Milwaukee 6021-21 User manual

TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S
MANUAL.
OPERATOR'S MANUAL
HEAVY-DUTY 5" RANDOM ORBIT SANDER
Cat. No.
6021-21

23
PERSONAL SAFETY
GENERAL POWER TOOL SAFETY WARNINGS
WORK AREA SAFETY
ELECTRICAL SAFETY
•Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
•Do notoperatepowertoolsinexplosiveatmos-
pheres, such as in the presence of flammable
liquids, gases or dust. Powertoolscreate 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.
•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.
•Avoid body contact with earthed or grounded
surfaces such as pipes, radiators, ranges and
refrigerators.Thereis an increased riskofelectric
shock if your body is earthed or grounded.
•Do notexposepower tools to rain orwet condi-
tions. Water entering a power tool will increase
the risk of electric shock.
•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.
•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.
•If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. Useof an RCD reduces
the risk of electric shock.
attached to a rotating part of the power tool may
result in personal injury.
•Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
•Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewel-
lery or long hair can be caught in moving parts.
•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.
WARNING READ ALL SAFETY WARNINGS AND ALL INSTRUCTIONS. Failure
to follow the warnings and instructions 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.
POWER TOOL USE AND CARE
•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.
•Do notuse the power tool ifthe switch does not
turn it on and off. Any power tool that cannot be
controlled with the switch is dangerous and must
be repaired.
•Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such pre-
ventivesafetymeasuresreduce the risk of starting
the power tool accidentally.
•Store idle power tools out of the reach of chil-
dren and do not allow persons unfamiliar with
the power tool or these instructions to operate
the power tool. Powertools are dangerous in the
hands of untrained users.
•Maintain power tools. 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. Manyaccidents
are caused by poorly maintained power tools.
•Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
•Use the power tool, accessories and tool bits
etc., in accordance with these instructions,
takinginto account the working conditionsand
the work to be performed. Use of the power tool
for operations different from those intended could
result in a hazardous situation.
•Stay alert, watch what you are doing and use
common sensewhen operating apower tool.Do
not use apower tool whileyou aretired or under
the influence of drugs, alcohol or medication. A
moment of inattention while operating power tools
may result in serious personal injury.
•Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearingprotectionusedforappropriateconditions
will reduce personal injuries.
•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. Carryingpowertools with
yourfingeronthe switch or energising power tools
that have the switch on invites accidents.
•Remove any adjusting key or wrench before
turning the power tool on. Awrench or a key left
SPECIFIC SAFETY RULES
SERVICE
•Have your power tool serviced by a qualified
repair person using only identical replacement
parts. Thiswillensurethatthesafetyof the power
tool is maintained.
•Holdpower tool by insulatedgripping surfaces,
because the belt may contact its own cord.
Cutting a “live” wire may make exposed metal
parts of the tool “live” and could give the operator
an electric shock.
•Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.
•WARNING : Somedustcreated by powersanding,
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 paint
• 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 dustmasksthatare spe-
cially designed to filter out microscopic particles.
FUNCTIONAL DESCRIPTION
SPECIFICATIONS
Cat.
No. Volts AC Amps Orbits Per Min. Paper Size
6021-21 120 3 7000-12,000 5" dia.
1. Air vents
2. Handle
3. On/Off switch
4. Backing pad
5. Dust bag
6. Variable speed dial
Grounded tools require a three wire extension
cord. Double insulated tools can use either a two
or three wire extension cord. As the distance from
thesupplyoutletincreases, you must use a heavier
gauge extension cord. Using extension cords with
inadequately sized wire causes a serious drop in
voltage,resultinginlossofpowerandpossibletool
damage.Refertothetableshown to determine the
required minimum wire size.
The smaller the gauge number of the wire, the
greater the capacity of the cord. For example, a 14
gauge cord can carry a higher current than a 16
gauge cord. When using more than one extension
cord to make up the total length, be sure each cord
contains at least the minimum wire size required.
If you are using one extension cord for more than
one tool, add the nameplate amperes and use the
sum to determine the required minimum wire size.
Guidelines for Using Extension Cords
•If you are using an extension cord outdoors, be
sureitis marked withthesuffix“W-A”(“W”in Cana-
da)toindicatethatit is acceptable for outdoor use.
•Be sure your extension cord is properly wired
and in good electrical 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 or wet areas.
READ AND SAVE ALL
INSTRUCTIONS FOR FUTURE USE.
* Based on limiting the line voltage drop to five volts at
150% of the rated amperes.
EXTENSION CORDS
Double Insulated
Amps
Volts
Alternating Current Only
OPM Orbits Per Minute (OPM)
Underwriters Laboratories, Inc.
United States and Canada
SYMBOLOGY
Recommended Minimum Wire Gauge
For Extension Cords*
Extension Cord Length
Nameplate
Amperes 25' 50' 75' 100' 150'
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
18
18
18
18
16
14
12
18
18
18
16
14
12
10
18
18
16
14
12
10
18
16
14
12
10
16
14
12
12
1
3
4
2
5
6

45
Selecting Sandpaper and Grits
Sandpaper can be made from various grit materi-
als and these should be selected according the
material to be sanded. The guidelines below list
materials and grit materials that should be used
with them.
•Fine woodwork – garnet or aluminum oxide
•Rough woodwork– aluminum zirconiaorceramic
aluminum oxide
•Manufactured wood products (particleboard,
medium density fiber board etc.) – silicon carbide
or aluminum oxide
•Solid surfacing materials (Corian, etc.) – silicon
carbide or aluminum oxide
•Metals – emery or aluminum oxide
Sandpaper is also graded by coarseness. Start
your work with an abrasive grit just coarse enough
to remove high spots and excessive roughness.
Follow with a second sanding using a grit one or
two grades finer. Continue with successively finer
grits until you obtain the desired finish.
Do not switch from a coarse grit to a very fine grit
in one step because it may be difficult to remove
the marks made by the coarse grit abrasive. Use
the finest grits practical for the roughing operation,
and finish by using successively finer grits.
Grit Type Typical Application
60
80 Course
Ideal for initial sanding on
rougher surfaces. For fast
stock removal. Rough sand-
ing and stripping of painted
and rusted surfaces.
100
120 Medium For intermediate sanding and
removal of minor surface im-
perfections.
150
180
220 Fine Ideal for fine sanding prior to
straining, priming, or sealing.
ASSEMBLY
WARNING To reduce the risk of injury,
always unplug tool before changing or re-
moving accessories. Only use accessories
specifically recommended forthis tool. Others
may be hazardous.
Attaching Hook-and-Loop Sanding Discs
1. Unplug the sander.
2. Align holes in hook-and-loop type sanding disc
withholesinpad,thencarefullypressfuzzyside
ofsanding disc against padastightly as possible.
NOTE: Hook-and-loop type sanding discs can
be reused for the life of the sanding abrasive. It
is recommended that you keep the sanding disc
backing pad clean to provide for best adhesion.
Clean occasionally by brushing lightly with a
small brush.
Fig. A
GROUNDING
WARNING Improperly connecting the
grounding wire can result in the risk of elec-
tric shock. Check with a qualified electrician
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug
provided with the tool. Never remove the
grounding prong from the plug. Do not use
the tool if the cord or plug is damaged. If
damaged, have it repaired by a MILWAUKEE
service facility before use. If the plug will not
fit the outlet, have a proper outlet installed by
a qualified electrician.
Grounded Tools: Tools with Three Prong Plugs
Tools marked “Grounding Required” have a three
wire cord and three prong grounding plug. The
plug must be connected to a properly grounded
outlet (See Figure A). If the tool should electrically
malfunction or break down, grounding provides a
low resistance path to carry electricity away from
the user, reducing the risk of electric shock.
The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool's
grounding system and must never be attached to
an electrically “live” terminal.
Your tool must be plugged into an appropri-
ate outlet, properly installed and
grounded in accordance with all
codes and ordinances. The plug
and outlet should look like those
in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require
grounding. They have a special double insula-
tion system which satisfies OSHA requirements
and complies with the applicable standards of
Underwriters Laboratories, Inc.,
the Canadian Standard Asso-
ciation and the National Elec-
trical Code. Double Insulated
tools may be used in either of
the 120 volt outlets shown in
Figures B and C. Fig. B Fig. C
Fig. 1
Changing the Sanding
Pad
The sander comes as-
sembled with the hook-
and-loop pad. To attach
the pressure sensitive
adhesive (PSA) pad, you
must first remove the
hook-and-loop pad.
Inspect sanding disc be-
foreinstalling.Donotuse
if broken or defective.
1. Unplug the sander.
2.Remove the four
screws that hold the
hook-and-loop pad in
place.
3. Removethehook-and-
loop pad.
4. Clean dust particles
from the pad brake.
5. Apply a thin layer of
lightweight grease to
the back of the pad.
6. Align the holes in the
pressure sensitive ad-
hesive (PSA) pad with
the four screw holes in
the sander.
7.Replace the four
screws securely.
Attaching PSA Sanding Discs
1. Unplug the sander.
2. Carefully peel paper backing from the pressure
sensitive adhesive type sanding disc.
3. Align holes in sanding disc with holes in back-
ing pad, then carefully press sticky side of disc
against pad as tightly as possible.
NOTE: Holes in sanding disc must line up with
holesinthebackingpadinorder for the dustless
feature of the sander to function properly.
NOTE:It is recommendedthatyou clean backing
pad occasionally by brushing lightly with a small
brush.Dustbuilduponbackingpadcouldcause
sanding disc not to stick properly.
Fig. 2
Remove PSA Sanding Disc Before Storage
Do not store the sander with the sanding disc in-
stalled. Heat generated from sanding causes the
pressuresensitiveadhesiveto flow and form a tight
bond between the backing pad and sanding disc.
Removing the sanding disc soon after you have
finished a sanding operation avoids letting the
adhesive set up. If the sanding disc is left on the
backing pad for an extended period of time after
use,theadhesivewill set up and cause the sanding
disc to become difficult to remove.
Itmayalso tear when removing. Whenthissituation
occurs,itbecomes difficult to clean thebackingpad
for the next sanding disc.
NOTE: If you forget to remove the sanding disc
after a sanding operation, sand for a few minutes
to soften the adhesive backing before attempting
to remove sanding disc.
Fig. 3
Fig. 4
Attaching the Sander to a Vacuum
You can easily attach the dust collection system of
the sander to a vacuum.
1. Unplug the sander.
2. Remove the dust bag from the sander.
3. Attach vacuum hose to blower exhaust.
NOTE: Smaller vacuum hoses fit inside blower
exhaust.Largervacuum hoses fit outside blower
exhaust.
4. Connect sander and vacuum to power supply.
Attaching The Dust Bag
The dust bag provides a dust collection system for
the sander. Sanding dust is drawn up through the
holes of the sanding disc and collected in the dust
bag during sanding. To attach the dust bag:
1. Unplug the sander.
2. Lineupthe“unlock”symbolonthedustbagwith
the arrow on the dust collection port and slide
thebagassemblyontothe port.To lock in place,
rotate the bag until the arrow on the port aligns
with the “lock” symbol on the bag.
WARNING When sander is not con-
nected to vacuum, always reinstall dust bag
assembly back onto sander. Failure to do so
could cause sandingdust or foreign objectsto
be thrown into your face or eyes which could
result in possible serious injury.

6
OPERATION
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side
shields.
WARNING To reduce the risk of injury,
alwaysunplugtool before attaching or remov-
ing accessories or making adjustments. Use
only specifically recommended accessories.
Others may be hazardous.
WARNING Finishsanding can produce
clouds of fine dust that could ignite in the
presence of sparks or open flame. Always
wear a suitable dust mask or respirator and
use your sander in a well-ventilated area.
WARNING To reduce the risk of injury,
inspect for and remove all raised nails and
fasteners from workpiece before sanding.
Striking a fastener while sanding could cause
loss of control.
Starting and Stopping the Tool
To start the sander, switch ON/OFF Switch to ON.
To stop sander, switch ON/OFF Switch to OFF.
Variable Speed Switch
The variable speed feature allows the sander to
operate at speeds that can be adjusted by rotat-
ing the dial on the variable speed switch from 1 to
6. The dial is conveniently located on the motor
housing, allowing operator control of disc speed.
Toincrease sanding disc speed, turn the dial onthe
variable speed switch to a higher setting. Turn dial
to a lower setting to decrease sanding disc speed.
•Check the workpiece frequently, random orbit
sanders work more aggressively than simple
orbital sanders.
General Sanding with Random Orbit Sanders
When using random orbit sanders there are a few
things to keep in mind:
•Unlikemostsanders,randomorbit sanders should
be placed on the workpiece BEFORE the tool is
started. If the sander is started before it is placed
on the workpiece, the free floating pad may be
spinningat a speedthatcancause scratches when
it is finally placed on workpiece.
•Unlike most sanders, random orbit sanders can
be moved across the workpiece in any direction
(in the case of wood, regardless of the direction
of the grain).
•Varying pressure applied to the sander will affect
its rotating speed. A light pressure is recom-
mendedfor fine work,moderatepressure for rough
work. Excessive pressure does not allow the pad
to rotate enough.
•Keep sanding pad flat on the workpiece. Tipping
the sander or using the edges of the pad may
produce an uneven finish, and reduce pad life.
•Keep sandermovinginbroadevenstrokes across
the workpiece. Sanding in one spot too long can
cause gouging and uneven results.
WARNING Properly secure workpiece
before sanding. Unsecured work could be
thrown towards the operator causing injury.
WARNING Do not wear loose cloth-
ing or jewelry when operating sander. They
could get caught in moving parts causing
serious injury. Keep head away from sander
and sanding area. Hair could be drawn into
sander causing serious injury.
1. Place sander on the workpiece and turn on
the sander.
2. Keepthesandingdisc flat againsttheworkpiece,
keep the sander moving across the workpiece,
and use long, sweeping strokes.
3. Begin sanding with a coarse grit sandpaper and
gradually use finer and finer grits of sandpaper
until the desired finish is reached. For example
when using the sander on wood, begin with an
80 grit followed by a 120 grit, then a 180 grit and
so on.
Removing Paint or Varnish
1. When removing several layers of paint or var-
nish, remove as much as possible with a paint
solvent or varnish remover.
2. Scrape away the residue with a putty knife or
other scraping tool and allow the surface to cool
anddrybefore applying sander to theworkpiece.
WARNING To reduce the risk of fire
and explosion, paint solvents and varnish
removers must be removed from the work-
piece and the workpiece must be completely
dry before sanding.
3. Select a coarse grit sandpaper disc to help pre-
vent the sandpaper from clogging.
4. Keepthesandermoving over new areastoavoid
heating and softening the old coating (paint or
varnish).
5. Work in wide, overlapping strokes to produce a
uniform finish.
6. Astheworkpiecebegins to show through the old
coating, switch to a medium grit sandpaper disc
toavoidscratchingthesurfaceof the workpiece.
Graduallyswitch to a finegrit sandpaper until you
achieve the desired finish.
Emptying the Dust Bag
For more efficient operation, empty the dust bag
when it is no more than half full. This will permit
theairtoflowthroughthebag better.Alwaysempty
and clean the dust bag thoroughly upon comple-
tion of a sanding operation and before placing the
sander in storage.
WARNING Collected sanding dust
from sanding surface coatings such as polyu-
rethanes, linseed oil, etc. can self-ignite in
the sander dust bag or elsewhere and cause
fire. To reduce the risk of fire always empty
the dust bag frequently (10-15 minutes) while
sanding and never store or leave a sander
without totally emptying its dust bag. Also
follow the recommendations of the coatings
manufacturers.
To empty the dust bag:
1. Unplug the sander.
2. Remove the dust bag from the sander.
3. Shake out the dust.
4. Reattach the dust bag to the sander.
Fig. 5
Maintaining Tools
Keep your tool in good repair by adopting a regular
maintenance program. Before use, examine the
general condition of your tool. Inspect guards,
switches, tool cord set and extension cord for
damage. Check for loose screws, misalignment,
binding of moving parts, improper mounting, bro-
ken parts and any other condition that may affect
its safe operation. If abnormal noise or vibration
occurs, turn the tool off immediately and have the
problem corrected before further use. Do not use a
damaged tool. Tag damaged tools “DO NOT USE”
until repaired (see “Repairs”).
Undernormalconditions, relubrication is not neces-
sary until the motor brushes need to be replaced.
After six months to one year, depending on use,
returnyourtool to the nearest MILWAUKEE service
facility for the following:
•Lubrication
•Brush inspection and replacement
•Mechanical inspection and cleaning (gears, spin-
dles, bearings, housing, etc.)
•Electrical inspection (switch, cord, armature, etc.)
•Testingtoassurepropermechanical and electrical
operation
WARNING To reduce the risk of injury,
electric shock and damage to the tool, never
immerse your tool in liquid or allow a liquid
to flow inside the tool.
MAINTENANCE
WARNING To reduce the risk of injury,
always unplug your tool before performing
any maintenance. Never disassemble the tool
or try to do any rewiring on the tool’s electrical
system.Contact a MILWAUKEE service facility
for ALL repairs.
Cleaning
Clean dust and debris from vents. Keep the tool
handles clean, dry and free of oil or grease. Use
only mild soap and a damp cloth to clean your
tool since certain cleaning agents and solvents
are harmful to plastics and other insulated parts.
Someof these include:gasoline,turpentine,lacquer
thinner,paintthinner,chlorinatedcleaningsolvents,
ammonia and household detergents containing
ammonia. Never use flammable or combustible
solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the
nearest service center.
ACCESSORIES
WARNINGTo reduce the risk of injury,
always unplug the tool before attaching or
removing accessories. Use only specifically
recommended accessories. Others may be
hazardous.
Rely only on high-grade power tools on our virtual shelves.