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router bits, and cutting wheels. Accessories
come in a variety of shapes and permit you to
do a number of different jobs. As you become
familiar with the range of accessories and their
uses, you will learn just how versatile your
Cordless Rotary Tool is. You’ll see dozens of
uses you hadn’t thought of before now.

The real secret of the Cordless 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 typical
electric drill is a low-speed, high torque tool;
the Cordless Rotary Tool is just the opposite
— a high-speed, low torque tool. The chief
difference to the user is that in the high speed
tools, the speed combined with the accessory
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 your Cordless
Rotary Tool different from other power tools.
The speed enables it to do jobs low speed
tools cannot do, such as cutting hardened
steel, engraving glass, etc.

Getting the most out of your Cordless Rotary
Tool is a matter of learning how to let this
speed work for you.

Read the next sections carefully. They will help
you use your Cordless Rotary Tool correctly
and help you select the correct accessory for
your job.

CHARGING THE TOOL

The Cordless Rotary Tool is not fully charged.
The tool is equipped with a removable battery
pack. 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 of
battery pack, and remove pack from back of
tool as shown on page 7.

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

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

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

Note:

When inserting a fully charged battery

pack into the charger, the charger’s green LED
light will not illuminate.

5. When charging is completed, squeeze
release tabs on battery pack and remove pack
from charger.

6. Align exterior shape of battery pack with
exterior shape of the housing of tool as shown.
Squeeze release tabs, insert battery pack into
back of tool, and release pressure on tabs so it
locks in place.

STALL PROTECTION

This tool has a stall protection feature built into
it to protect the motor and battery in the event
of a stall.  If you stall the tool for too long, or
bind the bit in a work piece, especially at high
speeds, it will automatically turn itself off.
Simply take the tool out of the material you
were stalled in, 

turn it off for 3 seconds

, then

turn it back on again to continue using it.
When the battery becomes close to empty, the
tool may shut down automatically more
frequent than normal.  If this happens, it is time
to recharge the battery.

FUEL GAUGE 

This tool is equipped with a Fuel gauge that
tells you how much charge your battery has.  A

fully charged battery is indicated when all three
LED lights are illuminated.  As the battery
discharges, the lights will turn off one by one
until only one light is on.  When the last light
starts "flashing", the battery is almost empty.
When the battery is dead, the tool will
automatically turn off.  This will be a sudden
stop as opposed to a gradual winding down of
the tool.  Simply recharge the battery and
reuse.

3 lights ˙ 100% charge remaining

2 lights ˙ 50% charge remaining

1 light ˙ 25% charge remaining

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

DM 2610945859 05-07  7/10/07  8:43 AM  Page 8

Summary of Contents for 800-49

Page 1: ... Using Operating Safety Instructions www dremel com 800 49 This symbol refers to the EMC requirements of the Australian Standards Australia 1300 30 70 44 New Zealand 0800 54 33 53 DM 2610945859 05 07 7 10 07 8 43 AM Page 1 ...

Page 2: ...the tool in unexpected situations Use safety equipment Always wear eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions Tool Use and Care 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 Do not force too...

Page 3: ...l 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 After changing the bits or making any adjustments make sure the collet nut and any other adjustment devices are securely tightened Loose adjustment device can unexpectedly shift causing loss of control lo...

Page 4: ...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 modif...

Page 5: ...in and eyes The battery liquid is caustic and could cause chemical burns to tissues If liquid comes in contact with skin wash quickly with soap and water If the liquid contacts your eyes flush them with water for a minimum of 10 minutes and seek medical attention Place charger on flat non flammable surfaces and away from flammable materials when re charging battery pack The charger and battery pac...

Page 6: ... Rotary Tool Model number 800 49 Voltage rating 10 8 V No load speed no 5 000 35 000 min Collet Capacities 0 8 mm 1 6 mm 2 4 mm 3 2 mm Charger Model number 856 02 Voltage rating 230 240 V 60 Hz Amperage rating 420 mA Battery pack 855 855 02 Charge time 3 Hr DOVE TAIL FEATURE RELEASE TAB HANGER BATTERY PACK SWITCH COLLET NUT COLLET CHARGER BATTERY PACK INDICATOR LIGHT ALIGNMENT ARROWS Cordless Rota...

Page 7: ...l 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 and give the accessory or collet a 1 4 turn Retighten collet nut and run the 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...

Page 8: ...harger alignment arrows on battery columm will point to the two arrows located on charger squeeze release tabs insert battery pack into charger as shown and release pressure on tabs so it locks in place 4 Plug charger into the power source The green LED light indicates connection has been made and the battery pack is charging Under normal usage the tool normally requires 3 5 hours charging time to...

Page 9: ...your hand and feel its weight and balance Feel the taper of the housing This taper permits the tool to be grasped much like a pen or pencil When you turn on the tool for the first time hold it 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 Practice on scrap materials first to see how the Cordless Rotar...

Page 10: ...ional speed for different materials and different accessories we have constructed a series of tables that appear on page 12 13 and 14 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...

Page 11: ...20 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 Glass Number Wood Wood Plastic Brass etc Stone 100 121 131 8 10 8 10 4 4 6 114 124 8 10 4 2 4 4 134 144 190 8 10 8 10 2 6 8 10 118...

Page 12: ...luminum Shell Ceramic Glass Number Wood Wood Plastic Brass etc Stone 541 903 911 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 12 Catalog Soft Hard Laminates Steel Aluminum Shell Ceramic Glass Number Wood Wood Plastic Brass etc Stone 9901 9902 8 10 6 2 8 10 4 6 8 10 8 10 9903 9904 9905 9906 9912 9909 9910 6 8 10 8 10 9911 Tungsten Carbi...

Page 13: ...scs Catalog Soft Hard Laminates Steel Aluminum Shell Ceramic Glass Number Wood Wood Plastic Brass etc Stone 502 503 504 8 10 6 2 8 10 8 10 505 Flapwheels Catalog Soft Hard Laminates Steel Aluminum Shell Ceramic Glass Number Wood Wood Plastic Brass etc Stone 511 4 4 2 4 4 Finishing Abrasive Buffs Catalog Soft Hard Laminates Steel Aluminum Shell Ceramic Glass Number Wood Wood Plastic Brass etc Stone...

Page 14: ...peak efficiency of the motor we recommend it be examined every six months Only a genuine Dremel replacement motor specially designed for your tool should be used Cleaning To avoid accidents always disconnect the tool and or charger from the power supply before cleaning The tool may be cleaned most effectively with compressed dry air Always wear safety goggles when cleaning tools with compressed ai...

Page 15: ... 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 removing rust These grinding stones can be resharped with a dressing stone In machine shops high spe...

Page 16: ...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...

Page 17: ...e 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 3 2 mm 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 sim...

Page 18: ...drel No 402 has a small screw at its tip and is used with emery cutting wheels and sanding discs Higher speeds usually maximum are best for most work including cutting steel Which is shown here The machine screw threading on Mandrel No 424 threads into polishing point No 427 This and other threaded mandrels must be screwed firmly down to the collar before being used DM 2610945859 05 07 7 10 07 8 4...

Page 19: ... the drum is sufficiently expanded to secure the band during use If sanding band is loose on the drum during operation it may fly off and strike you or bystanders WARNING The new 1 3 Ah battery pack has an integrated Dove tail feature that accommodates new attachments for additional functionality The Dove tail feature allows the use of the Flex Light and Flex Light with Magnifier These optional to...

Page 20: ... Speed Control Assembly 19 2914201664 Screw 4 Required 23 2610919753 Lock Button 25 2615297355 Collet Nut 26 2615110480 3 2 mm Collet In Tool 27 2610919754 Housing Cap 32 2610944356 Battery Pack 652 2610943970 Charger 801 2610947399 Housing Set 822 2610913818 Shaft Lock Assembly 4 19 MODEL 800 49 DM 2610945859 05 07 7 10 07 8 43 AM Page 20 ...

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