Wen AT6535 User manual

OSCILLATING
SPINDLE SANDER
Instruction Manual
IMPORTANT: Your new tool has been engineered and manufactured to WEN’s highest standards for dependability,
ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged,
trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use
your tool properly and for its intended purpose, you will enjoy years of safe, reliable service.
NEED HELP? CONTACT US!
Have product questions? Need technical support? Please feel free to contact us:
TECHSUPPOR[email protected]1-800-232-1195 (M-F 8AM-5PM CST)
For replacement parts and the most up-to-date instruction manuals, visit WENPRODUCTS.COM
MODEL AT6535

CONTENTS
WELCOME 3
Introduction ..................................................................................................... 3
Specifications................................................................................................... 3
SAFETY 4
General Safety Rules........................................................................................ 4
Spindle Sander Safety Warnings...................................................................... 6
Electrical Information....................................................................................... 8
BEFORE OPERATING 9
Know Your Spindle Sander ...............................................................................9
Assembly & Adjustments............................................................................... 11
OPERATION & MAINTENANCE 14
Operation ....................................................................................................... 14
Maintenance....................................................................................................15
Troubleshooting Guide....................................................................................16
Exploded View & Parts List.............................................................................17
Warranty Statement ........................................................................................20
To purchase accessories and replacement parts for your tool, visit WENPRODUCTS.COM
Sanding sleeves of various grits can be purchased from wenproducts.com
by searching your product's model number AT6535.
2

Model Number AT6535
Power 120V AC, 60 Hz, 3.5A
Motor Speed (No-Load) 2000 RPM
Spindle Oscillation (No-Load) 58 OPM
Spindle Diameter 1/2 Inch
Rubber Drum Diameter (4) 3/4", 1", 1-1/2", 2"
19mm, 26mm, 38mm, 51mm
Sanding Sleeve Diameter (5) 1/2", 3/4", 1", 1-1/2", 2" (80-Grit)
13mm, 19mm, 26mm, 38mm, 51mm
Dust Port Size 2" O.D., 1-7/8" I.D.
Work Table Bevel Angle 0º to 45º
Table Dimensions 14-1/2 in. x 14-1/2 in.
IP Rating IP20
Product Net Weight 33.2 Pounds
Assembled Dimensions 14-3/4 in. x 14-3/4 in. x 16-3/4 in.
SPECIFICATIONS
INTRODUCTION
Thanks for purchasing the WEN Spindle Sander. We know you are excited to put your tool to work, but first, please
take a moment to read through the manual. Safe operation of this tool requires that you read and understand this
operator’s manual and all the labels affixed to the tool. This manual provides information regarding potential safety
concerns, as well as helpful assembly and operating instructions for your tool.
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.
At WEN, we are continuously improving our products. If you find that your tool does not exactly match this manual,
please visit wenproducts.com for the most up-to-date manual or contact our customer service at 1-800-232-1195.
Keep this manual available to all users during the entire life of the tool and review it frequently to maximize
safety for both yourself and others.
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
or personal injury. However, please note that these instructions and warnings are not substitutes for proper ac-
cident prevention measures.
3

GENERAL SAFETY RULES
WORK AREA SAFETY
1. Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
2. Do not operate power tools in explosive atmo-
spheres, such as in the presence of flammable liquids,
gases or dust. Power tools create sparks which may ig-
nite the dust or fumes.
3. Keep children and bystanders away while operating
a power tool. Distractions can cause you to lose control.
ELECTRICAL SAFETY
1. Power tool plugs must match the outlet. Never mod-
ify 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.
2. Avoid body contact with earthed or grounded surfac-
es such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body
is earthed or grounded.
3. Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of elec-
tric shock.
4. Do not abuse the cord. Never use the cord for car-
rying, 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.
5. When operating a power tool outdoors, use an ex-
tension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the risk of electric
shock.
6. If operating a power tool in a damp location is un-
avoidable, use a ground fault circuit interrupter (GFCI)
protected supply. Use of a GFCI reduces the risk of elec-
tric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use com-
mon 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 inatten-
tion while operating power tools may result in serious
personal injury.
2. Use personal protective equipment. Always wear
eye protection. Protective equipment such as a respira-
tory mask, non-skid safety shoes and hearing protection
used for appropriate conditions will reduce the risk of
personal injury.
3. 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.
Carrying power tools with your finger on the switch or
energizing power tools that have the switch on invites
accidents.
4. Remove any adjusting key or wrench before turning
the power tool on. A wrench or a key left attached to a
rotating part of the power tool may result in personal
injury.
5. Do not overreach. Keep proper footing and balance
at all times. This enables better control of the power
tool in unexpected situations.
6. Dress properly. Do not wear loose clothing or jew-
elry. Keep your hair and clothing away from moving
parts. Loose clothes, jewelry or long hair can be caught
in moving parts.
Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool”
in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE SAFETY INSTRUCTIONS.
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.
4

GENERAL SAFETY RULES
7. 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.
POWER TOOL USE AND CARE
1. 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.
2. Do not use the power tool if the switch does not turn
it on and off. Any power tool that cannot be controlled
with the switch is dangerous and must be repaired.
3. 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 preventive safety measures reduce
the risk of starting the power tool accidentally.
4. Store idle power tools out of the reach of children
and do not allow persons unfamiliar with the power
tool or these instructions to operate the power tool.
Power tools are dangerous in the hands of untrained us-
ers.
5. 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 opera-
tion. If damaged, have the power tool repaired before
use. Many accidents are caused by poorly maintained
power tools.
6. Keep cutting tools sharp and clean. Properly main-
tained cutting tools with sharp cutting edges are less
likely to bind and are easier to control.
7. Use the power tool, accessories and tool bits, etc.
in accordance with these instructions, taking into ac-
count the working conditions and the work to be per-
formed. Use of the power tool for operations different
from those intended could result in a hazardous situa-
tion.
8. Use clamps to secure your workpiece to a stable
surface. Holding a workpiece by hand or using your
body to support it may lead to loss of control.
9. KEEP GUARDS IN PLACE and in working order.
SERVICE
1. Have your power tool serviced by a qualified repair
person using only identical replacement parts. This
will ensure that the safety of the power tool is main-
tained.
CALIFORNIA PROPOSITION 65 WARNING
Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities may contain
chemicals, including lead, known to the State of Califor-
nia 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 ex-
posure to these chemicals, work in a well-ventilated area
with approved safety equipment such as dust masks
specially designed to filter out microscopic particles.
Safety is a combination of common sense, staying alert and knowing how your item works. The term “power tool”
in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE SAFETY INSTRUCTIONS.
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.
5

SPINDLE SANDER SAFETY WARNINGS
SPINDLE SANDER SAFETY
1. TOOL PURPOSE. This sander is designed to sand
wood or wood-like products only. Sanding or grinding
other materials could result in fire, injury, or damage to
the workpiece. Using the machine for any other purpose
for which it is not designed may result in serious injuries,
machine damage and voiding of the warranty.
2. MACHINE MOUNTING. For operation safety, the
sander must be securely mounted onto a flat and stable
surface or stand.
3. PERSONAL SAFETY.
• Always wear ANSI Z87.1-approved glasses with side
shields, hearing protection and a dust mask.
• Do not wear loose clothing or jewelry, as they might
get drawn in by the tool. Tie back long hair.
• DO NOT wear gloves while operating this machine.
4. ELECTRIC CORDS. Keep cords away from heat, oil,
sharp edges, and moving parts of the tool. Have an
electrician replace or repair damaged or worn cords
immediately.
5. TOOL & ACCESSORIES INSPECTION. Before
operation, check the tool and accessories for any
damage or missing parts. Do not use the tool if any part
is missing or damaged. Make sure all adjustments are
correct and all connections are tight. Keep all guards in
place.
6. SANDING ACCESSORIES.
• Do not use sanding sleeves or drums that are damaged,
torn, or loose. Replace worn or damaged sanding sleeves
before operation.
• Always unplug the unit before making adjustments or
changing sandpaper, rubber drums or throat plates.
• Always use the throat plate that matches the diameter
of the drum to minimize the gap between the drum and
the throat plate opening; this will reduce the risk of
personal injury.
7. WORKPIECE REQUIREMENTS.
• Only stand workpieces sturdy enough to withstand the
force of the sanding spindle.
• Inspect the workpiece for imperfections, nails,
staples, etc. before sanding. Never sand stock that has
questionable imperfections or embedded foreign objects.
• When sanding a large workpiece, provide additional
support. Do not sand with the workpiece unsupported.
• Sand only one workpiece at a time.
8. PREVENTING ACCIDENTAL STARTING. Make sure
the power switch is in the OFF position prior to plugging
in the machine. Always make sure the power switch is
in the OFF position and the machine is unplugged when
doing any cleaning, assembly, setup operations, or when
not in use.
WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules.
Failure to follow the safety instructions may result in serious personal injury.
6

SPINDLE SANDER SAFETY WARNINGS
WARNING! Do not let comfort or familiarity with the product replace strict adherence to product safety rules.
Failure to follow the safety instructions may result in serious personal injury.
9. Do not operate this tool until it is completely assembled
and installed according to the instructions.
10. Remove scrap pieces and other objects from the
table and sanding sleeve before turning ON the sander.
11. FEEDING THE WORKPIECE.
• Allow spindle to reach full speed before feeding the
workpiece. Do not turn on the machine while the sanding
sleeve is contacting the workpiece.
• Be aware of the direction of the spindle’s rotation
(counterclockwise). Only feed the workpiece against the
rotation of the spindle.
• Firmly hold the workpiece and lightly ease it against
the spindle. Do not forcefully jam a workpiece into the
sanding surface.
12. DO NOT TOUCH MOVING PIECES. Keep hands away
from the drum during operation. If cleaning is necessary,
use a brush to remove sawdust and chips instead of your
hands.
13. Never perform layout, assembly or set-up work on
the table while the sander is operating.
14. TURNING OFF THE TOOL. After turning off the
sander, wait until the spindle comes to a complete stop
before touching the workpiece or leaving the work area.
15. Always turn off and unplug the machine before
cleaning, making adjustments or changing attachments.
Accidental start-ups may occur if the tool is plugged in
during an accessory change or adjustment.
16. CLEANING. Never use solvents to clean plastic
parts. Solvents could dissolve or otherwise damage
the material. Use only a soft damp cloth to clean plastic
parts.
These safety instructions can’t possibly warn of every scenario that may arise with this tool,
so always make sure to stay alert and use common sense during operation.
7

ELECTRICAL INFORMATION
AMPERAGE REQUIRED GAUGE FOR EXTENSION CORDS
25 ft. 50 ft. 100 ft. 150 ft.
3.5A 18 gauge 16 gauge 16 gauge 14 gauge
IMPORTANT: Servicing a double-insulated product requires extreme care and knowledge of the system, and
should be done only by qualified service personnel using identical replacement parts. Always use original factory
replacement parts when servicing.
1. 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 a proper outlet. Do not modify the machine plug
or the extension cord in any way.
2. Ground fault circuit interrupter protection (GFCI) should be provided on the circuit or outlet used for this power
tool to reduce the risk of electric shock.
3. Service and repair. To avoid danger, electrical appliances must only be repaired by a qualified service technician
using original replacement parts.
GUIDELINES AND RECOMMENDATIONS FOR 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 ampere rating. When in doubt, use a heavier cord. The
smaller the gauge number, the heavier the cord.
DOUBLE-INSULATED CHARGER
The tool’s electrical system is double-insulated where two systems of insulation are provided. This
eliminates the need for the usual three-wire grounded power cord. Double-insulated tools do not need
to be grounded, nor should a means for grounding be added to the product. All exposed metal parts are
isolated from the internal metal components with protecting insulation.
1. Examine extension cord before use. 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.
2. Do not abuse extension cord. Do not pull on cord to disconnect from receptacle; always disconnect by pulling on
plug. Disconnect the extension cord from the receptacle before disconnecting the product from the extension cord.
Protect your extension cords from sharp objects, excessive heat and damp/wet areas.
3. Use a separate electrical circuit for your tool. This circuit must not be less than a 12-gauge 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.
8

Dust Port (Back)
Table Bevel Knob
Accessory Storage
Spindle
Spindle Upper Washer
Sanding Drum & Sleeve
Throat Plate
Motor Ventilation Slots
ON/OFF Switch
with Safety Key
Work Table
Mouting Holes
CLEANING THE WORK TABLE SURFACE
Your sander's work table comes protected with a layer of anti-rust coating. Clean the rust-protected surfaces us-
ing a soft cloth, moistened with kerosene. Do not use gasoline or cellulose-based solvents such as paint thinner or
lacquer thinner, as these will damage the painted surfaces.
After cleaning, apply a coat of paste wax to the table to prevent rust. Wipe all parts thoroughly with a clean, dry cloth.
KNOW YOUR SPINDLE SANDER
UNPACKING
Carefully remove the spindle sander from the packaging and place it on a sturdy, flat surface. Make sure to take out
all contents and accessories. Do not discard the packaging until everything is removed. Check the packing list below
to make sure you have all of the parts and accessories. If any part is missing or broken, please contact customer
service at 1-800-232-1195 (M-F 8-5 CST), or email [email protected].
TOOL PURPOSE
Spindle sanding is the preferred method of removing material from inside curves and irregular edges. The oscil-
lating spindle moves up and down as it rotates to help smooth workpiece surfaces quickly and evenly. Refer to the
diagram below to become familiarized with the parts and controls of your spindle sander.
9
Circuit Breaker

KNOW YOUR SPINDLE SANDER
UNPACKING
Before using the spindle sander, you must configure the machine by instaling the appropriate sanding drum, sand-
ing sleeve, throat plate, and spindle washer for your operation. Check your packing list against the diagram below.
If any part is damaged or missing, please contact our customer service at 1-[phone], M-F 8-5 CST or email
us at [email protected].
Rubber Sanding Drums (4)
80-Grit Sanding Sleeves (5)
Bevel Sanding Throat Plates (5)
Spindle Upper Washers (5)
Horizontal Sanding
Throat Plates (5)
1/2"
(13mm)
3/4"
(19mm)
1"
(26mm)
1-1/2"
(38mm)
2"
(51mm)
Sanding sleeves of various grits can be purchased from wenproducts.com
by searching your product's model number AT6535.
10
Fig. 1
Spindle Nut
Wrench Lower Spindle Washer (1)

ACCESSORY SELECTION
Refer to the packing list diagram on page 10 to ensure that you are using the proper sizes of throat plates, drums
and washers for each respective sanding sleeve. To ensure the workpiece can be properly supported and to mini-
mize clearance, use the throat plate that matches the drum and sleeve that you’ll be working with. The size of the
throat plate is marked on the plate's surface. For horizontal sanding, use throat plates with circle openings; for bevel
sanding, use plates with an oblong openings.
NOTE: The smallest size sanding sleeve does not include a drum. It goes directly onto the bare spindle.
INSTALLING THE ACCESSORIES
1. Disconnect the machine from the power source.
2. Slide the lower spindle washer (Fig. 2 - 1) over the spin-
dle shaft.
3. Install the preferred rubber drum (Fig. 2 - 2) onto the
spindle shaft, followed by the corresponding sanding sleeve
(Fig. 2 - 3) and throat plate (Fig. 2 - 4). Make sure the
printed side of the throat plate is facing up.
NOTE: The 1/2" sleeve should be installed directly onto the
spindle.
4. Secure the sanding accessories in place with the cor-
responding washer (Fig. 2 - 5). Tighten the spindle nut on
top (Fig. 2 - 6) with the spindle nut wrench until the sand-
ing drum creates equal pressure to all sides of the sanding
sleeve. The sleeve should not be able to freely rotate with-
out also rotating the sanding drum.
ASSEMBLY & ADJUSTMENTS
WARNING! To prevent accidental starting, make sure the machine is switched OFF and the power plug is
disconnected before assembly, setting up or making adjustments.
Fig. 2
1
3
5
6
2
4
Align with
the notch
11

MACHINE MOUNTING
For safe operation, the machine must be secured onto a flat, secure workbench or stand. The base of the machine
has four 6 mm mounting holes. Place the sander on the mounting surface, and insert a pencil through the mounting
holes to mark the hole locations. Remove the sander and drill out the mounting holes. Then align the sander base
over the mounting holes and secure the machine using four mounting bolts, washers, locking washers and hex nuts
(mounting hardware not included). Securely tighten the hex nuts.
For temporary mounting, secure the sander to a mobile mounting board and use 2 large C-Clamps to secure the
mounting board to a solid surface.
ASSEMBLY & ADJUSTMENTS
WARNING! To prevent accidental starting, make sure the machine is switched OFF and the power plug is
disconnected before assembly, setting up or making adjustments.
TIP: Your spindle sander is compatible with the WEN 6588 Multipurpose Planer Stand, available at
wenproducts.com. Forget measuring and drilling holes on your workbench, simply mount your machine onto
the stand with pre-drilled holes, and transport your machine around the workshop with ease.
ADJUSTING THE WORK TABLE BEVEL
The work table has the capacity to tilt from 0 to 45 degrees
for sanding bevels on your workpiece. For any bevel sand-
ing operation, you must use the throat plate with an oblong-
shaped opening (Fig. 3 - 1).
To adjust the table bevel:
1. Disconnect the machine from the power source.
2. Loosen the table bevel knobs (Fig. 3 - 2) on both sides
of the sander.
3. Tilt the table until the pointer is indicating the desired
angle on the bevel gauge.
4. Re-tighten both bevel knobs.
Fig. 3
2
1
12

SQUARING THE TABLE TO THE SPINDLE
When sanding with the work table in the horizontal (0°) position, make sure that the table surface is square to the
sanding spindle. With the sanding drum and sleeve installed, check the alignment using a machinist's or combina-
tion. The square should be flat against the table and the spindle (Fig. 4). Periodically check for proper alignment
between the table and spindle. If the table and spindle are not square, adjust as follow:
ASSEMBLY & ADJUSTMENTS
1. Check that the table is in the 0-degree position.
2. Loosen both table bevel knobs (Fig. 5 - 1).
3. Adjust the corresponding fine adjustment nut beneath
the work table (Fig. 5 - 2) to bring the table perpendicular
to the spindle.
4. Lock both table bevel knobs and use a square to re-check
table/spindle alignment.
5. Repeat steps 2 - 4 until the table surface and sanding
spindle are perpendicular.
DUST COLLECTION
WARNING! Sanding operations are dusty and can
produce particles that are harmful to your health. Al-
ways wear a dust mask and use an adequate dust col-
lection system.
To connect a dust collection system to the machine:
1. Fit a 2-inch dust hose (not included) over the dust port
(Fig. 5 - 3) and secure the hose in place with a hose clamp
as needed.
2. Tug the hose to make sure the fitting is tight. A tight fit is
necessary for proper performance.
3. Connect the other end of the dust hose to the dust col-
lection system of your choice. A dust port adapter may be
needed (not included), depending on the inlet size of your
dust extractor.
NOTE: Failure to use a dust collector can cause sawdust to
build up in the machine, possibly leading to premature fail-
ure. Failure to use a dust collector will void the warranty.
Keep your sander clean!
Fig. 4
Fig. 5
2
1
2
1
3
13

OPERATION
WARNING! Do not plug in or turn on the tool until it is fully assembled according on the instructions. Failure
to follow the safety instructions may result in serious personal injury.
ON/OFF SWITCH WITH SAFETY KEY
The keyed ON/OFF switch (Fig. 6) is intended to prevent
unauthorized use of the sander.
1. To turn the sander ON, insert the safety key into the key
slot in the center of the switch. Lift the switch up to turn ON
the sander.
2. To turn the sander OFF, push switch down. Remove the
safety key when the sander has come to a complete stop by
gently pulling the key out.
WARNING! Remove the safety key whenever the sander is not in use. Place the key in a safe place and out
of the reach of children.
OPERATING THE SPINDLE SANDER
1. Make sure that the machine has been securely mounted,
and all accessories have been properly installed according
to the instructions in the "ASSEMBLY & ADJUSTMENTS"
section.
2. Plug in and turn ON the sander. Let the spindle reach full
speed.
3. Maintain a firm grip with both hands on the workpiece for
maximum control. Slowly guide the workpiece against the
rotation of the spindle (Fig. 7).
NOTE: The spindle rotates in a counterclockwise direction.
Guide the workpiece from the right to left. If you guide
the workpiece in the opposite direction, the forces of the
spinning sanding sleeve will tend to throw or bounce the
workpiece away from the sanding sleeve, possibly resulting
in injuries.
4. Maintain downward pressure on the workpiece against
the table, gently working it along the sanding sleeve until
the desired curve has been created. Do not force the work-
piece against the sanding sleeve.
5. When you are finished, turn OFF the sander and wait for
the spindle to come to a complete stop.
6. Remove the safety key and unplug the machine from
the outlet. Follow the maintenance instructions on the next
page to clean and maintain your sander.
Fig. 6
Fig. 7
ON
OFF
14

MAINTENANCE
WARNING! To avoid accidents, turn OFF and unplug the tool from the electrical outlet before cleaning, ad-
justing, or performing any maintenance or lubrication work.
WARNING! Any attempt to repair or replace electrical parts on this tool may be hazardous. Servicing of the
tool must be performed by a qualified technician. When servicing, use only identical WEN replacement parts.
Use of other parts may be hazardous or induce product failure.
ROUTINE INSPECTION
Before each use, inspect the general condition of the tool. If any of these following conditions exist, do not use until
parts are replaced or the sharpener is properly repaired.
Check for:
• Loose hardware or improper mounting,
• Misalignment or binding of moving parts,
• Damaged cord/electrical wiring,
• Cracked or broken parts, and
• Any other condition that may affect its safe operation
CLEANING & STORAGE
1. After every operation, use a vacuum to remove dust and chips from the tool surfaces, motor housing and work
area. Keep the ventilation openings free from dust and debris to prevent the motor from overheating.
2. Wipe the tool surfaces clean with a soft cloth or brush. Make sure water does not get into the tool.
3. Periodically, remove the throat plate and lower spindle washer and remove any dust accumulation in the throat
plate area.
CAUTION! Most plastics are susceptible to damage from various types of commercial solvents. Do not use
any solvents or cleaning products that could damage the plastic parts. Some of these include but are not limited
to: gasoline, carbon tetrachloride, chlorinated cleaning solvents, and household detergents that contain ammo-
nia.
4. Store the tool in a clean and dry place away from the reach of children. Store sanding accessories away from
extremely hot/dry temperatures. Do not bend or fold the sanding sleeves.
LUBRICATION
All ball bearings are sealed and permanently lubricated. No further lubrication is required.
PRODUCT DISPOSAL
Used power tools should not be disposed of together with household waste. This product contains electronic com-
ponents that should be recycled. Please take this product to your local recycling facility for responsible disposal and
to minimize its environmental impact.
15

PROBLEM CAUSE SOLUTION
Sander does not
turn on.
1. Power cord or extension cord damaged or
not properly plugged in.
1. Check the power cord, extension cord, power plug and the
power outlet. Make sure the tool is properly plugged in. Do not
use the if any cord is damaged.
2. Safety key is removed from power switch. 2. Insert the safety key into the power switch.
3. Defective power switch, defective motor or
wiring, short circuit or loose connections.
3. Stop using the tool and contact customer service at 1-(800)
232-1195, M-F 8-5 CST for assistance. Repairs must be done by
a qualified technician.
Motor
overheats.
1. Motor overloaded. 1. Reduce load on motor - reduce pressure on the workpiece
being sanded.
2. Extension cord too long with an insufficient
gauge.
2. Utilize an extension cord of appropriate gauge and length or
plug tool directly into outlet (see page 8).
Sanding grains
easily rub off.
1. Sanding sleeve has been stored in an incor-
rect environment.
1. Store sanding accessories away from extremely hot/dry
temperatures.
2. Sanding sleeve has been damaged or folded. 2. Store sanding accessories flat—not bent or folded.
Deep sanding
grooves or scars
in workpiece.
1. Sanding sleeve grit is too coarse for the
desired finish. 1. Use a finer-grit sanding accessory.
2. Workpiece sanded across the grain. 2. Sand with the grain of the wood.
3. Too much sanding force. 3. Reduce pressure on workpiece while sanding.
4. Workpiece held still against sanding surface
for too long. 4. Keep workpiece moving while sanding on the sanding sleeve.
Burns on work-
piece.
1. Using a sanding grit that is too fine. 1. Use a coarser-grit sanding accessory.
2. Using too much pressure. 2. Reduce sanding pressure on workpiece.
3. Work held still for too long. 3. Do not keep workpiece in one place for too long.
4. Sanding sleeve loaded with debris. 4. Clean or replace the sanding sleeve.
Sanding surface
clogs quickly.
1. Too much pressure against sleeve. 1. Clean sanding sleeve. Reduce pressure on workpiece while
sanding.
2. Sanding softwood. 2. Use different stock/sanding accessories, or accept that this
will happen and plan on cleaning or replacing sleeves frequently.
Sander
vibrates exces-
sively or has
noisy operation.
1. Sanding sleeve out of balance or is loose. 1. Ensure sleeve is properly installed.
2. Motor or internal components loose. 2. Inspect/replace damaged bolts/nuts and retighten with thread-
locking fluid.
3. Machine not properly mounted. 3. Tighten mounting hardware.
4. Faulty motor bearings. 4. Test by rotating shaft; rotational grinding/loose shaft requires
bearing replacement.
Sanding stops
oscillating.
1. Spindle drive belt is broken and requires
replacement.
1. Contact customer service at 1-[phone], M-F 8-5 CST
for assistance. Repairs must be done by a qualified technician.
TROUBLESHOOTING GUIDE
WARNING! Stop using the tool immediately if any of the following problems occur. Repairs and replace-
ments should only be performed by an authorized technician. For any questions, please contact our customer
service at 1-[phone], M-F 8-5 CST or email us at [email protected].
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