DEWALT D26451, D26450, D26453 - 5 Random Orbit Sander Manual

General Safety Instructions

Read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA

• Keep your work area clean and well lit. Cluttered benches and 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 bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

• Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adaptor plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. Applicable only to Class I (grounded) tools.
• Double insulated tools are equipped with a polarized plug (one blade is wider than the other.) This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system. Applicable only to Class II (double insulated) tools.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.
• Don't 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 to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately.Damaged cords increase the risk of electric shock.
• When operating a power tool outside, use an outdoor extension cord marked "W-A" or "W." These cords are rated for outdoor use and reduce the risk of electric shock. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. Amoment of inattention while operating power tools may result in serious personal injury.
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts.Loose clothing, jewelry, or long hair can be caught in moving parts. Air vents often cover moving parts and should also be avoided.
• Avoid accidental starting. Be sure switch is off before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents.
• Remove adjusting keys or wrenches before turning the tool on.Awrench or a key that is left attached to a rotating part of the tool may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times.Proper footing and balance enables better control of 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 tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
• Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool.Such preventative safety measures reduce the risk of starting the tool accidentally.
• Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.
• Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges are less likely to bind and are easier to control.
• Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool's operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.
• Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool, may become hazardous when used on another tool.

SERVICE

• Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.
• When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury.

Additional Safety Instructions for the Tool

• Accessories must be rated for at least the speed recommended on the tool warninglabel. Wheels and other accessories running over rated speed can fly apart and cause injury. Accessory ratings must be above listed minimum wheel speed as shown on tool nameplate.
• Hold tool by insulated gripping surfaces when performing an operation where the cut-ting tool may contact hidden wiring or its own cord. Contact with a "live" wire will make exposed metal parts of the tool "live" and shock the operator.
• Always wear eye protection and a respirator when sanding.
• Sanding of lead-based paint is not recommended. See Precautions To Take When Sanding Paintfor additional information before sanding paint.
• Do not operate the unit without the dust collection bag.
• Clean your tool out periodically.
• Empty dust bag frequently, especially when sanding resin coated surfaces such aspolyurethane, 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.
• Replace worn CFS disc when it causes high tool rpm. High tool rpm caused by a worn out CFS disc may result in separation of sanding pad from the sander, possibly causing personal injury. For instructions on replacing the CFS disc, see Tool Care.

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 (CCA).

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.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

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

Wear appropriate hearing protection 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 definitionsare as follows:

V	volts	A	amperes
Hz	hertz	W	watts
min	minutes		alternating current
	direct current	n0	no load speed
	Class II Construction		earthing terminal
	safety alert symbol	.../min	revolutions per minute

COMPONENTS

1. On/Off switch
2. Speed control dial (D26453)
3. Sanding pad
4. Dust collection bag
5. Vac-adapter
6. CFS disc

Motor

Your DEWALT tool is powered by a DEWALT built motor. Be sure your power supply agrees with the nameplate marking. (Volts, 120 AC only). Voltage decrease of more than 10% will cause loss of power and overheating. All DEWALT tools are factory tested; if this tool does not operate, check the power supply.

Attaching Sanding Discs

Your sander is designed to use 5" (127mm) sanding discs with an 8-hole dust extraction pattern. Sanding discs for the D26451 and D26453 attach with hook and loop. Sanding discs for the D26450 attach using pressure sensitive adhesive (PSA).

TO ATTACH PAPER TO THE SANDING PAD

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.

1. Turn the sander over so that the sanding pad is facing upward.
2. Clean the dust from the vinyl pad face.
3. Hold the pad with one hand to keep it from rotating.
4. With the other hand, align the holes and place the disc directly on top of the pad.
   

NOTE: Do not use sanding screen (e.g., screen used for sanding drywall) directly on the hook and loop pad. The screen will not hold and will damage the hooks on the pad. The hooks on the pad will wear very rapidly if left in contact with the work surface while the tool is operating.

Switch

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".

Speed Control Dial

For D26453
The speed control dial (B), shown in "COMPONENTS", allows you to increase or decrease speed from 7,000–12,000 Orbits Per Minute. The optimal speed setting for each application is very much dependent on personal preference. Generally, you will want to use a higher setting on harder materials and a lower setting on softer materials. Material removal rate increases as speed increases.

Dust Extraction

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.

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

OPERATION

To operate your sander, grasp it as shown in figures below and turn it on. Move the unit 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.

The random orbital action of your sander allows you to sand with the grain or at any angle across it for most sanding jobs. To produce the best finish possible, start with coarse grit sandpaper and change gradually to finer and finer paper. Vacuum and wipe surface with a tack cloth between grit steps. Your sander is designed to sand into small or confined areas. Its small size and light weight make it ideal for overhead work.

The rate at which the dust collection bag fills up will vary with the type of material being sanded and the coarseness of the sandpaper. For best results, empty the bag frequently. When sanding painted surfaces, (see the following for additional precautions when sanding paint) 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.

NOTE (D26450 only): When using PSA sanding discs, remove the disc soon after operation. PSA paper, if the disc is left on during tool storage, sometimes becomes difficult to remove. To aid in the removal of old PSA paper, sand for a few minutes to soften the adhesive backing prior to changing disc.

Precautions To Take When Sanding Paint

1. Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling thecontaminated 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 isbeing done until all clean up is completed.
2. A dust mask or respirator should be worn by all persons entering the work area. The filtershould 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 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.

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 milsthickness.
3. Sanding should be done in a manner to reduce tracking of paint dust outside the workarea.

CLEANING AND DISPOSAL

1. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for theduration 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 orother 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 thoroughlybefore being used again.

Tool Care

1. Keep your sander as clean as possible by wiping with a clean cloth and blowing air throughit after every 5 hours of use.
2. As part of CFS (Controlled Finishing System), your sander is equipped with a replaceable disc (F) which is located between the pad (C) and the sander body (G). It is designed to increase the dust collection efficiency and control the pad speed while the unit is off the work surface. The disc is designed to be a consumable part and will occasionally need to be replaced. Replacement is necessary when the pad speed increases very dramatically when the unit is lifted from the work surface.

TO REPLACE YOUR CFS DISC (FIG. 6)

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.

1. Remove the three screws from the bottom of the pad.
2. Remove the pad (C).
3. Remove worn CFS disc (F).
   
4. To install the new CFS disc, place the spring side of the disc toward the sander.
5. Align the notches (H) on the CFS disc with the seams in the sander body.
6. Replace the pad and the three screws. Be careful not to over-tighten screws.

3. Don't use harsh chemicals or solvents to clean the tool. These chemicals could seriouslydamage the plastic components of your sander.
4. Avoid overloading your sander. Overloading will result in a considerable reduction in speedand finish quality of your work. The unit may also become hot. In this event, run sander at a no load condition for a minute or two.
5. If you wrap the cord around the tool when you store it, leave a generous loop of cord suchthat the strain relief does not bend. This helps prevent premature cord failure.

Brush Replacement

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 top cap, as shown.
   
2. Pull the brush spring (I) back (be careful not to pull completely off) and slide out the oldbrush.
   
3. Pull the brush wire (J) 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 topof 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.

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.

ACCESSORIES

Recommended accessories for use with your tool are available at extra cost from your local dealer or authorized service center. If you need assistance in locating any accessory for your tool, contact: DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286 or call 1-800-4-DEWALT (1-800-433-9258).

The use of any other accessory not recommended for use with this tool could be hazardous.

Repairs

To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by authorized service centers or other qualified service organizations, always using identical replacement parts.

Three Year Limited Warranty

For further detail of warranty coverage and warranty repair information, visit www.dewalt.com or call 1-800-4-DEWALT (1-800-433-9258).

Documents / Resources

References

• DEWALT® Power Tools Official Site | Guaranteed Tough®

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