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Switch (Fig. 3)
To turn the unit on, depress the side of the dust-protected switch (A) that corresponds to the
symbol “I”. To turn the tool off, depress the side of the switch that corresponds to the symbol “O”.
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 twist-on dust collection bag (D) and a built-in
vac-adapter (E) which can be hooked directly to a shop vaccum system.
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 vac-adapter (E).
2. Gently shake or tap the dust collection bag to empty.
3. Twist dust collection bag back onto the vac-adapter.
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 well-worn fine sandpaper will produce a pro-
fessional-looking finish that in many cases will need no hand sanding at all. The rate at which
the dust collection bag will fill up will vary with the type of material being sanded and the coarse-
ness of the sandpaper. For best results, empty the bag frequently and check the opening for
clogging.
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 pick-up procedures. During clean up, children and pregnant
women should be kept away from the immediate work area.
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 1–5 for the second brush.
7. Replace the top cap and tighten the three screws. Be careful not to over-tighten screws.
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: D
EWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 or call 1-800-
4-DEWALT (1-800-433-9258).
FIG. 3
FIG. 4
H
FIG. 5
FIG. 2
FIG. 1
E
C
B
FIG. 6
FIG. 8
FIG. 9
FIG. 7A
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 1-800-4-D
EWALT (1-800-433-9258). This warranty does not apply to
accessories or damage caused where repairs have been made or attempted by others. This
warranty gives you specific legal rights and you may have other rights which vary in certain
states or provinces.
F
G
I
FIG. 7B
A
A
D
D
E
I
J
K
L