DEWALT DCM200 20V Max 18 Inch Brushless Bandfile Instruction Manual

DEWALT DCM200 20V Max 18 Inch Brushless Bandfile

Product Information

Specifications

• Model: DCM200
• Intended Use: Sanding wood, metal, plastics, and painted surfaces
• Optimal Battery Size: 5Ah or smaller

Features

• Variable speed dial
• Variable speed trigger
• Lockoff button
• Main handle
• Side handle
• Belt tensioning lever
• Belt tracking screw
• Straight arm
• Lock lever
• Dust shroud (sold separately)
• Dust port
• Rotatable LED worklight
• Battery pack
• Battery pack release button

Safety Alert Symbols and Words

• DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: 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.

Product Usage Instructions

General Power Tool Safety Warnings

• Read all safety warnings, instructions, illustrations, and specifications provided with this power tool.
• Failure to follow all instructions listed may result in electric shock, fire, and/or serious injury.

Work Area Safety

• Keep the 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.

Product Overview

1. Variable speed dial
2. Variable speed trigger
3. Lock‑off button
4. Main handle
5. Side handle
6. Belt tensioning lever
7. Belt tracking screw
8. Straight arm
9. Lock lever
10. Dust shroud (sold separately)
11. Dust port
12. Rotatable LED worklight
13. Battery pack
14. Battery pack release button

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

Intended use

Your Belt Sander Bandfile has been designed for sanding wood, metal, plastics and painted surfaces. For optimal balance, use 5Ah battery or smaller.

• DO NOT use under wet conditions or in presence of flammable liquids or gases. Your Belt Sander Bandfile is a professional power tool.
• 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.

• DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION : 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

WARNING: 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.

1. Work Area Safety

   • a ) Keep work area clean and well lit.
     Cluttered or dark areas invite accidents.

   • b ) 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.

   • c ) Keep children and bystanders away while
     operating a power tool. Distractions can cause you to lose control.

Electrical Safety

• a ) 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.
• b ) 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.
• c ) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
• d ) 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.
• e ) 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.
• f ) 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

• a ) 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.
• b ) 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.
• c ) 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.
• d ) 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.
• e ) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
• f ) 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.
• g ) 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.
• h ) 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

• a ) 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.
• b ) 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.
• c ) 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.
• d ) 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.
• e ) 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.
• f ) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
• g ) 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.
• h ) 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.

Battery Tool Use and Care

• a ) Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
• b ) Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
• c ) When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
• d ) Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
• e ) Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behavior resulting in fire, explosion or risk of injury.
• f ) Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 265 °F (130 °C) may cause explosion.
• g ) Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.

Service

• a ) 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.
• b ) Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

Belt Sander Supplemental Safety Warnings

• Always use proper eye protection and a respirator when sanding.

• Use clamps or another practical way to secure and support the workpiece to a stable platform. Holding the workpiece by hand or against your body leaves it unstable and may lead to loss of control.

• Sanding of lead‑based paint is not recommended. See Sanding Lead-Based Paint for additional information before sanding paint.

• Clean your tool out periodically.

• Do not wet sand with this sander. Liquids may enter the motor housing and cause damage to the belt sander.

• Static shocks are possible in dry areas or when the relative humidity of the air is low. This is only temporary and does not affect the use of the belt sander. To reduce the frequency of static shocks, add moisture to the air with a console, or installed humidifier.

• If included with tool, empty dust bag frequently. Especially when sanding resin‑coated surfaces such as polyurethane, varnish, shellac, etc. The accumulation of fine sanding dust particles may self‑ignite and cause fire.

• Do not operate this tool for long periods of time. Vibration caused by the operating action of this tool may cause permanent injury to fingers, hands, and arms. Use gloves to provide extra cushion, take frequent rest periods, and limit daily time of use.

• Sanding of lead‑based paint, chemically pressure treated lumber or other materials that may contain carcinogens is not recommended. Sanding of these materials should only be performed by a professional.

• ALWAYS disconnect tool from the power source before changing abrasive belts. Such preventive safety measures reduce the risk of starting the power
  tool accidentally.

• ALWAYS maintain a firm grip with both hands on the belt sander handles to prevent loss of control.

• ALWAYS keep fingers away from the moving belt and areas where the belt enters the housing to avoid severe abrasion.

• Do not operate belt sander without all guards and covers securely in place.

• To avoid injury, do not use this tool in a stand that would invert it for use as a stationary belt sander. This tool is not made for that application.

Specific Safety Warnings and Instructions: Sanders

Sanding Lead‑Based 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:

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.

NOTE: Only those dust masks suitable for working with lead paint dust and fumes should be used. Ordinary painting masks do not offer this protection. See your local hardware dealer for the proper (NIOSH approved) 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.

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.
• 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.

Additional Safety Information

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

WARNING: 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.

CAUTION: When not in use, place tool on its side on a stable surface where it will not cause a tripping or falling hazard. Some tools with large battery packs will stand upright on the battery pack but may be easily knocked over.

BATTERIES AND CHARGERS

The battery pack is not fully charged out of the carton. Before using the battery pack and charger, read the safety instructions below and then follow charging procedures outlined. When ordering replacement battery packs, be sure to include the catalog number and voltage.

READ ALL INSTRUCTIONS

Important Safety Instructions for All Battery Packs

WARNING : Read all safety warnings, instructions, and cautionary markings for the battery pack, charger and product. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• Do not charge or use the battery pack in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Inserting or removing the battery pack from the charger may ignite the dust or fumes.

• NEVER force the battery pack into the charger. DO NOT modify the battery pack in any way to fit into a non‑compatible charger as battery pack may rupture causing serious personal injury. Consult the chart at the end of this manual for compatibility of batteries and chargers.

• Charge the battery packs only in DEWALT chargers.

• DO NOT splash or immerse in water or other liquids.

• DO NOT allow water or any liquid to enter battery pack.

• Do not store or use the tool and battery pack in locations where the temperature may reach or exceed 104 °F (40 °C) (such as outside sheds or metal buildings in summer). For best life, store battery packs in a cool, dry location.
  NOTE: Do not store the battery packs in a tool with the trigger switch locked on. Never tape the trigger switch in the ON position.

• Do not incinerate the battery pack even if it is severely damaged or is completely worn out. The battery pack can explode in a fire. Toxic fumes and materials are created when lithium‑ion battery packs are burned.

• Do not expose a battery pack or appliance to fire or excessive temperature. Exposure to fire or temperature above 265 °F (130 °C) may cause explosion.

• Follow all charging instructions and do not charge the battery pack or appliance outside of the temperature range specified in the instructions. Charging improperly or at temperatures outside of the specified range may damage the battery and increase the risk of fire.

• If battery contents come into contact with the skin, immediately wash area with mild soap and water. If battery liquid gets into the eye, rinse water over the open eye for 15 minutes or until irritation ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium salts.

• Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If symptoms persist, seek medical attention.

• Battery liquid may be flammable if exposed to spark or flame.

• Never attempt to open the battery pack for any reason. If the battery pack case is cracked or damaged, do not insert into the charger. Do not crush, drop or damage the battery pack. Do not use a battery pack or charger that has received a sharp blow, been dropped, run over or damaged in any way (e.g., pierced with a nail, hit with a hammer, stepped on). Damaged battery packs should be returned to the service center for recycling.

Storage Recommendations

The best storage place is one that is cool and dry, away from direct sunlight and excess heat or cold. Store the fully charged battery pack out of the charger.

Battery Pack Cleaning Instructions

Dirt and grease may be removed from the exterior of the battery pack using a cloth or soft non‑metallic brush. Do not use water or any cleaning solutions.

Fuel Gauge Battery Packs (Fig. B)

Some battery packs include a fuel gauge. When the fuel gauge button is pressed and held, the LED lights will indicate the approximate level of charge remaining. This does not indicate tool functionality and is subject to variation based on product components, temperature, and end‑user application.

Transportation

WARNING: Fire hazard. Do not store, carry, or transport the battery pack so that metal objects can contact exposed battery terminals. For example, do not place the battery pack in aprons, pockets, tool boxes, product kit boxes, drawers, etc., with loose nails, screws, keys, coins, hand tools, etc. When transporting individual battery packs, make sure that the battery terminals are protected and well insulated from materials that could contact them and cause a short circuit. NOTE: Li‑ion battery packs should not be put in checked baggage on airplanes and must be properly protected from short circuits if they are in carry‑on baggage.

The RBRC® Seal

Please take your spent battery packs to an authorized DEWALT service center or to your local retailer for recycling. In some areas, it is illegal to place spent battery packs in the trash. You may also contact your local recycling center for information on where to drop off the spent battery pack. Do not place in curbside recycling. For more information visit www.call2recycle.org or call the toll‑free number in the RBRC® Seal.
RBRC® is a registered trademark of Call 2 Recycle, Inc.

Important Safety Instructions for All Battery Chargers

WARNING: Read all safety warnings, instructions, and cautionary markings for the battery pack, charger and product. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

• DO NOT attempt to charge the battery pack with any chargers other than a DEWALT charger. DEWALT chargers and battery packs are specifically designed to work together.

• These chargers are not intended for any uses other than charging DEWALT rechargeable battery packs. Charging other types of battery packs may cause them to overheat and burst, resulting in personal injury, property damage, fire, electric shock or electrocution.

• Do not expose the charger to rain or snow.

• Do not allow water or any liquid to enter charger.

• Pull by the plug rather than the cord when disconnecting the charger. This will reduce the risk of damage to the electric plug and cord.

• Make sure that the cord is located so that it will not be stepped on, tripped over or otherwise subjected to damage or stress.

• Do not use an extension cord unless it is absolutely necessary. Use of improper extension cord could result in risk of fire, electric shock or electrocution.

• When operating a charger outdoors, always provide a dry location and use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

• An extension cord must have adequate wire size (AWG or American Wire Gauge) for safety. The smaller the gauge number of the wire, the heavier the cord and thus the greater its capacity. 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 total length of all extension cords plugged together, and nameplate ampere rating. If in doubt, use the next heavier gauge.

• Do not place any object on top of the charger or place the charger on a soft surface that might block the ventilation slots and result in excessive internal heat. Place the charger in a position away from any heat source. The charger is ventilated through slots in the top and the bottom of the housing.

• Do not operate the charger with a damaged cord
  or plug. Have them replaced immediately.

• Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way. Take it to an authorized service center.

• Do not disassemble the charger; take it to an authorized service center when service or repair
  is required. Incorrect reassembly may result in a risk of electric shock, electrocution or fire.

• The charger is designed to operate on standard 120V household electrical power. Do not attempt to use it on any other voltage. This does not apply to the vehicular charger.

• Foreign materials of a conductive nature, such as, but not limited to, grinding dust, metal chips, steel wool, aluminum foil or any buildup of metallic particles should be kept away from the charger cavities and ventilation slots.

• Always unplug the charger from the power supply when there is no battery pack in the cavity.

Charging a Battery (Fig. A, C)

1. Plug the charger into an appropriate outlet.

2. Insert and fully seat battery pack  13 . The red charging light(s) will continuously blink while charging.

3. Charging is complete when the red charging light(s) remain(s) continuously ON. Battery pack can be left in charger or removed.
   WARNING: Only charge batteries in air temperature over 40 ° F (4.5 ° C) and below 104 ° F (40 ° C).

4. Charger will not charge a faulty battery pack, which may be indicated by the charging light(s) staying OFF. Take charger and battery pack to an authorized service center if light(s) stay(s) OFF.
   NOTE: Refer to label near charging light(s) on charger for blink patterns. Older chargers may have additional information and/or may not have a yellow indicator light. NOTE: To remove the battery pack, some chargers require the battery pack release button  14  to be pressed.

Hot/Cold Pack Delay

When the charger detects a battery pack that is too hot or too cold, it automatically starts a Hot/Cold Pack Delay, suspending charging until the battery pack has reached an appropriate temperature. The charger then automatically switches to the pack charging mode. This feature ensures maximum battery pack life. A cold battery pack may charge at a slower rate than a warm battery pack. The hot/cold pack delay will be indicated by the red light(s) continuing to blink but with the yellow light continuously ON. Once the battery pack has reached an appropriate temperature, the yellow light will turn OFF and the charger will resume the charging procedure.

DCB118 and DCB1112 Chargers

The DCB118 and DCB1112 chargers are equipped with an internal fan designed to cool the battery pack. The fan will turn on automatically when the battery pack needs to be cooled. Never operate the charger if the fan does not operate properly or if ventilation slots are blocked. Do not permit foreign objects to enter the interior of the charger.

Electronic Protection System

Li-ion tools are designed with an Electronic Protection System that will protect the battery pack against overloading, overheating or deep discharge. The tool will automatically turn off and the battery pack will need to be recharged.

Important Charging Notes

1. Longest life and best performance can be obtained if the battery pack is charged when the air temperature is between 65 ° F – 75 ° F (18 ° C– 24 ° C). DO NOT charge when the battery pack is below 40 ° F (4.5 ° C), or above 104 ° F (40 ° C). This is important and will prevent serious damage to the battery pack.
2. The charger and battery pack may become warm to the touch while charging. This is a normal condition, and does not indicate a problem. To facilitate the cooling of the battery pack after use, avoid placing the charger or battery pack in a warm environment such as in a metal shed or an uninsulated trailer.
3. If the battery pack does not charge properly:
   • a. Check operation of receptacle by plugging in a lamp or other appliance;
   • b. Check to see if receptacle is connected to a light switch which turns power off when you turn out the lights;
   • c. If charging problems persist, take the tool, battery pack and charger to your local service center.
4. You may charge a partially used pack whenever you desire with no adverse effect on the battery pack.

Charger Cleaning Instructions

WARNING:  Shock hazard. Disconnect the charger from the AC outlet before cleaning. Dirt and grease may be removed from the exterior of the charger using a cloth or soft non‑metallic brush. Do not use water or any cleaning solutions.

Wall Mounting

Some DEWALT chargers are designed to be wall mountable or to sit upright on a table or work surface. If wall mounting, locate the charger within reach of an electrical outlet, and away from a corner or other obstructions which may impede air flow. Use the back of the charger as a template for the location of the mounting screws on the wall. Mount the charger securely using drywall screws (purchased separately) at least 1” (25.4 mm) long, with a screw head diameter of 0.28–0.35” (7–9 mm), screwed into wood to an optimal depth leaving approximately 7/32” (5.5 mm) of the screw exposed. Align the slots on the back of the charger with the exposed screws and fully engage them in the slots.

SAVE THESE INSTRUCTIONS FOR FUTURE USE

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

ASSEMBLY AND ADJUSTMENTS

WARNING : To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Fitting and Removing Sanding Arms (Fig. D, E)

13 mm x 457 mm (1/2″ x 18″) width belts can be installed with the optional arms that are designed for the corresponding belt widths. Your tool is supplied with the following:

• A straight arm 8 (sanding width 13 mm). These parts are also available as an accessory from your DEWALT dealer:
• The offset arm 15 (sanding width 13 mm) (DCM2012OS sold separately).

NOTE: Your tool comes with the straight arm already assembled. Fitting

1. Make sure that the belt tensioning lever 6 is in the position shown in Fig. D.
2. Loosen and remove the belt tracking screw 7 .
3. Check that the spring 16 is located in its mounting hole.
4. Position the arm 8 or 15 as shown.
5. Fit the belt tracking screw and tighten it until the arm is aligned with the tool.

Removing

1. Remove the sanding belt 18 (if present) as described in the Fitting and Removing Sanding Belts section.
2. Loosen and remove the belt tracking screw 7 .
3. Remove the arm 8 or 15 .

WARNING! Be careful not to lose the spring.
WARNING : DO NOT touch the sanding arms after working as a high temperature may cause injury.

Fitting and Removing Sanding Belts (Fig. E, F1–F3)

WARNING! The spring must be fitted. Be careful not to lose the spring.

Fitting

1. Pull the belt tensioning lever  6  back.
2. Make sure that the arrows on the inside of the sanding belt  18  face the same direction as the arrow  17  on the housing.
3. Place the sanding belt over the rear pulley  20  first. The sanding belt should be placed under the shoulder  29 (Fig. F1, F2), then hook the other side over the front pulley  19 .
4. Move the belt tensioning lever to its original forward position.
5. Adjust the belt tracking as described in the Adjusting the Sanding Belt Tracking section.

NOTE: The sanding belt should not ride on the shoulder of the rear pulley (Fig. F3). Be sure to place the sanding belt under the shoulder.
NOTE: The area surrounding the rear pulley  20  must be cleaned after each use due to the risk of gathering dust.

Removing

1. Pull the belt tensioning lever  6  back to release the tension on the belt.
2. Slide the sanding belt  18  off the pulleys.

Adjusting the Sanding Belt Tracking (Fig. D, E, G, H)

1. Make sure that the sanding belt  18  is properly aligned with the straight arm  8 .
2. Switch the tool on and do a trial run at low speed.
3. Turn the belt tracking screw  7  clockwise to move belt to right, or counterclockwise to move belt to left until the sanding belt runs straight along the length of the arm.

Adjusting the Arm Inclination (Fig. M, N)

The straight arm  8  or offset arm  15  can pivot and be fixed at any desired angle within the range A (102 °) as shown in Fig. N. Make a comfortable working postion by adjusting the angle.

1. Loosen the lock lever  9  by flipping it downwards.
2. Pivot the arm to the desired position.
3. Secure the position of the arm firmly by flipping the lock lever up.

Attaching the Side Handle (Fig. J)

WARNING : This handle SHOULD BE USED AT ALL TIMES to maintain complete control of the tool. Always make sure the handle is tight.

Screw the side handle  5  tightly into the threaded mounting hole of the filehead body  21 .

Attaching the Dust Shroud (Fig. J)

The DCM200DC dust shroud (sold separately) is also available for use with this tool. This accessory connects to the tool’s filehead body. To attach the dust shroud  10 , FIRST disconnect the battery from the tool.

1. Place the ribs  22  of the dust shroud  10  along the groove of the filehead body  21 .
2. Position the dust port  11  against the filehead body to let the dust port hole align with the filehead body hole.
3. Use the side handle  5  to tighten the dust shroud to the filehead body.

Attaching a Dust Extractor to the Dust Shroud (Fig. R, S)

• WARNING: Do not attach the dust port and connect the dust extractor when grinding or sanding metals.
• WARNING : Risk of dust inhalation. To reduce the risk of personal injury, ALWAYS wear an approved dust mask.
• WARNING : Collected sanding dust from sanding surface coatings (polyurethane, linseed oil, etc.) can self‑ignite in a dust extractor or elsewhere and cause a fire. To reduce risk, strictly follow the sander manual and coating manufacturer’s instructions.

The DCM200DC dust shroud is compatible with the DWH161 DEWALT Universal Dust Extractor (sold separately).

• Friction‑fit the dust port  11  to the hose  23  of the DWH161 Universal Dust Extractor.

If available, the DWV9170 adaptor  30  can be used to connect your tool to the DEWALT AirLock™ connection system (sold separately).

1. Push the AirLock™ connector  31  onto the DWV9170 adaptor.
2. Friction‑fit the DWV9170 adaptor to the dust port.

OPERATION

Instructions for Use

• WARNING: Always observe the safety instructions and applicable regulations.
• WARNING: To reduce the risk of serious personal injury, turn tool off and disconnect battery pack before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.
• WARNING: DO NOT touch the filehead body during use as a high temperature may cause injury.

Installing and Removing the Battery Pack (Fig. I)

WARNING: Ensure the tool/appliance is in the off position before inserting the battery pack. NOTE: For best results, make sure your battery pack is fully charged.

1. To install the battery pack  13  into the tool handle, align the battery pack with the rails inside the tool’s handle and slide it into the handle until the battery pack is firmly seated in the tool and ensure that it does not disengage.
2. To remove the battery pack from the tool, press the battery pack release button  14  and firmly pull the battery pack out of the tool handle. Insert it into
   the charger as described in the charger section of this manual.

Proper Hand Position (Fig. L)

• WARNING: To reduce the risk of serious personal injury, ALWAYS use proper hand position as shown.
• WARNING : To reduce the risk of serious personal injury, ALWAYS hold securely in anticipation of a sudden reaction.

Proper hand position requires one hand on the main handle  4  and one hand on the side handle  5.

LED Worklight (Fig. A, P)

CAUTION : Do not stare into the LED worklight.

Serious eye injury could result. The rotatable LED worklight  12  can be adjusted at three levels through an angle of 60 °. When the tool is activated by depressing the variable speed trigger  2 , the rotatable LED worklight will automatically turn on. The rotatable LED worklight will turn off 20 seconds after the variable speed trigger has been released.
NOTE: Be careful not to scratch the lens of the worklight as loss of illumination may occur. Use a dry cloth to wipe dirt off the lens of the worklight.

Variable Speed Dial (Fig. Q)

The variable speed dial  1  allows you to adapt the speed of the tool to the workpiece material. The tool speed can be adjusted between 1 to 7. Use a low speed setting when using a fine grit, when working with plastics or ceramics and when removing painted or varnished surfaces. Use a high speed setting when using a coarse grit and when removing a lot of material.

• Set the variable speed dial  1  to the required setting.

Switching On and Off (Fig. A)

CAUTION: DO NOT pull the variable speed trigger hard without first unlocking the tool. Refer to the Lock-off Button section. This can cause a breakage to the variable speed trigger.

1. To start the tool, pull the variable speed trigger  2 .
2. To turn the tool off, release the variable speed trigger.

Lock‑off Button (Fig. K)

WARNING : To prevent accidental start‑up, this tool is equipped with a lock‑off button.

1. To lock the tool, depress the lock‑off button  3  to the locked position. When the lock‑off button is in the locked position, the tool is locked and the variable speed trigger  2  cannot be pulled.
2. To unlock the tool, depress the lock‑off button  3  to the unlocked position.

NOTE: The tool is locked and the speed trigger can’t be pulled while the arm is being pivoted to the storage position (beyond 102 °).

Special Applications (Fig. A, V–Z)

• WARNING: To reduce the risk of fire or serious injury, avoid sanding ignitable materials such as aluminum and magnesium.
• WARNING! DO NOT allow bystanders in front of the tool while in operation as there may be a risk of the sanding belt breaking and dislodging from the arm.

Straight Arm (Fig. V–Y)
Use the straight arm  8  for general use, sanding, deburring, and slotting. Work should always be performed within range (A) of the front pulley  19 (Fig. V) or within range (B) of the platen  32 , as shown on the straight arm (Fig. V).

• Refer to area C of the straight arm (Fig. W) for sanding in confined areas.
• Refer to areas D and E of the straight arm (Fig. X, Y) for general sanding.

Offset Arm (Fig. Z)

Where Supplied

• Use the offset arm  15  for sanding curved surfaces.
  • Refer to area F (Fig. Z) of the offset arm for sanding a curved surface.

Hints for Optimum Use

• Always hold the tool with both hands.
• Do not exert too much pressure on the tool.
• For best belt life, sand only with the bottom side of belt.
• Do not exert much force in line with the arm.
• Regularly check the condition of the sanding belt  18 . Replace when necessary.
• Always sand with the grain of the wood.
• When sanding new layers of paint before applying another layer, use extra fine grit.
• Consult your retailer for more information on available accessories.

Switching On and Off (Fig. A)

CAUTION: DO NOT pull the variable speed trigger hard without first unlocking the tool. Refer to the Lock-off Button section. This can cause a breakage to the variable speed trigger.

1. To start the tool, pull the variable speed trigger  2 .
2. To turn the tool off, release the variable speed trigger.

MAINTENANCE

WARNING: To reduce the risk of serious personal injury, turn unit off and remove the battery pack 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.

Tool Connect™ Chip (Fig. T)

WARNING : To reduce the risk of serious personal injury, turn unit off and remove the battery pack before making any adjustments or removing/installing attachments or accessories. An accidental start‑up can cause injury.

Your tool is Tool Connect™ Chip ready and has a location for installation of a Tool Connect™ Chip. Tool Connect™ Chip is an optional application for your smart device (such as a smart phone or tablet) that connects the device to utilize the mobile application for inventory management functions. Refer to Tool Connect™ Chip Instruction Sheet for more information.

Installing the Tool Connect™ Chip

1. Remove the retaining screws  24  that hold the Tool Connect™ Chip protective cover  25  into the tool.
2. Remove the protective cover and insert the Tool Connect™ Chip into the empty pocket  26 .
3. Ensure that the Tool Connect™ Chip is flush with the housing. Secure it with the retaining screws and tighten the screws.
4. Refer to Tool Connect™ Chip Instruction Sheet for further instructions.

Storage (Fig. M–O)

CAUTION: Be careful not to pinch your fingers when moving the straight arm. Failure to do so may cause personal injury.

The straight arm  8  can be folded up to save on storage space as shown in Fig. O. The straight arm can move through an angle of up to 172 °.

1. Loosen the lock lever  9  by flipping it down. Pivot the arm at an angle of 102 °.
2. Push the lock‑off button  3 , and then adjust the angle of the straight arm in the range B (102 ° to 172 °) shown in Fig. N.
3. Secure the lock lever by flipping it up to fix the arm. NOTE: The tool is locked and the speed trigger can’t be pulled while the arm is being pivoted to the storage position (beyond 102 °).

Cleaning

WARNING: 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. WARNING: 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

WARNING: 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.

Belt Hook (Fig. U)

Optional Accessory

• WARNING: To reduce the risk of serious personal injury, ONLY use the tool’s belt hook to hang the tool from a work belt. DO NOT use the belt hook for tethering or securing the tool to a person or object during use. DO NOT suspend tool overhead or suspend objects from the belt hook.
• WARNING: To reduce the risk of serious personal injury, ensure the screw holding the belt hook is secure.

IMPORTANT: When attaching or replacing the belt hook, use only the mounting screw  28  that is provided. Be sure to securely tighten the screw.

The belt hook  27  can be attached to either side of the tool using only the screw provided, to accommodate left‑ or right‑handed users. If the hook is not desired at all, it can be removed from the tool. To move belt hook, remove the screw that holds the belt hook in place, then reassemble on the opposite side. Be sure to securely tighten the screw.

Repairs

The worklight is not serviceable. The light bulb cannot be replaced by the user. The charger and batteries are not serviceable. There are no serviceable parts inside the charger or battery pack.

WARNING: To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment (including brush inspection and replacement, when applicable) should be performed by a factory service center or
an authorized service center. 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.

Warranty

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). LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country‑specific warranty information contained in the packaging, call the local company or see website for warranty information.

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.

References

• Call2Recycle | Leading the Charge For Battery Recycling
• DEWALT® Power Tools Official Site | Guaranteed Tough®
• DEWALT® Power Tools Official Site | Guaranteed Tough®

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