Fox FDW-550 User manual

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DRYWALL SANDER 110V
FOX Model FDW-550
ASSEMBLY AND OPERATING INSTRUCTIONS

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Drywall Sander 110V
FOX MODEL FDW-550
TABLE OF CONTENTS
Safety instructions……………………………………………………………………………………………Page 3
Specific safety instructions for drywall sanders.…………………………………………………………. Page 5
Specifications…………………………………………………………………………………………………Page 6
Noise information…………………………………………………………………………………………….Page 6
Vibration information…………………………………………………………………………………………Page 6
Electrical connections………………………………………………………………………………………. Page 7
Earthing instructions…………………………………………………………………………………………Page 7
Environmental protection……………………………………………………………………………………Page 8
Symbols……………………………………………………………………………………………………….Page 8
Machine identification………………………………………………………………………………………. Page 9
Product description…………………………………………………………………………………………..Page 10
Unpacking and setup……………………………………………………………………………………….. Page 10
Starting and stopping the tool………………………………………………………………..……………. Page 12
How to use the tool.………………………………………………………………………………………….Page 13
Maintenance……………....………………………….………………………………………………………Page 14
Wiring diagram….………………………………..…………………………………………………………..Page 15
Exploded view…..…………………………………………………………………………………….…….. Page 16
Parts list……………………………………………………………………………………………….………Page 17
DART Tool Group Guarantee……………………………………………………………………………… Page 18
Declaration of Conformity…………………………………………………………………………………...Page 19

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ATTENTION :
- Read the instructions for use carefully before using the machine
- This device meets current safety standards for electrical machines.
- Incorrect use may result in injury. Anyone not familiar with the instructions for use should not use the
machine. Keep these instructions for use safe.
SAFETY INSTRUCTIONS
ALWAYS DISCONNECT THE MACHINE FROM THE POWER SOCKET BEFORE ATTEMPTING ANY
MAINTENANCE.
Keep a safe working zone for both staff and equipment. NO CHILDREN must be allowed in the
working zone under any circumstance.
The machine must be always disconnected when not in use. Use the on/off switches on the machine. Always
disconnect the machine by pulling the plug, do not pull the power cord.
Before using the machine, remove all tools used for setup and keep them away from your working zone. Reconnect
the machine. Check that the working zone is clear and that there is plenty room to work with the wood.
Ensure you are in good working position. If the work will produce dust or small pieces, wear safety gear, protective
glasses, gloves, a mask and ear defenders. If you have long hair, tie it up. Do not wear watches or bracelets. Wear
shoes with good grip and remember to never place your fingers too near the blade.
Do not use the machine if you are tired or distracted because you risk injury.
Do not use this machine anywhere containing flammable liquids and/or volatile gases.
1. Keep your working area clean. Untidy working zones and busy workbenches invite injuries.
2. Avoid a dangerous environment. Do not expose machines to rain and not use them in wet places. Ensure your
working zone is well lit. Do not use the machine where there is gas or flammable liquids.
3. Protect yourself from electric shocks. Avoid touching earthed surfaces.
4. Keep children and visitors well away from the working area.
5. Tidy up any tools not in use. When tools are not used, they should be kept in a dry, locked place, out of reach of
children.
6. Do not force the machine. It will work better when used with the pressure it was designed for.
7. Use the correct tools. Do not force a small tool to do the work of a bigger tool. For example, do not use a circular
saw to cut branches or logs.

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8. Wear appropriate clothing. Avoid loose clothing, and remove jewellery which could become caught in moving parts.
Non-slip shoes are particularly recommended when working outside. Keep long hair tied up.
9. Always wear safety glasses. Also wear a mask if operating the machine creates dust.
10. Do not mistreat the power cord. Never use the power cord to pull out the plug. Keep the power cord away from
heat, oil and sharp edges.
11. Do not bend over the machine. Keep your balance at all times.
12. Keep tools in good condition. Clean tools to obtain the best results with them. Follow instructions to grease and
change accessories. Regularly check the power cord and replace it if damaged. Keep handles dry, clean and free
from oil and grease.
13. Disconnect the tool when not in use, before the maintenance and while changing accessories such as blades,
drills, etc.
14. Remove all maintenance tools. Get used to checking that all maintenance tools are removed before using the
machine.
15. Avoid accidentally starting the machine. Make sure that the switch is in the "OFF" position before connecting the
power.
16. When the tool is used outside, use only extension leads designed for outdoor use.
17. Be observant. Use common sense when operating machinery. Do not use the tool when tired.
18. Inspect parts before use. Before continuing to use the tool, inspect any protective parts) which could be damaged
to make sure that they work well. Verify that the moving parts are properly aligned, and are not jammed or broken.
Check the assembly and any other conditions which may affect the correct functioning of the machine. Any
damaged part or guard must be repaired or replaced by an approved after-sales service centre. Do not use the
tool if the switch does not work correctly.
19. Warning: the use of any non-recommended accessory can present a health risk.
20. Have the machine repaired by a qualified person. This machine is built according to relevant safety requirements.
Repairs must only be made by a qualified person using original spare parts, otherwise it may be very dangerous
for the user.
21. Keep these instructions.

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SPECIFIC SAFETY INSTRUCTIONS FOR DRYWALL SANDERS
Keep hands away from rotating sanding head area at all times.
Prolonged breathing of airborne dust from drywall sanding may affect respiratory function. Always use a vacuum
cleaner with a bag approved for drywall dust installed. Always wear a respirator approved for dust and mist.
Sanding LEAD-BASED paint is extremely toxic and should not be attempted. Only allow professionals with special
training and equipment to perform this task.
Maintain proper footing and balance at all times. Do not overreach. Use proper scaffolding.
Always wear appropriate safety equipment when operating the sander.
Important: after completing sanding, switch off the sander and wait for the coasting sanding head to stop completely
before putting the tool down.
Never operate the tool in an area with flammable solids, liquids or gases. Sparks from the commutator/carbon
brushes could cause a fire or explosion.
There are certain applications for which this tool was designed. The manufacturer strongly recommends that this
tool NOT be modified and/or used for any application other than that for which it was designed. If you any questions
relating to its application, DO NOT use the tool until you have written to the manufacturer and have been advised.
Use the machine with both hands at all times. Loss of control can cause personal injury.
Keep power supply cord clear from the working range of the machine. Always lead the cable away behind you.
Immediately switch off the machine if unusual vibrations or if other malfunctions occur. Check the machine in
order to find out the cause.

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SPECIFICATIONS
Motor : 550W –110V (0.75hp)
No load speed : 650-1600rpm
Full load speed : 280-950rpm
Sanding disc diameter : 225mm
Dimensions (h x l x d) : 1530x250x370mm
Weight : 4.7kg
NOISE INFORMATION
The noise level of the machine is measured according to the standard DIN IN ISO 3744; 11/95, E DIN IN 31201;
6/93, Annex A ISO 7960; 2/95 because the levels of sound pressure exceed 85 dbA during use. Protective measures
against the noise are necessary.
The quoted emission values are calculated according to standards and not related to use in the workplace. Although
there is a correlation between these various levels of emission, it is impossible to draw any conclusion on additional
necessary precautions. Factors having a potential influence on the level of sound transmission in the workplace
include the working time, the size of the room as well as the other sources of noise (e.g. the number of machines
being used, other noisy operations at the same time). The thresholds of sound level vary between countries. For
these reasons, we recommend users wear ear defenders when using this machine.
Sound pressure level LpA = 91dB(A)
Sound power level LWA = 102dB(A)
VIBRATION INFORMATION
Hand/arm vibration 3.2m/s2

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ELECTRICAL CONNECTIONS
EXTENSION CORDS
Before using an extension cord, ensure the insulation is not cut or worn. Immediately repair or replace a damaged
or frayed cord.
Length of the extension cord: up to 15m
Dimension of the wire: 3 x 2.5mm2
ATTENTION :
Extension cords must be removed from the work area or located so that they will not get caught in parts, tools or other
objects while using the tool.
ELECTRICAL CONNECTION
Your table saw contains a precision electric engine. It must be connected on an electrical supply of 110V, 50 Hz. If
your machine does not work when it is connected please check your electrical supply.
EARTHING INSTRUCTIONS
In case of malfunction or short circuit, grounding provides a path of least resistance for electric current to reduce the
risk of electric shock. This tool is equipped with a power cord with an earthing conductor and a grounding plug. The
plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes
and regulations.
Do not modify the plug provided. If it does not fit into the outlet, have a proper outlet installed by a qualified electrician.
Improper connection of the grounded equipment can result in a risk of electric shock. The green wire with or without
yellow stripes is the earth wire. If repair or replacement of the power cord is necessary, do not connect the grounding
conductor to a live terminal.
If the earthing instructions are not completely understood, check with a qualified electrician or a person responsible
for maintenance, or if there is any doubt that the tool is properly grounded.
If the power cable is damaged, it must be replaced by the manufacturer, after sales service or similarly qualified
persons in order to avoid a hazard. Do not operate the tool with a damaged power cable.
This tool is intended for use on an electrical circuit with a wall outlet and earthing pin.

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ENVIRONMENTAL PROTECTION
The crossed-out wheeled bin means that within the European Union the product must be taken to separate collection at
the product tend-of life. This applies to your device but also to any enhancements marked with this symbol. Do not
dispose of these products as unsorted municipal waste.
The European directive DEEE concerning the environment, states that iIt is forbidden to dispose of used
electric or electronic devices in household waste.
They must be taken to a compatible recycling facility.
ATTENTION:
The manufacturer reserves the right to change specifications without notice.
Images are supplied for information purposes only. Actual machine and accessories may differ in appearance.
SYMBOLS
Always wear protective goggles when
using this machine.
Read and understand the instruction
manual before using the machine
Always wear a protective mask if the
operation is dusty.
Always wear ear defenders when using
the machine.
Heavy lift. Transporting the machine
requires two people.
Product meets relevant CE standards.

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MACHINE IDENTIFICATION

PRODUCT DESCRIPTION
This electric drywall sander is specially designed for the most efficient sanding of drywall or plaster walls and ceiling
for both new construction and renovation work. It is designed to work in conjunction with a vacuum cleaner for
minimum dust and best sanding results. The pivoting sanding head allows excellent results with minimum time and
effort.
UNPACKING AND SETUP
Carefully remove the tool and all loose items from the shipping container.
Retain all packing materials until after you have inspected and satisfactorily operated the machine.
Carton Contents
1. Drywall sanding machine
2. Vacuum cleaner hose
3. Instruction manual
Do not operate this tool until you have read and understood the entire instruction manual.
To install a sandpaper disc:
1. Unplug the machine.
2. Peel away the worn-out sandpaper disc, leaving the sponge backing pad in place.
3. Carefully centre the new sandpaper disc and press into place. It will be held securely by the hook and loop
backing.
To replace the hook and loop sponge pad:
The sponge pad must be perfectly flat to get good sanding results. If it is deformed or damaged it will cause very
uneven sanding. Always replace it when damaged. It is hook and loop on both sides, so to replace it, peel it away
from the hook and loop on the sanding plate base and, taking great care to keep it perfectly centred, affix a new one.
The brush bristles on the edge of the sanding plate cover:
The brush bristles on the edge of the sanding plate cover serve two purposes. They keep the sanding disc properly
aligned with the work surface without gouging and they also help the efficiency of the dust collection by the vacuum
cleaner. These brush bristles will wear with continued use.
The sanding plate cover should be replaced when the bristles are too worn to ensure effective dust collection and
stabilisation of the sanding head.
To replace the cover, follow these steps:

Hold the sanding plate in one hand and with the other, using the L-hex wrench (supplied), first break free the centre
bolt clockwise (1/8 turn only!).
Then use only the L-hex wrench to hold the centre bolt from turning and spin off the sanding plate anti-clockwise.
Next, press the cover down against the spring and, using snap-ring pliers, remove the circlip which holds the sanding
plate cover to the bracket.
Finally, carefully work the vacuum hose free then lift the sanding plate cover away.
Replacement is the opposite of removal. Don’t forget the spring. Entrust all repairs to an authorised service centre.

To install the vacuum cleaner hose:
1. Unplug the machine.
2. Plug the vacuum cleaner hose bayonet mount into the swivel mount in the back
of the machine. Once the tangs of the bayonet mount are fully inserted in the
slots, hold the swivel mount from turning and turn the hose bayonet mount
clockwise to lock.
3. Removal is the opposite of assembly.
The vacuum cleaner:
Ensure that you have a bag installed in your vacuum cleaner which is approved and rated for drywall dust.
WARNING: failure to use an approved dust bag in your vacuum will increase the level of airborne dust in the
work area. Prolonged exposure to such dust may cause respiratory harm.
STARTING AND STOPPING THE TOOL
Make sure that the power circuit voltage is the same as that shown on the specification plate of the machine and that
the switch is OFF before connecting the tool to the power supply.
Switching the machine on and off
To switch on:
While holding with the left hand on the column and the right hand on the main
handle, press the rocker switch to the right with the thumb of the right hand. Be
prepared for the start-up torque when the machine first starts.
To switch off:
Press the rocker switch to the left. After the machine has been switched off, the
sanding disc will still rotate for a time. Take care that parts of your body do not come
into contact with the disc and do not set the machine down while it is still rotating!
Adjusting the rotation speed:
The speed of the machine is variable to suit different tasks. It can be adjusted from
650rpm up to 1600rpm with the thumb wheel. Using the right thumb, turn it in an
anticlockwise (downward) direction to increase the speed, and in a clockwise
(upward) direction to decrease the speed.
Generally, you should use the higher s peed for fast stock removal and the lower
speed for more precise control.

HOW TO USE THE TOOL
Effective control of this powerful sander requires two-handed operation for maximum safety and control.
The proper hold is to keep one hand on the main handle and the other hand on the sponge grip on the column. It is
vitally important to keep a stable footing at all times, especially when standing on scaffolding or stilts.
Mounting the Optional Bail Handle
1. Loosen the two thumb screws (05) and remove the clamp cap (04).
2. Place the handle in the desired position on the column.
3. Clamp the handle in place by replacing the clamp cap and tightening the two
thumb screws.
Sanding Operations
Once the machine and vacuum cleaner are set up and all safety measures and equipment are in place, begin by
turning on the vacuum cleaner and then the sander. If you are using a vacuum cleaner with integrated switching,
then simply turn the sander on.
Begin sanding and carefully contact the work surface as lightly as possible –just enough to keep the sanding head
flat against the surface.
The joints in the sanding head allow the sanding disc to follow the contours of the work surface.
The best technique is to use overlapping sweeps and keep the head in constant motion. Never stop too long in any
one place or there will be swirl marks. With experience it will be very easy to create excellent results.
NOTE: ensure that the sandpaper you are using is suited to the task. Overly coarse grit paper may remove
material too quickly to control, while overly fine grit paper my clog too often and not shape down the
surface.
CAUTION: take care to avoid pointed projections, nails, etc. This will wipe out the sandpaper and probably
damage the sponge pad as well.

MAINTENANCE
Keep the Tool Clean
Periodically blow out all air passages with dry compressed air. All plastic parts should be cleaned with a soft, damp
cloth. NEVER use solvents to clean plastic parts. They could possibly dissolve or otherwise damage the material.
Wear Safety Glasses While Using Compressed Air
Clean the vacuum swivel connector as too much dust will keep it from turning freely.
The Carbon Brushes
The carbon brushes are a normal wearing part and must be replaced when they reach their wear limit. When the
brushes are worn to a length of 1/4", they should be replaced.
NOTE: checking and replacing the carbon brushes should be entrusted to a qualified service centre.
To Change the Brushes
Unplug the machine.
Remove the brush cap with a slothead screwdriver.
Remove the brush.
Install new brushes in reverse order and replace the covers.
If it is necessary to replace the power cord, this must be down by the manufacturer or an approved agent in
order to avoid a safety hazard.

WIRING DIAGRAM

EXPLODED VIEW

PARTS LIST

DART TOOL GROUP GUARANTEE
DART TOOL GROUP takes pride in the quality of the power tools it supplies. The component
parts of our tools are inspected at various stages of production and each finished tool is subjected
to a final check before being packaged for shipment. Because of our confidence in our
engineering quality, DART TOOL GROUP agrees to repair or replace any part or parts of FOX
Power Tools and accessories which, upon examination, prove to be defective in workmanship or
material. The warranty period for the FOX branded products is one year for parts and labour and
three years for parts only. The guarantee does not include repair, labour or parts requiring
replacement because of misuse, abuse, or normal wear and tear. Repairs made by other than
the factory, DART TOOL GROUP service centre or authorised FOX service dealers relieves
DART TOOL GROUP of further liability under this guarantee. THIS GUARANTEE IS MADE
EXPRESSLY IN PLACE OF ALL OTHER GUARANTEES OR WARRANTIES, EXPRESSED OR
IMPLIED, WITH RESPECT TO QUALITY, MERCHANTABILITY, OR FITNESS FOR A
PARTICULAR PURPOSE.

CE DECLARATION OF CONFORMITY OF THE MANUFACTURER
SERRACON
WHEATFIELD ROAD
DUNNIKIER BUSINESS PARK
KIRKCALDY, UK, KY1 3PD
Tel. [phone] Fax: [phone]
Declares that the: DRYWALL SANDER 110V (FDW-550)
is in compliance with the regulations included in the Directives: CEE 2006/42-2004/108-2006/95
Person authorized to create the technical file: Robert Paterson
06.05.2011
The Director