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manual abstract
cutting full sized (9" x 11") sandpaper into 1/4 sheets of 4-1/2" x 5-1/2". b. cutting 1/2 sheet sandpaper into two 4-1/2" x 5 1/2" sheets. Pre-cut 4-1/2" x 5-1/2" sandpaper is available at extra cost. For normal operations, to attach the abrasive paper to your unit: 1. Soften the stiff sandpaper by pulling it over the 90° edge of a table or other straight edge (Fig. 1). Concentrate on softening the edges that will be clamped. 2. Release the front and rear clamps by pulling up on the clamp levers (A) Fig. 2, and disengaging them from the tabs on the base plate. 3. Insert one long edge of the abrasive paper (C) Fig. 4 under the front paper clamp until it contacts the paper-limiting ribs. Close the front paper clamp (B) Fig. 3 and hook it into the lock position behind the tab on the base plate. 4. Stretch the paper over the sanding pad and insert it under the opposite clamp in the same way. 5. If you are using the dust extraction feature, perforate the sandpaper with the provided paper punch (Fig. 5). SWITCH To turn the unit on, depress the "ON" side of the dust protected switch Fig. 6. To turn the tool off, depress the "OFF" side of the switch. PAPER PUNCH Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Be sure the switch is in the "OFF" position. A paper punch (Fig. 5) is provided with your sander to let you perforate regular sandpaper to make dust collection possible. To perforate your sandpaper, install the sandpaper on the tool as instructed in this manual. With the sander turned off and unplugged, place the paper punch on the paper so that the tabs at the edges of the punch are against any two adjacent sides (A) Fig. 5 of the sanding pad. Press the punch against the pad so that the 8 points penetrate the paper. Press the punch into the pad as far as it will go. Remove the paper punch. You can use an alternate method of perforating the paper by fastening the punch to a suitable work surface with #8 flathead screws. Two holes are provided in the punch for this purpose. Press the sander (with the paper attached) on the punch. To operate your sander, grasp it as shown in Fig. 9 and turn it on. Move it in long, sweeping strokes along the surface, letting it do the work. Pushing down on the tool while sanding actually slows the removal rate and produces an inferior quality surface. Be sure to check your work often. This sander is capable of removing material rapidly, especially with coarse paper. Your sander is designed to sand flush on three sides for sanding in corners. Its small size and light weight make it ideal for overhead work. On the final sanding steps, a better finish will result if you sand only with the grain. To produce the best finish possible, start with coarse grit sandpaper and change gradually to finer and finer paper. A final sanding with a piece of well-worn fine sandpaper will produce a professional looking finish that in many cases will need no hand sanding. The rate at which the dust container will fill up will vary with the type of workpiece and the coarseness of the sandpaper. For best results, empty the container frequently and check the opening for debris. When sanding painted surfaces, you may find that the sandpaper loads up and clogs with paint. A heat gun will work much better to remove paint before sanding. FOLLOW ALL SAFETY INSTRUCTIONS IN THE HEAT GUN INSTRUCTION MANUAL. TROUBLESHOOTING For assistance with your tool, visit our website at for a list of service centers, or call the Porter-Cable Customer Care Center at (888) 848-5175. MAINTENANCE KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air. All plastic parts should be cleaned with a soft damp cloth. NEVER use solvents to clean plastic parts. They could possibly dissolve or otherwise damage the material. Wear ANSI Z87.1 safety glasses while using compressed air. FAILURE TO START Should your tool fail to start, check to make sure the prongs on the cord plug are making good contact in the outlet. Also, check for blown fuses or open circuit breakers in the line. LUBRICATION This tool has been lubricated with a suffi cient amount of high grade lubricant for the life of the unit under normal operating conditions. No further lubrication is necessary. BRUSH REPLACEMENT Turn off and unplug the tool before making any adjustments or removing or installing attachments or accessories. Be sure the switch is in the "OFF" position. To replace the brushes, remove the three screws located in the top cap. Remove the top cap. Observe the brush holders (A) in Fig. 10 and the wires leading from the brushes to the motor field. Pull the wires from the motor field. Lift and hold out of the way one of the brush springs. Remove the old brush from the brush holder and discard the brush/wire assembly. Still holding the brush spring out of the way, insert the new brush, release the spring against the back of the brush, and plug the wire i...