WEN 23103 - 1-Amp Variable Speed Rotary Tool with 100+ Accessories Manual

PRODUCT SPECIFICATIONS

Compatible Rotary Tool Accessories Kits:
150-Piece (Model 230151A), 282-Piece (Model 230282A),
320-Piece (Model 230321A), 327-Piece (Model 230327A).

Your rotary tool is also compatible with the WEN 2305-KC Keyless Rotary Tool Chuck, available at wenproducts.com.

SAFETY INTRODUCTION

Thanks for purchasing the WEN Rotary Tool. If you like doing DIY projects that involve cutting, grinding, sanding, drilling, polishing, deburring, carving and who knows what else, then this is the right tool for you. This manual provides information regarding potential safety concerns, as well as helpful assembly and operating instructions. Safe operation of this tool requires that you read and understand this operator's manual and all labels affixed to the tool. Safety is a combination of common sense, staying alert, and knowing how your tool works.

SAFETY ALERT SYMBOL: Indicates danger, warning, or caution. The safety symbols and the explanations with them deserve your careful attention and understanding. Always follow the safety precautions to reduce the risk of fire, electric shock and personal injury. However, please note that these instructions and warnings are not substitutes for proper accident prevention measures.

Do not attempt to operate this tool until you have thoroughly read and understood all instructions and safety rules contained in this manual. Failure to comply can result in accidents involving fire, electric shock, or serious personal injury. Please keep this manual available to all users during the entire life of the tool. Review it frequently to maximize safety for both yourself and others.

NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur.

WEN reserves the right to change this product and specifications at any time without prior notice.

GENERAL SAFETY RULES

Safety is a combination of common sense, staying alert and knowing how your item works.

SAVE THESE SAFETY INSTRUCTIONS.

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and serious injury. To avoid mistakes and serious injury, do not plug in your tool until the following steps have been read and understood.

WORK AREA SAFETY

1. Keep work area clean and well lit. Cluttered or dark areas invite accidents. Do not work on floor surfaces that are slippery with sawdust or wax. Keep the ground clear of tripping hazards.
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 bystanders at a safe distance from the work area. Never allow children or pets near the tool.

ELECTRICAL SAFETY

1. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. Do not touch the power plug with wet hands.
2. Power tool plugs must match the outlet. Never modify the plug in any way. Modified plugs with non-matching outlets will increase the risk of electric shock.
3. Check all power supplies periodically. Do not use defective cords. Damaged or entangled cords 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.

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. Do not wear loose clothing, gloves, neckties, or jewelry (rings, watches, etc.) when operating the tool. Inappropriate clothing and items can get caught in moving parts and draw you in. Always wear non-slip footwear and tie back long hair.
3. Use personal protective equipment. Always wear safety goggles at all times that comply with ANSI Z87.1. Use ear protection such as plugs or muffs during extended periods of operation. Wear work gloves to protect your hands. Wear a face mask or dust mask to fight the dust.
4. Keep proper footing and balance at all times and do not overreach when operating the power tool.

Dust generated from certain materials can be hazardous to your health. Always operate the tool in a well-ventilated area and wear a dust mask. Use dust collection systems when processing wood and plastics. Dust extractors or dust bags must not be connected when processing metals.

POWER TOOL USE AND CARE

1. Avoid accidental start-ups. Make sure the power switch is in the OFF position before connecting the plug to a power source or carrying the tool.
2. Check power tool for damaged parts. Check for misalignment of moving parts, jamming, breakage, improper mounting, or any other conditions that may affect the tool's operation. Do not use the power tool if the switch does not turn ON/OFF. Any part that is damaged should be properly repaired or replaced before use.
3. Do not force the tool to do a job for which it was not designed. Always use the correct tool/accessory for the job and follow instructions to prevent a hazardous situation.
4. Never stand on the tool. Serious injury could occur if the tool is tipped over or if parts of the tool are unintentionally contacted.
5. Remove adjustment tools. Always make sure all adjustment tools or wrenches are removed from the tool before turning on the power tool.
6. Keep guards in place and in working order before operating the tool. All protection and safety devices must be in place after completing repair and maintenance procedures.
7. Never leave a running tool unattended. Do not leave the tool until it has come to a complete stop.

POWER TOOL MAINTENANCE

1. Always disconnect the power cord plug from the electrical outlet when making adjustments, changing parts, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
2. Maintain power tools properly. Safely store power tools out of the reach of children. Always keep tools clean and in good working order. Follow instructions for lubricating and changing accessories.
3. Use only identical replacement parts. Use of any other part can cause personal injury and damage to the tool. Only have your power tool serviced by a qualified repair person.

CALIFORNIA PROPOSITION 65 WARNING

This product and some dust created by power sanding, sawing, grinding, drilling, and other construction activities may contain chemicals, including lead, known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.

Some examples of these chemicals are:

• Lead from lead-based paints.
• Crystalline silica from bricks, cement, and other masonry products.
• 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 with approved safety equipment such as dust masks specially designed to filter out microscopic particles.

ELECTRICAL INFORMATION

DOUBLE INSULATION

Double insulation is a concept in safety in electric power tools, where two systems of insulation are provided. This eliminates the need for the usual three-wire grounded power cord. All exposed metal parts are isolated from the internal metal motor components with protecting insulation. Double insulated tools do not need to be grounded.

The double insulated system is intended to protect the user from electric shock resulting from a break in the tool's internal insulation. Observe all normal safety precautions to avoid electrical shock.

1. REPLACEMENT PARTS
   When servicing use only identical replacement parts.
   NOTE: Servicing of a product with double insulation requires extreme care and knowledge of the system and should be performed only by a qualified service technician. For service, we suggest bringing the product to you nearest authorized service center for repair. Always use original factory replacement parts when servicing.
2. POLARIZED PLUGS
   To reduce the risk of electric shock, this equipment has 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 the proper outlet. Do not change the plug in any way.
3. SERVICE AND REPAIR. To avoid danger, electrical appliances must only be repaired by qualified service technician using original replacement parts; otherwise this may result in considerable damage to the user.

To avoid electrocution, do not use in wet or damp areas or expose to rain.

GUIDELINES FOR USING EXTENSION CORDS

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 table below shows the correct size to be used according to cord length and nameplate ampere rating. When in doubt, use a heavier cord. The smaller the gauge number, the heavier the cord.

Make sure your extension cord is properly wired and in good condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it. Protect your extension cords from sharp objects, excessive heat and damp/wet areas.

Use a separate electrical circuit for your tools. This circuit must not be less than a #12 wire and should be protected with a 15A time-delayed fuse. Before connecting the motor to the power line, make sure the switch is in the OFF position and the electric current is rated the same as the current stamped on the motor nameplate. Running at a lower voltage will damage the motor.

ROTARY TOOL SAFETY RULES

Read and understand all warnings, cautions and operating instructions before using this equipment. Failure to follow all instructions listed below may result in personal injury and tool damage.

1. WORK ENVIRONMENT. Do not operate the tool in wet or damp conditions; doing so significantly increases the risk of electrical shock. Do not operate the tool in the presence of flammable liquids or gases.
2. TOOL INSPECTION. Before operation, check the tool for any damage or missing parts. Do not use the tool if any part is missing or damaged. Do not use the tool if the power switch is faulty, the plug or cable is damaged, or the tool produces sparks, smoke, or unpleasant odors (you may smell brushes burning for a few minutes as the tool breaks in during the first use, that is okay). Make sure all adjustments are correct and all connections are tight.
3. ACCESSORIES INSPECTION. The accessory must have a rated speed higher than or equal to 32,000 RPM (the maximum tool operating speed of your rotary tool), otherwise there is a risk of injury. The spindle size of the accessory must properly fit the tool's collet in order to be mounted securely. Before operation, inspect the accessories for any chips, cracks or excess wear. Do not use damaged accessories.
4. WORKPIECE INSPECTION. Check the workpiece for any cracks, bumps, nails or obstructions before commencing operation. Do not cut any workpiece that exceeds the rotary tool or the rotary tool bit's operation capacity. Check the position of all electrical wiring and plumbing equipment when drilling into walls, floors or ceilings.
5. SECURING THE WORKPIECE. Use clamps to secure the workpiece whenever possible to prevent wobble, damage to the workpiece, and personal injury.
6. PERSONAL SAFETY. Always use safety goggles, a dust mask and hearing protection when using the rotary tool. Always maintain a firm grip on the rotary tool by the insulated gripping surfaces only.
7. SETTING THE SPEED. Set the suitable speed for your operation, workpiece and accessory. Use slow speeds for some plastics and precious metals to prevent damaging the material. Use slow speeds (15,000 RPM or less) for all brushing applications using wire wheels and polishing operations using felt polishing accessories. Use higher speeds for drilling, carving, cutting, routing, shaping, cutting dadoes or rabbets in wood, metal and glass.
8. USING THE FLEX SHAFT. Never cross the flex shaft over itself during operation. Do not bend the flex shaft near its connection to the rotary tool. Do not operate the flex shaft with a sharp bend. The recommended minimum radius for the flex shaft is 5 inches. Bending the shaft farther than this can generate excessive heat and damage the flex shaft. Make sure to lubricate the flex shaft inner coil every couple of hours of operation.
9. TURNING ON THE TOOL. Before turning on the rotary tool, ensure that it is completely clear of the workpiece. Let the tool reach full speed before making contact with the workpiece.
10. DURING OPERATION. Do not apply excessive pressure to the tool or attempt to make an excessive depth of cut. Overstressing the tool may cause kickback and damage the tool and accessories. Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Never touch any moving parts of the tool by hand. Never press in the spindle lock button when the rotary tool is running.
11. TURNING OFF THE TOOL. Clear the tool from the workpiece before switching off the tool. Wait for the rotary bit to come to a complete stop before setting the tool down.
12. MAKING ADJUSTMENTS. Always turn off the machine and disconnect from the power source before making adjustments or changing attachments. Do not remove the attachment from the tool until it has completely stopped rotating. Do not touch the attachment immediately after operation, as it may be very hot. Allow time for the attachment to cool and calm down before removing it.

KNOW YOUR ROTARY TOOL

Carefully unpack the tool from the packaging. Check all components and compare against the graph below. If any part is damaged or missing, please contact our customer service at (800) 232-1195, M-F 8-5 CST or email us at techsupport@wenproducts.com.

101-PIECE ACCESSORY KIT

1. 2 pcs Collet (Ø 1/8" pre-installed, Ø 3/32" )
2. 1 pc Wrench
3. 1 pc Dressing Stone
4. 1 pc Screw Mandrel (Ø 1/8")
5. 2 pcs Felt Polishing Wheel
6. 1 pc Small Screw Mandrel (Ø 1/8")
7. 20 pcs Cut-Off Wheel
8. 54 pcs Sanding Disc
9. 4 pcs Sanding Band
10. 1 pc Sanding Drum (Ø 1/8")
11. 2 pcs Drill Bit (Ø 1/8", Ø 3/32")
12. 2 pcs Diamond Bit (Ø 1/8")
13. 10 pcs Grinding Bit (Ø 1/8")
14. 1 pc L-shaped Tool for Flex Shaft

KNOW YOUR ROTARY TOOL

Refer to the chart below for explanations and recommended applications for your rotary tool accessory bits.

ASSEMBLY AND ADJUSTMENTS

To avoid injury from accidental startups, always ensure that the tool is switched OFF and unplugged from the power supply before making adjustments or changing accessories.

INSTALLING ROTARY TOOL BITS

1. Switch off and unplug the tool before attempting any adjustments.
2. Hold down the spindle lock button (Fig. 1 - 1) and rotate the collet nut (Fig. 1 - 2) until the lock engages.
   
3. Using the included wrench, loosen the collet nut (Fig. 1 - 2) by turning it counterclockwise and remove. Release the spindle lock button.
4. The collet is located inside the collet nut. Your rotary tool is pre-installed with a 1/8" collet and includes a 3/32" collet as an accessory. Select the suitable collet to match the spindle diameter of your rotary tool bit. Insert the selected collet into the spindle hole and screw the collet nut back on, but do not tighten it all the way.
5. Fully insert the rotary bit into the center hole through the collet nut and collet. Press down the spindle lock button and fully tighten the collet nut using the included wrench. Check to ensure that the rotary bit is firmly secured inside the tool.

INSTALLING SANDING DISCS AND CUTTING WHEELS

Loosen and remove the screw at the top of the small screw mandrel. Remove the top red ring from the screw and slide the cutoff wheel or sanding disc above the bottom red ring (ensure the abrasive side of the disc is facing up). Slide the top red ring above the cutoff wheel or sanding disc, so that there is one red ring on each side of the wheel or disc. Reattach the screw onto the mandrel to secure the wheel/disc in place. Your accessory is now ready to be attached to the rotary tool (follow the steps in "Installing the Rotary Bits" above).

INSTALLING SANDING BANDS

Loosen the screw on the top of the sanding drum using the end of the wrench to contract the width of the drum. Slide the sanding band onto the sanding drum. Fully tighten the screw to expand the width of the sanding drum to hold the sanding band in place. Make sure the sanding drum is sufficiently expanded to secure the band during use. If sanding band is loose on the drum, it may fly off during operation and cause injuries.

INSTALLING FELT POLISHING ACCESSORIES

Thread the felt polishing accessory straight down onto the tip of the screw mandrel. The accessory must be threaded all the way down to touch the collar of the screw mandrel.

Before operation, check to make sure that all accessories are assembled correctly and securely.

ATTACHING THE FLEX SHAFT

(Fig. 2 - 10)

FOR VIDEO INSTRUCTIONS ON ATTACHING THE FLEX SHAFT, VISIT: http://bit.ly/wenflexshaft

1. Unscrew and remove the locking collar from the end of the rotary tool (Fig. 2).
   
2. Take the flex shaft and slide the inner core out about 2 to 3 inches (Fig. 3).
   
3. Loosen the collet nut on the rotary tool by pressing down on the spindle lock button and unscrewing the collet nut (Fig. 4). Use the 1/8 in. collet for attaching the flex shaft.
   
4. Insert the inner core of the flex shaft into the collet nut and collet (Fig. 5). Make sure that the golden metal ring is pressed tightly against the collet nut (Fig. 6). Press down on the spindle lock button, and fully tighten the collet nut with the included wrench.
   
   
5. Now that the inner core is secured to the collet nut, slide down the flex shaft adapter and screw it in place onto the rotary tool by turning it clockwise (Fig. 7).
   
6. Once secured, take the other end of the flex shaft. Find the L-shaped tool and insert it into the hole on the side of the flex shaft handle to prevent the flex shaft spindle from rotating (Fig. 8).
   
7. Unscrew the shaft collet nut and check the size of the collet against your rotary bit. Always select the correct size of collet for the operation (Fig. 9).
   
8. Install the collet and collet nut and fully insert the rotary bit into the center hole through the collet. Use the included wrench to fully tighten the collet nut and ensure that the bit is properly secured to the flex shaft (Fig. 10).
   

Follow the rules below when using your flex shaft to prevent overheating the flex shaft and personal injuries.

• Lubricate your flex shaft regularly to prevent overheating.
• Do not bend the flex shaft near its connection to the rotary tool. Keep it straight.
• Never cross the flex shaft over itself during operation. Do not operate the flex shaft with a sharp bend. The recommended minimum radius for the flex shaft is 5 inches. Bending the shaft farther than this can generate excessive heat and damage the flex shaft.
  

OPERATION

Read and thoroughly understand all instructions and safety information before operating this rotary tool. Failure to do so may cause serious injury.

ADJUSTING THE SPEED OF THE ROTARY TOOL

The variable speed adjustment dial on the top of the rotary tool is used to set the desired rotation speed. The speed for your rotary tool ranges from 10,000 to 32,000 RPM. To increase the speed, turn the wheel forward to a higher number. To decrease speed, turn the wheel backwards to a lower number.

Set the suitable speed for your operation, workpiece and accessory:

• Use slow speeds for plastics, ceramics, precious metals and low-melting point materials to prevent damaging the material. All brushing applications and delicate polishing require slow rotary speeds at 15,000 RPM or less.
• Use higher speeds wood, metal and glass. Drilling, carving, cutting, routing, shaping or rabbets are generally performed more efficiently at faster rotary speeds.
  

As a general rule, larger attachments should be used at a lower speed. The best way to determine the suitable speed is to test on a scrap piece of similar material, observe the results and adjust the speed accordingly.

OPERATING THE ROTARY TOOL

As with all power equipment, a rotary tool can be dangerous if it is not assembled or used properly. Do not operate this power tool if you have doubts or questions regarding operation safety. Call our customer service department at 1-800-232-1195 M-F 8-5 CST to address your questions or concerns.

Always wear safety glasses, safety gloves, safety shoes and suitable work clothing when operating this rotary tool. Do not wear jewelry, neckties or other loose clothing which could get caught in moving parts.

Do not start or operate this tool in the presence of flammable liquids or gases.

1. Inspect the tool for any damage before use. Immediately discard any accessories with bent shafts or other significant damage. Make sure that the ventilation slots are not obstructed; failure to keep them clear may cause the tool to overheat.
2. The power switch is located on the underside of the handle. It has O (OFF) and I (ON) settings.
   • To switch on the tool, flip it to I (the ON position).
   • To switch off the tool, simply flip the switch to O (the OFF position). Be certain the tool is in the OFF position when not in use and during all maintenance activities.
3. Do not exert excessive pressure on your tool as it may damage your workpiece and the tool bit.
4. For milling and engraving operations, holding the rotary tool like a pen will yield better control. For heavier work like drilling, holding the tool like a hammer will yield better results.
5. Use the correct rotary bits for the job, and use the included dressing stone to sharpen or shape any attachments dulled by repeated use.

MAINTENANCE

Disconnect the rotary tool from the power supply before carrying out any adjustments, service or maintenance.

Servicing of the tool requires extreme care and knowledge and should be performed only by a qualified service technician.

CLEANING AND INSPECTION

1. Always clean the tool and accessories after each use. Use a clean cloth and a soft brush to clean your tool.
2. NEVER use water or other liquids to clean the electrical portions of the tool.
3. Ensure that the ventilation slots are not blocked to prevent overheating.
4. Check the tools and accessories for any damage. Remove and dispose of damaged accessories.

LUBRICATING THE FLEX SHAFT

The flex shaft's inner coil rotates at high speed during operation, generating friction and heat. It is important to lubricate the inner coil of your flex shaft after several hours of operation to prevent it from overheating. To lubricate the flex shaft, pull the inner coil out from the flex shaft. Apply an even coat of multi-purpose grease onto the entire surface of the inner coil. Insert the inner coil back into the flex shaft.

CARBON BRUSHES INSPECTION AND REPLACEMENT

To maintain efficiency of the motor, inspect the two carbon brushes routinely. The wear on the carbon brushes depends on how frequently and how heavily the tool is used. Replace the brushes when the brush length gets down to 3/16 of an inch or when the tool stops working. Replacement carbon brushes (Model 23103-009) can be ordered at wenproducts.com.

1. Switch off and disconnect the tool from the power supply.
2. The carbon brush caps are located on the top and bottom of the rotary tool (Fig. 13 - 1). To access the brushes, unscrew and remove the two brush caps using the end of the wrench included with your tool kit.
   
3. Take out and inspect the carbon brushes (Fig. 14). If the brushes are worn to under 3/16 inch in length, replace them with new carbon brushes and reinstall the brush caps.
   

NOTE: Always keep carbon brushes clean and ensure that they slide freely in the brush holders. Both carbon brushes should be replaced at the same time.

PRODUCT DISPOSAL

Used power tools contain recyclable materials and should not be disposed with household waste. Please take this product to your local recycling facility for responsible disposal and to minimize its environmental impact.