Milwaukee 5936 Operator's Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND
OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET
BIEN COMPRENDRE LE MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y
ENTENDER EL MANUAL DEL OPERADOR.
HEAVY-DUTY BELT SANDERS
PONCEUSES À COURROIE INDUSTRIELLES
LIJADORAS DE CORREA PARA SERVICIO PESADO
Catalog No.
No de Cat.
Catálogo No.
5936
2 3
POWER TOOL USE AND CARE
16. 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.
17. 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.
18. 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 mea-
sures reduce the risk of starting the
tool accidentally.
19. Store idle power tools out of the
reach of children and do not allow persons unfamiliar with the
power tools or these instructions
to operate power tools. Power
tools are dangerous in the hands of
untrained users.
20. 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. Many acci-
dents are caused by poorly maintained
power tools.
21. Keep cutting tools sharp and
clean. Properly maintained cutting
tools with sharp cutting edges are less
likely to bind and are easier to control.
SERVICE
23. 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 maintained.
WORK AREA SAFETY
ELECTRICAL SAFETY
PERSONAL SAFETY
WARNING!
READ ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in electric shock, fire
and/or serious injury. The term "power tool" in all of the warnings listed
below refers to your mains-operated (corded) power tool or batteryopearted (cordless) power tool.
SAVE THESE INSTRUCTIONS
GENERAL SAFETY RULES-FOR ALL POWER TOOLS
1. Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
2. Do not operate power tools in ex-
plosive 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 children and bystanders
away while operating a power tool.
Distractions can cause you to lose
control.
4. 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.
5. Avoid body contact with earthed
or grounded surfaces such as
pipes, radiators, ranges and refrigerators. There is an increased
risk of electric shock if your body is
earthed or grounded.
6. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of
electric shock.
7. 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.
9. Stay alert, watch what you are do-
ing 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.
10. Use safety equipment. Always
wear eye protection. Safety equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection used for appropriate conditions
will reduce personal injuries.
11. Avoid accidental starting. Ensure
the switch is in the off-position
before plugging in. Carrying tools
with your finger on the switch or plugging in power tools that have the
switch on invites accidents.
12. Remove any adjusting key or
wrench before turning the power
tool on. A wrench or a key left at-
tached to a rotating part of the power
tool may result in personal injury.
13. Do not overreach. Keep proper
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
8. When operating a power tool out-
doors, use an extension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
14. Dress properly. Do not wear loose
clothing or jewellery. Keep your
hair, clothing and gloves away from
moving parts. Loose clothes,
jewellery, or long hair can be caught in
moving parts.
15. If devices are provided for the
connection of dust extraction and
collection facilities, ensure these
are connected and properly used.
Use of these devices can reduce dustrelated hazards.
22. Use the power tool, accessories
and tool bits etc., in accordance
with these instructions and in the
manner intended for the particular type of power tool, taking into
account the working conditions
and the work to be performed. Use
of the power tool for operations different from those intended could result in
a hazardous situation.
4 5
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 appropriate 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 insulation system which satisfies
OSHA requirements and complies with the
applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association and the National Electrical Code.
Double Insulated tools may be used in either of the 120 volt outlets shown in
Figures B and C.
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.
Fig. B
Fig. C
Fig. A
Improperly connecting the
grounding wire can result in the
risk of electric 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.
GROUNDING
WARNING!
1. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact
with a live wire will make exposed metal parts of the tool live and shock the operator.
2. Maintain labels and nameplates. These carry important information. If
unreadable or missing, contact a MILWAUKEE service facility for a free replacement.
3. WARNING! 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 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 dust masks that are specifically
designed to filter out microscopic particles.
SPECIFIC SAFETY RULES
Amperes
Double Insulated
Symbology
Canadian Standards
Association
Underwriters
Laboratories, Inc.
Volts Alternating/
Direct Current
Speed Feet per Minute
Speed
feet/min.
1400
Volts
AC/DC
120
Cat.
No.
5936
Specifications
Amps
10
Belt Size
4" x 24"
SFPM
6 7
FUNCTIONAL DESCRIPTION
1. Power cord
2. Front handle
3. Belt
4. Front roller
5. Base plate
6. Belt release lever
7. Rear roller
8. Dust bag
9. Lock button
10. Switch trigger
11. Switch handle
12. Tracking knob
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 the supply outlet increases, you must use a heavier
gauge extension cord. Using extension
cords with inadequately sized wire causes
a serious drop in voltage, resulting in loss
of power and possible tool damage. Refer
to the table shown 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 out-
doors, be sure it is marked with the
suffix W-A (W in Canada) to indicate that it is acceptable for outdoor
use.
Be sure your extension cord is prop-
erly 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.
Recommended Minimum Wire
Gauge for Extension Cords*
Extension Cord Length
* Based on limiting the line voltage drop to
five volts at 150% of the rated amperes.
Nameplate
Amperes
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
25'
18
18
18
18
16
14
12
75'
18
18
16
14
12
10
100'
18
16
14
12
10
150'
16
14
12
12
50'
18
18
18
16
14
12
10
EXTENSION CORDS
1
2
3
4
5
6
7
8
9
12
11
10
8 9
WARNING!
To reduce the risk of injury, wear
safety goggles or glasses with
side shields. Unplug the tool before changing accessories or
making adjustments.
OPERATION
WARNING!
TOOL ASSEMBLY
To reduce the risk of injury,
always unplug tool before attaching or removing accessories
or making adjustments. Use only
specifically recommended accessories. Others may be hazardous.
Installing Dust Bag
The belt sander is equipped with a large
dust bag for constant, powerful dust collection.
1. To install the dust bag, line up the slot in
the dust tube at the end of the bag with
the pin inside the dust bag hole in the
rear of the sander.
2. Slide dust tube into dust bag hole.
3. To secure, twist dust tube 1/4 turn towards the sander.
4. To remove the dust bag, twist the dust
tube 1/4 turn away from the sander and
slide the tube out of the hole.
Selecting Sanding Belts
It is very important to select the proper
sanding belt for each job. There are two
types of sanding belts: closed coat and
open coat. The surface of a closed coat
belt is densely covered with as much grit
as the adhesive will hold. On an open coat
belt, the grit is applied evenly, but openly to
the surface. An open coat belt will not clog
or fill as readily as a closed coat belt. Refer to the chart below to select the right
belt for your job.
Installing and Removing Sanding Belts
1. Unplug the sander and place it on its
side.
2. To remove the belt, pull the release lever out toward the rear roller until it
snaps into position. Slide the belt off
the rollers (Fig. 1).
3. To install a belt, slide the belt over the
rollers and push the release lever in
toward the front roller (Fig. 2).
Fig. 1
Fig. 2
Starting and Stopping the Sander
1. Plug in the tool.
2. To start the sander, squeeze the trigger.
3. To stop the sander, release the trigger.
Locking the Trigger
The lock button locks the trigger for continuous sanding.
1. To lock the trigger, hold in the lock button while squeezing the trigger. Release the trigger and it will lock in place.
2. To release the lock button, squeeze and
release the trigger. The lock button will
disengage.
Application Coat
Grit
Coarse: for
fast sanding
Medium: for
smoothing
Fine: for
finishing
General purpose sanding
Sanding fiberglass, plastic,
stone, marble, glass,
aluminum, cast iron, copper,
solder and other nonferrous materials.
Removing paint or varnish.
Open or Closed
Open
Open
36-50
36-50
36-50
60-100
60-100
60-100
120-220
120-220
120-220
Sanding
1. Be sure the cord is clear of the belt.
Grasp the handles firmly.
2. Start the sander off of the work surface to avoid gouging.
3. Keeping the sander level, begin the
sanding stroke as you lower the sander
to the work surface.
4. Use short, overlapping strokes, moving the sander slowly back and forth
across the work surface.
5. Avoid tilting or rocking the sander or
sanding in one spot for too long. This
causes gashes and hollows in the surface.
Do not apply pressure to the sander.
The sander is weighted for the amount
of pressure needed. Adding pressure
may cause gouging.
6. To stop, lift the sander from the work
surface before turning it off. Disengage
the lock button. Allow the sander to
come to a complete stop before setting
it down. A moving belt will cause the
sander to "run away" even if the motor
is off.
See the "Applications" section for special
techniques in a variety of situations.
WARNING!
Keep hands and clothing away
from moving belt.
Tracking Belt
The belt edge should always be even with
the edge of the base plate.
1. Rest the sander on the housing behind
the rear roller. Be sure the rollers and
belt are clear of the bench top and
power cord.
2. To move the belt to the outside, squeeze
the trigger and turn the tracking knob
toward the rear roller.
3. To move the belt to the inside, squeeze
the trigger and turn the tracking knob
toward the front roller.
NOTE: Moving the belt too far causes
sparks as the belt rubs against the
wear bar.
10 11
APPLICATIONS
Finishing Wood
To level a rough surface quickly, use a
coarse grit belt. Firmly hold the sander at
an angle to the grain, moving it with the
grain (Fig. 3). Work the entire surface with
overlapping strokes.
Fig. 3
For a very fine surface, change belts two
or three times, using a finer grit belt each
time. Hold the sander parallel to the grain
and work the entire surface with each grit
(Fig. 4). Move with the grain to remove
scratches left by the coarser belts. Always
finish your work by sanding with the grain.
Fig. 4
Be careful not to run off the end of the wood;
this will round the edge. Always keep the
sander flat against the work surface.
Sanding Doors and Trim
When sanding doors, trim, and other millwork, be careful not to sand the cross
grain at the joints where the direction of
the grain changes.
Finishing Metal, Plastics and Stone
(Fig. 5)
Use a sweeping circular movement across
the entire surface, overlapping strokes for
an even finish. For a fine finish, change
belts two or three times, using a finer grit
each time. Do not use oil or other coolants;
the belt will throw the liquid and contaminate the tool.
Removing Paint or Varnish
When removing several layers of paint or
varnish, remove as much as possible with
a pint solvent or varnish remover. Scrape
the residue away and allow the surface to
dry thoroughly before sanding.
Select a coarse grit, open coat belt to prevent clogging. Use short backward strokes,
lifting the sander quickly at the end of each
stroke to avoid burning the coating and
clogging the belt. Start each stroke in a
new area. As the base begins to show
through the coating, switch to a medium
grit to avoid scratching the surface of the
base.
Fig. 5
Emptying the Dust Bag
Empty the dust bag when it is about 3/4
full.
1. To empty the dust bag, remove the dust
bag from the sander.
2. Unzip the zipper and shake the bag over
a wastebasket.
3. Occasionally, slip the bag off of the wire
frame and turn it inside out. Brush dust
from the lining with a soft brush to allow the bag to "breathe" better.
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, broken
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).
Under normal conditions, relubrication is
not necessary until the motor brushes
need to be replaced. After six months to
one year, depending on use, return your
tool to the nearest MILWAUKEE service
facility for the following:
Lubrication
Brush inspection and replacement
Mechanical inspection and cleaning
(gears, spindles, bearings, housing,
etc.)
Electrical inspection (switch, cord,
armature, etc.)
Testing to assure proper mechanical
and electrical operation
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.
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.
Vacuum System
Vacuum system failure may occur when
the sander is clogged with dust. To remove the dust, remove the dust bag from
the sander. Force air into the opening where
the bag was attached. Air can also be
forced into the opening behind the rear
roller underneath the sander. If the vacuum
system still fails to work, it may be clogged
with a foreign object. Should this happen,
return the entire sander to a MILWAUKEE
service facility for repair. Do not disassemble the sander.
MAINTENANCE
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. Some of
these include: gasoline, turpentine, lacquer
thinner, paint thinner, chlorinated cleaning
solvents, 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.
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