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5
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 out-
let, properly installed and grounded
in accordance with all codes and or-
dinances. 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 Elec-
trical Code. Double In-
sulated tools may be
used in either of the 120
volt outlets shown in
Figures B and C.
Fig. B
Fig. C
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
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.
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
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.
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 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 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
60
80
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.
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 cush-
ion.
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 sandpa-
per. 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