Milwaukee 2460-21, 2460-20 User Manual
Cat. No.
No de cat.
2460-20
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
M12™ CORDLESS ROTARY TOOL
OUTIL ROTATIF SANS FIL M12™
HERRAMIENTA ROTATORIA INALÁMBRICA M12™
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S
MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET BIEN
COMPRENDRE LE MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y ENTENDER EL
MANUAL DEL OPERADOR.
GENERAL POWER TOOL SAFETY WARNINGS
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.
The term "power tool" in the warnings refers to your mains-operated (corded) power tool or
battery-operated (cordless) power tool.
• Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, 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 conditions. 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.
• 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.
Save all warnings and instructions for future reference.
WORK AREA SAFETY
ELECTRICAL SAFETY
• Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
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.
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
preventive safety measures reduce the risk of
starting the power tool accidentally.
• Store idle power tools out of the reach of children 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
PERSONAL SAFETY
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.
BA TTER Y T OOL USE AND CARE
• Recharge only with the charger specifi ed by
the manufacturer. A charger that is suitable for
one type of battery pack may create a risk of fi re
when used with another battery pack.
2
• Use power tools only with specifi cally desig-
nated battery packs. Use of any other battery
packs may create a risk of injury and fi re.
• When battery pack is not in use, keep it away
from other metal objects like paper clips,
coins, keys, nails, screws, or other small metal
objects that can make a connection from one
terminal to another. Shorting the battery termi-
nals together may cause burns or a fi re.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact
accidentally occurs, fl ush with water. If liquid
contacts eyes, additionally seek medical help.
Liquid ejected from the battery may cause irritation
or burns.
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.
SPECIFIC SAFETY RULES
Safety Warnings Common for Grinding, Sanding, Wire Brushing, Polishing, Carving or Abrasive Cutting-Off Operations:
• This power tool is intended to function as a
grinder, sander, wire brush, polisher, carving or cut-off tool. Read all safety warnings,
instructions, illustrations and specifi cations
provided with this power tool. Failure to follow
all instructions listed below may result in electric
shock, fi re and/or serious injury.
• Do not use accessories which are not specifi -
cally designed and recommended by the tool
manufacturer. Just because the accessory can
be attached to your power tool, it does not assure
safe operation.
• The rated speed of the accessory must be at
least equal to the maximum speed marked on
the power tool. Accessories running faster than
their rated speed can break and fl y apart.
• The outside diameter and the thickness of your
accessory must be within the capacity rating
of your power tool. Incorrectly sized accessories
cannot be adequately controlled.
• The arbour size of wheels, sanding drum or any
other accessory must properly fi t the spindle
or collet of the power tool. Accessories that do
not match the mounting hardware of the power
tool will run out of balance, vibrate excessively
and may cause loss of control.
• Mandrel mounted wheels, sanding drums, cutters or other accessories must be fully inserted
into the collet or chuck. The “overhang” or the
length of the mandrel from the wheel to the
collet must be minimal. If the mandrel is insuf-
fi ciently held and/or the overhang of the wheel is
too long, the mounted wheel may become loose
and ejected at high velocity.
• Do not use a damaged accessory. Before each
use inspect the accessory such as abrasive
wheels for chips and cracks, sanding drum
for cracks, tear or excess wear, wire brush for
loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install
an undamaged accessory. After inspecting and
installing an accessory, position yourself and
bystanders away from the plane of the rotating
accessory and run the power tool at maximum
no-load speed for one minute. Damaged acces-
sories will normally break apart during this test
time.
• Wear personal protective equipment. Depending on application, use face shield, safety
goggles or safety glasses. As appropriate,
wear dust mask, hearing protectors, gloves
and workshop apron capable of stopping small
abrasive or workpiece fragments. The eye pro-
tection must be capable of stopping fl ying debris
generated by various operations. The dust mask
or respirator must be capable of fi ltrating particles
generated by your operation. Prolonged exposure
to high intensity noise may cause hearing loss.
• Keep bystanders a safe distance away from
work area. Anyone entering the work area
must wear personal protective equipment.
Fragments of workpiece or of a broken accessory
may fl y away and cause injury beyond immediate
area of operation.
• Hold power tool by insulated gripping surfaces
only, when performing an operation where the
cutting accessory may contact hidden wiring
or its own cord. Cutting accessory contacting a
"live" wire may make exposed metal parts of the
power tool "live" and could give the operator an
electric shock.
• Always hold the tool fi rmly in your hands dur-
ing the start-up. The reaction torque of the motor,
as it accelerates to full speed, can cause the tool
to twist.
• Use clamps to support workpiece whenever
practical. Never hold a small workpiece in one
hand and the tool in the other hand while in
use. Clamping a small workpiece allows you to use
both hands to control the tool. Round material such
as dowel rods, pipes or tubing have a tendency to
roll while being cut, and may cause the bit to bind
or jump toward you.
• Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or
snagged and your hand or arm may be pulled into
the spinning accessory.
•
Never lay the power tool down until the accessory has come to a complete stop. The spinning
accessory may grab the surface and pull the power
tool out of your control.
• After changing the bits or making any adjustments, make sure the collet nut, chuck or any
other adjustment devices are securely tightened. Loose adjustment devices can unexpect-
edly shift, causing loss of control, loose rotating
components will be violently thrown.
• Do not run the power tool while carrying it at
your side. Accidental contact with the spinning
accessory could snag your clothing, pulling the
accessory into your body.
• Regularly clean the power tool’s air vents. The
motor’s fan will draw the dust inside the housing
and excessive accumulation of powdered metal
may cause electrical hazards.
3
• Do not operate the power tool near fl ammable
materials. Sparks could ignite these materials.
• Do not use accessories that require liquid
coolants. Using water or other liquid coolants
may result in electrocution or shock.
Kickback and Related Warnings
Kickback is a sudden reaction to a pinched or
snagged rotating wheel, sanding band, brush or
any other accessory. Pinching or snagging causes
rapid stalling of the rotating accessory which in turn
causes the uncontrolled power tool to be forced in
the direction opposite of the accessory’s rotation
at the point of the binding.
For example, if an abrasive wheel is snagged or
pinched by the workpiece, the edge of the wheel
that is entering into the pinch point can dig into
the surface of the material causing the wheel to
climb out or kick out. The wheel may either jump
toward or away from the operator, depending on
direction of the wheel’s movement at the point of
pinching. Abrasive wheels may also break under
these conditions. Kickback is the result of power
tool misuse and/or incorrect operating procedures
or conditions and can be avoided by taking proper
precautions as given below.
• Maintain a fi rm grip on the power tool and
position your body and arm to allow you to
resist kickback forces. The operator can control
kickback forces, if proper precautions are taken.
• Use special care when working corners, sharp
edges etc. Avoid bouncing and snagging the
accessory. Corners, sharp edges or bouncing
have a tendency to snag the rotating accessory
and cause loss of control or kickback.
• Do not attach a thin toothed saw blade. Such
blades create frequent kickback and loss of control.
• Always feed the bit into the material in the
same direction as the cutting edge is exiting
from the material (which is the same direction
as the chips are thrown). Feeding the tool in the
wrong direction causes the cutting edge of the bit
to climb out of the work and pull the tool in the
direction of this feed.
• When using steel saws, cut-off wheels, highspeed cutters or tungsten carbide cutters,
always have the work securely clamped. These
wheels will grab if they become slightly canted
in the groove, and can kickback. When a cut-off
wheel grabs, the wheel itself usually breaks. When
the steel saw, high-speed cutters or tungsten
carbide cutter grab, it may jump from the groove
and you could lose control of the tool.
Safety Warnings Specific for Grinding and
Abrasive Cutting-Off Operations:
• Use only wheel types that are recommended
for your power tool and only for recommended
applications. For example: do not grind with
the side of a cut-off wheel. Abrasive cut-off
wheels are intended for peripheral grinding, side
forces applied to these wheels may cause them
to shatter.
• For threaded abrasive cones and plugs use
only undamaged wheel mandrels with an
unrelieved shoulder fl ange that are of correct
size and length. Proper mandrels will reduce the
possibility of breakage.
• Do not “jam” a cut-off wheel or apply excessive
pressure. Do not attempt to make an excessive
depth of cut. Overstressing the wheel increases
the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of
kickback or wheel breakage.
• Do not position your hand in line with and
behind the rotating wheel. When the wheel, at
the point of operation, is moving away from your
hand, the possible kickback may propel the spinning wheel and the power tool directly at you.
• When wheel is binding or when interrupting a
cut for any reason, switch off the power tool
and hold the power tool motionless until the
wheel comes to a complete stop. Never attempt
to remove the cut-off wheel from the cut while
the wheel is in motion otherwise kickback may
occur. Investigate and take corrective action to
eliminate the cause of wheel binding.
• Do not restart the cutting operation in the
workpiece. Let the wheel reach full speed and
carefully reenter the cut. The wheel may bind,
walk up or kickback if the power tool is restarted
in the workpiece.
• Support panels or any oversized workpiece to
minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their
own weight. Supports must be placed under the
workpiece near the line of cut and near the edge
of the workpiece on both sides of the wheel.
• Use extra caution when making a “pocket cut”
into existing walls or other blind areas. The pro-
truding wheel may cut gas or water pipes, electrical
wiring or objects that can cause kickback.
Safety Warnings Specifi c for Wire Brushing
Operations:
• Be aware that wire bristles are thrown by the
brush even during ordinary operation. Do not
overstress the wires by applying excessive
load to the brush. The wire bristles can easily
penetrate light clothing and/or skin.
• Allow brushes to run at operating speed for
at least one minute before using them. During
this time no one is to stand in front or in line
with the brush. Loose bristles or wires will be
discharged during the run-in time.
• Direct the discharge of the spinning wire
brush away from you. Small particles and tiny
wire fragments may be discharged at high velocity
during the use of these brushes and may become
imbedded in your skin.
Additional Safety Warnings
•
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 specially designed to fi lter out microscopic particles.
SPECIFICATIONS
Cat. No.
2460-20 12 5000 - 32000 1/8" * 2"
* accepts standard collet sizes 1/32", 1/16", 3/32", 1/8"
Volts
DC No load RPM Collet
Max.
Accessory
Diameter
SYMBOLOGY
Direct Current
Underwriters Laboratories, Inc.
United States and Canada
No Load Revolutions per
Minute (RPM)
FUNCTIONAL DESCRIPTION
5
4
3
2
1
3. Speed dial
1. Collet nut
2. Spindle lock
4. Fuel gauge
5. On/Off switch
ASSEMBLY
WARNING Recharge only with the
charger specifi ed for the battery. For
specifi c charging instructions, read the opera-
tor’s manual supplied with your charger and
battery.
Inserting/Removing the Battery
To remove the battery, push in the release buttons
and pull the battery pack away from the tool.
To insert the battery, slide the pack into the body of
the tool. Make sure it latches securely into place.
WARNING Always remove battery
pack before changing or removing accessories. Only use accessories specifi cally
recommended for this tool. Others may be
hazardous.
WARNING Only use accessories with
Maximum Safe Operating Speed rated
at least equal to the maximum speed marked
on the power tool. This speed is based on the
strength of the accessory, allowing for a reasonable measure of safety. It is not meant to imply
a best or most effi cient operating speed. Do not
exceed the Maximum Safe Operating Speed.
WARNING T o reduce the risk of injury ,
always clean mandrels before inserting
them into the collet and securely tighten the
collet nut and. Otherwise the high-speed rotation of the tool could force the accessory to
fl y out of the collet.
WARNING Everyone in the area must
wear protective clothing and safety
goggles or face shields. Damaged accessories may fl y apart with considerable force,
causing potential for serious injury.
Installing Accessories
1. Remove the battery pack.
2. Remove dust and debris from the
collet, collet nut, and accessory
shank.
3. Insert the collet into the spindle.
4. Loosely screw the collet nut onto
the spindle.
5. Insert the accessory shank into the
collet at least 3/4".
6. Press in the spindle lock button
and tighten the collet nut securely using the 3/8" collet wrench.
Note: Do not tighten the collet nut
without an accessory installed. This
could damage the collet.
7. Insert a battery pack and test the
accessory by letting it spin for one
minute before applying it to the
workpiece.
8. To remove, reverse procedure.
4
5
WARNING T o reduce the risk of injury ,
the operator should be instructed in the
use, care and protection of accessories.
Typical Applications
A large variety of accessories are available for applications such as grinding, sanding, and cutting.
Grinding/Sanding
Use sanding and grinding accessories that are:
• less than 2" in diameter.
• correct accessory type and grit for the job.
• rated at or above the RPM listed on the tool's
nameplate.
Wheel Brushes
Wire wheel brushes are useful for removing rust,
scale, burrs, weld slag, etc. A wide variety of wire
brushes are available for many applications.
When applying brush to work, avoid using too much
pressure. This causes over-bending of wires and
heat build-up resulting in premature wire breakage,
rapid dulling and reduced brush life. Instead of using
more pressure, try a wire wheel brush with more
aggressive cutting action (increased wire size, decreased wire length or different brush type, i.e. knot
type instead of crimped wire type).
Cutting
Always handle cutting wheels carefully to avoid
damage. Before installing any wheel, always inspect it for cracks. If wheel is cracked, discard it to
prevent others from using it. Cutting wheels should
be protected from:
• wetness and extreme humidity
• any type of solvent
• extreme changes in temperature
• dropping and bumping
If a cutting wheel encounters any of these situations, discard the wheel immediately.
Fuel Gauge
OPERATION
To determine the amount of charge left in the battery, turn the tool ON. The Fuel Gauge will light up
for 2-3 seconds. When less than 10% of charge is
left, 1 light on the fuel gauge will fl ash slowly.
To signal the end of charge, all lights on the fuel
gauge will fl ash quickly for 2-3 seconds and the tool
will not run. Charge the battery pack.
T o prevent accidental starting, if the battery pack is
inserted when the tool switch is in the "ON" position,
all lights on the fuel gauge will fl ash twice and the
tool will not run. Turn the tool off, then back on to
begin work.
If the tool or battery becomes too hot, the fuel
gauge lights will fl ash in an alternating pattern and
the tool will not run. Allow the tool and battery to
cool down.
To protect against high torque, binding, stalling,
and short circuit situations, the tool will shut down
and all the fuel gauge lights will fl ash. Release the
trigger and restart.
WARNING Always remove battery
pack before changing or removing accessories. Only use accessories specifi cally
recommended for this tool. Others may be
hazardous.
Selecting speed
To set the maximum speed, rotate the speed dial.
Set the speed dial to "1" for the lowest speed
(5000 RPM). Set the speed dial to "6" for the highest speed (32000 RPM).
Accessory Material Speed
Grinding/Sanding point Wood 2
Steel 3
Aluminum 2
Steel cutters Wood 6
Plastic 2
Steel 2
Aluminum 3
Grinding stone Plastic 2
Steel 6
Aluminum 1
Wire brushes Steel 2
Aluminum 2
Polishing point Wood 1
Plastic 1
Steel 1
Aluminum 1
Cutting wheel Wood 6
Plastic 1
Steel 6
Aluminum 6
Drill bit Wood 6
Plastic 1
Steel 3
Aluminum 3
Router bit Wood 6
6
Using the Rotary Tool
Determine the best grip for your job. The rotary tool
can be held like a pencil for fi ne work, or gripped
around the body when less precision is needed.
Practice on scrap material to determine the best
speed, correct accessory, and get a feel for the
job.
Do not press the accessory into the workpiece.
Little or no operator force should be needed when
the correct accessory and speed are used. Touch
the accessory to the workpiece and guide it over the
work, making muliple passes when necessary.
Move the tool in the same direction as the bit is
spinning (as indicated by the arrow near the front
of the tool). Moving the tool in the opposite direction
can cause the tool to kickback, ending up in loss of
control and damage to the workpiece
WARNING Everyone in the area must
wear protective clothing and safety
goggles or face shields. Damaged accessories may fl y apart with considerable force,
causing potential for serious injury.
Starting/Stopping
1. Use a clamp, vise or other practical means to
hold your work, freeing both hands to control
your tool.
2. To start the tool, grasp the tool and slide the
switch forward to the ON (I) position.
3. Allow the tool to come to full speed before beginning work.
4. Use the speed control dial to set the maximum
speed. Select "1" for low speed (5000 RPM) up
to "6" for high speed (32000 RPM).
5. To stop the tool, slide the switch back to the
OFF (0) position. Make sure the tool comes to a
complete stop before laying the tool down.
NOTE: Do not press the spindle lock button while
tool is running or the accessory is moving. This
could damage the tool.
MAINTENANCE
WARNING T o reduce the risk of injury ,
always unplug the charger and remove
the battery pack from the charger or tool
before performing any maintenance. Never
disassemble the tool, battery pack or charger.
Contact a MILWAUKEE service facility for ALL
repairs.
Maintaining Tool
Keep your tool, battery pack and charger in good repair by adopting a regular maintenance program.
After six months to one year, depending on use,
return the tool, battery pack and charger to a
MILWAUKEE service facility for:
• Lubrication
• Mechanical inspection and cleaning (gears,
spindles, bearings, housing, etc.)
• Electrical inspection (battery pack, charger,
motor)
• Testing to assure proper mechanical and
electrical operation
If the tool does not start or operate at full power
with a fully charged battery pack, clean the contacts
on the battery pack. If the tool still does not work
properly, return the tool, charger and battery pack,
to a MILWAUKEE service facility for repairs.
WARNING To reduce the risk of per-
sonal injury and damage, never immerse your
tool, battery pack or charger in liquid or allow
a liquid to fl ow inside them.
Cleaning
Clean dust and debris from charger and tool vents.
Keep tool handles clean, dry and free of oil or grease.
Use only mild soap and a damp cloth to clean the
tool, battery pack and charger 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
For repairs, return the tool, battery pack and charger to the nearest service center.
ACCESSORIES
WARNING Always remove battery
pack before changing or removing accessories. Only use accessories specifi cally
recommended for this tool. Others may be
hazardous.
For a complete listing of accessories refer to your
MILWAUKEE Electric Tool catalog or go online
to www.milwaukeetool.com. To obtain a catalog,
contact your local distributor or service center.
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