Milwaukee 6021-21 User manual

Brand: Milwaukee

Model: 6021-21

Category: Power tools

Type: User manual

Milwaukee 6021-21

The Milwaukee 6021-21 is a heavy-duty 5" random orbit sander that is ideal for a variety of sanding applications, including:

Removing paint and varnish
Smoothing rough surfaces
Polishing metal
Sanding wood

The sander has a variable speed dial that allows you to adjust the speed of the sander from 7000 to 12,000 orbits per minute, so you can choose the right speed for the job at hand. The sander also has a dust bag that collects dust as you sand, so you can keep your work area clean.

Here are some of the key features of the Milwaukee 6021-21:

Powerful 3 amp motor

Milwaukee 6021-21

The Milwaukee 6021-21 is a heavy-duty 5" random orbit sander that is ideal for a variety of sanding applications, including:

Removing paint and varnish
Smoothing rough surfaces
Polishing metal
Sanding wood

Here are some of the key features of the Milwaukee 6021-21:

Powerful 3 amp motor

TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S

MANUAL.

OPERATOR'S MANUAL

HEAVY-DUTY 5" RANDOM ORBIT SANDER

Cat. No.

6021-21

PERSONAL SAFETY

GENERAL POWER TOOL SAFETY WARNINGS

WORK AREA SAFETY

ELECTRICAL SAFETY

• Keep work area clean and well lit. Cluttered or

dark areas invite accidents.

• Do not operate power tools in explosive atmos-

pheres, 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.

• 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 condi-

tions. 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.

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.

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.

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 chil-

dren 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.

• 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

SPECIFIC SAFETY RULES

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.

• 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.

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 spe-

cially designed to ﬁ lter out microscopic particles.

FUNCTIONAL DESCRIPTION

SPECIFICATIONS

Cat.

No.

Volts

Amps

Orbits

Per Min.

Paper

Size

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

1. Air vents

2. Handle

3. On/Off switch

4. Backing pad

5. Dust bag

6. Variable speed dial

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.

READ AND SAVE ALL

INSTRUCTIONS FOR FUTURE USE.

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

150% of the rated amperes.

EXTENSION CORDS

Double Insulated

Amps

Volts

Alternating Current Only

OPM

Orbits Per Minute (OPM)

Underwriters Laboratories, Inc.

United States and Canada

SYMBOLOGY

Recommended Minimum Wire Gauge

For Extension Cords*

Extension Cord Length

Nameplate

Amperes

25' 50' 75' 100' 150'

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

Selecting Sandpaper and Grits

Sandpaper can be made from various grit materi-

als 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

Course

Ideal for initial sanding on

rougher surfaces. For fast

stock removal. Rough sand-

ing and stripping of painted

and rusted surfaces.

100

120

Medium

For intermediate sanding and

removal of minor surface im-

perfections.

150

180

220

Fine

Ideal for ﬁ ne sanding prior to

straining, priming, or sealing.

ASSEMBLY

WARNING To reduce the risk of injury,

always unplug tool before changing or re-

moving accessories. Only use accessories

speciﬁ cally recommended for this tool. Others

may be hazardous.

Attaching Hook-and-Loop Sanding Discs

1. Unplug the sander.

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

with holes in pad, then carefully press fuzzy side

of sanding disc against pad as tightly as possible.

NOTE: Hook-and-loop type sanding discs can

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.

Fig. A

GROUNDING

WARNING Improperly connecting the

grounding wire can result in the risk of elec-

tric 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 appropri-

ate 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 insula-

tion system which satisﬁ es OSHA requirements

and complies with the applicable standards of

Underwriters Laboratories, Inc.,

the Canadian Standard Asso-

ciation and the National Elec-

trical 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. 1

Changing the Sanding

Pad

The sander comes as-

sembled with the hook-

and-loop pad. To attach

the pressure sensitive

adhesive (PSA) pad, you

must first remove the

hook-and-loop pad.

Inspect sanding disc be-

fore 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-and-

loop 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 ad-

hesive (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 back-

ing 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.

Fig. 2

Remove PSA Sanding Disc Before Storage

Do not store the sander with the sanding disc in-

stalled. 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. 3

Fig. 4

Attaching the Sander to a Vacuum

You 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.

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. To lock in place,

rotate the bag until the arrow on the port aligns

with the “lock” symbol on the bag.

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.

OPERATION

WARNING To reduce the risk of injury,

wear safety goggles or glasses with side

shields.

WARNING To reduce the risk of injury,

always unplug tool before attaching or remov-

ing accessories or making adjustments. Use

only speciﬁ cally recommended accessories.

Others may be hazardous.

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.

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 rotat-

ing 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.

To 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.

• Check the workpiece frequently, random orbit

sanders work more aggressively than simple

orbital sanders.

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 recom-

mended 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.

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 work-

piece 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 comple-

tion of a sanding operation and before placing the

sander in storage.

WARNING Collected sanding dust

from sanding surface coatings such as polyu-

rethanes, 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

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, bro-

ken 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 neces-

sary 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, spin-

dles, bearings, housing, etc.)

• Electrical inspection (switch, cord, armature, etc.)

• Testing to assure proper mechanical and electrical

operation

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

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.

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.

Rely only on high-grade power tools on our virtual shelves.

Milwaukee 6021-21 User manual

Brand: Milwaukee

Model: 6021-21

Category: Power tools

Type: User manual

Milwaukee 6021-21

The Milwaukee 6021-21 is a heavy-duty 5" random orbit sander that is ideal for a variety of sanding applications, including:

Milwaukee 6021-21 User manual

Milwaukee 6021-21 User manual

Related papers

Other documents