ETS Series Random Orbit Sanders Supplemental User`s Manual
Contents
1. FESTOO ETS Series Random Orbit Sanders ETS 1251 3 EQ Plus ETS 150 3 EQ Plus ETS 150 5 EQ Plus Supplemental User s Manual WARNING To reduce the risk of serious injury read and understand all safety A precautions and instructions in this manual before using this tool Limited Warranty 30 Day Money Back Guarantee Buy with confidence If you are not completely satisfied return your tool to the selling dealer within 30 days and you will receive a refund of either your purchase price or the lowest retail price at which the same item has been offered since your date of purchase Freight charges are not refundable Service All Inclusive Warranty Festool USA warrants that all new Festool power tools pur chased from authorized dealers in the U S and Canada will be free from defects in materials and workmanship for a term of three years from the date of original retail purchase Conditions of Service All Inclusive Warranty This warranty applies for three years from the date of original retail purchase Proof of purchase is required This warranty is void if the tool is not used operated repaired and maintained in accordance with the tool s instruction manual Excluded from this warranty s coverage are gt Accessories and or attachments including but not limited to saw blades drill bits router bits sanding discs and apparel gt Tools purchased from outside of the U S or Canada gt Repairs2. such as paint stripping or high resin woods gt Aluminum Oxide P40 P3000 gt Synthetic Resin Latex Base Bond gt Semi close Coat The latex base bond provides greater flexibility of the grit coating which makes Titan idea for polishing tasks on solid surface plas tics and finishes The semi closed coat and open leveled top bond result in finer sanding with fewer scratches However with the stearate coating it is not recommended for water borne finishes S400 S4000 gt Silicon Carbide gt Synthetic Resin gt Open Coated gt Foam The tight woven grit base and foam backing makes Platin ideal for a high gloss surface in plastic solid surface and finishes The permeable foam and fiber results in consistent dust extraction across the whole disk and cooler surface temperatures gt Al Ox or Si Carb gt Synthetic Resin gt Stearate Si C A120 A800 The elastic fiber mat with impregnated grit makes Vlies ideal for deep pore cleaning of woods and scouring or de rusting of metals Supplemental Owner s Manual 9 Setup Changing Sanding Pads Each model sander may be used with a variety of sanding pad options It may also be necessary to change sanding pads for different sanding purposes or when they become worn CAUTION Do not use a sanding pad if it no longer holds the sanding disk in place Using a worn pad can result in the sanding disk to fly off the pad and cause injury Sanding pads are consid
3. the brush holder by disconnecting the terminal from the motor winding Otherwise you may skip this step ee ae and ves ee ae Holder 18 warn beyond their usable life If your sander stops working it is likely that the brushes have warn and need replace ment Contact Festool for replacement brushes 5 Insert the new brush into the brush holder WAAAAANG Brush Holder 6 Reconnect the wire terminal if it was previously disconnected 7 Loosely route the wires and the coil approximately as shown 8 While pressing the brush into the brush holder insert the brush holder into the motor tilted downward as shown 9 Continue pressing the brush holder toward the motor until it can rest into its retaining pocket 10 Tuck the coil in neatly along the sander housing and make sure the terminal and coil wires will not be pinched when the cover is replaced Tilt in brush end first ETS Series Random Orbit Sanders 11 With the power switch in the off position lift the switch 16 Make sure the brush coil and the brush wires are tucked rocker straight up off the pivot post in neatly and won t be pinched when the motor is 12 Carefully lift the switch module out of the housing Take replaced care to not let any components snag on wires as you lift 17 Reconnect the switch module wires if they were previ it out ously disconnected 18 Carefully reinsert the switch module by fitting the pins into their socke
4. chemicals or substances known to the State of California and others to cause cancer birth defects or other reproductive harm Some examples of these chemicals substances are lead from lead based paints crystalline silica from bricks cement and other masonry products arsenic and chromium from chemically treated lumber and some wood Sander Overview Intended Use The ETS sanders are designed for dry sanding and polishing of wood plastic metal composite materials paint varnish filler and similar materials The sander must not be used when wet or damp or oper ated in a damp environment for electrical safety reasons Use this sander only for dry sanding The tool should not Technical Specifications gt To reduce the risk of serious injury never alter or misuse the power tool the safety of the power tool is maintained gt Do not use the sander if the sanding pad fails to retain the Sanding disk Replace the sanding pad A loose sanding disk can come free and cause personal injury gt Take care when disposing of fine sanding dust Fine particle dust may become explosive Do not throw sanding dust on an open flame gt Never sand materials containing asbestos dusts especially from hardwoods but also from some soft woods such as Western Red Cedar The 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 ventilate
5. grit the goal is abrasive pad of a non woven fiber impregnated with abra to level the surface With this comes the trade off between sive into the fiber The flexible fiber mesh and 3 dimensional speed versus deeper scratches The key is to choose the abrasive make these ideal for polishing finishes and metal finest of the coarse grits that will provide the leveling ina Surfaces reasonable amount of time and effort Choosing too coarse of a grit may actually increase the amount of sanding later to remove excess scratching The purpose of fine sanding is the removal of previous scratches The key here is to sand only up to the finest grit necessary for the desired finish type The final grit size should be commensurate with the grain or structure size of the material being sanded Metals plastics and finishes for example have a very fine structure and may be sanded to a finer grit Wood on the other hand has a relatively large grain structure and should not be sanded beyond a medium grit unless a burnished finished is desired Burnishing tends to close the wood pores and reduces the absorption of stains Choosing the Appropriate Grit and finishes Selecting the best sanding grit for a task is fairly subjective In Summary you should avoid starting too coarse or finish and depends on the task The adage of working progres ing too fine for the particular material or surface type sively up through the grits is based on the principle
6. leave fewer scratches but the scratches are less visible because each one is different Supplemental Owner s Manual Random Orbit This name random orbit is a slight misnomer because it isn t the eccentric orbit that is random but the disk rota tion that is random The motion of the sanding pad is still considered dual action but the rotational component of the motion is not constrained to follow a strict ratio of the orbits like a gear driven sander The disk rotation is permitted to freewheel about the orbit and this includes even rotating backward at times It is this freewheel motion that permits the sander to be both fairly aggressive but to also leave very few visible scratches Again it isn t because there are fewer scratches but that the scratches are even less visible What makes the rotation of the disk somewhat random is friction with the sanding surface Inertia causes the disk to want to rotate in unison with the orbital motion but friction with the workpiece tempers this motion and causes the disk to speed up slow down or even turn backward a You may have noticed that when hand sanding wood there is more resistance to sanding across the grain than there is with the grain The same is true for a random orbit sander As a result when the orbital motion is moving across the grain the freewheel rotational motion will resist moving across the grain The net result will be more scratches being pa
7. of sandpaper affect its performance These are shown below and explained in the subsequent sections StickFix is a short nap hook and loop system for retaining the sandpaper to the Festool sanding pad The stiff short nap hooks resist heating effects and therefore last longer Backing is the primary substrate for the sandpaper The backing type determines the performance and longevity of the sandpaper Stiffer backings resist the pressure of the individual grit particles and is therefore more aggressive in sanding Softer backings conform to the grit particles more so the result is shallower scratches from the grit particles Paper backing is the most common and economical type and comes in different thicknesses designated by a letter weight of b c d or e with the higher the letter the heavier stiffer the paper Cloth backed disks are the stiffest and intended for extreme usage conditions where long life is important The extra durability makes them ideal for a metal working environ ment but they may also be used for aggressive sanding in woodworking Foam backed disks provide the softest backing for the shal lowest scratches This permits the disk to better contour to the surface being sanded and is ideal for polishing Abrasive is the material that performs the actual sanding or abrasion The two most common types of abrasive mate rial are aluminum oxide and silicon carbide with aluminum oxide being the more common
8. of the two Silicon carbide is a very hard material with very sharp edges Because silicone carbide is so hard it fractures easily and this exposes new cutting edges to the sanding operation This keeps the sandpaper very sharp for cutting hard materials but the grit gets smaller with usage A side benefit of this is that a coarse grit sandpaper will become a finer grit with use which is typically desired in the sand ing process Silicon carbide is best suited for finish sanding where reduced sanding pressure reduces how frequently the grit cleaves Aluminum oxide is almost as hard as silicon carbide but the crystals are pyramid shaped and do not cleave the edges during use The edges aren t as sharp but that is what permits them to last longer This long life is the reason alu minum oxide is one of the most common abrasive materials Grit is the size of the abrasive particles The smaller the grit number the larger the grit particle size Larger grit particles will cut deeper into the sanded surface and therefore more aggressively However the deeper the cut the deeper the scratches This is the reason why sanding is performed with 8 progressively finer grits to remove the scratches left behind from the coarser grits Dispersion Coat is the spacing between grit particles that coat the substrate The term open coat for example means that at least 70 of the substrate is open or uncoated A closed coating mean
9. or replacements not performed by an authorized Festool Service Center outside of routine maintenance as set forth in the instruction manual gt Parts or components not supplied by Festool or that have been modified gt Damage caused by misuse abuse accident impact abnor mal wear and tear improper storage and or exposure to the elements or neglect gt Damage caused by anything other than defects in materials and workmanship gt Normal adjustments and recommended maintenance as set forth in the tool s instruction manual Damage from the operation of the tool at a voltage or fre quency different from the tool s rating including the use of M Ha The following is an exemplar Festool limited warranty The actual warranty that comes with your power tool is controlling N Tool must be returned in complete and whole condition as supplied to include Systainer cutter blade power cord etc 3 For purposes of this warranty power tools are defined as any Festool branded product that bears a serial number S Nr or M Nr 4 To determine if your application is excluded from the warranty under this condition please contact the Festool Service Center at 800 554 8741 Repairs If your Festool power tool requires repair whether it be warranty or non warranty you must contact our Service Liability Statement This product has been built to the high standards of Festool Please do not attempt to operate or repair
10. sure the dust collection vacuum is set for reduced power Too much vacuum will apply too much pressure to the sanding surface Reduce your sanding pressure Too much sanding force reduces the freewheel motion of the Sanding pad which results in sanding swirls With the sander turned off inspect the freewheel motion of the sanding pad If the free wheel seems too stiff apply a thin lubricant such as paste wax between the pad brake and Sanding pad Make sure you are holding the sander level on the work surface Tilting the sander or even applying uneven down force can cause it to jump Reduce sanding pressure and make sure the dust collection vacuum is running at reduced power Inspect the sanding pad for proper installation A loose or misaligned sanding pad can result in runout in the orbital motion Supplemental Owner s Manual 17 Motor Brush Replacement Motor brushes provide electricity to the spinning motor armature and will wear over time The brushes are designed to disconnect power to the motor when they have ETS 125 Motor Brushes WARNING To avoid the risk of electrical shock A make sure the sander is unplugged from power 1 Unplug the sander from power 2 Remove the 2 T15 Torx screws that secure the motor cover and remove the cover Mounting Screws 3 Tilt the rear brush out of its socket and then slide it back away from the motor to remove it 4 If the new brushes come with new brush holders remove
11. the high grit abrasive risk of creating deeper waves is less likely Removing Installing the Pad 1 Unplug the sander for safety 2 For the ETS 125 remove the four T15 Torx screws and remove the pad Mounting Screws 4 10 3 For the ETS 150 using the 5mm hex key stored in the base remove the socket head cap screw from the center of the pad and remove the pad gt During replacement make sure to align the flats on the pad and spindle Changing Sandpaper The sandpaper is held in place with a hook amp loop system and can be changed by simply pulling off the old disk and pressing on a new one However for the integral dust collec tion make sure to align the holes in the sandpaper with the dust extraction inlets in the sanding pad ETS Series Random Orbit Sanders Using the Turbo Collection Bag To install the collection bag on the ETS 150 holder slide the rear flange over the retaining tab and tilt the rear flange to The ETS sander has an integral vacuum blower for self the vertical position contained dust extraction with a turbo collection bag The disposable collection bags are held to the sander with the removable bag holder To install the bag holder slide it over the dust port of the sander and past the alignment pin and then tighten the clamping screw ay 1 i i J 2 ETS 150 ETS 125 Bag Holder Bag Holder Then slide the bag flange over the bag por
12. always desired to begin sanding with the coarsest grit available Avoid starting with too coarse of a grit For example when working with pre planed lumber there should be little need to use a coarser grit that 120 unless there is the need for joint leveling Even with joint leveling only a slightly coarser grit may be called for with coarser grits reserved for joint leveling of wider panels Similarly the highest grit chosen should be commensurate with the type of material and surface finish desired The grit size should be consistent with the grain size of the material Very high grits should be used for achieving a high gloss Surface on paints finishes and plastics However because the grain size of wood is much larger than man made mate rials the highest unfinished sanding grit should be much more limited 14 When sanding bare wood in preparation for applying most surface build finishes a sanding grit of approximately 220 grit should be considered the maximum or even slightly lower for very high build finishes On the other hand for non build finishes or when the bare wood is the final finish then higher grits may be called for Using too high of a grit will tend to burnish the wood With some non build finishes or for bare wood this is desired However for most surface build finishes burnishing can hinder finish penetration of the Surface For colorants and especially pigmented stains the higher the bare woo
13. aving the vacuum set too high will also increase the depth of Sanding scratches and make them more difficult to remove through the higher sanding grits The optimal vacuum power will vary depending on the size of the sander and even the coarseness of the sandpaper with finer grits needing less power To use the dust extraction system slide the vacuum hose over the dust collection port as described on page 13 2 Plug the sander into the electrical receptacle on the front of the dust extractor and turn the power switch to Auto gt When the power switch is in the manual or off position the electrical outlet will not have any power 3 Turn the speed control dial counterclockwise to reduce the power of the vacuum Tool s Power Cord Power Switch Set to Auto 13 Choosing Hand Positions While it may sound trivial on the face of it how you hold the sander plays a pivotal role in the optimal performance of the sander Balance control and comfort are the keys in deciding what hand positions work best for you It is recom mended to spend some time practicing and refining your handhold positions to suit your needs They will vary from user to user but the information below presents the most common starting point for many users The ETS 125 is a palm grip sander and is typically held with one hand on the top of the sander Choose a hand position that is comfortable and well balanced If the sander motion fee
14. complete exclu sion of both surfaces This calls for an oval pattern over lapping onto the lower surface yet focused on the upper Surface Supplemental Owner s Manual little bit when necessary With random orbit sanders anything that diminishes the randomness of the pad rotation increases the occur rence of visible scratches Initial intuition may suggest that slowing down the pad rotation is good but the opposite is true If the pad is not freely spinning then the motion is not random and too much down force is being applied to the Sander NOTE The effect of the vacuum created below the lt sanding pad from the dust extractor will add some downward force to the sander It is important to reduce the power of the dust extractor so it is not applying too much down force on the sander As the joint becomes more level the pattern should switch to perpendicular to the joint in tight overlapping loops Example Wood Panel Joint Leveling In a similar fashion initial leveling should focus on the higher surface but not to the exclusion of the lower surface Some overlap across the joint is required to avoid the likeli hood of creating a slight depression on the high surface just inside the joint As leveling progresses the sanding pattern should become more balanced across the two pieces 15 Example Faceframe Leveling Example Frame to Carcase Leveling While the temptation may be to focus sanding
15. cords for damage or missing prongs gt The motor brushes may have worn and need replacement Please note that the power switch is a sealed pneumatically actuated switch that is not prone to dust ingestion Do not attempt to open the switch Make sure the Plug it cord is properly tightened Inspect the plug and tool power inlet for Signs of overheating If signs of overheating are present discontinue use and have the tool serviced If the Plug it cord shows signs of overheating do not use the cord for other tools as it can damage the inlet of the other tool Make sure the disk is firmly pressed onto the pad To make Sure it isn t a defective disk try using a different disk Make sure the bottom of the pad is clean and free of debris The sanding pad is a wear item and may need replacement Sanding generates heat and heat will degrade the Stickfix hooks on the sanding pad Avoid operations that generate excessive heat such as holding the sander motionless on sharp edges gt gt gt gt gt The most likely cause is that scratches from a coarse grit paper are too deep for the cur rent final grit paper Make sure you don t skip a grit in progression gt Rework the finish with a grit appropriate to remove the scratches and progress to finish grit gt Avoid beginning with too coarse of a grit for the need Begin sanding with a grit only coarse enough to meet the smoothing and leveling needs of the project Make
16. d area and use a properly functioning dust extraction system When the inhalation of dust cannot be substantially controlled i e kept at or near the ambient background level the operator and any bystanders should wear a respirator approved by NIOSH for the type of dust encountered be altered or used for any other purpose other than as specified in these operating instructions Using the tool in contravention to this manual will void your warranty and may lead to injury The user shall be responsible and liable for damages and accidents resulting from misuse or abuse of this sander pT 1285 3 ETS 150 3 ETS 150 5 Power Consumption 200 W 310 W 310 W Motor Speed 6000 14000 rpm 6000 10500 rpm 6000 10500 rpm 3 mm 3 mm 5 mm These specifications are subject to change without notice Supplemental Owner s Manual 5 Functional Description ETS 125 with Turbo Bag ETS 150 with Turbo Bag ETS 150 with Vac Name or Description Ref Page s Power Switch Trigger Trigger Lock ETS 150 Item Name or Description Ref Page s F Dust Collection Port G VacuumHose u H_ Dust Bag Holder 1 Turbo Dust Bag 3_ Pad Change Wrench 6 ETS Series Random Orbit Sanders Plug It Power Port Sanding Pad Item A B Speed Control Dial D E Sanding Action The Festool ETS sander is a random orbit sander which is a form of dual action sander Dual Action is the broader term which encompasses several s
17. d sanding grit the less the colorant will pen etrate the wood In some cases this can even lead to a loss of grain definition in the final finish However this can also be used to an advantage for controlling the intensity of a colorant by using a coarser grit for a darker intensity and a higher grit for a lighter intensity The purpose of progressing through the grits from coarse to fine is so that each successive grit is aggressive enough to remove enough material to remove the scratches of the previous grit while only leaving smaller scratches itself This is most apparent in the coarser grits where the grit scratches are deeper ETS Series Random Orbit Sanders Sanding Techniques Establishing Optimal Sanding Pressure The amount of downward force applied to the sander will have a varying impact on how aggressive the sander will perform but also on the controllability and finish level too More downward force will make the sander operate more aggressively but it will also tend to make the sander more difficult to control and reduce the quality of the finish The general rule for any rotational type sander is to keep mini mal downward force on the sander and let the sander to the work on its own The primary sign that you are applying too much down pressure is that the sander will lurch and jitter as it moves across the sanding surface When this happens reduce the Sanding pressure which even includes lifting the sander a Sand
18. directly over Leveling the joint between a solid wood frame and a ply a frame s joint this should be avoided To reduce the chance wood veneer carcase is one of the most precarious sanding of a depression at the corner a general L shaped pattern operations due to the likelihood of sanding through the thin should be used extending well beyond the joint For more veneer The key is to evenly remove enough of the solid emphasis at the joint a mixture of both short and long wood frame without sanding into the veneer strokes should be used but never just stationary over the While the temptation may be to sand the frame with only the edge of the sanding pad this will invariably result in a slight bevel to the frame Instead keep the center of the pad centered over the frame but held as perfectly parallel to the surface as possible Sand the frame flush and then begin working out into the veneer surface Here are some tips to safely achieving flush joints joint Using a soft wide lead pencil scribble across the veneer near the joint As long as the pencil lines remain you will not be sanding through the veneer gt Use the firmest sanding pad available to avoid rounding the edge of the frame gt Avoid using too coarse of a disk as the veneer can be damaged too quickly if you tilt the sander gt Operate the sander with authority and firm pressure to maintain maximum control but reduce the pressure as Once the
19. e use Many accidents are caused by poorly maintained power tools gt Keep cutting tools sharp and clean Properly maintained tools with sharp cutting edges are less likely to bind and are easier to control gt Use the power tool accessories and tool bits etc in accor dance with these instructions taking into account the working ETS Series Random Orbit Sanders 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 gt Have your power tool serviced by a qualified repair person using only identical replacement parts This will ensure that Specific Safety Rules for Sanders gt Know the material you are sanding and take precautions accordingly Some materials contain chemicals elements or fibers which may be toxic or harmful when abraded Take caution to prevent dust or vapor inhalation and skin contact gt Always perform sanding in a well ventilated area and use personal respiratory protection gt Do not use in wet environments Ingestion of water into the motor may result in electrocution hazard Respiratory Exposure Safety Warnings Substantial or repeated inhalation of dust and other airborne contaminants in particular those with a smaller particle size may cause respiratory or other illnesses Various dusts created by power sanding sawing grinding drilling and other construc tion activities contain
20. epaid if the repair or replace ment is covered under this Limited Warranty FESTOOL SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES REGARDLESS OF THE THEORY OF LAW ON WHICH THE CLAIM IS BASED ALL WARRANTIES IMPLIED BY STATE LAW INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY LIMITED TO THE DURATION OF THREE YEARS SOME STATES IN THE U S AND SOME CANADIAN PROVINCES DO NOT ALLOW EXCLUSIONS LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES AND OR LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE IN THE U S AND FROM PROVINCE TO PROVINCE IN CANADA With the exception of any warranties implied by state or province law as limited above the foregoing limited warranty is exclusive and in lieu of all other warranties guarantees agree ments and similar obligations of Festool No agent representa tive distributor dealer or employee of Festool has the authority to increase or otherwise modify the obligations or limitations of this warranty Warrantor Festool USA Festool Canada USA 888 337 8600 Canada 613 363 0169 Phone 400 N Enterprise Dr Lebanon IN 46052 festoolusa com SAI festoolcanada com SAI Department at 888 337 8600 613 363 0169 Canada for authorization and address detai
21. ered a wear item and should be replaced when the StickFix hook amp loop fibers cannot firmly hold the sanding disk A NOTE Excessive heat from sanding will cause the sanding pads to wear faster To maximize your pad life avoid operations that generate excessive friction and heat such as sanding stationary on a sharp edge or applying too much pressure while sanding Choosing the Correct Sanding Pad Sanding pads come in different grades of hardness soft ness for improved performance for different sanding tasks The hardness or softness of the sanding pad determines how much the sanding pad conforms to the surface being sanded A harder sanding pad is best for course sanding on flat sur faces The firmer pad resists creating a wavy surface where there are softer and harder portions of the wood fiber This is especially important with woods that have a wide spacing in their annular growth rings or significant differences in the density of the wood fiber between rings A slightly softer sanding pad is best used for progressively finer sanding of the workpiece This permits the pad to slightly conform to the surface to ensure previous grit sand ing marks are removed but is less prone to creating a wavy surface because the grit is less aggressive Similarly a very soft sanding pad is best used for fine sanding or sanding of finishes Having greater conformance to the very small waves in the surface is desired and with
22. g in any way Do not use any adapter plugs with earthed grounded power tools Unmodified plugs and matching outlets will reduce risk of electric shock gt 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 gt Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock gt Do not abuse the cord Never use the cord for carrying pull ing 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 gt When operating a power tool outdoors use an extension cord suitable for outdoor use Use of a cord for outdoor use reduces the risk of electric shock Personal Safety gt Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury gt Use personal protective equipment Always wear eye pro tection Protective equipment such as dust mask non skid safety shoes hard hat or hearing protection used for appro priate conditions will reduce personal injuries gt Prevent unintentional starting Ensure the switch is in the off positi
23. g should be carried out only by an authorized Customer Service Center see your dealer for information on locating a service center CAUTION Any maintenance or repair work that Routine Maintenance Dust and debris from some materials can be extremely abrasive and cause components within the sander to wear prematurely It is important to keep moving parts cleared of abrasive dusts debris Even soft wood dust can be abrasive over time Examine all moving parts for dust and debris gt Sanding pads are considered a wear item and will need to be replaced periodically Replace the pad when it no gt AS a general rule keep the sander clean of all dust and longer holds sanding disks in place Troubleshooting Symptom Possible Causes Motor does not start Sander runs sporadically or looses power Sanding disk doesn t stick or flies off during sanding Deep scratches in finish sanding Excessive swirl marks Sander jumps or is hard to control gt Check that the cord is properly plugged into an outlet gt Make sure the Plug it connector is properly inserted and fully tightened gt Make sure the outlet has power Check the circuit breaker or try another outlet gt If used with a Festool dust extractor make sure the selector switch is pointing to Auto The auxiliary outlet on the dust extractor has power only when the selector is at Auto gt Inspect the power cord including extension
24. ing Pattern and Movement One key to achieving a quality sanded finish is to establish an effective and smooth sanding pattern for moving the Sander across the workpiece Different patterns and speeds of motion will be optimal for different material types and even different grits of sand paper Because the sanding pad is moving in a clockwise dual motion a general clockwise sanding pattern produces the least resistance to movement and therefore the smoothest pattern As much as possible make your motions and direc tion changes in a general clockwise direction For homogenous materials that do not have a discernible grain direction such as metals plastics solid surface and finishes a circular pattern may be best These types of pat terns do not have a stopping or sharp transition point where the direction of the sander is abruptly changed For materials with an inherent grain structure such as wood and even some plastics the sander motion should be kept generally in line with the grain as much as reasonably pos sible This leads to a linear back and forth motion but the transitions for changing direction should be as smooth as possible without an abrupt stop start Example Solid Surface Joint Leveling Solid surface material has a non oriented grain structure It is therefore best to sand in a generally circular pattern For initial leveling sanding emphasis should be applied to the higher of the two surfaces but not to the
25. joints are leveled the entire frame should be the joint gets closer to flush sanded but this too should have a pattern While not as Avoid the tendency to tilt the sander away from the critical the general approach is to sand those frame mem veneer as this will create a bevel on the frame bers which are captive between other frame members first In other words sand the horizontal rails first followed by the vertical stiles This results in your longer sanding strokes covering over the previous transitions from the end of the short strokes gt As the joint gets close to flush expand your strokes to include more of the veneer surface and continue sanding until the pencil marks are gone 16 ETS Series Random Orbit Sanders Maintenance and Adjustment WARNING To reduce the risk of electrocution or NOTICE Do not use compressed air to clean the A motor housing of the tool as you could inject for eign objects into the motor through the ventilation openings other personal injury always unplug the tool from the power supply outlet before performing any maintenance or repair work on the tool NOTICE Certain cleaning agents and solvents are harmful to plastic parts Some of these include but are not limited to Gasoline Acetone Methyl Ethyl Ketone MEK Carbonyl Chloride cleaning solutions containing Chlorine Ammonia and household clean ers containing Ammonia requires opening of the motor or gear hous in
26. ls use or misuse of this equipment Festool assumes no liability for incidental special or consequential damage of any kind Equipment specifications applications and options are subject to change at the sole discretion of Festool without notice Festool is a trademark and service mark of TTS Tooltechnic Systems AG amp Co KG Plug It and Systainer are registered trademarks of TTS Tooltechnic Systems AG amp Co KG www festoolusa com ETS Series Random Orbit Sanders Contents About This Manual ssssssssnunnnnnnnnnnnnnnnnnnnnnnnnnn 3 GUND sis i 10 TOO S VIN DONS arrire ipi r rn AE AAN Changing Sanding PadsS cccccccceeeeeeeeeeeeeeaaes 10 General Power Tool Safety Warnings Choosing the Correct Sanding Pad 10 Work Area Safety ccccccccceeeeeeensseceeseeeennnnnns Changing Sandpaper ccc e cece cee eeeeee ee eee eeeeaees 10 Electrical Safety siscccicacvaiencaaaesvectaventanasderaxainan Using the Turbo Collection Bag sssssssesssssssss 11 Personal Safety saiceccccnssexnanasneseseasenenusaddesaustans Connecting a Dust Extractor sssssssssrsrsssesen 11 Power Tool Use and Care cccc cece ee eeeeen eee eeeees Connecting the Plug It Power Cord 85 12 DCI VICE arpe AA E Setting the Variable Speed cccccec cece eee eeeee 12 Specific Safety Rules for Sanders s ssssssesererersesu Turning on the Sander sssssesesssssssrensnsnrrsrrsnne 12 Respira
27. ls jittery it is a sign that it is not being held balanced and level with the sanded surface The ETS 150 is a combination pistol grip and palm grip sander It can be held one handed or two or from the pistol grip palm grip or both Regardless which type of grip is used it should be balanced with respect to the pressure on the sanding pad When experimenting with different hand grips use varying Sandpaper grits The goal is to hold the sander in such a way that balance and control are achieved which results in the smoothest motion of the sander as you move it about the workpiece Here are some signs that your grip on the sander is not balanced gt Uneven resistance to movement If the sander resists more in one direction than the opposite direction itis a sign that you are slightly tilting the sander gt If you experience excessive jumping and jitter it means your grip is not balanced you re moving too fast and you are applying too much down force to the sander Working With Sanding Grits Generally speaking the sanding process begins with the coarser grits and progresses up to the finer grits However not all sanding tasks are the same So choosing which grits to use will vary depending on the task The adage of pro gressing through the grits holds true for nearly all sanding but where to begin and where to end isn t always clear While the coarsest grits provide rapid material removal and leveling it isn t
28. nsidered one of the most important Pad Brake Pad brakes reduce the freewheeling motion of the sanding pad when the sander is not in contact with the workpiece This prevents gouging of the wood when the sander first contacts the surface During sanding however the pad brake should have a minimal impact on pad rotation A new sander will contain a thin lubricating film between the Sanding pad and the pad brake This prevents the pad brake from being too aggressive in reducing the motion of the Using Dust Extraction Using dust extraction on an ETS sander isn t just a matter of keeping the work area clean or protecting your health which of course is very important The sander itself is spe cifically designed to perform best when used with either the on board Turbo collection bag or with a workshop vacuum Sanding wouldn t be very effective if a layer of sanding dust was permitted to accumulate between the sanding pad and the sanded surface Festool sanders incorporate Airstream technology to help get the sanding dust away from the sanding surface as efficiently as possible With traditional sanding pads dust accumulates at the center of the disk because it can t get drawn out by the vacuum Airstream technology creates airflow from the center of the pad radially outward to the dust extraction holes as well as the normal airflow from the perimeter This keeps the dust clear and allows the sanding grit to work on the sanding Su
29. of each finer grit removing the scratches that the coarser grit leaves behind Best Sandpaper for the Task gt Aluminum Oxide P40 P220 The heavy weight paper backing and strong top bond make this gt e Wt Paper Sandpaper very good for long lasting use on bare wood metal and gt Synthetic Resin auto body fillers gt Closed coat gt Aluminum Oxide P40 P1500 gt Synthetic Resin Closed coat The non wax stearated coating and lighter paper weight make this a very good universal sandpaper for finished and unfinished wood metal plastic solid surface and composite materials The high density closed coat grit is more uniform for reduced scratches gt Aluminum Oxide P40 P400 gt Synthetic Resin gt Closed coat The lighter weight paper and thinner top bond results in shallower scratches for good sanding results in harder woods finishes and paints The open leveled top bond and anti static coating loads less when sanding finishes gt Aluminum Oxide P24 P100 gt Cloth backing gt Semi close Coat gt Closed leveled The cloth backing semi closed coating and closed leveled bond make these disks very durable workhorses for sanding and leveling on hard wood metal fiberglass and reinforced plastics gt Aluminum Oxide P40 P120 gt Phenolic Resin gt Open coat The broad open coat dispersion of this disk makes it ideal for aggressive sanding without loading on clog prone materials
30. on before connecting to power source picking up or carrying the tool Carrying power tools with your finger on the switch or energizing power tools that have the switch on invites accidents gt Remove adjusting key or wrench before turning the power Power Tool Use and Care gt 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 is designed gt 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 gt Disconnect the plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally gt Store idle tools out of reach of children and do not allow persons unfamiliar with the power tool or these instructions A Save all warnings and instructions for future reference tools create sparks which may ignite the dust or fumes gt Keep children and bystanders away while operating a power tool Distractions can cause you to lose control gt If operating a power tool in a damp location is unavoidable use a ground fault circuit interrupter GFCI protected supply Use of a GFCI reduces the risk of electric shock gt Never use an extension cord that is damaged including cuts exposed wires o
31. r bent missing prongs Damaged extension cords increase the risk of fire or electric shock gt Use only extension cords rated for the purpose gt Use only extension cords rated for the amperage of this tool and the length of the cord Using too small of an extension cord can cause the cord to overheat Extension Cord Ratings Cord Length Size AWG lt 50 Ft 14 50 100 Ft gt 100 Ft Not recommended tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury gt Do not overreach Keep proper footing and balance at all times This enables better control of the tool in unexpected situations gt Dress properly Do not wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts If devices are provided for the connection of dust extrac tion and collection facilities ensure these are connected and properly used Use of dust collection can reduce dust related hazards gt Always wear safety glasses complying with ANSI Z87 1 Ordinary glasses are not proper protection to operate the power tool Power tools are dangerous in the hands of untrained users gt 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 befor
32. rallel to the wood grain than across the grain Unlike a singular orbital motion orbital sander or a singu lar rotational motion grinder whose scratch patterns will be circular a random orbital scratch pattern will be more V shaped and in the direction of the wood grain Because these are less geometric in shape they are less visible to the eye The tighter this V shape the less noticeable the scratches will be Y Y Random Orbit Scratch Patterns Orbital Scratch Patterns Grinder Scratch Patterns Optimizing Random Orbit Optimizing the sanding doesn t remove the number of scratches it just makes them less visible to the eye The least visible scratches are those that are not geometric and are in line with the wood grain Both of these conditions are optimized by letting the friction between the sanding pad and sanded surface control the rotation of the sanding disk Many operators will apply excessive downward pressure to the sander to slow down the freewheel motion of the pad but this will increase the amount of friction and make the scratches more geometric and more visible Instead using a light pressure allows the cross grain friction to be larger than the in line friction and the ideal scratch pattern shown above will be the result The best random orbit motion is when the sanding pad has very little pressure and is permitted to freewheel on its own f Anatomy of Sandpaper The various parts
33. rface Dust Extraction Makeup Air Passage With HEPA filtration auto start and variable speed Festool dust extractors are ideally suited for use with ETS sanders The variable speed is of particular importance because it permits adjusting the power of the vacuum for the optimal performance of the sander Too high of a vacuum pressure Supplemental Owner s Manual stages of any type of project because it is often the first stage of the finishing phase Even given its great impor tance the nuances of sanding are often overlooked and it is viewed as more of a chore than a productive aspect of the overall project Discovering the optimal nuances of your sander will help you get the most out of your sander but may take some practice and learning Sanding pad when the pad and brake are new and dust free As the sander is used buildup of fine dust particles act as an interface lubricant Although not required for normal operation if you feel the pad brake is not slipping enough during normal sanding you may wish to apply a lubricant such as paste wax between the pad and brake can suck the sander tight to the workpiece which reduces sanding quality and diminishes controllability of the sander For best results the power of the vacuum should be reduced below maximum A sign that the vacuum is too strong is a lack of controllability with excessive jumping and jitter in the movement of the sander across the workpiece H
34. s cccccceeesseeseeneeees 20 About This Manual Save These Instructions It is important for you to read and understand this manual The information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS The symbols below are used to help you recognize this information WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a potential situation which if not avoided can result in property damage or damage to the tool Note Indicates information notes or tips for improving your success using the tool Tool Symbols V Volts W Watts Hz Hertz Alternating Current AC n No load Speed Class II Double Insulated Supplemental Owner s Manual 3 General Power Tool Safety Warnings A WARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury Work Area Safety gt Keep your work area clean and well lit Cluttered or dark work areas invite accidents gt Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power Electrical Safety gt Power tool plugs must match the outlet Never modify the plu
35. s that the substrate is nearly fully coated and a semi open coat falls somewhere in between the two The dispersion is most noticeable in the coarser grits where an open coat results in visible exposure of the substrate see image below A more open dispersion leaves more room for sanding dust called swarf to clear the sanding grit to avoid buildup and clogging but also permits the grit to penetrate deeper into the sanded workpiece leaving deeper scratches E Open Coat T Sandpaper Base Bond and Top Bond is the material and or method for adhering the abrasive to the backing material The grit material is impregnated into the bonding agent to slightly encapsulate the grit material for better adhesion and less fracturing of the grit The thickness of the top bond is called the level ing as it tends to fill in the valleys and level the bond coating An open leveled top bond is lighter and leaves deeper valleys to permit greater swarf removal Open Leveled 45 A closed leveled top bond is thicker and fills in the valleys but provides a stronger bond of the abrasive grit particles The prevents the grit from breaking loose from the substrate for longer lasting durable abrasive proper ties but may clog faster when sanding materials that generate more swarf ETS Series Random Orbit Sanders Non Woven Fiber Vlies pronounced fleece is a special For initial stages of sanding with a coarse
36. sconnect the wire terminal from the motor winding 20 11 12 13 14 9 Remove the brushes from their brush holders 10 While inserting the new brushes in their brush hold ers compress the spring so the contact plate remains straight Fully compress the brush into the holder to help ensure that the contact plate remains straight and is resting against the rear wall of the holder Insert the brush holder into the motor with the brush tilted downward toward the motor commutator Continue pressing the brush holder toward the motor until it can rest into its retaining pocket Reconnect the brush wires to their terminals Carefully replace the control module over the alignment pins in the motor housing Tuck in all wires ETS Series Random Orbit Sanders Notes Supplemental Owner s Manual 21 FES TOOL Tools for the toughest demands Festool USA 400 N Enterprise Blvd Lebanon IN 46052 www festoolusa com Service Questions 800 554 8741 Application Questions 888 337 8600
37. t until it seats against the front of the bag holder ETS 150 To install the collection bag on the ETS 125 holder slide the Connecting a Dust Extractor rear flange over the retaining tab and then slide the bag The dust port on the back of the sander connects to a flange over the bag port a Festool 27mm vacuum hose To connect the hose rock it ETS 125 back and forth over the ribs while pressing inward Supplemental Owner s Manual Connecting the Plug It Power Cord The sander comes equipped with a removable Plug It power cord The cord can be removed for easier storage of the tool To install the power cord insert the cord into the inlet port on the tool with the key and keyway aligned and twist the locking ring turn until it clicks Reverse the procedure to remove the cord NOTICE Make sure to fully tighten the plug it cord a full quarter turn until it clicks If the plug is not fully locked the socket and cord can overheat and be damaged NOTE The 18 gauge plug it cord is interchangeable with other tools that use the same size cord but it cannot be used with larger tools such as routers and saws The plug has an extra key to prevent it from being used on a larger tool that would otherwise damage the cord Larger cords may be used with Smaller tools but not the reverse a n a aq a Key amp Keyway Locking Ring Turning on the Sander For best control and sanding results
38. the sander should be placed on the sanding surface with no downward pressure before turning it on and lifted from the surface before turning it off The ETS sanders have soft start circuitry so there will be a slight delay before the sander reaches the set motor speed To turn on the ETS 150 pull up on the power trigger and release to turn the sander off To lock the trigger in the on position press in on the trigger lock and then release the trigger Pulling up on the trigger again will release the trigger lock To turn on the ETS 125 sander toggle the power switch to the on position To turn the sander off toggle the power switch to the off position 12 Setting the Variable Speed The speed of the sander is adjustable with the speed control dial Most operations are best performed at full speed but a lower speed can sometimes improve control or reduce aggressiveness for finer operations such as polishing or buffing The speed may be adjusted with the motor either on or off The slowest speed is 1 and the highest speed is 6 ETS Series Random Orbit Sanders Operation Aside from installing sandpaper your ETS sander is ready to use right out of the box There is no special setup adjust ment or break in procedure required before using your Sander However new users may want to practice with the sander to become familiar with its operation function and even the best way to hold the sander Sanding is frequently co
39. this equipment with out adequate training Any use operation or repair in contra vention of this document is at your own risk By acceptance of this system you hereby assume all liability consequent to your Proprietary Notice All drawings and information herein are the property of Festool TTS Tooltechnic Systems AG amp Co KG All unauthorized use and reproduction is prohibited Written and Illustrated by Rick Christopherson 2014 TTS Tooltechnic Systems AG amp Co KG Festool USA is a division of Tooltechnic Systems LLC 2 gt Damage resulting from the use of any non Festool accessories or attachments gt Tools used in high volume industrial applications4 Should any failure covered by this Limited Warranty occur the purchaser must contact Festool through our website www festoolusa com SAI or call 888 337 8600 for authorization and shipping information For purchases made in Canada contact our website www festoolcanada com SAI or call 613 363 0169 Festool in its sole discretion may elect to repair replace or refund the purchase price of any tool covered by this Limited Warranty that is found to be defective at no cost to the pur chaser Warranty returns will be processed by Festool according to normal work flow and availability of replacement parts and components Festool will issue a prepaid shipping label for return of the tool to the Festool Service Center and will also return the repaired tool freight pr
40. tory Exposure Safety WarningS ssse0s 5 QPEraHON sidnve cece cincerccisncsievinvewsrs wcatieneserescnnss 13 Sander OVErvieW scscccccccccccnnnneseeeeseseeessnnneeeenes 5 POG ADI KC iach ntsacinea ean sassatee E E 13 Intended USC cc citictarscnwnesariestadwaanioasehmareanarteeboind 5 Using Dust Extraction 0 ccc cece ccce eee eeee eee eeeee 13 Technical SpecificationS cccceeeeseeeeeeeeeeeeeeeenaes 5 Choosing Hand Positions cccceeeeee eee eee eeeeees 14 Functional Description cccceeeeeeeeeessennneneeeses 6 Working With Sanding Grits cc cc eeeee eens 14 Sahin ACHO ereraa 7 Sanding TechniqueS sssssssssssssssssensnsnesrsses 15 PUGFACHO ciwiastaandnartacersiatinnpiesainiworeeeamnsnisas 7 Establishing Optimal Sanding Pressure 15 RaNGOM OFDIE asctanatwacipsacisanianasaetaaaaaneeeiasanann 7 Sanding Pattern and Movement seeeeeee 15 Optimizing Random Orbit cccceeseeeeeeeeeeeeeeee 7 Maintenance and Adjustment cccsssssceennnnees 17 Anatomy Of Sandpaper ccceeeeseeeeeeeeeeeeeeeeeenees 8 Routine Maintenance cc ccce eee ee eee eee ee eeee eens 17 Choosing the Appropriate Grit ccceeeeeeeee 9 TWOUDIGSNOOUNG sicschivantanutanmivegtecumanesesiabananies 17 Best Sandpaper for the Task cccccesseeeeeeeeeees 9 Motor Brush Replacement cccceeeeeeeeeeeeeenees 18 ETS 125 Motor Busnes siscsisiovessastaasesecveesnnats 18 ETS 150 Motor Brushe
41. ts Switch Module 13 Move the switch module out of the way If desired remove the control board and motor winding wires 19 Replace the switch rocker 20 As you replace the motor cover make sure no wires are pinched between the motor housing and the cover Refer to the image below for final wiring coil and component placement 14 Tilt the front brush out of its socket and then slide it back away from the motor to remove it 15 Install the new brush into the brush holder in the same manner you did for the rear brush and reinstall the brush holder Supplemental Owner s Manual 19 ETS 150 Motor Brushes WARNING To avoid the risk of electrical shock 7 Tilt the front brush out of its socket and then slide it back away from the motor to remove it 8 Disconnect the wire terminal from the motor winding make sure the sander is unplugged from power 1 Unplug the sander from power 2 Remove the 4 T15 Torx screws that secure the motor cover and remove the cover Mounting g Screws i 3 Before beginning make note of the control module wire routing for later replacement 4 Carefully lift the control module straight up while simul taneously freeing the wires from the their clips Move the module to the side to access the brushes Th Fa T sy a ree pete ay k 5 Tilt the rear brush out of its socket and then slide it back away from the motor to remove it 6 Di
42. ubset types of motion which includes gear driven and random orbit types Sanding is defined as scratching or abrading a surface So when we discuss scratches and scratch patterns the goal is to minimize them or make them less visible to the eye but they will always be present Dual Action Dual action means that the sanding pad moves in two distinct motions simultaneously The primary motion is an eccentric orbit similar to the motion of a bicycle pedal The center of the sanding disk moves in a small eccentric circle about the center of the at sander The diameter of this orbital path ranges from 2mm to 5mm depending on the model sander Refer to Technical Specifications on page 5 The second motion is the rotation of the disk about the disk s center Because the sanding disk is eccentric to the machine center so is this path of rotation The effect of this dual motion is that each point on the sanding pad traces out a geometric shape called a roulette You may be familiar with this shape from the children s drawing toy Spirograph The exact shape of this roulette depends on the ratio between the orbital radius and the radius of the pad rotation This means that each part of the sanding pad traces out a slightly different shape This minimizes the visibility of the scratch patterns on the wood because each part of the sanding disk leaves slightly differ ent scratch shapes Dual action sanders don t
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