Milwaukee 6020-21 User Manual

OPERATOR'S MANUAL MANUEL de L'UTILISATEUR MANUAL del OPERADOR

Cat. No.

No de cat.

6020-21

HEAVY-DUTY 1/4 SHEET SANDER EXTRA ROBUSTE PONCEUSE 1/4 DE FEUILLE LIJADORA DE 1/4 DE HOJA

TO REDUCE THE RISK OF INJURY, USER MUST READ OPERATOR'S MANUAL. AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE LE MANUEL DE

L'UTILISATEUR. PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER EL MANUAL DEL

OPERADOR.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING READ ALL SAFETY WARNINGS AND INSTRUCTIONS.

Failure to follow the warnings and instructions may result in electric shock, ﬁ re and/or serious injury.

Save all warnings and instructions for future reference

The term "power tool" in all of the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

WORK AREA SAFETY

• Keep work area clean and well lit. Cluttered or dark areas invite accidents.

• Do not operate power tools in explosive atmospheres, such as in the presence of ﬂ ammable liquids, gases or dust. Power tools create

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.

ELECTRICAL SAFETY

• 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. Unmodiﬁ ed 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. There is an increased risk of elec-

tric shock if your body is earthed or grounded.

• Do not expose power tools to rain or wet conditions. W ater 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. Use of an RCD reduces

the risk of electric shock.

PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the inﬂ uence of drugs, alcohol or medi- cation. 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 hearing protection used for appropriate conditions 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. Carrying power tools

with your ﬁ nger on the switch or energising power tools that have the switch on invites accidents.

• 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.

• 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

these devices can reduce dust-related hazards.

• 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.

POWER TOOL USE AND CARE

• 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.

• 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.

• 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 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 operation. If damaged, have the power tool repaired before use. Many accidents

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, 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.

SERVICE

• Have your power tool serviced by a qualiﬁ ed repair person using only identical replacement parts. This will ensure that the safety of the power

tool is maintained.

SPECIFIC SAFETY RULES

• Hold power tools by insulated gripping sur-

faces 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.

• Maintain labels and nameplates. These carry

important information. If unreadable or missing, contact a MILWAUKEE service facility for a free replacement.

• WARNING : Some dust created by power sand-

ing, 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.

Y our risk from these exposures varies, depending

on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to ﬁ lter out microscopic par- ticles.

Symbology

Double Insulated

Volts Alternating Current

Amps

Underwriters Laboratories, Inc., United States and Canada

OPM

Orbits Per Minute (OPM)

Speciﬁ cations

Cat. No. 6020-21 120 3 14,000 1/4 sheet

Volts

Amps

Orbits

Per Min.

FUNCTIONAL DESCRIPTION

1. Dust bag

2. Paper clamp

3. Lever

4. Platen

5. Sanding pad

6. On/Off Switch

7. Paper Punch

Paper

Size

GROUNDING

WARNING Improperly connecting the

grounding wire can result in the risk of electric shock. Check with a qualiﬁ ed 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 ﬁ t the outlet, have a proper outlet installed by a qualiﬁ ed 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

EXTENSION CORDS

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.

READ AND SAVE ALL

INSTRUCTIONS FOR

FUTURE USE.

cord must be the only wire connected to the tool's grounding system and must never be attached to an electrically “live” terminal.

Y our 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 satisﬁ es OSHA require- ments 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.

Guidelines for Using Extension Cords

• If you are using an extension cord outdoors, be sure it is marked with the sufﬁ x “W-A” (“W” in Canada) to indicate that it 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 qualiﬁ ed person before using it.

• Protect your extension cords from sharp objects, excessive heat and damp or wet areas.

Recommended Minimum Wire Gauge

Nameplate

* Based on limiting the line voltage drop to ﬁ ve volts at 150% of the rated amperes.

for Extension Cords*

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

Extension Cord Length

25'

18 18 18 18 16 14 12

Fig. B

50'

18 18 18 16 14 12 10

Fig. A

75'

18 18 16 14 12 10

100'

18 16 14 12 10

Fig. C

150'

16 14 12 12

ASSEMBLY

WARNING To reduce the risk of in-

jury, always unplug tool before changing or removing accessories. Only use accessories speciﬁ cally recommended for this tool. Others may be hazardous.

Selecting Sandpaper and Grits

Sandpaper can be made from various grit materials 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 zirconia or ce- ramic aluminum oxide

• Manufactured wood products (particleboard, medium density ﬁ ber board etc.) – silicon carbide or aluminum oxide

• Solid surfacing materials (Corian, etc.) – sili- con 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 ﬁ ner. Continue with successively ﬁ ner grits until you obtain the desired ﬁ nish.

Do not switch from a coarse grit to a very ﬁ ne grit in one step because it may be difﬁ cult to remove the marks made by the coarse grit abrasive. Use the ﬁ nest grits practical for the roughing operation, and ﬁ nish by using successively ﬁ ner grits.

Grit Type Typical Application

Ideal for initial sanding on

60 80

100 120

150 180 220

Course

Medium

Fine

rougher surfaces. For fast stock removal. Rough sanding and stripping of painted and rusted surfaces.

For intermediate sanding and removal of minor surface imperfections.

Ideal for ﬁ ne sanding prior to straining, priming, or sealing.

Installing Sandpaper

Inspect sandpaper before installing. DO NOT use if broken or defective.

1. Unplug the sander.

2. Pull out lever to open paper clamp.

3. Pull up on paper clamp and insert end of new 1/4 sheet sandpaper approximately 1/4 in. under the paper clamp.

4. Close paper clamp by returning lever to its original position. Apply downward pressure to conform sandpaper to platen.

5. Wrap sandpaper around cushion. Pull out lever

on opposite end of sander and pull up on paper clamp. Insert loose end of sandpaper under paper clamp. Fit sandpaper tight against cushion.

6. Close paper clamp by returning lever to its

original position.

7. Multiple sheets of sandpaper can be installed at

one time for convenience.

Fig. 1

Paper Punch

A paper punch template has been supplied with the sander for aligning and punching holes in sandpaper. The punched holes must align with the holes in the sander cushion.

1. Install sand-

paper on the sander.

2. Align sander

cushion over the paper punch.

3. Push down on

sander.

Fig. 2

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 platen and collected in the dust bag during sanding. To attach the dust bag:

1. Unplug the sander.

2. Line up the “unlock” symbol on the dust bag with the arrow on the dust collection port and slide the bag assembly onto the port. T o lock in place, rotate the bag until the arrow on the port aligns with the “lock” symbol on the bag.

Fig. 3

OPERATION

WARNING To reduce the risk of injury ,

always unplug tool before attaching or removing accessories or making adjustments. Use only speciﬁ cally recommended accessories. Others may be hazardous.

WARNING To reduce the risk of injury ,

wear safety goggles or glasses with side shields.

Starting and Stopping the Tool

To start the sander, switch ON/OFF Switch to ON.

To stop sander, switch ON/OFF Switch to OFF.

Attaching the Sander to a Vacuum

Y ou 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 ﬁ t inside blower

exhaust. Larger vacuum hoses ﬁ t outside blower exhaust.

4. Connect sander and vacuum to power supply.

WARNING When sander is not con-

nected to vacuum, always reinstall dust bag assembly back onto sander. Fail ure to do so could cause sanding dust or foreign objects to be thrown into your face or eyes which could result in possible serious injury.

Fig. 4

WARNING Finish sanding can produce

clouds of ﬁ ne dust that could ignite in the presence of sparks or open ﬂ ame. 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.

General Sanding with 1/4 Sheet Sanders

When using sanders there are a few things to keep in mind:

• Varying pressure applied to the sander will affect its speed. A light pressure is recommended for ﬁ ne work, moderate pressure for rough work. Excessive pressure does not allow the pad to move enough.

• Keep sanding pad ﬂ at on the workpiece. Tipping the sander or using the edges of the pad may produce an uneven ﬁ nish, and reduce pad life.

• Keep sander moving in broad even strokes across the workpiece. Sanding in one spot too long can cause gouging and uneven results.

1. To prevent rough action due to starting under

load, turn ON/OFF Switch ON before applying sander to workpiece.

2. Work in slow, overlapping strokes parallel to

grain. Your Finishing Sander is designed for even weight distribution. Excessive pressure may damage workpiece and motor as well as cause premature sandpaper wear.

3. Repeat operation using successively ﬁ ner grits

of sandpaper until desired ﬁ nish is obtained. Example: 60 Coarse, 100 Medium, 150 Fine.

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.

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 and dry before applying sander to the workpiece.

WARNING To reduce the risk of ﬁ re

and explosion, paint solvents and varnish removers must be removed from the workpiece and the workpiece must be completely dry before sanding.

3. Select a coarse grit sandpaper disc to help prevent the sandpaper from clogging.

4. Keep the sander moving over new areas to avoid heating and softening the old coating (paint or varnish).

5. Work in wide, overlapping strokes to produce a uniform ﬁ nish.

6. As the workpiece begins to show through the old coating, switch to a medium grit sandpaper disc to avoid scratching the surface of the workpiece. Gradually switch to a ﬁ ne grit sandpaper until you achieve the desired ﬁ nish.

Emptying the Dust Bag

WARNING Collected sanding dust

from sanding surface coatings such as polyurethanes, linseed oil, etc. can self-ignite in the sander dust bag or elsewhere and cause ﬁ re. To reduce the risk of ﬁ re 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.

For more efﬁ cient operation, empty the dust bag when it is no more than half full. This will permit the air to ﬂ ow through the bag better. Always empty and clean the dust bag thoroughly upon completion of a sanding operation and before placing the sander in storage.

Fig. 5

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.

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.

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. T ag 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 T o reduce the risk of injury ,

electric shock and damage to the tool, never immerse your tool in liquid or allow a liquid to ﬂ ow inside the tool.

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 ﬂ ammable or combustible solvents around tools.

Repairs

If your tool is damaged, return the entire tool to the nearest service center.

ACCESSORIES

WARNING T o reduce the risk of injury ,

always unplug the tool before attaching or removing accessories. Use only speciﬁ cally recommended accessories. Others may be hazardous.

For a complete listing of accessories refer to your MILWAUKEE Electric Tool catalog or go on-line

to www.milwaukeetool.com. To obtain a catalog, contact your local distributor or a service center.

Paper Punch

Cat. No. 49-80-2060

Sandpaper

See your MILWAUKEE Electric Tool catalog for a listing of sandpaper.

FIVE YEAR TOOL LIMITED WARRANTY

Every MILWAUKEE electric power tool (including battery charger) is warranted to the original purchaser only to be free from defects in material and workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace any part on a electric power tool which, after examination, is determined by MILWAUKEE to be defective in material or workmanship for a period of ﬁ ve (5) years* after the date of purchase. Return the electric power tool and a copy of proof of purchase to a MILWAUKEE factory Service/Sales Support Branch location or MILWAUKEE Authorized Service Station, freight prepaid and insured, are requested for this warranty to be effective. This warranty does not apply to damage that MILW AUKEE determines to be from repairs made or attempted by anyone other than MILWAUKEE authorized personnel, misuse, alterations, abuse, normal wear and tear, lack of maintenance, or accidents.

* The warranty period for Hoists (lever, hand chain, & electric chain hoists), all Ni-CD battery packs, W ork Lights (cordless ﬂ ashlights), Job Site Radios, and Trade Titan™ Industrial Work Carts is one (1) year from the date of purchase. *The warranty period for Li-Ion battery packs that do not contain V™-technology –

4.0 volts through 18.0 volts - is two (2) years from the date of purchase. *There is a separate warranty for V™-technology Li-Ion Battery Packs V™18 volts and above that ac-

company V™-technology cordless power tools: *Every MILWAUKEE V™-technology Li-Ion Battery Pack 18 volts or above is covered by an initial 1000

Charges/2 Years free replacement warranty. This means that for the earlier of the ﬁ rst 1000 charges or two (2) years from the date of purchase/ﬁ rst charge, a replacement battery will be provided to the customer for any defective battery free of charge. Thereafter, customers will also receive an additional warranty on a pro rata basis up to the earlier of the ﬁ rst 2000 charges or ﬁ ve (5) Years from the date of purchase/ﬁ rst charge. This means that every customer gets an additional 1000 charges or three (3) years of pro rata warranty on the V™-technology Li-Ion Battery Pack 18 volts or above depending upon the amount of use. During this additional warranty period, the customer pays for only the useable service received over and above the ﬁ rst 1000 Charges/2 years, based on the date of ﬁ rst charge and number of charges found on the battery pack via Milwaukee’s V™-technology Service Reader.

Warranty Registration is not necessary to obtain the applicable warranty on a MILW AUKEE product. The manufacturing date of the product will be used to determine the warranty period if no proof of purchase is provided at the time warranty service is requested.

ACCEPTANCE OF THE EXCLUSIVE REP AIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE TO THIS CONDITION, YOU SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MIL WAUKEE BE LIABLE FOR ANY INCIDENT AL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR FOR ANY COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED TO BE AS A CONSEQUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF PROFITS. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, MILWAUKEE DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR USE OR PURPOSE, AND ALL OTHER WARRANTIES.

This warranty applies to product sold in the U.S.A., Canada and Mexico only. Please consult the ‘Service Center Search’ in the Parts & Service section of MILW AUKEE’ s web-site www.

milwaukeetool.com or call 1.800.SAWDUST (1.800.729.3878) to locate your nearest service facility for warranty and non-warranty service on a MILWAUKEE electric power tool.

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