Switch (Fig. 3)
To turn the unit on, depress the side of the
Paper Punch (Fig. 4, 5)
CAUTION: Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Be sure the switch is in the OFF position.
A paper punch (H) is provided with your sander to let you perforate regular sandpaper to make dust collection possible.
TO PERFORATE YOUR SANDPAPER
Install the sandpaper on the tool as instructed in this manual. With the sander turned off and unplugged, place the paper punch on the paper so that the tabs (I) at the edges of the punch are against any two adjacent sides of the sanding pad, as shown. Press the punch against the pad so that the 8 points penetrate the paper, as shown in Figure 5. (Press the punch into the pad as far as it will go.) Remove the paper punch and the paper is ready.
An alternate method of perforating the paper is to securely fasten the punch to a suitable work surface. Two holes are provided in the punch for this purpose. Use #8 flat head screws. Press the sander (with the paper attached) down on the punch.
Dust Extraction (Fig. 6)
CAUTION: Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Be sure the switch is in the OFF position.
Your sander has two dust collection methods: a
TO EMPTY DUST BAG
1.While holding the sander, grasp the dust collection bag (D) at the end nearest the sander and twist off of the
2.Gently shake or tap the dust collection bag to empty.
3.Twist dust collection bag back onto the
You may notice that all the dust will not come free from the bag. This will not affect sanding performance but will reduce the sander’s dust collection efficiency. To restore your sander’s dust collection efficiency, depress the spring inside the dust bag when you are emptying it and tap it on the side of the trash can or dust receptacle.
CAUTION: Never operate these tools unless the dust collector is in place. Sanding dust exhaust may create a breathing hazard.
OPERATION (Fig. 7)
To operate your sander, grasp it as shown in Figure 7A or 7B and turn it on. Move it in long, sweeping strokes along the surface being sanded, letting the sander do the work. Pushing down on the tool while sanding actually slows the removal rate and produces an inferior quality sur- face. Be sure to check your work often, this sander is capable of removing material rapidly, espe- cially with coarse paper.
Your sander is designed to sand flush on three sides for sanding in corners, and its small size and light weight make it ideal for overhead work.
The orbital action of your sander allows you to sand with the grain or at any angle across it for most sanding jobs. On the final sanding steps, as discussed below, a better finish will result if you sand only with the grain.
To produce the best finish possible, start with coarse grit sandpaper and change gradually to finer and finer paper. A final sanding with a piece of
When sanding painted surfaces, you may find that the sandpaper loads up and clogs with paint. A heat gun will work much better to remove paint before sanding. FOLLOW ALL SAFETY INSTRUCTIONS IN HEAT GUN INSTRUCTION MANUAL.
Precautions To Take When Sanding Paint
1.Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling the contaminated dust. The greatest danger of lead poisoning is to children and pregnant women.
2.Since it is difficult to identify whether or not a paint contains lead without a chemical analysis, we recommend the following precautions when sanding any paint:
PERSONAL SAFETY
1.No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.
2.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 N.I.O.S.H. approved dust mask.
3.NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingest- ing 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
1.Paint should be removed in such a manner as to minimize the amount of dust generated.
2.Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils thickness.
3.Sanding should be done in a manner to reduce tracking of paint dust outside the work area.
CLEANING AND DISPOSAL
1.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.
2.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
3.All toys, washable furniture and utensils used by children should be washed thoroughly before being used again.
Tool Care
•Keep your machine as clean as possible by wiping with a clean cloth and blowing through it with air after every 5 hours of use.
•Don’t use harsh chemicals or solvents to clean the tool. These chemicals could seriously damage the plastic.
•Avoid overloading your sander. Overloading will result in a considerable reduction in speed and efficiency and the unit will become hot. In this event, run sander at a “no load” condition for a minute or two.
Brush Replacement (Fig. 8, 9)
CAUTION: Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Be sure the switch is in the OFF position.
TO REPLACE BRUSHES
1.Remove the three screws from the top cap and lift off the top cap, as shown in Figure 8.
2.Pull the brush spring (J) back (be careful not to pull completely off) and slide out the old brush.
3.Pull the brush wire (L) which is connected to the brush, out of the motor field (K).
4.Plug the new brush wire back into the motor field.
5.Still holding the brush spring back, slide in the new brush with the wire coming out the top of the brush and release the brush spring.
6.Repeat steps
7.Replace the top cap and tighten the three screws. Be careful not to
8.Always replace both brushes.
Accessories
Recommended accessories for use with your tool are available at extra cost from your local deal- er or authorized service center. If you need assistance in locating any accessory for your tool, contact: DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 or call
FIG. 1
D
A 
E
F 
B
C
G
FIG. 2 | FIG. 3 |
A 
FIG. 4 | H | FIG. 5 |
I
I
FIG. 6 | E | D |
FIG. 7A | FIG. 7B |
FIG. 8 | FIG. 9 |
J | K |
| |
| L |
CAUTION: The use of any other accessory not recommended for use with this tool could be hazardous.
Lubrication
Self lubricating bearings are used in the tool and periodic relubrication is not required. However, it is recommended that, once a year, you take or send the tool to a service center for a thorough cleaning and inspection.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by authorized service centers or other qualified service personnel, always using identical replacement parts.
Three Year Limited Warranty
DEWALT will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call