Milwaukee 6125 Operator's Manual
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.
Cat. No.
No de cat.
6125
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
HEAVY-DUTY RANDOM ORBIT SANDER
PONCEUSE INDUSTRIELLE À TOURNAGE ALÉATOIRE
LIJADORA DE ORBITA VARIABLE PARA SER VICO PESADO
2 3
WORK AREA SAFETY
ELECTRICAL SAFETY
PERSONAL SAFETY
WARNING
READ ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in electric shock, fi re and/or
serious injury. The term "power tool" in all of the warnings listed below refers to your
mains-operated (corded) power tool or battery-operated (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 fl ammable 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.
Unmodifi ed 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.
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.
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 infl uence 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 fi nger 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 attached to a rotating part of the power tool may result in
personal injury.
13. Do not overreach. Keep proper foot-
ing and balance at all times. This
enables better control of the power tool
in unexpected situations.
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 connec-
tion of dust extraction and collection
facilities, ensure these are connected
and properly used. Use of these de-
vices can reduce dust-related hazards.
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 preven-
tive safety measures 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 accidents 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.
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.
SERVICE
23. 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
1. Accessories must be rated for at least
the speed recommended on the tool
warning label. Wheels and other acces-
sories running over rated speed can fl y
apart and cause injury.
2. Hold tool by insulated gripping sur-
faces when performing an operation
where the cutting tool may contact
hidden wiring or its own cord. Con-
tact with a “live” wire will make exposed
metal parts of the tool “live” and shock
the operator.
3. Maintain labels and nameplates.
These carry important information.
If unreadable or missing, contact a
MILWAUKEE service facility for a free
replacement.
4. 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 chemicallytreated 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 specifi cally designed to
fi lter out microscopic particles.
4 5
FUNCTIONAL DESCRIPTION
Double Insulated
Symbology
Volts Alternating Current/
Direct Current
Amps
Underwriters Laboratories, Inc.,
United States and Canada
O.P.M.
10,000
Volts
AC/
DC
120
Cat.
No.
6125
Specifi cations
Amps
5.5
Spindle
Size
5/8" - 11
Pad Size
5"
O.P.M.
Orbits per Minute
1. Side handle
2. Sander head
3. Sanding pad
4. Spindle nut (not shown)
5. Spindle lock button
6. Motor housing
7. Paddle switch
1
2
3
6
7
5
4
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 re-
quirements 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. B
Fig. C
Fig. A
Improperly connecting the grounding
wire can result in the risk of electric
shock. Check with a qualifi ed electri-
cian 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 MILW AUKEE service facility before use. If the plug will
not fi t the outlet, have a proper outlet
installed by a qualifi ed electrician.
GROUNDING
WARNING
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 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.
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
fi ve 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
6 7
WARNING
TOOL ASSEMBL Y
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.
1. To change counterweights or convert
sander sizes, remove the sanding pad.
2. Use either a slotted screwdriver or a
Torx (T-25) to loosen and remove the
screws that fasten the counterweights
to the sander head as shown.
3. Install the appropriate counterweights
following the chart below.
4. Replace the screws and tighten securely.
Sander
Size
Counterweight Confi guration
5"
6"
6 laminated counterweights or
1 solid counterweight labeled
5"
7 laminated counterweights or
1 solid counterweight labeled
6"
Fig. 1
Laminated
counterweight
Solid
counterweight
Attaching and Removing Sanding Pads
MILWAUKEE Sanding Pads are available in
both standard and contour versions. Standard pads are suitable for most applications.
Contour pads are softer and more pliable,
making them ideal for applications on slightly
contoured surfaces.
1. T o attach a sanding pad, unplug tool and
place it upside down on a fl at surface
with the tool body facing you.
2. While holding the spindle nut securely with the 3/4" wrench provided to
prevent the nut from turning, rotate
the sanding pad clockwise by hand to
tighten it securely to the sander head.
3. To remove a sanding pad, reverse the
procedure.
NOTE: When storing the tool, do not
rest it on the pad as this could cause it
to permanently deform.
Attaching Sandpaper Discs
1. Unplug tool and place it on a fl at surface
with the pad facing up.
2. Clean dust and debris from pad face
with a dry cloth. Do not use solvents
or immerse pad in liquids as this may
damage the pad.
3. Align sandpaper disc with the pad face
and fi rmly press the sandpaper onto the
disc. The sandpaper is approximately 1/8"
larger than the pad face to prevent the pad
from contacting the work surface.
4. Run the sander on scrap material momentarily, pressing fi rmly down on the
sandpaper. This will secure the sandpaper to the pad.
5. To remove the sandpaper disc, peel it
away from the pad and discard.
NOTE: Do not store tool with sandpaper
disc on pad. Heat is generated during
sanding operations, which increases the
adhesive bond between the sandpaper
disc and the pad. If the disc is left on
the pad for extended periods, it may be
diffi cult to remove.
Installing the Side Handle
The side handle may be installed on either
side of the tool for the best control and
comfort. Always use the side handle when
operating the tool.
Converting Sander Sizes
It is possible to convert MILWAUKEE Random Orbit Sanders from 5" to 6" sanders.
The counterweights (either laminated or
solid (Fig. 1)) required for the conversion are
included with your MILWAUKEE standard
and contour pads. Use the following chart
to determine the counterweight confi guration
needed for the size conversion.
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
Selecting Sandpaper Discs
Random Orbit Sanders feature a ball bearing system that allows the head of the tool
to orbit randomly while it simultaneously
rotates randomly. This random orbit action
produces an even, swirl-free fi nish on a
variety of materials.
The tool is supplied with three sandpaper
discs: one each of 80 grit, 120 grit, and 180
grit. Refer to the following chart to select the
proper sandpaper disc for your application.
See "Accessories" for a complete list of all
sandpaper discs.
Grit
80
100
120
150
180
220
Type
Coarse
Medium
Fine
Typical Application
Ideal for initial sanding on
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 staining, priming, or
sealing.
Starting and Stopping
T o start the tool, make sure pad is in contact
with work surface. Then squeeze the paddle
switch. Release the paddle switch to stop
the tool, keeping the pad in contact with the
work surface.
WARNING
To reduce the risk of injury, keep
hands and cord away from all moving parts.
Sanding
1. Use a clamp, vise, or other practical
means to secure your work, freeing both
of your hands to control the tool. Firmly
grasp both the body of the tool and side
handle before starting tool and while tool
is in operation.
2. The tool will perform best when the
sanding disc is kept flat against the
workpiece and long, sweeping strokes
are used. Tipping the sander or using
the edges of the pad may produce an
uneven fi nish, cause the tool to over-
heat, and cause the pad to rupture.
Avoid sanding in one spot too long or
applying excessive pressure on the
sander. This causes gashing and depressions in the work surface.
3. Begin your application with a sandpaper
disc applicable to your application and
gradually change to a fi ner grit paper.
You will achieve the best fi nish in the
quickest time if you change the grits of
sandpaper very gradually. For example,
begin with an 80 grit followed by a 120
grit, then a 180 grit and so on. Using too
few grits during an application will take
more time in the long run and will not
produce the best fi nish possible.
Finishing Wood
T o level a rough surface quickly, use a coarse
grit sandpaper disc such as 80 grit. Traditional sanders are usually moved at an angle
to the grain for rough sanding, but random
orbit sanders can be moved in any direction
because of the random orbit feature.
For intermediate sanding, use and intermediate grit sandpaper disc such as 100, 120
or 150 grit.
For fi ne sanding, change to a fi ne grit sand-
paper disc and gradually use fi ner grits until
you achieve the desired fi nish.
Be careful not to run of the end of the wood;
this will round the edge. Always keep the
sander fl at against the work surface.
WARNING
Always wear a dusk mask or respirator and use your sander in a
well ventilated area. Finish sanding
can produce clouds of fi ne dust
that could ignite in the presence of
sparks or open fl ame.
8 9
Removing Paint or Varnish
1. When removing several layers of paint
or varnish, remove as much as possible with a paint solvent or varnish
remover.
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.
2. Select a coarse grit sandpaper disc to
help prevent the sandpaper from clogging.
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:
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 fl ow inside the tool.
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 fl ammable or
combustible solvents around tools.
Repairs
If your tool is damaged, return the entire tool
to the nearest service center.
ACCESSORIES
WARNING
To 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 T ool catalog or go
on-line to www.milwaukeetool.com. T o obtain
a catalog, contact your local distributor or a
service center.
3. Keep the sander moving over new areas
to avoid heating and softening the workpiece. Work in wide, overlapping strokes
to produce a uniform fi nish.
4. As the workpiece begins to show
through the 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.
Cabinets and Doors
Because this tool works in a circular patter,
you can sand joining pieces in any direction
regardless of grain. Begin work with a coarse
grit sandpaper disc and gradually change to
fi ner grit paper for an excellent fi nish.
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 an 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. This warranty does
not apply to damage that MILWAUKEE 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), Ni-Cd battery
packs, Work Lights (cordless fl ashlights), Job Site Radios, and Trade Titan™ Industrial Work
Carts is one (1) year from the date of purchase.
*There is a separate warranty for V™-technology Li-Ion Battery Packs 18 volts or above that
accompany the 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 MILWAUKEE
product. However, proof of purchase in the form of a sales receipt or other information deemed
suffi cient by MILWAUKEE is requested.
ACCEPTANCE OF THE EXCLUSIVE REP AIR AND REPLACEMENT REMEDIES DESCRIBED
HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF EVERY MIL W AUKEE
PRODUCT . IF YOU DO NOT AGREE TO THIS CONDITION, YOU SHOULD NOT PURCHASE
THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY INCIDENTAL,
SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR FOR ANY COSTS, A TT ORNEY
FEES, EXPENSES, LOSSES OR DELAYS ALLEGED T O 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, MIL WAUKEE
DISCLAIMS ANY IMPLIED W ARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE, AND ALL OTHER WARRANTIES.
This warranty applies to product sold in the U.S.A., Canada and Mexico only.
• 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
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