can cause loss of control andkick-back.

The direction of feed with the bit into thematerial when carving, routing or cutting isvery important. Always feed the bit into thematerial in the same direction as the cuttingedge is exiting from the material (which isthe same direction as the chips arethrown). Feeding the tool in the wrongdirection, causes the cutting edge of the bit toclimb out of the work and pull the tool in thedirection of this feed.

If the workpiece or bit becomes jammed orbogged down, turn the tool “OFF” by theswitch. Wait for all moving parts to stopand unplug the tool, then work to free thejammed material. If the switch to the tool is left“ON” the tool could restart unexpectedlycausing serious personal injury.

Do not leave a running tool unattended, turnpower off. Only when tool comes to acomplete stop it is safe to put it down.

Do not grind or sand near flammablematerials. Sparks from the wheel could ignitethese materials.

Do not touch the bit or collet after use. Afteruse the bit and collet are too hot to be touchedby bare hands.

Regularly clean the tool's air vents bycompressed air. Excessive accumulation ofpowdered metal inside the motor housing maycause electrical failures.

Do not allow familiarity gained fromfrequent use of your rotary tool to becomecommonplace. Always remember that acareless fraction of a second is sufficient toinflict severe injury.

Do not alter or misuse tool. Any alteration ormodification is a misuse and may result inserious personal injury.

This product is not intended for use as adental drill, in human or veterinary medicalapplications. Serious personal injury mayresult.

When using the steel saws, cutoff wheels,high speed cutters or tungsten carbidecutters, always have the work securelyclamped. Never attempt to hold the workwith one hand while using any of theseaccessories. The reason is that these wheelswill grab if they become slightly canted in thegroove, and can kickback causing loss ofcontrol resulting in serious injury. Your secondhand should be used to steady and guide thehand holding the tool. When a cutoff wheelgrabs, the wheel itself usually breaks. Whenthe steel saw, high speed cutters or tungstencarbide cutter grab, it may jump from thegroove and you could lose control of the tool.

Some dust created bypower sanding, sawing,

grinding, drilling, and other constructionactivities contains chemicals known tocause cancer, birth defects or otherreproductive harm. Some examples ofthese chemicals are:• Lead from lead-based paints,

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

• Arsenic and chromium from chemicallytreated lumber.

Your risk from these exposures varies,depending on how often you do this type ofwork. To reduce your exposure to thesechemicals: work in a well ventilated area, andwork with approved safety equipment, such asthose dust masks that are specially designedto filter out microscopic particles.

This appliance is not intended for use byyoung children or infirmed persons unless theyhave been adequately supervised by aresponsible person to ensure that they can usethe appliance safely.

Young children should be supervised to ensurethat they do not play with the appliance.

! WARNING

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Battery/ChargerBefore using battery charger, read allinstructions and cautionary markings on(1) battery charger, (2) battery pack, and (3)product using battery.Use only the charger which accompaniedyour product or direct replacement aslisted in the catalog or this manual. Do notsubstitute any other charger. Use only Dremelapproved chargers with your product. SeeFunctional Description and Specifications.

Do not disassemble charger or operate thecharger if it has received a sharp blow,been dropped or otherwise damaged in anyway. Replace damaged cord or plugsimmediately. Incorrect reassembly or damagemay result in electric shock or fire.

Do not recharge battery in damp or wetenvironment. Do not expose charger to rainor snow. If battery case is cracked orotherwise damaged, do not insert intocharger. Battery short or fire may result.

Charge only Dremel approvedrechargeable batteries. See FunctionalDescription and Specifications. Other types ofbatteries may burst causing personal injuryand damage.

Charge battery pack in temperatures above+40 degrees F (4 degrees C) and below

+105 degrees F (41 degrees C). Store tooland battery pack in locations wheretemperatures will not exceed 120 degrees F(49 degrees C). This is important to preventserious damage to the battery cells.

Battery leakage may occur under extremeusage or temperature conditions. Avoidcontact with skin and eyes. The batteryliquid is caustic and could cause chemicalburns to tissues. If liquid comes in contact withskin, wash quickly with soap and water. If theliquid contacts your eyes, flush them withwater for a minimum of 10 minutes and seekmedical attention.

Place charger on flat non-flammablesurfaces and away from flammablematerials when re-charging battery pack.The charger and battery pack heat duringcharging. Carpeting and other heat insulatingsurfaces block proper air circulation which maycause overheating of the charger and batterypack. If smoke or melting of the case areobserved unplug the charger immediately anddo not use the battery pack or charger.

Use of an attachment not recommended orsold by Dremel may result in a risk of fire,electric shock or injury to persons.

When batteries are not intool or charger, keep them

away from metal objects. For example, toprotect terminals from shorting DO NOTplace batteries in a tool box or pocket with

nails, screws, keys, etc. Fire or injury may result.

DO NOT PUT BATTERIES INTO FIRE OREXPOSE TO HIGH HEAT. They mayexplode.

! WARNING

Battery Care

Do not attempt to disas-semble the battery or

remove any component projecting from thebattery terminals. Fire or injury may result.Prior to disposal, protect exposed terminalswith heavy insulating tape to prevent shorting.

At the end of the battery’s useful life, do notthrow out the battery. Please bring yourbattery to a proper battery disposal locationor contact your local Dremel distributor.

! WARNING

Battery Disposal

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Functional Description and Specifications

Disconnect battery pack from tool before making any assembly,adjustments or changing accessories. Such preventive safety measures

reduce the risk of starting the tool accidentally.

! WARNING

SHAFT LOCKBUTTON

Rotary ToolModel number 800-49Voltage rating 10.8 VNo load speed no 5,000-35,000/minCollet Capacities 0,8 mm, 1,6 mm, 2,4 mm, 3,2 mm

ChargerModel number 856-02Voltage rating 230-240 V 60 HzAmperage rating 420 mA

Battery pack 855, 855-02Charge time 3 Hr

DOVE-TAILFEATURE

RELEASETAB

HANGER

BATTERYPACK

SWITCH

COLLETNUT

COLLET

CHARGER

BATTERYPACK

INDICATOR LIGHT

ALIGNMENTARROWS

Cordless Rotary Tool

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Operating Instructions

Assembly

Disconnect battery packfrom tool before making

any assembly, adjustments or changingaccessories. Such preventive safetymeasures reduce the risk of starting the toolaccidentally..

COLLET — To loosen, first press shaft lockbutton and rotate the shaft by hand until thelock engages the shaft preventing furtherrotation.

Do not engage lock whilethe Rotary Tool is running.

With the shaft lock engaged use the colletwrench to loosen the collet nut if necessary.Change accessories by inserting the new oneinto the collet as far as possible to minimizerunout and unbalance. With the shaft lockengaged, finger tighten the collet nut until theaccessory shank is gripped by the collet. Avoidexcessive tightening of the collet nut.

COLLETS — Four different size collets (seeillustration), to accommodate different shanksizes, are available for your Cordless RotaryTool. To install a different collet, remove thecollet nut and remove the old collet. Insert theunslotted end of the collet in the hole in theend of the tool shaft. Replace collet nut on the

shaft. Always use the collet which matchesthe shank size of the accessory you planto use. Never force a larger diameter shankinto a collet.

BALANCING ACCESSORIES — Forprecision work, it is important that allaccessories be in good balance (much thesame as the tires on your automobile). To trueup or balance an accessory, slightly loosencollet nut and give the accessory or collet a 1/4turn. Retighten collet nut and run the Tool. Youshould be able to tell by the sound and feel ifyour accessory is running in balance. Continueadjusting in this fashion until best balance isachieved. To maintain balance on abrasivewheel points, before each use, with the wheelpoint secured in the collet, turn on the CordlessRotary Tool and run the 415 Dressing Stonelightly against the revolving wheel point. Thisremoves high spots and trues up the wheelpoint for good balance.

COLLET IDENTIFICATION CHART — Colletsizes can be identified by the rings on the backend of collet.

0,8 mm Collet has one (1) ring.1,6 mm Collet has two (2) rings.2,4 mm Collet has three (3) rings.3,2 mm Collet has no rings.

! WARNING

! CAUTION

SHAFTLOCK

BUTTON

TO LOOSEN

TO TIGHTENCOLLET

NUT

COLLET

COLLET NUT

IDENTIFICATIONRINGS

480 3,2 mm COLLET

481 2,4 mm COLLET

482 1,6 mm COLLET

483 0,8 mm COLLET

COLLETWRENCH

INTRODUCTIONThe Cordless Rotary Tool is a handful of high-speed power. It serves as a carver, a grinder,polisher, sander, cutter, power brush, drill andmore.

Your Cordless Rotary Tool has a small,powerful electric motor, is comfortable in thehand, and is made to accept a large variety ofaccessories including abrasive wheels, drillbits, wire brushes, polishers, engraving cutters,

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router bits, and cutting wheels. Accessoriescome in a variety of shapes and permit you todo a number of different jobs. As you becomefamiliar with the range of accessories and theiruses, you will learn just how versatile yourCordless Rotary Tool is. You’ll see dozens ofuses you hadn’t thought of before now.

The real secret of the Cordless Rotary Tool isits speed. To understand the advantages of itshigh speed, you have to know that thestandard portable electric drill runs at speedsup to 2,800 revolutions per minute. The typicalelectric drill is a low-speed, high torque tool;the Cordless Rotary Tool is just the opposite— a high-speed, low torque tool. The chiefdifference to the user is that in the high speedtools, the speed combined with the accessorymounted in the collet does the work. You don’tapply pressure to the tool, but simply hold and

guide it. In the low speed tools, you not onlyguide the tool, but also apply pressure to it, asyou do, for example, when drilling a hole.

It is this high speed, along with its compactsize and wide variety of special accessoriesand attachments that makes your CordlessRotary Tool different from other power tools.The speed enables it to do jobs low speedtools cannot do, such as cutting hardenedsteel, engraving glass, etc.

Getting the most out of your Cordless RotaryTool is a matter of learning how to let thisspeed work for you.

Read the next sections carefully. They will helpyou use your Cordless Rotary Tool correctlyand help you select the correct accessory foryour job.

CHARGING THE TOOLThe Cordless Rotary Tool is not fully charged.The tool is equipped with a removable batterypack. Be sure to charge pack prior to initial use.

TO CHARGE THE TOOL:1. Put the switch in the “OFF” position.

2. Squeeze release tabs on both sides ofbattery pack, and remove pack from back oftool as shown on page 7.

3. Align exterior shape of battery pack withexterior shape of charger (alignment arrows onbattery columm will point to the two arrowslocated on charger), squeeze release tabs,insert battery pack into charger as shown andrelease pressure on tabs so it locks in place.

4. Plug charger into the power source. Thegreen LED light indicates connection has been

made and the battery pack is charging. Undernormal usage the tool normally requires 3-5hours charging time to reach full capacity.When charging is complete, LED on chargerwill turn off.

Note: When inserting a fully charged batterypack into the charger, the charger’s green LEDlight will not illuminate.

5. When charging is completed, squeezerelease tabs on battery pack and remove packfrom charger.

6. Align exterior shape of battery pack withexterior shape of the housing of tool as shown.Squeeze release tabs, insert battery pack intoback of tool, and release pressure on tabs so itlocks in place.

STALL PROTECTIONThis tool has a stall protection feature built intoit to protect the motor and battery in the eventof a stall. If you stall the tool for too long, orbind the bit in a work piece, especially at highspeeds, it will automatically turn itself off.Simply take the tool out of the material youwere stalled in, turn it off for 3 seconds, thenturn it back on again to continue using it.When the battery becomes close to empty, thetool may shut down automatically morefrequent than normal. If this happens, it is timeto recharge the battery.

FUEL GAUGE This tool is equipped with a Fuel gauge thattells you how much charge your battery has. A

fully charged battery is indicated when all threeLED lights are illuminated. As the batterydischarges, the lights will turn off one by oneuntil only one light is on. When the last lightstarts "flashing", the battery is almost empty.When the battery is dead, the tool willautomatically turn off. This will be a suddenstop as opposed to a gradual winding down ofthe tool. Simply recharge the battery andreuse.

3 lights ˙ 100% charge remaining

2 lights ˙ 50% charge remaining

1 light ˙ 25% charge remaining

1 "Flashing" light ˙ tool is about to shut off.

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IMPORTANT CHARGING NOTES

1. The charger was designed to fast chargethe battery only when the battery temperatureis between 40˚F (4˚C) and 105˚F (41˚C).

2. A substantial drop in operating time percharge may mean that the battery pack isnearing the end of its life and should bereplaced.

3. If battery does not charge properly:

a. Check for voltage at outlet by pluggingin some other electrical device.

b. Check to see if outlet is connected to alight switch which turns power “off” whenlights are turned off.

c. Check battery pack terminals for dirt.Clean with cotton swab and alcohol ifnecessary.

d. If you still do not get proper charging,take or send tool, battery pack andcharger to your Dremel Service Center.

Note: Use of chargers or battery packs notsold by Dremel may void the warranty.

For best control in close work, grip theRotary Tool like a pencil between yourthumb and forefinger.

The “handgrip” method of holding the toolis used for operations such as grinding aflat surface or using cutoff wheels.

USING THE CORDLESS ROTARY TOOLThe first step in learning to use the CordlessRotary Tool is to get the “feel” of it. Hold it inyour hand and feel its weight and balance.Feel the taper of the housing. This taperpermits the tool to be grasped much like a penor pencil.

When you turn on the tool for the first time,hold it away from your face. Accessories canbe damaged during handling, and can fly apartas they come up to speed. This is notcommon, but it does happen.

Practice on scrap materials first to see how theCordless Rotary Tool cuts. Keep in mind thatthe work is done by the speed of the tool andby the accessory in the collet. You should notlean on or push the tool into the work.

Instead, lower the spinning accessory lightly tothe work and allow it to touch the point atwhich you want cutting (or sanding or etching,etc.) to begin. Concentrate on guiding the toolover the work using very little pressure fromyour hand. Allow the accessory to do the work.

Usually, it is best to make a series of passeswith the tool rather than attempt to do all thework in one pass. To make a cut, for example,pass the tool back and forth over the work,much as you would a small paint brush. Cut alittle material on each pass until you reach thedesired depth. For most work, the deft, gentletouch is best. With it, you have the bestcontrol, are less likely to make errors, and willget the most efficient work out of theaccessory.

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The speed of Model 800 is controlled byrotating this dial to desired setting on dial.

Switch Setting Speed Range

0 OFF Position

*2 5,000 – 11,000 RPM

4 12,000 – 20,000 RPM

6 21,000 – 25,000 RPM

8 26,000 – 30,000 RPM

10 31,000 – 35,000 RPM

*2 is the maximum speed setting for wirebrushes.

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Set the speed indicator to fit the job toachieve the best job results when workingwith differentmaterials.

To select the right speed for each job, use apractice piece of material. Vary speed tofind the best speed for the accessory youare using and the job to be done.

Your Cordless RotaryTool is equipped with avariable speed control dial. To turn the toolON, rotate dial to desired number to select theoperating speed needed from 5,000 – 35,000RPM. To turn tool OFF, rotate dial to the “0” offposition.

You can refer to the charts on page 12, 13,and 14 to determine the proper speed, basedon the material being worked and the type ofaccessory being used. These charts enableyou to select both the correct accessory andthe optimum speed at a glance.

NEEDS FOR SLOWER SPEEDSCertain materials, however, (some plastics, forexample) require a relatively slow speedbecause at high speed the friction of the toolgenerates heat and causes the plastic to melt.

Most work is done at high speed on yourCordless Rotary Tool. Lower speeds areneeded only for certain tasks.

Operating Speeds For Accessories

To aid you in determining the optimumoperational speed for different materials anddifferent accessories, we have constructed aseries of tables that appear on page 12, 13and 14. By referring to these tables, you candiscover the recommended speeds for eachtype of accessory. Look these tables over andbecome familiar with them.

Ultimately, the best way to determine thecorrect speed for work on any material is topractice for a few minutes on a piece of scrap,even after referring to the chart. You canquickly learn that a slower or faster speed ismore effective just by observing what happensas you make a pass or two at different speeds.When working with plastic, for example, startat a slow rate of speed and increase the speeduntil you observe that the plastic is melting atthe point of contact. Then reduce the speedslightly to get the optimum working speed.

Some rules of thumb in regard to speed:

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

2. Polishing, buffing and cleaning with a wirebrush must be done at speeds below15,000 RPM to prevent damage to thebrush.

3. Wood should be cut at high speed.

4. Iron or steel should be cut at top speed ifusing tungsten carbide accessory, but atslower speeds if using high speed steelcutters. If a high speed steel cutter starts tochatter — this normally means it is runningtoo slow.

5. Aluminum, copper alloys, lead alloys, zincalloys and tin may be cut at various speeds,depending on the type of cutting beingdone. Use paraffin or other suitablelubricant on the cutter to prevent the cutmaterial from adhering to the cutter teeth.

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Increasing the pressure on the tool is not theanswer when it is not cutting as you think itshould. Perhaps you should be using adifferent cutter, and perhaps an adjustmentin speed would solve the problem. Butleaning on the tool seldom helps.

Your 10.8v Cordless Rotary Tool can beused with all screw-on attachments for addedversatility. A few older attachments, such as

2217 Tool Holder, 330 Router, and 231Shaper / Router Table are not compatiblewith the 10.8V Cordless Rotary Tool.

The 220 Drill Press requires a free adapterkit which you can get by calling 03-5415317.

The 225 Flex Shaft is compatable with yourtool, but you may experience reduced runtimes when using it.

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone7103, 7105, 8-10 6 - - - 8-10 8-10 8-107117, 7120,7122, 7123,7134, 7144

Diamond Wheel Points

Use only Dremel™ tested, high performance accessories.* Speed for light cuts; Caution - burning on deep grooves.

• Depending on cutting direction relative to grain.

Speed Settings

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone100, 121, 131 8-10 8-10 4 4 6 - - -114, 124, 8-10 4 2 4 4 - - -134, 144190 8-10 8-10 2 6 8-10 - - -118, 191, 192, 8-10 8-10 2 4 8-10 - - -193, 194116, 117, 8-10 4 2 4 4 - - -125, 196115 8-10 8-10 2 4 4 - - -198 8-10 6 2 4 4 - - -199 8-10 6 2 4 4 - - -

High Speed Cutters

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone105, 108 8-10 8-10 6 2 4 - - -106, 109, 8-10 8-10 4 2 4 - - -107, 110 8-10 8-10 4 2 4 - - -111 8-10* 8-10* 6* 2 4 - - -112 8-10* 8-10* 4* 2 4 - - -113 8-10* 8-10* 4* 2 4 - - -

Engraving Cutters

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone9931, 9932, 8-10 6 2 - 4 - - -9933, 9934,9935, 9936

Structured Tooth Tungsten Carbide Cutters

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Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone612, 640 8-10* 6* - - - - - -

615, 617, 618, 8-10* 8-10* - - - - - -650, 652, 654 8-10* 6* - - - - - -

High Speed Router Bits

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone83142, 83322, - - 4 8-10 2 4 8-10 8-1083702, 84922,85422, 85602,85622

Silicon Carbide Grinding Stones

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone516, 517, 2-4 2-4 - 6 4 - - -518500 2-4 2-4 - 4-6 2-4 - - -

Abrasive Points

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone541,903, 911, 8-10 8-10 - 6 2 4 8-10 -921, 932, 941, 945, 952, 953, 954, 971, 997, 8153, 8175, 8193, 8215

Aluminum oxide grinding stones

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Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone9901, 9902, 8-10 6 2 8-10 4 6 8-10 8-109903, 9904,9905, 9906,99129909, 9910 6 8-10 8-109911

Tungsten Carbide Cutters

Use only Dremel™ tested, high performance accessories.* Speed for light cuts; Caution - burning on deep grooves.

• Depending on cutting direction relative to grain.

Speed Settings (Continued)

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone453, 454, - - - 8-10 - - - -455

Chain Saw Sharpening Stones

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Use only Dremel™ tested, high performance accessories.* Speed for light cuts; Caution - burning on deep grooves.

• Depending on cutting direction relative to grain.

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone461, 462, 463 - - - 2 2 2 2 2414, 422, 429 - - - 2 2 2 2 2425, 427 - - - 2 2 - - -423 - - - 2 2 2 2 2403, 404, 405 2 2 2 2 2 - - -530, 531, 532 - 2 - 2 - - - -428, 442, 443 2 2 2 2 2 - - -535, 536, 537 2 2 - 2 2 2 - -

Polishing Accessories

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone430, 431, 438 2-10 2-10 2-4 8-10 8-10 2-10 2-10 -439, 440, 444 2-10 2-10 2-4 8-10 8-10 2-10 2-10 -407, 408, 432 2-10 2-10 2-4 8-10 8-10 2-10 2-10 -411, 412, 413 6 6 2 - 2 - - -

Sanding Bands and Discs

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone502, 503, 504, 8-10 6 2 8-10 8-10 - - -505

Flapwheels

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone511 4 4 2 4 4 - - -

Finishing Abrasive Buffs

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone150 8-10 8-10 2 - 4 - - -

Drill Bit

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone569,570 For Use on Wall and Floor Grout 4-6

Grout Removal Bits

Catalog Soft Hard Laminates Steel Aluminum, Shell Ceramic GlassNumber Wood Wood Plastic Brass, etc. Stone409, 420, 426 - - 2 8-10 8-10 8-10 8-10 -540542 8-10 6-8 2 - - - -545 6-8 6 - - - 4-6 4-6 -560 For use on drywall. For best results, use at 30,000 rpm.561 4-8 4-8 2 - 8-10 - - -562 - - - - - - 8-10

Cutting Accessories

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The number and variety of accessories for theRotary Tool are almost limitless. There is acategory suited to almost any job you mighthave to do — and a variety of sizes and shapeswithin each category which enables you to getthe perfect accessory for every need.

Refer to the DREMEL ACCESSORY ORDERFORM for illustrations of the accessoriesavailable. These accessories may be foundat your local hardware, hobby or homecenter dealers.

ColletsIf you expect to use a variety of accessories,we recommend that in the beginning youpurchase a complete set of four collets. Storethese so that you will have the proper size ofcollet for any accessory or drill bit you want touse. Currently, the 3,2 mm, 2,4 mm, 1,6 mmand 0,8 mm collets accommodate all of theavailable Dremel accessories. 3,2 mmcollets are included in most rotary tool kits.

-14-

Maintenance

ServiceNO USER SERVICEABLEPARTS INSIDE. Preventive

maintenance performed by unauthorizedpersonnel may result in misplacing ofinternal wires and components whichcould cause serious hazard. We recommendthat all tool service be performed by a DremelService Center. SERVICEMEN: Disconnecttool and/or charger from power source beforeservicing.

D.C. motorsThe motor in your tool has been engineered formany hours of dependable service. Tomaintain peak efficiency of the motor, werecommend it be examined every six months.Only a genuine Dremel replacement motorspecially designed for your tool should be used.

CleaningTo avoid accidents, alwaysdisconnect the tool and/or

charger from the power supply beforecleaning. The tool may be cleaned mosteffectively with compressed dry air. Alwayswear safety goggles when cleaning toolswith compressed air.Ventilation openings and switch levers must bekept clean and free of foreign matter. Do notattempt to clean by inserting pointed objectsthrough opening.

Certain cleaning agents andsolvents damage plastic

parts. Some of these are: gasoline, carbontetrachloride, chlorinated cleaning solvents,ammonia and household detergents thatcontain ammonia.

! WARNING ! WARNING

! CAUTION

Extension CordsIf an extension cord isnecessary, a cord with

adequate size conductors that is capable ofcarrying the current necessary for your toolmust be used. This will prevent excessivevoltage drop, loss of power or overheating.Grounded tools must use 3-wire extensioncords that have 3-prong plugs and receptacles

RECOMMENDED SIZES OF EXTENSION CORDS240 VOLT ALTERNATING CURRENT TOOLS

! WARNING

Dremel Accessories

Use only Dremel™, high-performance accessories. Other accessories arenot designed for this tool and may lead to personal injury or property damage.! WARNING

Max. ToolAmpere Rating

Cord AmpereRating

Cord Sizes inmm2

10 10 1,0 25

10 15 1,5 32

Cord Lengthin Meters

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High Speed CuttersAvailable in many shapes, high speed cuttersare used in carving, cutting and slotting inwood, plastics and soft metals such asaluminum, copper and brass. These are theaccessories to use for freehand routing orcarving in wood or plastic, and for precisioncutting. Made of high quality steel. 3,2 mm shank.

Tungsten Carbide CuttersThese are tough, long-lived cutters for use onhardened steel, fired ceramics and other veryhard materials. They can be used forengraving on tools and garden equipment. 3,2mm shanks.

.

Engraving CuttersThis group has a wide variety of sizes andshapes, and are made for intricate work onceramics (greenware), wood carvings, jewelryand scrimshaw. They often are used in makingcomplicated printed circuit boards. Theyshould not be used on steel and other veryhard materials but are excellent on wood,plastic and soft metals. 2,4 mm shank.

Structured Tooth Tungsten Carbide CuttersFast cutting, needle-sharp teeth for greatermaterial removal with minimum loading. Useon fiberglass, wood, plastic, epoxy and rubber.3,2 mm shank.

Aluminum Oxide Grinding Stones(red/brown)

Round, pointed, flat — you name the shapeand there is one available in this category.These are made of aluminum oxide and covervirtually every possible kind of grindingapplication. Use them for sharpening lawnmower blades, screwdriver tips, knives,scissors, chisels and other cutting tools. Use toremove flash from metal castings, deburringany metal after cutting, smoothing weldedjoints, grinding off rivets and removing rust.These grinding stones can be resharped with adressing stone. In machine shops, high speeddrills and cutters normally are ground withaluminum oxide wheels. 3,2 mm shank.

-15-

Dremel Accessories (Cont.)

MandrelsA mandrel is a shank with a threaded or screwhead, which are required when you usepolishing accessories, cutting wheels, sandingdiscs, and polishing points. The reasonmandrels are used is that sanding discs,cutting wheels and similar accessories must bereplaced frequently. The mandrel is a per-manent shank, allowing you to replace only theworn head when necessary, thus saving theexpense of replacing the shaft each time.

Screw Mandrel No. 401This is a screw mandrel used with the feltpolishing tip and felt polishing wheels. 3,2 mmshank.

Small Screw Mandrel No. 402This is a mandrel with a small screw at its tip,and is used with emery and fiberglass cuttingwheels, sanding discs and polishing wheels.3,2 mm shank.

Threaded Tip Mandrel No. 424This is a mandrel with a threaded tip whichthreads into the polishing point accessory No.427. 3,2 mm shank.

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Silicon Carbide Grinding Stones(blue/green)

Tougher than aluminum oxide points, theseare made especially for use on hard materialssuch as glass and ceramics. Typical usesmight be the removal of stilt marks and excessglaze on ceramics and engraving on glass. 3,2mm shank.

Diamond Wheel PointsExcellent for fine detail work on wood, jade,ceramic, glass and other hard material. Bitsare covered with diamond particles. 3,2 mmshanks.

Wire BrushesThree different shapes of wire brushes areavailable. For best results wire brushesshould be used at speeds not greater than15.000 RPM. Refer to Operating Speedssection for proper tool speed setting. Thethree shapes come in three different materials:stainless steel, brass and carbon wire. Thestainless steel perform well on pewter,aluminum, stainless steel, and other metals,without leaving "after-rust". Brass brushes arenon sparking, and softer than steel; makingthem good for use on soft metal like gold,cooper and brass. The carbon wire brushesare good for general purpose cleaning.

Bristle BrushesThese are excellent cleaning tools onsilverware, jewelry and antiques. The threeshapes make it possible to get into tightcorners and other difficult places. Bristlebrushes can be used with polishing compoundfor faster cleaning or polishing.

Brushing Pressure1. Remember, the tips of a wire brush do thework. Operate the brush with the lightestpressure so only the tips of the wire come incontact with the work.

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

3. Apply the brush to the work in such a waythat as much of the brush face as possible is infull contact with the work. Applying the side oredge of the brush to the work will result in wirebreakage and shortened brush life.

Polishing AccessoriesThese include an impregnated polishing pointand an impregnated polishing wheel forbringing metal surfaces to smooth finish; a feltpolishing tip and felt polishing wheel, and clothpolishing wheel, all used for polishing plastics,metals, jewelry and small parts. Also included

in this group is a polishing compound (No. 421)for use with the felt and cloth polishers. Polishing points make a very smooth surface,but a high luster is obtained using felt or clothwheels and polishing compound. For bestresults polishing accessories should beused at speeds not greater than 15.000RPM.No polishing compound is needed when usingthe 425 Polishing Wheel or 427 Polishing point.

-16-

Dremel Accessories (Cont.)

CORRECT:Wire tips doing the work.

INCORRECT:Excessive pressure can cause wire breakage.

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Aluminum Oxide Abrasive WheelsUse to remove paint, deburr metal, polishstainless steel and other metals. Available infine and medium grits. 3,2 mm shank.

Sanding AccessoriesSanding discs in fine, medium and coarsegrades are made to fit mandrel No. 402. Theycan be used for nearly any small sanding jobyou might have, from model making to finefurniture finishing. In addition, there is the drumsander, a tiny drum which fits into the RotaryTool and makes it possible to shape wood,smooth fiberglass, sand inside curves andother difficult places, and other sanding jobs.You replace the sanding bands on the drum asthey become worn and lose their grit. Bandscome in fine and coarse grades. Flapwheelsgrind and polish flat or contoured surfaces.They are used most effectively as a finishingsander after heavier surface sanding andmaterial removal is completed. Flapwheelscome in fine and coarse grades. Buffs are agreat finishing accessory for cleaning and lightsanding. They work effectively on metal, glass,wood, aluminum and plastics. Coarse andmedium buffs are sold together. 3,2 mm shank.

Grinding WheelUse for deburring, removing rust, and generalpurpose grinding. Use with Mandrel #402.

Cutting WheelsThese thin discs of emery or fiberglass areused for slicing, cutting off and similaroperations. Use them for cutting off frozen boltheads and nuts, or to reslot a screw headwhich has become so damaged that thescrewdriver won’t work in it. Fine for cuttingBX cable, small rods, tubing, cable and cuttingrectangular holes in sheet metal.

Drywall Cutting BitGives you fast, clean cuts in drywall.

Tile Cutting BitCuts ceramic wall tile, cement board, andplaster.

Spiral Cutting BitCuts through all types of wood and woodcomposites.

High Speed Router BitsFor routing, inlaying, and mortising in woodand other soft materials. Use with Dremel No.330 Router attachment and No. 231Shaper/Router table.

-17-

Dremel Accessories (Cont.)

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-18-

Mandrel No. 401 is used with the feltpolishing tip and wheels. Thread the tip on tothe screw carefully. The felt tip must thread

down straight on the screw Mandrel, and beturned all the way to the collar.

Mandrel No. 402 has a small screw at its tip,and is used with emery cutting wheels andsanding discs. Higher speeds, usually

maximum, are best for most work, includingcutting steel. Which is shown here.

The machine-screw threading on MandrelNo. 424 threads into polishing point No. 427.This and other threaded mandrels must be

screwed firmly down to the collar before beingused.

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-19-

To replace a band on the Drum Sander,loosen the screw without removing it tocontract the drum then slide the old band off.Slide the new sanding band on and thenexpand the drum by tightening the screwonce again.

Before each use, check tomake certain that all

components are assembled to accessoryshank and that the drum is sufficientlyexpanded to secure the band during use. Ifsanding band is loose on the drum duringoperation it may “fly” off and strike you orbystanders.

! WARNING

The new 1.3 Ah battery pack has an integratedDove-tail feature that accommodates newattachments for additional functionality. TheDove-tail feature allows the use of the Flex

Light and Flex Light with Magnifier. Theseoptional tools allow you to better aluminate andview your project work areas.

ON

OFF

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2610945859 07/07 Printed in Mexico

25

26

23

801

32

2

822

801

19

652

27

CODE PARTNO. NO. DESCRIPTION

2 2610919750 Motor Assembly4 2610919742 Speed Control Assembly19 2914201664 Screw (4 Required)23 2610919753 Lock Button25 2615297355 Collet Nut26 2615110480 3.2 mm Collet (In Tool)27 2610919754 Housing Cap32 2610944356 Battery Pack652 2610943970 Charger801 2610947399 Housing Set822 2610913818 Shaft Lock Assembly

4

19

MODEL 800-49

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