DENALI 18V Cordless Sander Instruction Manual

18V Cordless Sander
Instruction Manual

WARNING
Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.

Tool Description

1. variable speed dial
2. Dust exhaust
3. Battery slot
4. Dust bag
5. Backing pad
6. Vacuum adapter
7. Sanding disc
8. Ventilation openings
9. On/off switch

Intended Use

• This tool is intended for smoothing, polishing, cleaning and prepping surfaces (wood, plastic, metal, filler and painted surfaces) with sanding discs.
• This tool is intended to be used indoor and on dry surfaces only. Do not use the tool for wet sanding.
• This tool is intended for private use only.
• Use in well ventilated areas.
• Do not sand materials that has loose knots, splits, defect or foreign objects (e.g. nails, metal, stones).
• Do not sand small or thin hand-held workpieces.

Before First Use

DANGER Risk of suffocation!
Keep any packaging materials away from children and pets — these materials are a potential source of danger, e.g. suffocation.

• Remove all the packing materials.
• Remove and review all components before use.
• Check the tool for transport damages.
• Do not use the tool if it appears damaged.

Preparation

4.1 Attaching the battery pack
Ree Risk of injury!
Switch the tool off before attaching or detaching the battery pack.
NOTICE
Use the tool with a fully charged battery pack that is suitable for this tool. Use this tool only with the provided battery pack (model ABY5197B-00, ABYS197B-OOE, ABYS196B-00, or ABYS196B-00E) and charger. Use of non-compliant battery packs and chargers may cause risk of fire and/or explosion.

1. Align the raised ribs on the battery pack with the battery slot (C} on the tool.
2. Slide the battery pack onto the tool (Fig. 1). The battery pack snaps and locks into place.

Detaching the battery pack

1. Press and hold the battery-release button located on the front o f the battery pack to release it from the battery slot (C).
2. Slide the battery pack upwards off the tool (Fig. 2).

Attaching the dust bag

CAUTION Risk of injury!
Switch the tool off before attaching/detaching the dust bag (D).
Align the rib of the tool with the slot of the dust bag (D), push the dust bag (D) onto the dust exhaust (B) (Fig. 3). The dust bag (D) locks into place with a “click” sound.

Detaching the dust bag

Pull off the dust bag (D) from the dust exhaust (B) to detach it. For maximum efficiency, empty the dust bag (D) frequently during operation.

Attaching/detaching vacuum

CAUTION Risk of fire and damage!
Do not use a regular/standard household vacuum cleaner to extract sanding dust. The dust created during the sanding process is very fine, and it may damage/block the filter  o f the vacuum cleaner. If the dust enters the motor o f the vacuum cleaner, it may cause fire from overheating.
Alternatively, the tool can be connected to a suitable vacuum cleaner/dust extractor instead o f using the dust bag (D).
For users in the United States, directly connect the vacuum cleaner/dust extractor to the dust exhaust (B) (Fig. 4).

For users outside of the United States, use the provided vacuum adapter (F) to connect the vacuum cleaner/dust extractor to the tool (Fig. 5). Twist the vacuum adapter (F) to the dust exhaust (B) until it is firmly attached.

Attaching sanding discs

CAUTION SB Risk of injury!
Switch the tool off before attaching sanding discs (G). Never use the tool without the sanding disc (G) attached.
This kit includes a total of 15 sanding discs (G) of 5 different grit. The grit number is printed on the back of the sanding discs (G) (Fig. 6) (refer to chapter 6.3 Grit number for further details on selecting the most suitable grit for the desired application).

1. Hold the tool upside down.
2. Remove any dust or debris from the backing pad (E).
3. Align the holes o f the sanding disc (G) with the holes on the backing pad (E), then press the sanding disc (G) firmly against the backing pad (E) (Fig. 7).

USE

Before each use

Wear personal protective equipment (PPE). Depending on the application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and full body suit capable o f stopping small abrasive or workpiece fragments (Fig. 8).

• Check the tool and its accessories for damage. Do not use the tool if it is damaged or worn out.
• Check for loose screws, misalignment or binding of moving parts, or any other condition that may affect the operation. If abnormal vibration or noise occurs, switch the  tool off immediately and have the problem corrected before further use.
• Check that the sanding disc (G) and the dust bag (D) or vacuum cleaner are properly and firmly attached to the tool.
• Check the condition of the battery pack. Charge the battery pack if needed. Do not use the battery if it is bulging or hot.
• Always firmly hold the tool by its contours. Keep the tool clean and wear clean gloves to maintain a firm grip while in use.
• Check that the ventilation openings (H) are not obstructed. Obstructed ventilation Openings can cause overheating. Clean the tool with compressed dry air if needed.
• Switch the tool off immediately if bystanders are interrupting the work. Never lay the tool down until the accessory has come to a complete stop. The spinning accessory may grab the surface and pull the tool out of your control.
• Do not work continuously for extensive amounts of time with the tool. Take breaks in between work to ensure full concentration while using the tool.

Adjusting the sanding speed

CAUTION Risk of injury!
Switch the tool off before adjusting the sanding speed.
If it is uncertain which sanding speed it sufficient for the current work on hand, start with a slower speed and test it on a piece of scrap wood or a small, less obvious location  on the workpiece. Adjust and test the speed setting until the desired result is achieved.
Adjust the variable speed dial (A) to increase/decrease the sanding speed of the tool (Fig. 9). Position “1” is the slowest speed and position “6” is the fastest speed.

Switching on/off

To switch the tool on: Set the on/off switch (I) to I position (Fig. 10).
To switch the tool off: Set the on/off switch (I) to O position (Fig. 10).

TIPS

NOTICE
Applying additional pressure slows the motor, rapidly wears sanding disk , and greatly reduces tool speed. Excessive pressure will overload the motor, possibly causing damage from motor overheating and can result in inferior work.

Sanding techniques

• If the surface is rough, begin with lower grit number and then increase the grit number until the surface has reached the desired smoothness. Because the random orbit action is so effective, it is often possible to begin sanding with a medium grit disc and go directly to fine finishing.
• Do not skip more than one grit size when going from lower to higher grit number, and do not sand in one area for too long to avoid uneven results. When the job is completed, gently lift the tool from the workpiece.
• Take the tool off the workpiece before switching it off.
• Prevent the workpiece from sliding by securing it with clamps. Do not attempt to hold a workpiece in place with hands or not at all.
• Move the sander in a steady circular motion, overlapping the strokes by as much as 75 % (Fig. 11).

Wait for the tool to reach its selected speed before starting to sand.
Sanding speed may vary depending on personal preference, the workpiece and the grit. In general, higher speed settings may be used on harder materials and a lower speed  setting on softer materials. The higher the sanding speed, the faster the material is removed from the workpiece. The lower the grit number the faster and more material is  removed when paired with a higher sanding speed.
Apply even pressure on the tool while sanding and make sure the sanding disc (G) is flat and fully in contact with the workpiece to prevent uneven sanding.
Take special care when sanding near edges to avoid accidentally rounding the edges.
Keep pressure even and the tool flat.
Do not press the tool too hard on the workpiece. If the pressure is too high, the rotating speed of backing pad (E) is diminished. Excess pressure can also cause the motor to  work harder and may lead to it overheating. Excessive pressure will result in poor handling, increase vibrations, uneven sanding, and unwanted sanding marks.
Use a pencil to make light marks on the workpiece before sanding. While sanding, use the pencil marks as an indicator to visually gage the uniformity and the progress of the  sanding. This is especially helpful when sanding large workpieces.
When working with plywood, sand lightly, taking care to not sand off the surface layer of wood. Plywood is not the same as solid wood, a layer of wood veneer is glued together and sandwiched between a top and bottom layer of wood. If the plywood is over-sanded, the inner wood veneer layer will appear on the surface.
Hand-sanding with the final grit may produce a smoother finish compared to sanding with the tool.

Abrasive grain types

When purchasing sanding discs for a project, always check the packaging/instructions to see that it is suitable for the intended application.
Use sanding accessories that are high quality.
There are a few types of abrasive grains that are available on the market. They are used for different purposes:

Sanding and polishing wood, soft metals, fiberglass, drywall, painted/primed surfaces
Silicon carbide| Ideal for wood and metal work
Sanding and polishing rough surfaces, hard metals, glass, stone, marble, MDF, cork
Ceramic| Ideal for metal work
Sanding and polishing stainless steel
Zirconium| Belt sanding, power sanding for metal

Grit number

Selecting the correct grit is an important step in achieving optimum results. The higher the grit number the finer the abrasive material i s on the disc. The lower the grit  number the coarser the abrasive material is on the disc. Different grits serves different purposes:

Rough lumber
P 8 0| Hardwood| Starting grit for hardwoods
Shallow scratches
Saw blade burns
P120| Softwood Hardwood| Starting grit for softwoods
Prep for polyurethane and enamel paints
P180| Softwood Hardwood Steel Aluminum| Raised wood grain fibers
Surface irregularities
Prep for latex and acrylics
2nd and 3rd level sanding
Begin surface finishing
Prep for wood stain
P240
Material| Appropriate grit
---|---
| Coarse sanding| Fine sanding
Paintwork| P180| P400
Softwood| P60| P240
Hardwood| P60| P180
Plywood| P240| P320

NOTICE
Switch the tool off and detach the battery pack before cleaning, maintenance, storage, or transportation.
During cleaning do not immerse the tool in water or other liquids. Never hold the tool under running water.

Cleaning the housing

• To clean the tool, wipe with a soft, slightly damp cloth.
• Wipe the tool dry after cleaning.
• Never use corrosive detergents, wire brushes, abrasive scourers, metal or sharp utensils to clean the tool.

NOTICE The tool may be cleaned most effectively with compressed dry air. When doing so, do not exceed the pressure of 43 PSI (3 bar) and always wear safety goggles.
NOTICE Certain cleaning agents and solvents damage plastic parts. Some of these are: gasoline, carbon tetrachloride, chlorinated cleaning solvents, ammonia and household detergents that contain ammonia. Do not use cleaning agents and solvents containing these, as they can damage the tool.

Emptying the dust bag

Empty the dust bag into a waste bin when it becomes 1/3 full (refer to chapters
4.3 Attaching the dust bag and 4.4 Detaching the dust bag).
7.3 Repair
This tool does not contain any parts that can be repaired by the user. Contact a professional repair center or a professional technician to have the tool checked out and repaired.
7.4 Transport
Make sure the tool is secured safely for transit.
Avoid vibrations and shocks.
7.5 Storage
Clean the tool before storing.
Store the tool in its original packaging in a dry area. Keep away from children and pets.

Spare parts/replacement parts

CAUTION XB Risk of injury!
Using parts that are not compatible with the tool may cause accidents that can result in serious injury.

ABY5197B-00, ABY5196B-00
European market and United Kingdom:
ABY5197B-00E, ABY5196B-00E
Battery charger| North American market: ASC5358B-00
European market: ASC5358B-00E
United Kingdom: ASC5358B-00U

Maintenance

CAUTION Risk of injury!
Maintenance performed by unauthorized personnel may result in misplacing of internal wires and components which could cause a serious injury.
Any other servicing than mentioned in this manual should be performed by a professional repair center.
Any other servicing than mentioned in this manual should be performed by a professional repair center.

Frequently Asked Questions

Check if the battery pack is attached to the tool properly.
Check if battery pack of correct type is connected (model ABY5197B-00, ABY5197B-O0E,  ABY5196B-00, ABY5196B-00E).
Faulty on/off switch. Have the switch replaced by a professional repair center.
Unsatisfactory sanding result.| The sanding disk is worn. Replace with a new sanding disk.
The sanding disks not suitable for the workpiece. Use the correct sanding disk.
The tool is over-loaded.| Switch off the tool, wait for a few minutes and try again.
The battery pack is overheated.| Switch off the tool and allow the battery pack to cool before trying again.
The tool speed decreased.| The dust bag is full. For maximum efficiency, empty the dust bag frequently during operation.
Motor is overheated. Clean the ventilation openings.
Motor is overheated. Reduce the pressure on the tool.
Excessive sparking visible through the ventilation openings.| This may indicate the carbon brushes have worn out. Stop using the tool and dispose of the tool appropriately.

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Documents / Resources

| DENALI 18V Cordless Sander [pdf] Instruction Manual
18V Cordless Sander, Cordless Sander, Sander
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References

• Denali

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