Dremel 4200 Operating/Safety Instructions Manual

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Operating/Safety Instructions

Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

1-800-4-DREMEL (1-800-437-3635) www.dremel.com

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Consumer Information

& Service Locations

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de service après-vente,

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P.O. Box 081126 Racine, WI 53408-1126

4200

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Work area safety

Keep work area clean and well lit. Cluttered

or dark areas invite accidents.

Do not operate power tools in explosive

atmospheres, such as in the presence of

flammable liquids, gases or dust. Power

tools create sparks which may ignite the dust

or fumes.

Keep children and bystanders away while

operating a power tool. Distractions can

cause you to lose control.

Electrical safety

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.

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.

Do not expose power tools to rain or wet

conditions. Water entering a power tool will

increase the risk of electric shock.

Do not abuse the cord. Never use the cord

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.

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.

If operating a power tool in a damp location

is unavoidable, use a Ground Fault Circuit

Interrupter (GFCI) protected supply. Use of

an GFCI reduces the risk of electric shock.

Personal safety

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.

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.

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.

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.

Do not overreach. Keep proper footing and

balance at all times. This enables better

control of the power tool in unexpected

situations.

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.

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.

Power tool use and care

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.

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.

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 WARNINGS 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.

!

WARNING

General Power Tool Safety Warnings

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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.

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.

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.

Keep cutting tools sharp and clean. Properly

maintained cutting tools with sharp cutting

edges are less likely to bind and are easier to

control.

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.

Service

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.

Hold power tool by insulated gripping

surfaces, because the cutter may contact

its own cord. Cutting a ”live” wire may make

exposed metal parts of the power tool ”live”

and shock the operator.

Use clamps or another practical way to

secure and support the workpiece to a

stable platform. Holding the work by your

hand or against the body leaves it unstable

and may lead to loss of control.

Accessories must be rated for at least the

speed recommended on the tool warning

label. Wheels and other accessories running

over rated speed can fly apart and cause

injury.

If cutting into existing walls or other blind

areas where electrical wiring may exist is

unavoidable, disconnect all fuses or circuit

breakers feeding this worksite.

Do not operate the flexible shaft with a

sharp bend. Over bending the shaft can

generate excessive heat on the jacket or hand

piece. The recommended minimum is 5"

radius.

Always disconnect the power cord from

the power source before making any

adjustments or attaching any accessories.

You may unexpectedly cause the tool to start

leading to serious personal injury.

Be aware of the switch location, when

placing the tool down or when picking the

tool up. You may accidentally activate the

switch.

Always hold the hand piece firmly in your

hands during the start-up. The reaction

torque of the motor, as it accelerates to full

speed, can cause the shaft to twist.

Always wear safety goggles and dust

mask. Use only in well ventilated area.

Using personal safety devices and working in

safe environment reduces risk of injury.

Do not reach in the area of the spinning

bit. The proximity of the spinning bit to your

hand may not always be obvious.

Allow brushes to run at opera ting speed

for at least one minute before using wheel.

During this time no one is to stand in front

or in line with the brush. Loose bristles or

wires will be discharged during the run-in time.

Wire and bristle brushes must never be

operated at speeds greater than

15,000/min. Direct the discharge of the

spinning wire brush away from you. Small

particles and tiny wire fragments may be

discharged at high velocity during the

“cleaning” action with these brushes and may

become imbedded in your skin. Bristles or

wires will be discharged from the brush at high

speeds.

Safety Rules for Rotary Tools

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Wear protective gloves and face shield

with wire or bristle brushes. Apply wire or

bristle brushes lightly to the work as only

the tips of the wire/bristles do the work.

“Heavy” pressure on bristles will cause the

wire or bristle to become overstressed,

resulting in a wiping action and will cause the

bristles/wire to be discharged.

Carefully handle both the tool and

individual grinding wheels to avoid

chipping or cracking. Install a new wheel if

tool is dropped while grinding. Do not use

a wheel that may be damaged. Fragments

from a wheel that bursts during operation will

fly away at great velocity possibly striking you

or bystanders.

Never use dull or damaged bits. Sharp bits

must be handled with care. Damaged bits

can snap during use. Dull bits require more

force to push the tool, possibly causing the bit

to break.

Use clamps to support workpiece

whenever practical. Never hold a small

workpiece in one hand and the tool in the

other hand while in use. Allow for

sufficient space, at least 6", between your

hand and the spinning bit. Round material

such as dowel rods, pipes or tubing have a

tendency to roll while being cut, and may

cause the bit to “bite” or jump toward you.

Clamping a small workpiece allows you to use

both hands to control the tool.

Inspect your workpiece before cutting.

When cutting irregularly shaped

workpieces, plan your work so it will not

slip and pinch the bit and be torn from

your hand. For example, if carving wood,

make sure there are no nails or foreign objects

in the workpiece. Nails or foreign objects can

cause the bit to jump.

Never start the tool when the bit is

engaged in the material. The bit cutting

edge may grab the material causing loss of

control of the cutter.

Avoid bouncing and snagging the wheel,

especially when working corners, sharp

edges etc. This can cause loss of control and

kick-back.

The direction of feed with the bit into the

material when carving, routing or cutting is

very important. Always feed the bit into

the material in the same direction as the

cutting edge is exiting from the material

(which is the same direction as the chips

are thrown). Feeding the tool in the wrong

direction, causes the cutting edge of the bit to

climb out of the work and pull the tool in the

direction of this feed.

If the workpiece or bit becomes jammed or

bogged down, turn the tool “OFF” by the

switch. Wait for all moving parts to stop

and unplug the tool, then work to free the

jammed material. If the switch to the tool is

left “ON” the tool could restart unexpectedly

causing serious personal injury.

Do not leave a running tool unattended,

turn power off. Only when tool comes to a

complete stop is it safe to put it down.

Do not grind or sand near flammable

materials. Sparks from the wheel could ignite

these materials.

Do not touch the bit or collet after use.

After use the bit and collet are too hot to be

touched by bare hands.

Regularly clean the tool's air vents by

compressed air. Excessive accumulation of

powdered metal inside the motor housing may

cause electrical failures.

Do not allow familiarity gained from

frequent use of your rotary tool to become

commonplace. Always remember that a

careless fraction of a second is sufficient to

inflict severe injury.

Do not alter or misuse tool. Any alteration or

modification is a misuse and may result in

serious personal injury.

This product is not intended for use as a

dental drill, in human or veterinary medical

applications. Serious personal injury may

result.

When using the steel saws, cut off wheels,

high speed cutters or tungsten carbide

cutters, always have the work secure ly

clamped. Never attempt to hold the work

with one hand while using any of these

accessories. The reason is that these wheels

will grab if they become slight ly canted in the

groove, and can kick back causing loss of

control resulting in serious in jury. Your second

hand should be used to steady and guide the

hand holding the tool. When a cutoff wheel

Safety Rules for Rotary Tools - (cont.)

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Additional Safety Warnings

GFCI and personal protection devices like

electrician’s rubber gloves and footwear will

further enhance your personal safety.

Do not use AC only rated tools with a DC

power supply. While the tool may appear to

work, the electrical components of the AC

rated tool are likely to fail and create a hazard

to the operator.

Keep handles dry, clean and free from oil

and grease. Slippery hands cannot safely

control the power tool.

Use clamps or other practical way to secure

and support the workpiece to a stable

platform. Holding the work by hand or against

your body is unstable and may lead to loss of

control.

Develop a periodic maintenance schedule

for your tool. When cleaning a tool be

careful not to disassemble any portion of

the tool since internal wires may be

misplaced or pinched or safety guard return

springs may be improperly mounted.

Certain cleaning agents such as gasoline,

carbon tetrachloride, ammonia, etc. may

damage plastic parts.

Risk of injury to user. The power cord must only

be serviced by a Dremel Service Facility..

Some dust created by power

sanding, sawing, grinding,

drilling, and other construction activities

contains chemicals known to cause cancer,

birth defects or other reproductive harm.

Some examples of these chemicals are:

• Lead from lead-based paints,

• Crystalline silica from bricks and cement and

other masonry products, and

• Arsenic and chromium from chemically-

treated lumber.

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.

!

WARNING

Safety Rules for Rotary Tools - (cont.)

grabs, the wheel itself usually breaks. When

the steel saw, high speed cutters or tungsten

carbide cutter grab, it may jump from the

groove and you could lose control of the tool.

Use only Dremel

®

, high-performance

accessories. Other accessories are not

designed for this tool and may lead to personal

injury or property damage.

After changing bits or making any

adjustments, make sure the bit is properly

secured by pulling the EZ Change™ levers

forward. Loose adjustment devices can

unexpectedly shift, causing loss of control,

loose rotating components may be ejected.

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IMPORTANT: Some of the following symbols may be used on your tool. Please study them

and learn their meaning. Proper interpretation of these symbols will allow you to operate the

tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Diameter Size of drill bits, grinding wheels, etc.

n

0

No load speed Rotational speed, at no load

n Rated speed Maximum attainable speed

.../min Revolutions or reciprocation Revolutions, strokes, surface speed,

per minute orbits etc. per minute

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque or position settings.

I, II, III, Higher number means greater speed

Infinitely variable selector with off Speed is increasing from 0 setting

Arrow Action in the direction of arrow

Alternating current Type or a characteristic of current

Direct current Type or a characteristic of current

Alternating or direct current Type or a characteristic of current

Class II construction Designates Double Insulated

Construction tools.

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Li-ion RBRC seal Designates Li-ion battery recycling

program

Ni-Cad RBRC seal Designates Ni-Cad battery recycling

program

Read manual symbol Alerts user to read manual

Wear eye protection symbol Alerts user to wear eye protection

Symbols

0

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This symbol designates that this tool is listed by Underwriters Laboratories.

This symbol designates that this tool is listed by the Canadian Standards

Association.

This symbol designates that this tool is listed by the Canadian Standards

Association, to United States and Canadian Standards.

This symbol designates that this tool complies to NOM Mexican Standards.

This symbol designates that this tool is listed by the Intertek Testing

Services, to United States and Canadian Standards.

Symbols (continued)

IMPORTANT: Some of the following symbols may be used on your tool. Please study them

and learn their meaning. Proper interpretation of these symbols will allow you to operate the

tool better and safer.

This symbol designates that this component is recognized by Underwriters

Laboratories.

This symbol designates that this tool is listed by Underwriters Laboratories,

to United States and Canadian Standards.

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Disconnect the plug from the power source before making any

assembly, adjustments or changing accessories. Such preventive safety

measures reduce the risk of starting the tool accidentally.

!

WARNING

Model number 4200

Voltage rating 120V 50 - 60Hz

Amperage rating 1.6A

No load speed n

0

5,000-35,000/min

Collet capacities 1/32, 1/16", 3/32", 1/8"

Functional Description and Specifications

Model 4200 High Speed Rotary Tool EZ Change™

ON/OFF SWITCH

CORD

BRUSH COVER

(one on each side)

VARIABLE SPEED

DIAL

VENTILATION

OPENINGS

VENTILATION

OPENINGS

HANGER

COLLET

EZ CHANGE™

LEVERS

EZ CHANGE™

CHUCK

FIG. 1

HOUSING

CAP

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Always unplug Rotary Tool

before changing accessories,

changing collets or servicing your Rotary Tool.

After changing bits or

making any adjustments,

make sure the bit is properly secured by

pulling the EZ Change™ levers forward.

Loose adjustment devices can unexpectedly

shift, causing loss of control, loose rotating

components may be ejected.

INSTALLING AND REMOVING

ACCESSORIES

Your Dremel 4200 is equipped with the EZ

Change™ mechanism which will allow you to

quickly and easily change accessories without

the use of a wrench.

1. To install a accessory, pull and hold the EZ

Change™ levers in direction of arrows 1 as far

as they will go (Fig. 2).

2. Insert accessory into the collet as far as

possible to minimize runout and unbalance, and

then and release EZ Change™ levers.

3. Press EZ Change™ levers towards the nose

of the tool to fully secure the bit. If slipping of the

bit while in use occur, the tool needs service.

4. To remove accessories, pull and hold the EZ

Change™ levers in direction of arrows 1 as far

as they will go and simply remove accessory

from the EZ Change™ chuck.

Do not engage the EZ

Change™ levers while the

Rotary Tool is running as the bit may be

ejected.

COLLETS

Four different size collets to accommodate

different shank sizes, are avail able for your

Rotary Tool (Fig. 3).

Always use the collet which

matches the shank size of

the accessory you plan to use. Never force a

larger diameter shank into a collet.

Note: Most rotary tool kits do not include all four

collets sizes. Other collets sizes can be ordered

through the Dremel Service Center or on-line.

CHANGING COLLETS

To install a different collet, remove collet from

EZ Change™ chuck by using needle nose

pliers (Fig. 4). Lightly depress the finger of the

collet until it is clear of the detent feature

(Fig. 5) and pull collet free from chuck. Insert

Assembly

!

WARNING

!

WARNING

1

2

EZ CHANGE™

CHUCK

FIG. 2

EZ CHANGE™

LEVERS

ACCESSORY

COLLET

IDENTIFICATION

RINGS

1/8"

COLLET

3/32"

COLLET

1/16"

COLLET

1/32"

COLLET

FIG. 3

COLLET IDENTIFICATION CHART

Collet sizes can be identified by the rings

on the back end of collet.

1/32" Collet has one (1) ring.

1/16" Collet has two (2) rings.

3/32" Collet has three (3) rings.

1/8" Collet has no rings. 1/8" is included

in the 4200 kit.

!

CAUTION

!

CAUTION

NEEDLE

NOSE

PLIERS

COLLET

FIG. 4

EZ CHANGE™

CHUCK

COLLET

DETENT

Push collet finger with needle nose pliers

until clear of detents and then pull it out

FINGER

FIG. 5

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Operating Instructions

Dremel 4200

Thank you for purchasing the Dremel 4200.

This product was designed by the many

Dremel users who passionately use their rotary

tools daily. This tool was designed to give you

an easy way to change accessories and the

ultimate performance when working on projects.

The Dremel 4200 is the FIRST rotary tool that

easily change accessories without using a

wrench. It uses a fully integrated mechanism

that clamps the accessory through a lever

system. In addition, the Dremel 4200 is a high

performance rotary tool with electronic

feedback that allows the tool to maintain its

speed under load. The design of the tool is

symmetrical and contains plenty of soft grip so

the tool can be held comfortably in many

positions. You will appreciate the many

applications that the Dremel 4200 can easily

tackle.

Rotary Tool Introduction

The Rotary Tool has a small, powerful electric

universal motor, is comfort able in the hand, and

is made to accept a large variety of accessories

including abrasive wheels, drill bits, wire

brushes, polishers, engraving cutters, router

bits, cutting wheels and attachments.

Accessories come in a variety of shapes and

permit you to do a number of different jobs. As

you be come familiar with the range of

accessories and their uses, you will learn just

how versatile the Rotary Tool is. You’ll see

dozens of uses you hadn’t thought of before.

The real secret of the Rotary Tool is its speed.

To understand the advantages of its high

speed, you have to know that the standard

portable electric drill runs at speeds up to 2,800

revolutions per minute. The Rotary Tool

operates at speeds up to 35,000 revolutions

per minute. The typical electric drill is a low-

speed, high torque tool; the Rotary Tool is just

the opposite – a high-speed, low torque tool.

The major difference to the user is that in the

high speed tools, the speed combined with the

acces sory mounted in the collet does the work.

You don’t apply pressure to the tool, but simply

hold and guide it. In the low speed tools, you

not only guide the tool, but also apply pressure

to it, as you do, for example, when drilling a hole.

It is this high speed, along with its compact size

and wide variety of special accessories and

attachments, that makes the Rotary Tool differ -

ent from other tools. The speed enables it to do

jobs low speed tools cannot do, such as cutting

hardened steel, en graving glass, etc.

Getting the most out of your Rotary Tool is a

matter of learning how to let this speed work for

you. To learn about more uses and the

versatility of Dremel accessories and

attachments refer to this Owner's Manual or

check our website at www.Dremel.com.

Using the Rotary Tool

The first step in learning to use the Rotary Tool

is to get the “feel” of it. Hold it in your hand and

feel its weight and balance. Feel the taper of

the housing.

Always hold the tool

away from your face.

Accessories can be

damaged during

handling, and can fly

apart as they come up

to speed. This is not

common, but it does happen.

Whenever you hold the

tool, be careful not to cover

the air vents with your hand. This blocks

the air flow and causes the motor to

overheat.

narrow end of the new collet completely into the

EZ Change™ chuck. The fingers of the collet

must be aligned with the detents of the EZ

Change™ chuck to be fully inserted.

BALANCING ACCESSORIES — For precision

work, it is important that all accessories be in

good balance (much the same as the tires on

your automobile). To true up or balance an

accessory, slightly loosen collet nut by pulling

back on the EZ Change™ levers and give the

accessory a 1/4 turn. Release EZ Change™

levers and run the Rotary Tool. You should be

able to tell by the sound and feel if your

accessory is running in balance. Continue

adjusting in this fashion until best balance is

achieved. To maintain balance on abrasive

wheel points, before each use, with the wheel

point secured in the collet, turn on the Rotary

Tool and run the 415 Dressing Stone lightly

against the revolving wheel point. This removes

high spots and trues up the wheel point for

good balance.

WARNING

Wear Eye Protection



CAUTION

!

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For best control in close work, grip the Rotary

Tool like a pencil between your thumb and

forefinger (Figure 6).

The “Golf Grip” method of holding the tool is

used for more aggressive operations such as

grinding a flat surface or using cutoff wheels

(Figure 7).

Practice on scrap materials first to see how the

Rotary Tool's high speed action performs. Keep

in mind that the work is done by the speed of

the tool and by the accessory in the collet. You

should not lean on or push the tool during use.

Instead, lower the spinning accessory lightly to

the work and allow it to touch the point at which

you want cutting (or sanding or etching, etc.) to

begin. Con centrate on guiding the tool over the

work using very little pressure from your hand.

Allow the accessory to do the work.

Usually, it is best to make a series of passes

with the tool rather than attempt to do all the

work 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 a

little material on each pass until you reach the

desired depth. For most work, the gentle touch

is best. With it, you have the best control, are

less likely to make errors, and will get the

most effi cient work out of the accessory.

The hanger is provided for the use of hanging

your tool while using the flex-shaft or for

storage. If you do not use the hanger, snap it

back into place so it will be out of the way while

the tool is in use.

To select the right speed for each job, use a

practice piece of material.

NOTE: Speed is affected by voltage

changes. A reduced incoming voltage will

slow the RPM of the tool.

SLIDE "ON/OFF" SWITCH

The tool is switched "ON" by the slide switch

located on the topside of the motor housing.

TO TURN THE TOOL "ON", slide the switch

button forward.

TO TURN THE TOOL "OFF", slide the switch

button backward.

HIGH PERFORMANCE MOTOR

Your tool is equipped with a high performance

rotary tool motor. This motor expands the

versatility of the rotary tool by driving additional

attachments such as the Dremel Mini-Saw and

Dremel Right Angle.

ELECTRONIC FEEDBACK

Your tool is equipped with an internal electronic

feedback system that provides a “soft start”,

which will reduce the stresses that occur from

a high torque start. The system also helps to

keep the preselected speed virtually constant

between no-load and load conditions.

VARIABLE SPEED DIAL

Your tool is equipped with a variable speed

dial. The speed may be adjusted during

operation by presetting the dial on or

between any one of the settings.

You can refer to the charts on page 21, 22,

23 and 24 to determine the proper speed,

based on the materi al being worked and the

type of accessory being used. These charts

enable you to select both the correct acces -

sory and the optimum speed at a glance.

Operating Speeds

FIG. 7

FIG. 6

Questions or Problems? Call 1-800-437-3635

or check our website at www.Dremel.com

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The speed of Rotary Tool is controlled by

setting this dial on the housing (Fig. 8).

Settings for Approximate Revolutions.

Switch Setting Speed Range

5 15,000-7,000 RPM

*10 17,000-10,000 RPM

15 13,000-17,000 RPM

20 18,000-23,000 RPM

25 23,000-27,000 RPM

30 28,000-32,000 RPM

35 33,000-35,000 RPM

* Wire Brush Setting.

Needs for Slower Speeds

Certain materials, however, (some plastics and

precious metals, for ex ample) require a

relatively slow speed because at high speed

the friction of the accessory generates heat

and may cause damage to the material.

Slow speeds (15,000 RPM or less) usually are

best for polishing operations employing the felt

polishing ac ces sories. They may also be best

for working on deli cate projects as “eggery”

work, delicate wood carving and fragile model

parts. All brushing applications require

lower speeds to avoid wire discharge from

the holder.

Higher speeds are better for carving, cutting,

routing, shaping, cutting dadoes or rabbets in

wood.

Hardwoods, metals and glass require high

speed operation, and drilling should also be

done at high speeds.

Many applications and accessories in our line

will provide the best performance at full speed,

but for certain materials, applications, and

accessories, you need slower speeds, which is

the reason our variable speed models are

available.

To aid you in determining the optimum

operational speed for differ ent materials and

different accessories, we have construct ed a

series of tables that appear on page 21, 22, 23

and 24. By referring to these tables, you can

discover the recommended speeds for each

type of accessory. Look these tables over and

become familiar with them.

Ultimately, the best way to determine the

correct speed for work on any material is to

practice for a few minutes on a piece of scrap,

even after referring to the chart. You can

quickly learn that a slower or faster speed is

more effective just by observing what hap pens

as you make a pass or two at different speeds.

When working with plastic, for example, start at

a slow rate of speed and increase the speed

until you observe that the plastic is melting at

the point of contact. Then reduce the speed

slight ly to get the optimum working speed.

Some rules of thumb in regard to speed:

1. Plastic and other materials that melt at low

temperatures should be cut at low speeds.

2. Polishing, buffing and cleaning with any type

of bristle brush must be done at speeds not

greater than 15,000 RPM to prevent damage

to the brush from bristles flying toward

operator.

3. Wood should be cut at high speed.

4. Iron or steel should be cut at high speed. If a

high speed steel cutter starts to chatter — this

normally means it is running too slow.

5. Aluminum, copper alloys, lead alloys, zinc

alloys and tin may be cut at various speeds,

depending on the type of cutting being done.

Use paraffin or other suitable lubricant on the

cutter to prevent the cut material from adhering

to the cutter teeth.

Increasing the pressure on the tool is not the

answer when it is not performing as you think it

should. Perhaps you should be using a

different accessory, and perhaps an

adjustment in speed would solve the problem.

Leaning on the tool does not help.

Let speed do the work!

Use only Dremel

®

, high-performance accessories.

FIG. 8

VARIABLE SPEED

DIAL

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13

Service

Preventive maintenance

pe r formed by unauthorized

per so n nel may result in misplacing of

internal wires and components which could

cause serious hazard. We recommend that

all tool service be performed by a Dremel

Service Facility.

To avoid injury from

unexpected starting or

electrical shock, always remove plug from

wall outlet before performing service or

cleaning.

CARBON BRUSHES

The brushes and commutator in your tool have

been engineered for many hours of

dependable service.

In order to prepare your brushes for use, run

your tool at full speed for 5 minutes under no

load. This will properly “seat” your brushes,

which extends the life of both your brushes

and your tool.

To maintain peak efficiency of the motor, we

recommend every 40 - 50 hours the brush es

be examined. Only genuine Dremel replace -

ment brushes specially designed for your tool

should be used.

MAINTENANCE OF REPLACEABLE

BRUSHES ON MODEL 4200

The brushes should be inspected frequently

when tools are used continuously. If your tool

runs spo rad ically, loses power, makes unusual

noises or runs at a reduced speed, check the

brushes.

To continue using the tool

in this condition will

permanently damage your tool.

Follow these steps to check/change the rotary

tool brushes:

1. With the power cord unplugged, place the

tool on a clean surface. Use a screwdriver to

remove the brush caps in a counter-clockwise

direction (Figure 9).

2. Remove the brushes from the tool by

pulling on the spring that is attached to the

carbon brush. If the brush is less than 1/8"

long and the end surface of the brush that

contacts the commutator is rough and/or

pitted, they should be replaced. Check both

brushes (Figure 10).

Usually the brushes will not wear out simul -

taneously. If one brush is worn out, replace

both brushes. Make sure the brushes are

installed as illus trated. The curved surface of

the brush must match the curvature of the

commutator. Also check that the brush caps sit

flush with the tool housing.

3. After replacing brushes the tool should be

run at no-load; place it on a clean surface and

run it freely at full speed for 5 minutes before

loading (or using) the tool. This will allow the

brushes to “seat” properly and will give you

more hours of life from each set of brushes.

This will also extend the total life of your tool

since the com mutator surface will “wear”

longer.

Maintenance Information

CAUTION

!

WARNING

!

WARNING

FIG. 9

BRUSH

BRUSH SPRING

BRUSH CAP

CURVED END OF

BRUSH MUST

MATCH

CURVATURE OF

COMMUTATOR

FIG. 10

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14

If an extension cord is

necessary, a cord with

adequate size conductors that is capable of

carrying the current necessary for your tool

must be used. This will prevent excessive

voltage drop, loss of power or overheating.

Grounded tools must use 3-wire extension

cords that have 3-prong plugs and receptacles.

NOTE: The smaller the gauge number, the

heav i er the cord.

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

BEARINGS

Model 4200 has ball bearing construction.

Under normal use no additional lubrication is

required.

Cleaning

To avoid accidents always

dis connect the tool from

the power supply before cleaning or

performing any main tenance. The tool may

be cleaned most effectively with compressed

dry air. Always wear safety gog gles when

cleaning tools with compressed air.

Ventilation openings and switch levers must be

kept clean and free of foreign matter. Do not

at tempt to clean by inserting pointed objects

through openings.

Certain cleaning agents

and sol vents damage

plastic parts. Some of these are: gasoline,

carbon tetrachlo ride, chlo rinated cleaning

solvents, ammonia and house hold detergents

that contain ammonia.

!

WARNING

CAUTION

!

Tool’s

Ampere

Rating

Cord Size in A.W.G.

Wire Sizes in mm

2

3-6

6-8

8-10

10-12

12-16

18 16 16 14 0.75 0.75 1.5 2.5

18 16 14 12 0.75 1.0 2.5 4.0

16 16 14 12 1.0 2.5 4.0 —

14 12 —— ————

25 50 100 150 15 30 60 120

Cord Length in Feet Cord Length in Meters

!

WARNING

Extension Cords

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15

The Dremel 4200 will work with a variety of

Dremel attachments including the attachments

included in the kit. Before purchasing an

individual Dremel attachment, always check for

the compatibility with the Dremel 4200. Please

note that the PL400 and MS400 attachments,

as well as some other older attachments, will

NOT fit on this rotary tool. When in doubt,

please contact customer service.

The adapter kit provided with your 4200 will

allow you to use the optional 225, 575 and 670

Dremel attachment.

INSTALLING ADAPTER

1. Remove accessory from the EZ Change™

chuck (Fig. 2).

2. Unscrew housing cap and remove from tool

(Fig. 11).

3. Insert drive coupling into the EZ Change™

chuck (Fig. 12).

4. Thread adapter onto the tool until tight

(Fig. 12).

INSTALLING OPTIONAL ATTACHMENTS

Make sure the square end of the center core of

desired attachment engages the square hole

socket in the driver coupling and thread

attachment onto end of adapter.

The number and variety of accessories for the

Rotary Tool are almost limitless. There is a

category suited to almost any job you might

have to do — and a variety of sizes and shapes

within each category which en ables you to get

the perfect accessory for every need.

Collets

If you expect to use a variety of accessories,

we recommend that in the beginning you

purchase a complete set of four collets. Store

these so that you will have the proper size of

collet for any accessory or drill bit you want to

use. Currently, the 1/8", 3/32",1/32" and

1/16" collets accommodate all of the avail -

able Dremel accessories. 1/8" collets are

included in most rotary tool kits.

The collets used in the Dremel 4200 are

different from the ones used in any other

Dremel Rotary Tool. Collets 480, 481, 482,

483 and 4485 cannot be used in the 4200.

Mandrels

A mandrel is a shank with a threaded or screw

head, which are required when you use

polishing accessories, cutting wheels, sanding

discs, and pol ish ing points. The reason

mandrels are used is that sanding discs,

cutting wheels and similar accesso ries must be

replaced frequently. The mandrel is a per -

manent shank, allowing you to replace only the

worn head when necessary, thus saving the

expense of replacing the shaft each time.

Screw Mandrel N° 401

This is a screw mandrel used with the felt

polishing tip and felt polishing wheels. 1/8"

shank.

Dremel Attachments

Use only Dremel

®

, high-performance accessories. Other accessories are not

designed for this tool and may lead to personal injury or property damage.

!

WARNING

Dremel Accessories

DRIVE

COUPLING

ADAPTER

Tighten

Loosen

HOUSING

CAP

Tighten

Loosen

FIG. 11

FIG. 12

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16

High Speed Cutters

Available in many shapes, high speed cutters

are used in carving, cutting and slotting in

wood, plastics and soft metals such as

aluminum, copper and brass. These are the

accessories to use for freehand routing or

carving in wood or plastic, and for precision

cutting. Made of high quality steel. 1/8" shank.

Tungsten Carbide Cutters

These are tough, long-lived cutters for use on

hard ened steel, fired ceramics and other very

hard ma terials. They can be used for

engraving on tools and garden equipment. 1/8"

shanks.

Engraving Cutters

This group has a wide variety of sizes and

shapes, and are made for intricate work on

ceramics (greenware), wood carvings, jewelry

and scrimshaw. They often are used in making

complicat ed printed circuit boards. They

should not be used on steel and other very

hard materials but are excellent on wood,

plastic and soft metals. 3/32" shank.

Structured Tooth Tungsten Carbide Cutters

Fast cutting, needle-sharp teeth for greater

material removal with minimum loading. Use

on fiberglass, wood, plastic, epoxy and rubber.

1/8" shank.

Aluminum Oxide Grinding Stones

(red/brown)

Round, pointed, flat — you name the shape

and there is one available in this category.

These are made of aluminum oxide and cover

virtually every possible kind of grinding

application. Use them for sharpening lawn

mower blades, screwdriver tips, knives,

scissors, chisels and other cutting tools. Use to

remove flash from metal castings, deburring

any metal after cutting, smoothing welded

joints, grinding off rivets and re mov ing rust.

These grinding stones can be resharped with a

dressing stone. In machine shops, high speed

drills and cut ters normally are ground with

aluminum oxide wheels. 1/8" shank.

Silicon Carbide Grinding Stones

(blue/green)

Tougher than aluminum oxide points, these are

made es pecially for use on hard materials

such as glass and ce ramics. Typical uses

might be the removal of stilt marks and excess

glaze on ceramics and engraving on glass.

1/8" shank.

Diamond Wheel Points

Excellent for fine detail work on wood, jade,

ceramic, glass and other hard material. Bits

are covered with diamond particles. 3/32"

shanks. (Not recommended for drilling)

Small Screw Mandrel N° 402

This is a mandrel with a small screw at its tip,

and is used with emery and fiberglass cutting

wheels, sanding discs and polishing wheels.

1/8" shank.

EZ Lock™ Mandrel N° 402

The Dremel EZ Lock makes accessory

changes easy as PULL - TWIST - RELEASE.

The one-piece mandrel design simplifies the

process of changing cutting wheels, buffs and

detail abrasive brushes (EZ Lock compatible

accessories).

EZ Drum™ Mandrel N° EZ407SA

The Dremel EZ Drum makes accessory

changes easy as PULL - PLACE - SECURE.

The one-piece mandrel design simplifies the

process of changing sanding discs.

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17

Wire Brushes

Three different shapes of wire brushes are

available. For best results wire brushes

should be used at speeds not greater than

15,000 RPM. Refer to Operating Speeds

section for proper tool speed setting. The

three shapes come in three different materials:

stainless steel, brass and carbon wire. The

stainless steel perform well on pewter,

aluminum, stainless steel, and other metals,

without leaving "after-rust". Brass brushes are

non sparking, and softer than steel; making

them good for use on soft metal like gold,

cooper and brass. The carbon wire brushes

are good for general purpose cleaning.

Bristle Brushes

These are excellent cleaning tools on

silverware, jew elry and antiques. The three

shapes make it possible to get into tight

corners and other difficult places. Bristle

brushes can be used with polishing compound

for faster cleaning or polishing.

Brushing Pressure

1. Remember, the tips of a wire brush do the

work. Operate the brush with the lightest

pressure so only the tips of the wire come in

contact with the work.

2. If heavier pressures are used, the wires will

be overstressed, resulting in a wiping action;

and if this is continued, the life of the brush will

be shortened due to wire fatigue.

3. Apply the brush to the work in such a way

that as much of the brush face as possible is in

full contact with the work. Applying the side or

edge of the brush to the work will result in wire

breakage and shortened brush life.

Polishing Accessories

These include an impregnated polishing point

and an impregnated polishing wheel for

bringing metal sur faces to smooth finish; a felt

polishing tip and felt polish ing wheel, and cloth

polishing 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 cloth

wheels and polishing compound. For best

results polishing accessories should be

used at speeds not greater than 15,000

RPM.

No polishing compound is needed when using

the 425 Polishing Wheel.

Aluminum Oxide Abrasive Wheels

Use to remove paint, deburr metal, polish

stainless steel and other metals. Available in

medium grit. 1/8" shank.

Dremel Accessories (Cont.)

CORRECT:

Wire tips doing the work.

INCORRECT:

Excessive pressure can cause wire breakage.

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18

Sanding Accessories

Sanding discs in fine, medium and coarse

grades are made to fit on a mandrel. They can

be used for nearly any small sanding job you

might have, from model making to fine furniture

finish ing. In addition, there is the drum sander,

a tiny drum which fits into the Rotary Tool and

makes it possible to shape wood, smooth

fiberglass, sand inside curves and other diffi cult

places, and other sanding jobs. You replace the

sanding bands on the drum as they become

worn and lose their grit. Bands come in fine

medium and coarse grades. Flapwheels grind

and polish flat or contoured surfaces. They are

used most effectively as a finishing sander after

heavier surface sanding and material removal

is completed. Flapwheels come in fine and

coarse grades. Buffs are a great finishing

accessory for cleaning and light sanding. They

work effectively on metal, glass, wood,

aluminum and plastics. Coarse and medium

buffs are sold together. All buffs are sold

individually. Do not exceed 15,000 RPM in

speed. 1/8" shank.

Grinding Wheel

Use for deburring, removing rust, and general

purpose grinding. Use with Mandrel #402.

Cutting Wheels

These thin discs of emery or fiberglass are

used for slicing, cutting off and similar

operations. Use them for cutting off frozen bolt

heads and nuts, or to reslot a screw head

which has become so damaged that the

screwdriver won’t work in it. Fine for cutting

BX cable, small rods, tubing, cable and cutting

rectangular holes in sheet metal.

Drywall Cutting Bit

Gives you fast, clean cuts in drywall.

Tile Cutting Bit

Cuts ceramic wall tile, cement board, and

plaster.

Spiral Cutting Bit

Cuts through all types of wood and wood

composites.

High Speed Router Bits

For routing, inlaying, and mortising in wood

and other soft materials. Use with Dremel No.

335 Router attachment and No. 231

Shaper/Router table.

Drill bits

The following drill bits (628, 660, 661) can only

be used with the 4200 if the 1/8" collet that

comes with the tool is changed with the collet

that matches the drill bit shank size (1/32" or

1/16" or 3/32").

3 Jaw Chuck

The following chucks (4484, 4486) can not be

used with the 4200 due to the absence of a

threaded cone in the EZ Change™

mechanism.

Dremel Accessories (Cont.)

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Always unplug rotary tool

before changing accessories.

Incorrect seating of wheel on mandrel may

lead to personal injury orproperty damage.

To load accessory:

1. Pull EZ Change™ levers down towards

unlock sign on the tool (Fig. 1). Place EZ

Lock™ mandrel (1) into EZ Change™ chuck

(2) as deep as possible (Fig. 2) and release EZ

Change™ levers to tighten (Fig. 3). Note:

there is a blue spacer (3) on the mandrel that

will bottom out on the EZ Change™ chuck,

setting the mandrel to the correct depth.

2. Pull spring-loaded sleeve (4) DOWN

towards tool with one hand and hold. You can

brace the tool on the body or work-bench for

extra leverage (Fig. 4).

3. With the other hand, align bowtie shape on

cut-off wheel with mandrel and make sure

metal insert is facing away from the tool (Fig. 5).

4. Place wheel on the mandrel to a point just

below the bowtie on the mandrel and twist 90

degrees until the bowtie shape on the wheel

aligns with the sleeve. Release sleeve. Wheel

should lock in place (Fig. 6).

5. When mounting sanding and polishing

accessories, align bowtie with metal insert on

bottom of accessory (Fig. 7a & 7b).

To check for proper seating, hold collet lock

button and twist accessory. Accessory will not

be able to rotate on mandrel.

To unload accessory:

1. Pull spring-loaded sleeve DOWN toward

tool with one hand (Fig. 4).

2. Hold sleeve down while twisting accessory

90 degrees.

3. Remove accessory.

During use

Avoid damage to EZ lock™ mandrel by not

letting it contact the workpiece.

19

EZ Lock

™

Mandrel No. EZ402 has a spring loaded sleeve and is used with cutting wheels,

abrasive buffs and polishing cloth.

!

WARNING

EZ Lock

™

and EZ Drum

™

Operating Instructions

90˚

FIG. 1

FIG. 2

FIG. 5

FIG. 6

FIG. 3

FIG. 4

4

1

2

3

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20

90˚

EZ Drum™ Mandrel No. EZ407SA has a

spring loaded sleeve and is used with sanding

bands.

1. Pull EZ Change™ levers down towards

unlock sign on the tool (Fig. 1). Place EZ

Drum™ mandrel (1) into EZ Change™ chuck

(2) as deep as possible (Fig. 2) and release EZ

Change™ levers to tighten (Fig. 3). Note:

there is a blue spacer (3) on the mandrel that

will bottom out on the EZ Change™ chuck,

setting the mandrel to the correct depth.

Always unplug rotary tool

before changing accessories.

Incorrect seating of sanding band on mandrel

may lead to personal injury orproperty damage.

To load accessory:

2. As indicated, place two fingers underneath

the mandrel and pull firmly up. This will place

the EZ Drum™ in the "unlocked" position (Fig. 2).

3. Keeping two fingers beneath the mandrel,

slide the sanding band down until the entire

blue mandrel is covered (Fig. 3).

4. To return to "locked" position, press firmly

down on the top of the mandrel (Fig. 4).

Removing the sanding band on

the mandrel:

1. Place two fingers underneath the mandrel

and pull firmly up. This will place the EZ

Drum™ in the "unlocked" position (Fig. 2).

2. Sanding band will now easily slide off

mandrel. (Do not squeeze sanding band when

removing from EZ Drum ™ mandrel. This can

lead to rubber band pulling off mandrel and

becoming inoperable (Fig. 4).

1

FIG. 7a FIG. 7b

FIG. 2

FIG. 3

!

WARNING

2

FIG. 1

3

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Dremel 4200 Operating/Safety Instructions Manual

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