Milwaukee Tool 6021-21 User Manual [en, es, fr]

Cat. No.

No de Cat.

6021-21

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

HEAVY-DUTY 5" RANDOM ORBIT SANDER
EXTRA ROBUSTE PONCEUSE À MOUVEMENTS ORBITAUX
ASYNCHRONES DE 125 mm (5 po)
125 mm (5 pulg.) HEAVY DUTY LIJADORAS DE ÓRBITA ALEATORIA

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.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING READ ALL SAFETY WARNINGS AND ALL 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 the warnings refers to your mains-operated (corded) power tool or battery-operated
(cordless) power tool.

• Keep work area clean and well lit. Cluttered or

WORK AREA SAFETY

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 electric

shock if your body is earthed or grounded.

• Do not expose power tools to rain or wet condi­tions. Water entering a power tool will increase

the risk of electric shock.

• Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled cords

increase the risk of electric shock.

• When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use

of a cord suitable for outdoor use reduces the risk
of electric shock.

• If operating a power tool in a damp location
is unavoidable, use a residual current device
(RCD) protected supply. 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 medication. A

moment of inattention while operating power tools
may result in serious personal injury.

• Use personal protective equipment. Always
wear eye protection. Protective equipment such

as dust mask, non-skid safety shoes, hard hat, or
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

dust collection can reduce dust-related hazards.

POWER TOOL USE AND CARE

• Do not force the power tool. Use the correct
power tool for your application. The correct

power tool will do the job better and safer at the
rate for which it was designed.

• Do 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 pre-

ventive 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’s 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.

2

SPECIFIC SAFETY RULES

• Hold power tool by insulated gripping surfaces,

because the belt may contact its own cord.

Cutting a “live” wire may make exposed metal
parts of the tool “live” and could give the operator
an electric shock.

• Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact a MILWAUKEE service facility for a free
replacement.

• WARNING : 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.
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 particles.

FUNCTIONAL DESCRIPTION

2

3

4

5

6

1. Air vents

2. Handle

3. On/Off switch

1

4. Backing pad

5. Dust bag

6. Variable speed dial

SPECIFICATIONS

Cat.

Volts

No.

6021-21 120 3 7000-12,000 5" dia.

AC

Amps

Orbits

Per Min.

Paper

Size

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 outdoors, be
sure it is marked with the suffi x “W-A” (“W” in Cana-
da) 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

For Extension Cords*

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

* Based on limiting the line voltage drop to fi ve volts at

150% of the rated amperes.

Extension Cord Length

25' 50' 75' 100' 150'

18

18

18

18
18
18
18
16
14
12

18
18
16
14
12
10

18
16
14
12
10

16
14
12
10

READ AND SAVE ALL

INSTRUCTIONS FOR FUTURE USE.

SYMBOLOGY

Double Insulated

Amps

Volts

Alternating Current Only

EXTENSION CORDS

OPM

3

Orbits Per Minute (OPM)
Underwriters Laboratories, Inc.

United States and Canada

16
14
12
12

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
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 satisfi es 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.

Fig. A

Fig. B

Fig. C

ASSEMBLY

WARNING T o reduce the risk of injury ,

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 ceramic
aluminum oxide

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

• Solid surfacing materials (Corian, etc.) – silicon
carbide or aluminum oxide

• Metals – emery or aluminum oxide

Sandpaper is also graded by coarseness. Start
your work with an abrasive grit just coarse enough
to remove high spots and excessive roughness.
Follow with a second sanding using a grit one or
two grades 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

Course

80

100

Medium

120
150

180
220

Attaching Hook-and-Loop Sanding Discs

1. Unplug the sander.

2. Align holes in hook-and-loop type sanding disc

NOTE: Hook-and-loop type sanding discs can

4

Fine

with holes in pad, then carefully press fuzzy side
of sanding disc against pad as tightly as possible.

be reused for the life of the sanding abrasive. It
is recommended that you keep the sanding disc
backing pad clean to provide for best adhesion.
Clean occasionally by brushing lightly with a
small brush.

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.

Changing the Sanding
Pad

The sander comes as­sembled with the hook­and-loop pad. To attach
the pressure sensitive
adhesive (PSA) pad, you
must first remove the
hook-and-loop pad.
Inspect sanding disc be­fore installing. Do not use
if broken or defective.

1. Unplug the sander.

2. Remove the four
screws that hold the
hook-and-loop pad in
place.

3. Remove the hook-and­loop pad.

4. Clean dust particles
from the pad brake.

5. Apply a thin layer of
lightweight grease to
the back of the pad.

6. Align the holes in the
pressure sensitive ad­hesive (PSA) pad with
the four screw holes in
the sander.

7. Replace the four
screws securely.

Attaching PSA Sanding Discs

1. Unplug the sander.

2. Carefully peel paper backing from the pressure
sensitive adhesive type sanding disc.

3. Align holes in sanding disc with holes in back­ing pad, then carefully press sticky side of disc
against pad as tightly as possible.

NOTE: Holes in sanding disc must line up with

holes in the backing pad in order for the dustless
feature of the sander to function properly.

NOTE: It is recommended that you clean backing

pad occasionally by brushing lightly with a small
brush. Dust buildup on backing pad could cause
sanding disc not to stick properly.

Remove PSA Sanding Disc Before Storage

Do not store the sander with the sanding disc in­stalled. Heat generated from sanding causes the
pressure sensitive adhesive to fl ow and form a tight
bond between the backing pad and sanding disc.
Removing the sanding disc soon after you have
fi nished a sanding operation avoids letting the
adhesive set up. If the sanding disc is left on the
backing pad for an extended period of time after
use, the adhesive will set up and cause the sanding
disc to become diffi cult to remove.
It may also tear when removing. When this situation
occurs, it becomes diffi cult to clean the backing pad
for the next sanding disc.
NOTE: If you forget to remove the sanding disc
after a sanding operation, sand for a few minutes
to soften the adhesive backing before attempting
to remove sanding disc.

Fig. 1

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 disc 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

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.

Fig. 4

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.

5

OPERATION

WARNING T o 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 T o 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.

Variable Speed Switch

The variable speed feature allows the sander to
operate at speeds that can be adjusted by rotat­ing the dial on the variable speed switch from 1 to

6. The dial is conveniently located on the motor
housing, allowing operator control of disc speed.
T o increase sanding disc speed, turn the dial on the
variable speed switch to a higher setting. Turn dial

to a lower setting to decrease sanding disc speed.

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 T o 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 Random Orbit Sanders

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

• Unlike most sanders, random orbit sanders should
be placed on the workpiece BEFORE the tool is
started. If the sander is started before it is placed
on the workpiece, the free fl oating pad may be
spinning at a speed that can cause scratches when
it is fi nally placed on workpiece.

• Unlike most sanders, random orbit sanders can
be moved across the workpiece in any direction
(in the case of wood, regardless of the direction
of the grain).

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

• Check the workpiece frequently, random orbit
sanders work more aggressively than simple
orbital sanders.

WARNING Properly secure workpiece

before sanding. Unsecured work could be
thrown towards the operator causing injury.

WARNING Do not wear loose cloth-

ing or jewelry when operating sander. They
could get caught in moving parts causing
serious injury. Keep head away from sander
and sanding area. Hair could be drawn into
sander causing serious injury.

1. Place sander on the workpiece and turn on

the sander.

2. Keep the sanding disc fl at against the workpiece,

keep the sander moving across the workpiece,
and use long, sweeping strokes.

3. Begin sanding with a coarse grit sandpaper and

gradually use fi ner and fi ner grits of sandpaper
until the desired fi nish is reached. For example
when using the sander on wood, begin with an
80 grit followed by a 120 grit, then a 180 grit and
so on.

Removing Paint or Varnish

1. When removing several layers of paint or var-

nish, remove as much as possible with a paint
solvent or varnish remover.

2. Scrape away the residue with a putty knife or

other scraping tool and allow the surface to cool
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 pre-

vent 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

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.

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.

To empty the dust bag:

1. Unplug the sander.

2. Remove the dust bag from the sander.

3. Shake out the dust.

4. Reattach the dust bag to the sander.

Fig. 5

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.

MAINTENANCE

WARNING T o 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. 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.)

• T esting 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.

6

7