DeWalt DWE6411 Manual

Intended Use

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

To reduce the risk of injury, read the instruction manual.

This quarter sheet sander is designed for sanding wood, metal, plastic and painted surfaces. This drywall sander is a professional power tool.

DO nOT use under wet conditions or in presence of flammable liquids or gases.

DO nOT let children come into contact with the tool.

Supervision is required when inexperienced operators use this tool.

Definitions: Safety Alert Symbols and Words
This instruction manual uses the following safety alert symbols and words to alert you to hazardous situations and your risk of personal injury or property damage.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE: Indicates a practice not related to personal injury which, if not avoided, may result in property damage.
(Used without word) Indicates a safety related message.

GENERAL POWER TOOL SAFETY WARNINGS

Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below 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.

Work Area Safety

1. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
2. 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.
3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety

1. 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.
2. 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.
3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
4. 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.
5. 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.
6. If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric shock.

Personal Safety

1. 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.
2. Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non‑skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
3. 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.
4. 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.
5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
6. 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.
7. 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.
8. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

Power Tool Use and Care

1. 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.
2. 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.
3. Disconnect the plug from the power source and/ or remove the battery pack, if detachable, 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.
4. 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.
5. Maintain power tools and accessories. 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.
6. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
7. 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.
8. Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.

Service

1. 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.

Additional Safety Instructions for Sanders

• Always wear eye protection and a respirator when sanding.
• Sanding of lead‑based paint is not recommended. See Precautions to Take When sanding Paint for additional information before sanding paint.
• Do not operate the unit without a dust collection system.
• Clean your tool out periodically.
• Empty dust bag frequently, especially when sanding resin coated surfaces such as polyurethane, varnish, shellac, etc. Dispose of coated dust particles according to the finish manufacturer's guidelines, or place in a metal can with a tight‑fitting metal lid. Remove coated dust particles from the premises daily. The accumulation of fine sanding dust particles may self ignite and cause fire.

Additional Safety Information

Never modify the power tool or any part of it. Damage or personal injury could result.

ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection. WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California 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.

• Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lie on the skin may promote absorption of harmful chemicals. Direct particles away from face and body.
  
  Always wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.
• Use the appropriate dust extractor vacuum to remove the vast majority of static and airborne dust. Failure to remove static and airborne dust could contaminate the working environment or pose an increased health risk to the operator and those in close proximity.
• Use clamps or other practical ways to secure and support the workpiece to a stable platform. Holding the workpiece by hand or against your body is unstable and may lead to loss of control and injury.
• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts.
• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the greater the capacity of the cable, that is, 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. When using more than one extension to make up the total length, be sure each individual extension contains at least the minimum wire size. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The lower the gauge number, the heavier the cord.

Minimum gauge for Cord sets

Volts		Total length of Cord in Feet (meters)
120 V		25 (7.6)	50 (15.2)	100 (30.5)	150 (45.7)
240 V		50 (15.2)	100 (30.5)	200 (61.0)	300 (91.4)
Ampere Rating		American Wire gauge
More Than	not More Than
0	6	18	16	16	14
6	10	18	16	14	12
10	12	16	16	14	12
12	16	14	12	Not Recommended

Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

Always wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

The label on your tool may include the following symbols. The symbols and their definitions are as follows:

V volts

Hz hertz

min minutes

or DC direct current

earthing terminal

n_o no load speed

n rated speed

PSIpounds per square inch

Class I Construction (grounded)

safety alert symbol

visible radiation–do not stare into the light

.../min per minute

BPM beats per minute

IPM impacts per minute

wear respiratory protection

OPM oscillations per minute

wear eye protection

RPM revolutions per minute

wear hearing protection

sfpm surface feet per minute

SPM strokes per minute

read all documentation

A amperes

do not expose to rain

W watts

Wh watt hours

Ah amp hours

or AC alternating current

or AC/DC alternating or direct current

Class II Construction (double insulated)

Motor

Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than 10% will cause loss of power and overheating. DeWALT tools are factory tested; if this tool does not operate, check power supply.

Components

Fig. A

1. On/Off switch
2. Front paper clamp
3. Front clamp button
4. Base plate/pad
5. Paper‑limiting ribs
6. Rear paper clamp
7. Side clamp levers
8. Holding tabs
9. Dust chute
10. Dust bag
11. Dust bag collar

ASSEMBLY AND ADJUSTMENTS

To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Attaching Abrasive Paper (Fig. B - E)
Fig. B

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 is designed to use 1/4‑sized sanding sheets. Precut 4‑1/2" x 5‑1/2" (11 cm X 14 cm) sandpaper is available at extra cost.

TO MAKE 4-1/2" X 5-1/2" (11 cm X 14 cm) SANDPAPER

1. Cut full‑sized (9" x 11" [23 cm x 28 cm]) sandpaper into 1/4 sheets of 4‑1/2" x 5‑1/2" (11 cm X 14 cm).
2. Cut 1/2 sheet sandpaper into two 4‑1/2" x 5‑1/2" (11 cm X 14 cm) sheets.

FITTING REGULAR SANDING SHEETS
For normal operation, assemble the abrasive paper to your unit as follows:

1. Soften the stiff sandpaper by pulling it over the 90° edge of a table or other straight edge, as shown in Figure B. Concentrate on softening the edges to be clamped.
2. Release the rear paper clamp 6 by pulling up on the side clamp levers 7 and disengaging them from the holding tabs 8 on the base plate/pad 4 as shown in Figure C.
3. Disengage the front paper clamp 2 (Fig. D) by applying and holding pressure on the front clamp button 3 while inserting the 4‑1/2" edge of the abrasive paper under the front paper clampuntil if hits the paper‑limiting ribs 5 . Release the front paper clamp to secure the front of the paper.
4. Stretch paper over the base plate/pad and begin to pivot the rear paper clamp around to its locking position. Lock one side clamp lever by placing it behind the holding tab 8 (Fig. E) on the base plate/pad and then repeat with the second side clamp lever.
5. If you are using the dust extraction feature, perforate the sandpaper (see Paper Punch).

Paper Punch (Fig. F, G)

Fig. G

Turn off and remove the battery pack from 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 12 is provided with your sander to let you perforate regular abrasive paper to make dust collection possible.

To Perforate your Abrasive Paper
Install the abrasive paper on the tool as instructed in this manual. With the sander turned off and battery removed, place the paper punch on the paper so that the tabs 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 F. (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 Collection (Fig. A, H)

Collected sanding dust from sanding surface coatings (polyurethane, linseed oil, etc.) can self ignite in sander dust bag or elsewhere and cause fire. To reduce risk, empty bag frequently and strictly follow sander manual and coating manufacturer's instructions.

Your sander has a dust chute 9 which allows either the supplied dust bag 10 or a shop vacuum system to be connected. The built‑in outlet utilizes the DeWALT AirLock connection making it compatible with the DeWALT dust extractor.

To Attach the Dust Bag

1. While holding the sander, fit the dust bag collar 11 to the dust chute as shown in Fig. H.
   
2. Turn the dust bag collar clockwise to lock the dust bag in place.

To Empty the Dust Bag

1. While holding the sander, turn the collar counterclockwise to unlock the dust bag.
2. Remove dust bag from the sander and gently shake or tap the dust bag to empty.
3. Reattach the dust bag back onto the outlet and lock into place by turning the dust bag collar clockwise.

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.

Never operate these tools unless the dust collector is in place. Sanding dust exhaust may create a breathing hazard.

OPERATION

To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Switch (Fig. A)

To turn the unit on, depress the side of the dust‑protected switch 1 that corresponds to the symbol "I". To turn the tool off, depress the side of the switch that corresponds to the symbol "O".

Proper Hand Position (Fig. I, J)

Fig. J

nOTE: This sander is not to be used in drywall applications.

1. To operate your sander, grasp it as shown in Figure I or J and turn it on.
2. 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 surface. Be sure to check your work often, this sander is capable of removing material rapidly, especially 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 professional‑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 coarseness 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
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.

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:

1. PERsOnAl sAFETY

• ‑ No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.
• ‑ 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 NIOSH‑approved dust mask.
• ‑ NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingesting 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.

2. EnViROnMEnTAl sAFETY

• Paint should be removed in such a manner as to minimize the amount of dust generated.
• Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils thickness.
• Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

3. ClEAning AnD DisPOsAl

• 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.
• 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.
• 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 inspection and replacement should be completed by your local dealer or authorized service center.

MAINTENANCE

To reduce the risk of serious personal injury, turn unit off and disconnect it from power source before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Your DeWALT power tool has been designed to operate over a long period of time with a minimum of maintenance. Continuous satisfactory operation depends upon proper tool care and regular cleaning.

Cleaning

Blow dirt and dust out of all air vents with clean, dry air at least once a week. To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when performing this procedure.

Never use solvents or other harsh chemicals for cleaning the non‑metallic parts of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

Accessories

Since accessories, other than those offered by DeWALT, have not been tested with this product, use of such accessories with this product could be hazardous. To reduce the risk of injury, only DeWALT recommended accessories should be used with this product.

Recommended accessories for use with your product are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory, please contact DeWALT. Call 1‑800‑4‑DeWALT (1‑800‑433‑9258) or visit our website: www.dewalt.com.

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 (including brush inspection and replacement) should be performed by a DeWALT factory service center, a DeWALT authorized service center or other qualified service personnel. Always use identical replacement parts.

Register Online
Thank you for your purchase. Register your product now for:

• WARRAnTY sERViCE: Registering your product will help you obtain more efficient warranty service in case there is a problem with your product.
• COnFiRMATiOn OF OWnERshiP: In case of an insurance loss, such as fire, flood or theft, your registration of ownership will serve as your proof of purchase.
• FOR YOUR sAFETY: Registering your product will allow us to contact you in the unlikely event a safety notification is required under the Federal Consumer Safety Act.
• Register online at www.dewalt.com.

Three Year Limited Warranty
For warranty terms, go to https://www.dewalt.com/support/warranty

To request a written copy of the warranty terms, contact: Customer Service at DeWALT Industrial Tool Co., 701 East Joppa Road, Towson, MD 21286 or call 1‑800‑4‑DeWALT (1‑800‑433‑9258).

FREE WARning lABEl REPlACEMEnT: If your warning

labels become illegible or are missing, call 1‑800‑4‑DeWALT (1‑800‑433‑9258) for a free replacement.