Matco Tools RL400 Product manual

RL400 1 Rev. 02/05/03
RL400
6" Dual Action
Sander
• Operating Instructions
• Warning Information
• Parts Breakdown
Free Speed . . . . . . . . . . . . . . . . . . . 10,000 rpm
Min. Hose Size . . . . . . . . . . . . . . . . . . . . . .3/8"
Air Inlet . . . . . . . . . . . . . . . . . . . . . . . 1/4" NPT
Rec. Air Pressure. . . . . . . . . . . . . . . . . . . .90 psi
Avg. Air Consumption. . . . . . . . . . . . . . . . 4 cfm
Pad Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6”
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1/2"
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1/2"
Net Weight. . . . . . . . . . . . . . . . . . . . .4-3/5 lbs.
SPECIFICATIONS
ALWAYS READ
INSTRUCTIONS
BEFORE USING
POWER TOOLS
ALWAYS WEAR
SAFETY GOGGLES
WEAR HEARING
PROTECTION
AVOID
PROLONGED
EXPOSURE TO
VIBRATION
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.
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.
rl400_man020503.indd 1 9/29/04 10:59:32 AM

RL400 2 Rev. 02/05/03
THIS INSTRUCTION MANUAL CONTAINS
IMPORTANT SAFETY INFORMATION.
READ THIS INSTRUCTION MANUAL
CAREFULLY AND UNDERSTAND ALL
INFORMATION BEFORE OPERATING
THIS TOOL.
• Always operate, inspect and maintain this
tool in accordance with American National
Standards Institute Safety Code of Portable
Air Tools (ANSI B186.1) and any other
applicable safety codes and regulations.
• For safety, top performance and maximum
durability of parts, operate this tool at 90
psig/6.2 bar max air pressure with 3/8"
diameter air supply hose.
• Always wear impact-resistant eye and face
protection when operating or performing main-
tenance on this tool. Always wear hearing
protection when using this tool.
• High sound levels can cause permanent
hearing loss. Use hearing protection as
recommended by your employer or OSHA
regulation.
• Keep the tool in efficient operating condi-
tion.
• Operators and maintenance personnel must
be physically able to handle the bulk,
weight and power of this tool.
• Air under pressure can cause severe injury.
Never direct air at yourself or others.
Always turn off the air supply, drain hose of
air pressure and detach tool from air supply
before installing, removing or adjusting any
accessory on this tool, or before performing any
maintenance on this tool. Failure to do so
could result in injury. Whip hoses can cause
serious injury. Always check for damaged,
frayed or loose hoses and fittings, and
replace immediately. Do not use quick
detach couplings at tool. See instructions for
correct set-up.
• Air powered tools can vibrate in use.
Vibration, repetitive motions or
uncomfortable positions over extended
periods of time may be harmful to your
hands and arms. Discontinue use of tool if
discomfort, tingling feeling or pain occurs.
Seek medical advice before resuming use.
• Place the tool on the work before starting the
tool.
FAILURE TO OBSERVE THESE WARNINGS COULD RESULT IN INJURY.
• Slipping, tripping and/or falling while
operating air tools can be a major cause of
serious injury or death. Be aware of excess
hose left on the walking or work surface.
• Keep body working stance balanced and
firm. Do not overreach when operating the
tool.
• Anticipate and be alert for sudden changes
in motion during start up and operation of
any power tool.
• Do not carry tool by the hose. Protect the
hose from sharp objects and heat.
• Tool shaft may continue to rotate briefly
after throttle is released. Avoid direct
contact with accessories during and after
use. Gloves will reduce the risk of cuts or
burns.
• Keep away from rotating end of tool. Do
not wear jewelry or loose clothing. Secure
long hair. Scalping can occur if hair is
not kept away from tool and accessories.
Choking can occur if neckwear is not kept
away from tool and accessories.
• Never mount a grinding wheel on a sander.
A grinding wheel that bursts can cause very
serious injury or death when not properly
guarded. Inspect backing pad before each
use. Do not use if cracked of damaged.
• Avoid direct contact with moving sanding
pad to prevent pinching or cutting of hands
or other body parts.
• Do not lubricate tools with flammable or
volatile liquids such as kerosene, diesel or
jet fuel.
• Do not force tool beyond its rated
capacity.
• Do not remove any labels. Replace any
damaged labels.
rl400_man020503.indd 2 9/29/04 10:59:33 AM

123
4
56789
10
11
13
15
14
12
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
45
46
44
43
39
38
39
40
53
35
37
34
33
32 54
50
55
56
51
52
57
58
47
48
49
20
42
41
RL400 3 Rev. 02/05/03
RL400
6" Dual Action Sander
Ref. # Item # DESCRIPTION QTY.
1 RS87513 6" DA bonded Pad (Std.) 1
2 RS91502 Cap Screw 1
3 RS91503 Washer 1
4 RS203N04 Counterweight 1
5 RS203N06 Drive Cover 1
6 RS91506 Spring Washer 1
7 RS91507 Retaining Ring 1
8 RS91508 Spring Washer 1
9 RS203N09 Pad Nut 1
10 RS6201-NSK Ball Bearing 1
11 RS203N11 Orbital Hub 1
12 RS91512 Socket Head Cap Screw 1
13 RS91513 Set Screw 1
14 RS91514 Spring Washer 1
15 RS91515 Spindle Screw 1
16 RS91516 Motor Housing 1
17 RS203N18 Front End Plate 1
18 RS91518 Rotor Shaft 1
19 RS6200-NSK Ball Bearing 1
20 RS203N21 Rotor Shim 4
21 RS91521 Rotor 1
22 RS91522 Set Screw 1
23 RS203N23 Rotor Blade 5
24 RS6200-NSK Ball Bearing 1
25 RS91525 Bearing Seal 1
26 RS203N26 Cylinder 1
27 RS91527 Liner Dowel 1
28 RS203N28 Rear End Plate 1
29 RS203N29 Exhaust Diffuser Plate 1
Ref. # Item # DESCRIPTION QTY.
30 RS91530 Spring Washer 4
31 RS91531 Diffuser Plate Mounting Screw 4
32 RS91532 Throttle Valve 1
33 RS91533 Throttle Spring 1
34 RS91534 O-Ring 1
35 RS91535 Retaining Ring 1
36 RS91536 Flat Washer 1
37 RS91537 Rubber Washer 1
38 RS91538 Screw 2
39 RS91539 O-Ring 2
40 RS91540 Regulator Valve 1
41 RS91541 O-Ring 1
42 RS91542 Regulator Knob 1
43 RS91543 Lockwasher 1
44 RS91544 Screw 1
45 RS203N37 Throttle Valve Stem 1
46 RS91546 Throttle Valve Bushing 1
47 RS203N32 Muffler 1
48 RS203N34 Sponge 1
49 RS101049-1ADO Cover 1
50 RS91550 Screw 2
51 RS91551 Throttle Lever Bracket 1
52 RS1010-2M Throttle 1
53 RS91553 Screw 1
54 RS91554 Nut 1
55 RS91555 Lever Return Spring 1
56 RS91556 Locking Nut 1
57 RS91557 Handle Grip 1
58 RS91558 Handle 1
36
rl400_man020503.indd 3 9/29/04 10:59:34 AM

RL400 4 Rev. 02/05/03
Tools of this class operate on a wide range of air
pressures. It is recommended that air pressure of these
tools measure 90 PSI at the tool while running free.
Higher pressure and unclean air will shorten tool life
because of faster wear and may create a hazardous
condition.
Water in the air line will cause damage to the tool.
Drain the air tank daily. Clean the air inlet filter
screen on at least a weekly schedule. The recommended
hook-up procedure can be viewed in Figure 2.
The air inlet (A) Figure 1, used for connecting air
supply, has standard 1/4" NPT American Thread.
Line pressure should be increased to compensate for
unusually long air hoses (over 25 feet). Minimum hose
diameter should be 3/8" I.D. and fittings should have
the same inside dimensions
AIR SUPPLY
The air regulator knob can be used as an air throttle
and can be used for setting positive speed control. Lift
the air regulator lever up for maximum speed.
Let the sander do the work. The normal weight of the
machine is sufficient for efficient sanding. Do not put
additional pressure on the machine. This will only
slow down the speed of the pad, reduce sanding
efficiency and put an additional burden on the motor.
Start the sander off the work, set it down on the work
evenly and move it slowly back and forth in wide,
overlapping areas. When finished sanding, lift it off
the work before stopping the motor.
OPERATION
TROUBLESHOOTING
LUBRICATION & MAINTENANCE
WARRANTY
Other factors outside the tool may cause loss of
power or erratic action. Reduced compressor
output, excessive drain on the air line, moisture or
restrictions in air pipes or the use of hose connections
of improper size or poor conditions may reduce air
supply. If outside conditions are in order, and the
tool still performs erratically, disconnect tool from
hose and take tool to your nearest Matco authorized
service center.
Lubricate the tool daily with a good grade of air tool
oil. If no air line oiler is used, run a teaspoon of oil
through the tool. The oil can be squirted into the tool
air inlet (A) Figure 1, or into the hose at the nearest
connection to the air supply, then run the tool. A rust
inhibitive oil is acceptable for air tools.
Matco warrants its air tools for a period of 1 year
to the consumer. We will repair any air tool covered
under this warranty which proves to be defective in
material or workmanship during the warranty period.
In order to have your tool repaired, return the tool to
any Matco Authorized Warranty Center, freight
prepaid. Please include a copy of your proof of
purchase and a brief description of the problem. The
tool will be inspected and if any part or parts are
found to be defective in material or workmanship,
they will be repaired free of charge and the repaired
tool will be returned to you freight prepaid.
This warranty gives you specific rights. You may also
have other rights which vary from state to state.
The foregoing obligation is Matco's sole liability
under this or any implied warranty and under no
circumstances shall Matco be liable for any incidental
or consequential damages.
Note: Some states do not allow the exclusion or
limitation of incidental or consequential damages so
the above limitation or exclusion may not apply to you.
Nipple
Figure 1
Figure 2
Air Inlet (A)
rl400_man020503.indd 4 9/29/04 10:59:36 AM