Porter-Cable 7615 User manual

Double Insulated
Disc Sander/Grinder
Instruction
manual
MODELS 7615, 7616, 87615, and 87616
IMPORTANT
Please make certain that the person who is to use
this equipment carefully reads and understands
these instructions before starting operations.
§
The Model and Serial No. plate is located on the
main housing of the tool. Record these numbers in
the spaces below and retain for future reference.

IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using electric tools, basic safety precautions
should always be followed to reduce the risk of fire, electric shock
and personal injury, including the following:
READ AND FOLLOW ALL INSTRUCTIONS.
There are certain applications for which this tool was designed.
Porter-Cable strongly recommends that this tool NOT be modified
and/or used for any application other than for which it was designed.
If you have any questions relative to its application DO NOT use the
tool until you have written Porter-Cable and we have advised you.
Manager of Product Engineering
Porter-Cable Corporation
Youngs Crossing at Highway 45
P.O. Box 2468
Jackson, Tn 38301
1. KEEP WORK AREA CLEAN. Cluttered areas and benches
invite injuries.
2. AVOID DANGEROUS ENVIRONMENT. Don’t expose power
tools to rain. Don’t use power tools in damp or wet locations. Keep
area well lit. Avoid chemical or corrosive environment. Do not use
tool in presence of flammable liquids or gases.
3. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact
with grounded surfaces. For example: pipes, radiators, ranges,
refrigerator enclosures.
4. KEEP CHILDREN AWAY. Do not let visitors contact tool or
extension cord. All visitors should be kept away from work area.
5. STORE IDLE TOOLS. When not in use, tools should be stored in
dry and high or locked-up place — out of the reach of children.
6. DON’T FORCE TOOL. It will do the job better and safer at the
rate for which it was intended.
7. USE RIGHT TOOL. Don’t force small tool or attachment to do
the job of a heavy duty tool. Don’t use tool for purpose not intended—
for example—do not use a circular saw for cutting tree limbs or logs.
8. DRESS PROPERLY. Do not wear loose clothing or jewelry.
Loose clothing, draw strings and jewelry can be caught in moving
parts. Rubber gloves and non-skid footwear are recommended when
working. Wear protective hair covering to contain long hair.
9. USE SAFETY GLASSES. Wear safety glasses or goggles while
operating power tools. Also face or dust mask if operation creates
dust. All persons in the area where power tools are being operated
should also wear safety glasses and face or dust mask.
10. DON’T ABUSE CORD. Never carry tool by cord or yank it to
disconnect from receptacle. Keep cord from heat, oil, and sharp
edges. Have damaged or worn power cord and strain reliever
replaced immediately.
2

11. SECURE WORK. Use clamps or a vise to hold work. It’s safer
than using your hand and it frees both hands to operate tool.
12. DON’T OVERREACH. Keep proper footing and balance at all
times.
13. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean
for better and safer performance. Follow instructions for lubricating
and changing accessories. Inspect tool cords periodically and if
damaged, have repaired by authorized service facility. Inspect
extension cords periodically and replace if damaged. Have all worn,
broken or lost parts replaced immediately. Keep handles dry, clean
and free from oil and grease.
14. DISCONNECT TOOLS. When not in use, before servicing,
and when changing accessories such as blades, bits, cutters, etc.
15. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit
of checking to see that keys and adjusting wrenches are removed
from the tool before turning it on.
16. AVOID UNINTENTIONAL STARTING. Don’t carry plugged-
in tool with finger on switch. Be sure switch is off when plugging in.
17. OUTDOOR USE EXTENSION CORDS. When tool is used
outdoors, use only extension cords marked "Suitable for use with
outdoor appliances - store indoors when not in use."
18. STAY ALERT. Watch what you are doing. Use common sense.
Do not operate tool when you are tired or while under the influence of
medication, alcohol or drugs.
19. CHECK DAMAGED PARTS. Before further use of the tool, a
guard or other part that is damaged should be carefully checked to
determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of moving
parts, breakage of parts, mounting, and any other conditions that
may affect its operation. A guard or other part that is damaged should
be properly repaired or replaced by an authorized service center
unless otherwise indicated elsewhere in this instruction manual.
Have defective switches replaced by authorized service center. Do
not use tool if switch does not turn it on and off.
SAVE THESE INSTRUCTIONS
ADDITIONAL SAFETY RULES FOR DISC SANDER/GRINDER
1. NEVER use the spindle lock pin to stop the spindle from
rotating.
2. ALWAYS use guards with those accessories that require such
equipment.
3. ALWAYS position the guard so that flying chips or pieces of a
wheel that might accidentally break will be deflected away from the
operator.
4. MAKE SURE that grinding wheels, discs, pads, etc., are in good
condition, free of cracks or chips and that RATED SPEED EXCEEDS
THAT INDICATED ON THE TOOL SPECIFICATION PLATE.
3

REPLACEMENT PARTS
When servicing use only identical replacement parts.
MOTOR
Most Porter-Cable tools will operate on either D.C., or single phase
25 to 60 cycle A.C. current and voltage within plus or minus 5 percent
of that shown on the specification plate on the tool. Several models,
however, are designed for A.C. current only. Refer to the
specification plate on your tool for proper voltage and current rating.
CAUTION: Do not operate your tool on a current on which the
voltage is not within correct limits. Do not operate tools rated A.C.
only on D.C. current. To do so may seriously damage the tool.
EXTENSION CORD SELECTION
If an extension cord is used, make sure the conductor size is large
enough to prevent excessive voltage drop which will cause loss of
power and possible motor damage. A table of recommended
extension cord sizes will be found below. This table is based on
limiting line voltage drop to 5 volts (10 volts for 230 volts) at 150% of
rated amperes.
If an extension cord is to be used outdoors it must be marked with the
suffix W-A following the cord type designation. For example —
SJTW-A to indicate it is acceptable for outdoor use.
RECOMMENDED EXTENSION CORD SIZES FOR USE WITH PORTABLE ELECTRIC TOOLS
Length of Cord in Feet |
115V
25 Ft. 50 Ft.
100 Ft.
150 Ft.
200 Ft.
250 Ft.
300 Ft. 400 Ft. 500 Ft.
230V
50 Ft. 100 Ft.
200 Ft.
300 Ft. 400 Ft.
500 Ft.
600 Ft.
800 Ft.
1000 Ft.
0-2
18 18
18
16
16
14
14
12
12
05
2-3
18
18
16 14
14
12
12
10 10
c
3-4
18 18
16 14
12 12
10
10
8
DC
4-5 18
18
14
12
12
10
10
8 8
05
CD
5-6 18
16 14
12
10
10
8 8 6
a
E
6-8
18
16
12
10
10
8
6 6
6
<
8-10
18
14
12
10 8
8
6
6
4
TO
10-12 16 14
10
8
8
6
6 4
4
a
CD
12-14
16
12
10
8
6
6
6 4
2
E
co
14-16
16
12
10
8
6
6 4 4
1 2
Z
16-18 14
12
8
8
6
4
4
2
2
18-20
14
12
8
6
6 4
4 2
2
OPERATING INSTRUCTIONS
FOREWORD
Your Porter-Cable Disc Sander/Grinder is designed for numerous
sanding and grinding operations when used with appropriate
recommended accessories.
Typical applications are smoothing rough boards, removing paint
and varnish, auto body sanding, smoothing welding beads, removing
gates and flash from castings, removing rust, leveling form seams
from concrete, and the like.
4

TO START AND STOP MACHINE
1. Connect machine to power circuit. Make sure power circuit
voltage is the same as that shown on the specification plate.
2. Squeeze switch trigger (A) Fig. 1, to start motor. Release trigger
to stop motor.
Fig. 1
3. A LOCK BUTTON is provided to keep the motor running
without holding the trigger switch ON.
To lock the trigger switch ON, squeeze the trigger (A) while sliding
finger forward to engage lock button (B) Fig. 1, and release trigger
switch.
To unlock, lock button, squeeze trigger switch (A) and release,
allowing lock button free to spring back.
TO INSTALL AUXILIARY HANDLE
An auxiliary handle (H) Fig. 2, is furnished with your machine and can
be installed on either side of the front housing. This handle SHOULD
BE USED AT ALL TIMES to maintain complete control of the
machine.
Fig. 2
THE DISC SANDER
When sanding, use an abrasive disc with a flexible backing disc and a
quick change backup pad (see Fig. 3). Refer to the back of this
manual for a list of available accessories recommended for use with
your machine.
5

TO INSTALL SANDING DISC
1. Disconnect machine from power circuit.
2. Rest machine on tool rest and rear handle.
3. Place washer (E) Fig. 3, on spindle (F).
Fig. 3
4. Depress Spindle Lock Pin (G) and rotate Back-up Pad (D)
clockwise onto shaft (F) until it seats. Then rotate the flexible disc (C)
onto shaft until it seats.
5. Place retaining nut (A) through hole in sanding disc (B) and
rotate clockwise on shaft until it seats. Normal operation of the
Sander will tighten the Sanding Disc.
6. To remove Sanding Disc, disconnect machine from power
source, depress spindle lock pin (G) and Rotate sanding disc (B)
together with the flexible disc (C) counterclockwise and remove.
USING A DISC SANDER
This machine has a directional arrow cast into the top of the gear
housing which indicates the direction any accessory will rotate. See
Fig. 6.
1. Secure work to prevent it from moving during the sanding
operation. Friction between the sanding disc and work will try to spin
work away from sander and may cause bodily injury.
2. Wear Safety Glasses and dust mask.
6

Wrong Pad Position for Sanding Right Pad Position for Sanding
Fig. 4
3. Hold sander firmly by the rear and auxiliary handles, making
sure sanding disc is clear of work and foreign objects. Start sander
and lower at an angle so that approximately 1" to 1 'A" of the sanding]
disc contacts the work. See Fig. 4. Too great an angle may result in
gouging or snagging the work, while too small an angle results in
extreme difficulties in controlling the sander.
4. Move sander in long sweeping overlapping strokes as you go
back and forth. Do not move sander in a circular motion or stay in one
spot too long as this will produce swirls and an uneven finish. The
weight of the sander applies sufficient pressure for fast stock
removal. Additional pressure will only slow the sander down and
decrease removal of stock.
5. Lift sander from work before turning off motor.
6. Always be sure motor has stopped before setting sander down.
A tool rest is provided on the top of the sander for resting the sander
upside down when not in use.
SANDING TIPS
For rough sanding and quick stock removal, use a coarse grit sanding
disc. For a fine finish, use a medium grit disc, followed by a fine grit
disc. Do not go directly from a coarse grit to a fine grit, as it is difficult
to remove marks left by the coarse grit disc.
THE GRINDER
When disc grinding, use a depressed center wheel with a wheel
adapter and wheel guard. (See Fig. 6). ALWAYS USE A WHEEL
GUARD OF THE CORRECT SIZE WITH DEPRESSED CENTER
WHEEL. Refer to the back of this manual for a list of available
accessories recommended for use with your machine.
7

INSTALLING DEPRESSED CENTER WHEEL GUARD
1. Disconnect machine from power circuit.
2. Rest machine on tool rest and rear handle.
3. Loosen clamp nuts (A) Fig. 5, and slip guard clamp (B) over gear
housing cover collar.
Fig. 5
4. Position the guard (C), so that flying chips or pieces of wheel
that might accidentally break will be deflected away from the
operator. Fig. 6 shows the guard installed for use with depressed
center grinding wheel.
5. Firmly tighten clamp nuts (A) Fig. 5.
Fig. 6
INSTALLING DEPRESSED CENTER WHEEL
1. Disconnect machine from power circuit.
2. Rest machine on tool rest and rear handle.
3. Assemble wheel guard by following instructions listed under
INSTALLING DEPRESSED CENTER WHEEL GUARD.
4. Place washer (A) Fig. 7, on spindle (B).
5. Thread wheel adapter (C) to shaft shoulder with flange face
outward. CAUTION - For ease of wheel adapter removal, hand
tighten only.
8

Fig. 7
6. Mount depressed center wheel (D) and thread wheel nut (E) to
spindle and tighten with hex wrench (F).
7. To secure wheel nut (E), depress the spindle lock pin (G) while
holding the machine in one hand. Then tighten the nut using the hex
wrench by rotating it in a clockwise direction with the other hand.
8. To remove, reverse the foregoing procedure.
SMOOTHING WELDING BEADS, CASTING GATES,
CASTING FLASHES, ETC.
Use depressed center grinding wheel with wheel adapter kit and
safety guard (see Fig. 6). ALWAYS USE SAFETY GUARD WITH
DEPRESSED CENTER GRINDING WHEEL. The guard shall be
positioned so that flying chips or pieces of a wheel that might
accidentally break will be deflected away from the operator. Install
auxiliary handle in either side of the gear housing. Firmly grip the
auxiliary and rear handles. Lift up rear handle so only the front sector
of the grinding wheel contacts work before starting or stopping the
motor. When the grinder is not being used, rest it on the tool restand
rear handle.
INSTALLING FLARING CUP WHEEL GUARD
AND FLARING CUP WHEEL
1. Disconnect machine from power circuit.
2. Rest machine on tool rest and rear handle.
3. Place washer (A) Fig. 8, on spindle as shown.
4. Mount the guard (B) by sliding clamp over gear housing collar.
9

Fig. 8
5. Position the guard so that flying chips or pieces of wheel that
might accidentally break will be deflected away from the operator.
Note - Fig. 9 shows guard installed for use with the flaring cup wheel.
6. Firmly tighten clamp nut (C) Fig. 8.
7. Depress spindle lock pin (D) Fig. 8, and thread backup flange
(G) to spindle with counterbored side toward machine. Tighten
firmly with the spanner wrench (E) provided.
8. Note: Flaring cup wheels are available from local suppliers. Use
a wheel with % - 11 mounting threads and a rated speed higher than
the rated speed of your machine.
Fig. 9
9. Loosen skirt adjusting screws (A) Fig. 9, and adjust skirt so that
it is flush with the bottom of the grinding wheel. Tighten screws
securely. NOTE: As grinding wheel wears readjust skirt as required.
10. To remove flaring cup wheel, disconnect machine from power
source, depress spindle lock pin and revolve wheel until lock pin
seats in spindle. Using a strap wrench, turn wheel counterclockwise
to loosen and remove.
10

11. Loosen clamp nut on wheel guard and remove guard from gear
housing.
12. To remove backup flange, depress spindle lock pin and revolve
flange until lock pin seats in spindle. Using spanner wrench provided,
turn flange counterclockwise to loosen and remove.
LEVELING FORM SEAMS FROM CONCRETE, ETC.
Use flaring cup wheel and flaring cup wheel guard. For installation
see INSTALLING FLARING CUP WHEEL GUARD AND FLARING
CUP WHEEL.
MAINTENANCE
KEEP TOOL CLEAN
Periodically blow out all air passages with compressed air. Wear
safety glasses while performing this operation. All plastic parts
should be cleaned with soft damp cloth. NEVER use solvents, to
clean plastic parts. They could possibly dissolve or otherwise
damage the material.
FAILURE TO START
Should your tool fail to start, check to make sure the prongs on the
cord plug are making good contact in the outlet. Also, check for
blown fuses or open circuit breakers in the line.
BRUSH INSPECTION AND LUBRICATION
Because this model is “Double Insulated” which provides two
complete sets of insulation to protect the user from the electric
current within the tool, brush inspection and replacement should
ONLY be performed by an AUTHORIZED PORTER-CABLE
SERVICE STATION.
At approximately 100 hours of use, take or send your tool to your
nearest Authorized Porter-Cable Service Station to be thoroughly
cleaned and inspected; worn parts replaced, when necessary; re¬
lubricated with fresh lubricant, if required; reassembled with new
brushes; and performance tested.
Any loss of power before the above maintenance check may indicate
the need for immediate servicing of your tool. DO NOT CONTINUE
TO OPERATE TOOL UNDER THIS CONDITION. If proper operating
voltage is present, return your tool to the Service Station for
immediate service.
SERVICE AND REPAIRS
All quality tools will eventually require servicing or replacement of
parts due to wear from normal use. These operations, including
brush inspection and replacement, should ONLY be performed by
either an AUTHORIZED PORTER-CABLE SERVICE STATION or a
PORTER-CABLE SERVICE CENTER. All repairs made by these
11

agencies are fully guaranteed against defective material and
workmanship. We can not guarantee repairs made or attempted by
anyone other than these agencies.
Should you have any questions about your tool, feel free to write us at
any time. In any communications, please give all information shown
on the nameplate of your tool (model number, type, serial number,
etc.).
ACCESSORIES
The testing of this tool has been accomplished with the following
accessories. For safety operation, it is recommended that only these
accessories be used with this product.
WARNING - Since accessories other than those listed have not been
tested with this product, use of such accessories could be hazardous.
ACCESSORY EQUIPMENT
FOR ANGLE DISC SANDERS
Abrasive Disc Backup System
WRENCHLESS
ACCESSORIES
The rubber backup pad and the disc
itself thread on to the spindle
making abrasive disc removal a
cinch. By holding the phenolic disc
with the finger, the retaining nut can
be loosened by simply turning the
abrasive disc counterclockwise.
No. 55741 - 7 " abrasive backup kit.
Includes pad, disc and nut.
No. 55742 - 9" abrasive backup kit.
Includes pad, disc and nut.
No. 55747 - abrasive retaining nut -
replacement nut.
12

ACCESSORY EQUIPMENT TO
CONVERT ANGLE SANDERS
TO GRINDERS
WHEEL GUARD ASSEMBLY
Used with depressed
center wheels.
No. 54342 - 7" guard.
No. 54343 - 9" guard.
No. 54347 - Depressed center wheel
backup kit. Designed especially for
more stability to reduce vibration
and obtain smoother grinding. Kit
includes backup hub, 54348
retaining nut, retaining nut wrench
and spacing washer.
No. 54348 - Depressed center wheel
retaining nut. Replacement nut for
54347 backup kit.
* Guards must be used with all
depressed Center Wheels.
FLARED CUP
WHEEL
GUARDS
New style extra safe guards comply¬
ing with ANSI B7.1-1978 safety
standard. These guards protect the
operator by shielding better than
half of the grinding wheel. The
shield is adjustable as the wheel
wears down. Each is equipped with
54349 threaded cup wheel backup
flange and spanner wrench.
No. 54349 - Cup wheel flange. %" -
11 threaded flange for use as
backup for 4”, 5" and 6" abrasive
cup wheels.
No. 54350 - 4" cup wheel guard.
No. 54351 - 5” cup wheel guard.
No. 54352 - 6" cup wheel guard.
13

PORTER-CABLE LIMITED
ONE YEAR WARRANTY
Porter-Cable warrants its Professional Power Tools fora period of one year from the date of
original purchase. We will repair or replace at our option, any part or parts of the product
and accessories covered under this warranty which examination proves to be defective in
workmanship or material during the warranty period. For repair or replacement return the
complete tool or accessory, transportation prepaid, to your nearest Porter-Cable Service
Center or Authorized Service Station as listed under'TOOLS-ELECTRIC" in the Yellow
Pages of your telephone directory. Proof of purchase may be required. This warranty does
not apply to repair or replacement required due to misuse, abuse, normal wear and tear or
repairs attempted or made by other than our Service Centers or Authorized Service
Stations.
To obtain information on warranty performance please write to: PORTER-CABLE
CORPORATION, Youngs Crossing At Highway 45, P.O. BOX 2468, Jackson, Tennessee
38301; Attention: Product Service. The foregoing obligation is Porter-Cable's sole liability
under this or any implied warranty and under no circumstances shall Porter-Cable be liable
for any incidental or consequential damages. Some states do not allow limitations on how
long an implied warranty lasts on the exclusionor limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may also have other legal rights which
vary from state to state.
14

PORTER-CABLE SERVICE CENTERS
Parts and Repair Service for Porter-Cable Power Tools
are Available at These Locations
ALABAMA
Birmingham 35209
Suite 105
131 West Oxmoor Road
Phone; [phone]
CALIFORNIA
Los Angeles 90007
2400 South Grand Avenue
Phone: [phone]
Orange 92668
385 North Anaheim Blvd.
Phone: [phone]
Santa Clara 95050
2305 De La Cruz Boulevard
Phone: [phone]
San Leandro 94577
3039 Teagarden Street
Phone: [phone]
COLORADO
Denver 80207
4900 East 39th Avenue
Phone: [phone]
CONNECTICUT
Manchester 06040 (Hartford)
57 Tolland Turnpike
Phone: [phone]
FLORIDA
Hialeah 33014
16373-75 NW 57th Ave.
Phone: [phone]
Jacksonville 32205
517 Cassat Avenue
Phone: [phone]
Tampa 33609
4538 W. Kennedy Boulevard
Phone: [phone]
Orlando 32803
1807’/a Winter Park Road
Phone: [phone]
GEORGIA
Forest Park 30050 (Atlanta)
4017 Jonesboro Road
Phone: [phone]
ILLINOIS
Melrose Park 60160 (Chicago)
4533 West North Avenue
Phone: [phone]
INDIANA
Indianapolis 46268
5317 West 86th Street
Park 100—Building 6
Phone: [phone]
LOUISIANA
Kenner 70062 (New Orleans)
2440-0 Veterans Memorial Blvd.
Phone: [phone]
MARYLAND
Baltimore 21205
4714 Erdman Avenue
Phone: [phone]
Hyattsville 20781
4811 Kenilworth Avenue
Phone: [phone]
MASSACHUSETTS
Allston 02134 (Boston)
414 Cambridge Street
Phone: [phone]
MICHIGAN
Grand Rapids 49506
Indian Village Mall
2750 Birchcrest Drive S.E.
Phone: [phone]
Southfield 48037 (Detroit)
18650 W. Eight Mile Road
Phone: [phone]
MINNESOTA
Minneapolis 55429
4315 68th Avenue North
Phone: [phone]
MISSOURI
North Kansas City 64116
1141 Swift Avenue
Phone: [phone]
St. Louis 63139
2348 Hampton Avenue
Phone: [phone]
NEW JERSEY
Union 07083
945 Ball Avenue
Phone: [phone]
NEW YORK
New York 10013 (Manhattan)
132 Lafayette Street
Phone: (212). 966-2726
Flushing 11365
175-25 Horace Harding Expwy.
Phone: [phone]
Syracuse 13224
2740 Erie Blvd. East
Phone: [phone]
NORTH CAROLINA
Charlotte 28209
4612 South Boulevard
Phone: [phone]
OHIO
Columbus 43214
4560 Indianola Avenue
Phone: [phone]
OKLAHOMA
Oklahoma City 73107
3631 Northwest 23rd Street
Phone: [phone]
OREGON
Portland 97212
51 N.E. Hancock
Phone: [phone]
PENNSYLVANIA
Ben Salem 19020
1-95 Industrial Center
3599 Meadow Lane
Phone: [phone]
RHODE ISLAND
East Providence 02914
1009 Waterman Avenue
Phone: [phone]
TENNESSEE
Memphis 38116
1004 East Brooks Road
Phone: [phone]
TEXAS
Dallas 75247
3160 Commonwealth Drive
Suite 180, Commonwealth Plaza
Phone: [phone]
Houston 77092
5201 Mitchelldale B-9
Phone: [phone]
San Antonio 78218
Suite 107
2800 N.E. Loop 410
Phone: [phone]
UTAH
Salt Lake City 84115
2990 Southwest Temple
Phone: [phone]
VIRGINIA
Richmond 23230
1705 Dabney Road
Phone: [phone]
WASHINGTON
Seattle 98101
1918 Minor Avenue
Phone: [phone]
WISCONSIN
Milwaukee 53222
10700 W. Burleigh Street
Phone: [phone]
Authorized Porter-Cable Service Stations are located in all
large cities. For the one nearest you, see the classified section
in your phone book (under “Tools - Electric").
15

Printed in U.S.A.