Milwaukee 2680-20 Operator's Manual
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
TO REDUCE THE RISK OF INJURY, USER MUST READ OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE LE MANUEL DE
L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER EL MANUAL DEL
OPERADOR.
Cat. No.
No de cat.
2680-20
HEAVY-DUTY 4-½" CUT-OFF / GRINDER
EXTRA ROBUSTE MEULE À TRONÇONNER DE 115 mm (4½")
AMOLADORA PARA TROCEAR DE HEAVY-DUTY 115 mm (4½")
2
3
PERSONAL SAFETY
GENERAL POWER TOOL SAFETY WARNINGS
WORK AREA SAFETY
ELECTRICAL SAFETY
• 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 elec-
tric shock if your body is earthed or grounded.
• Do not expose power tools to rain or wet conditions. W ater 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.
or under the infl uence of drugs, alcohol or
medication. A moment of inattention while oper-
ating 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.
• 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 these devices can reduce dust-related
hazards.
WARNING READ ALL SAFETY WARNINGS AND INSTRUCTIONS.
Failure to follow the warnings and instructions may result in electric shock, fi re and/or
serious injury.
Save all warnings and instructions for future reference
The term "power tool" in all of the warnings refers to your mains-operated (corded) power
tool or battery-operated (cordless) power tool.
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
and any other condition that may affect the
power tool 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.
BATTER Y T OOL USE AND CARE
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.
• 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.
• 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.
SPECIFIC SAFETY RULES
• 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
Safety Warnings Common for Grinding, Sanding, Wire Brushing or Abrasive Cutting-Off
Operations:
• This power tool is intended to function as a
grinder, sander, wire brush 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.
• Operations such as polishing are not recom-
mended to be performed with this power tool.
Operations for which the power tool was not designed may create a hazard and cause personal
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 guarded or controlled.
• The arbour size of wheels, fl anges, backing
pads or any other accessory must properly
fi t the spindle of the power tool. Accessories
with arbour holes that do not match the mounting
hardware of the power tool will run out of balance, vibrate excessively and may cause loss of
control.
• Do not use a damaged accessory. Before each
use inspect the accessory such as abrasive
wheels for chips and cracks, backing pad 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 accessories will normally break apart
during this test time.
• Wear personal protective equipment. Depend-
ing on application, use face shield, safety
goggles or safety glasses. As appropriate,
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5
wear dust mask, hearing protectors, gloves
and work shop apron capable of stopping
small abrasive or workpiece fragments. The
eye protection 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 shock the operator.
• Position the cord clear of the spinning acces-
sory. 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 ac-
cessory has come to a complete stop. The
spinning accessory may grab the surface and pull
the power tool out of your control.
• 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.
• 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, backing pad, 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
Cat. No. Volts DC No Load RPM Spindle Thread Size Wheel Size
2680-20 18 9000 5/8”-11 4-1/2”
Specifi cations
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. Always use auxiliary
handle, if provided, for maximum control over
kickback or torque reaction during start-up.
The operator can control torque reactions or
kickback forces, if proper precautions are taken.
• Never place your hand near the rotating acces-
sory. Accessory may kick back over your hand.
• Do not position your body in the area where
power tool will move if kickback occurs. Kickback will propel the tool in direction opposite to
the wheel’s movement at the point of snagging.
• 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 saw chain woodcarving blade
or toothed saw blade. Such blades create frequent kickback and loss of control.
Safety Warnings Specific for Grinding and
Abrasive Cutting-Off Operations:
• Use only wheel types that are recommended
for your power tool and the specifi c guard
designed for the selected wheel. Wheels for
which the power tool was not designed can not
be adequately guarded and are unsafe.
• The guard must be securely attached to the
power tool and positioned for maximum safety,
so the least amount of wheel is exposed towards the operator. The guard helps to protect
operator from broken wheel fragments and accidental contact with wheel.
• Wheels must be used only for recommended
applications. For example: do not grind with
the side of cut-off wheel. Abrasive cut-off wheels
are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
• Always use undamaged wheel fl anges that are
of correct size and shape for your selected
wheel. Proper wheel fl anges support the wheel
thus reducing the possibility of wheel breakage.
Flanges for cut-off wheels may be different from
grinding wheel fl anges.
• Do not use worn down wheels from larger
power tools. Wheel intended for larger power tool
is not suitable for the higher speed of a smaller
tool and may burst.
Additional Safety Warnings Specifi c for Abra-
sive Cutting-Off Operations:
• Do not jam the 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 body in line with and
behind the rotating wheel. When the wheel, at
the point of operation, is moving away from your
body, 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 “pocketcut”
into existing walls or other blind areas. The
protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.
Safety Warnings Specifi c for Sanding Opera-
tions:
• Do not use excessively oversized sanding disc
paper. Follow manufacturers recommendations, when selecting sanding paper. Larger
sanding paper extending beyond the sanding
pad presents a laceration hazard and may cause
snagging, tearing of the disc or 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
over stress the wires by applying excessive
load to the brush. The wire bristles can easily
penetrate light clothing and/or skin.
• If the use of a guard is recommended for wire
brushing, do not allow any interference of the
wire wheel or brush with the guard. Wire wheel
or brush may expand in diameter due to workload
and centrifugal forces.
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.
Symbology
Direct Current
Underwriters Laboratories, Inc.
United States and Canada
No Load Revolutions
per Minute (RPM)
6
7
ASSEMBLY
WARNING T o reduce the risk of injury ,
always remove battery pack before changing
or removing accessories. Only use accessories specifi cally recommended for this tool.
Others may be hazardous.
Inserting/Removing Battery Pack
Insert the battery pack by sliding battery pack into
the body of the tool. Insert the battery pack until
the battery latches lock.
To remove the battery pack, press in both battery
latches and slide the battery pack off of the tool.
WARNING Recharge only with the
charger specifi ed for the battery. For specifi c
charging instructions, read the operator’s
manual supplied with your charger and
battery. This tool is not compatible with V™-
technology or NiCd systems.
Functional Description
1. Side handle
2. Spindle lock
3. Side handle sockets
4. Paddle switch
5. Switch lock-off
6. Guard
7. Guard lock lever
Installing Side Handle
The side handle may be installed on either side
or the top of gear case. Position side handle in
the location which offers best control and guard
protection. To install, thread side handle into side
handle socket and tighten securely.
Installing, Removing and Adjusting the Guard
This tool is shipped with a guard. A guard must be
used when using the tool as a grinder. The guard
may be removed when using tool as a sander.
1. To remove the guard, remove the battery pack
and remove any accessories from spindle.
2. Press in the lock lever and rotate the guard to
line up the tabs on the grinder with the slots in
the guard.
3. Press in the lock lever and lift the guard straight
up and away from the tool.
4. To install the guard, remove the battery pack
and remove any accessories from the spindle.
5. Line up the tabs on the grinder with the slots in
the guard.
6. Press in the lock lever and press the guard onto
the tool.
7. To adjust the guard, press in the lock lever and
rotate the guard to one of fi ve detent slots.
WARNING To reduce the risk of injury
when grinding:
• ALWAYS use the proper guard.
• ALWAYS properly install the guard.
• ALWAYS hold the tool fi rmly with both
hands using the handles provided before
and during grinding.
• NEVER use a wheel that has been dropped.
• NEVER bang grinding disc onto work.
• NEVER grind without proper safety
equipment.
1
4
5
6
7
3
2
Tab
slots
Fig. 1
Detent
slots
OPERATION
WARNING T o reduce the risk of injury ,
wear safety goggles or glasses with side
shields.
Controlled Start
The controlled start feature reduces the torque
reaction "jerk" when its trigger is pulled.
Paddle Switch Operation
To start the tool, grasp the handle and side handle
fi rmly. Pull the lock-off button back and squeeze
the paddle switch.
To stop the tool, release the paddle switch. Make
sure the tool comes to a complete stop before laying the tool down.
General Operation
1. If you have just installed an accessory or are
beginning a period of work, test it by letting it spin
for one minute before applying it to the workpiece.
Out-of-balance or damaged accessories can mar
workpiece, damage the tool, and cause stress
that may cause accessory failure.
2. Use a clamp, vise or other practical means to
hold your work, freeing both hands to control the
tool.
3. Hold tool securely with both hands.
4. Start the tool.
5. Allow accessory to come to full speed before
beginning work.
6. Control pressure and surface contact between
accessory and workpiece. Too much pressure
slows speed.
If the tool stalls, release the trigger to reset.
Lighten pressure to avoid stalling.
7. When fi nished, turn off the tool and make sure
it comes to a complete stop before laying it
down.
Installing/Removing Accessories
Make sure the wheel does not extend beyond the
bottom of the guard. Threaded hub grinding wheels
may require a deeper guard (see "Accessories").
1. Remove the battery pack.
2. Properly position the guard (Fig. 2).
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 wheel, 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.
Fig. 2
Operator's Zones
Flange nut
position for
1/8" thick or less wheels
Spindle
Flange
Wheel
Flange nut
Fig. 4
Fig. 3
1/8"
1/4"
3. Wipe the flange, flange nut and spindle to
remove dust and debris. Inspect the parts for
damage. Replace if needed.
5. Place the selected wheel on the spindle and
align it with the fl ange.
6. Position the fl ange nut over the spindle accord-
ing to wheel thickness (Fig. 4).
7. Press in the spindle lock button while turning the
fl ange nut clockwise. Tighten securely using a
spanner wrench.
8. To remove wheel, remove the battery pack and
reverse the procedure.
Flange nut
position for
1/4" thick or more wheels
4. Place the fl ange on spindle, as shown.
WARNING T o reduce the risk of injury ,
always remove battery pack before changing
or removing accessories or making adjustments. Use only specifi cally recommended
accessories. Others may be hazardous.
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9
Wire
Wheel
Brush
Fig. 8
Guard
WARNING T o reduce the risk of injury ,
the operator should be instructed in the use,
care and protection of grinding wheels.
Fig. 5
For best result use only this portion of disc
Hold at a
Hold at a
5° to 15°
5° to 15°
angle
angle
USING GRINDING WHEELS
Care of Grinding & Cut-Off Wheels
Grinding/cut-off wheels should be protected from:
• wetness and extreme humidity
• any type of solvent
• extreme changes in temperature
• dropping and bumping
Grinding and cut-off wheels should be stored:
• in an organized way so wheels can be removed
without disturbing or damaging other wheels
• with their safety information
Grinding and cut-off wheels should NOT be dropped,
rolled or bumped.
Discard wheels that have been dropped, rolled,
bumped, subjected to extreme changes in temperature, or come into contact with solvents or wetness.
Grinding
When grinding, hold tool at a 5
o
to 15o angle, using
constant pressure for a uniform fi nish. T oo great an
angle causes concentrated pressure on small areas
which may gouge or burn work surface.
Grinding Wheel Selection
Use grinding wheels, and accessories that are:
• correct size as written on tool’s nameplate.
• rated at or above the RPM listed on the tool’s
nameplate.
• correct accessory, wheel type and grit for the job.
Grinding is the cutting action of thousands of abrasive grains on the face of a grinding wheel. When
grinding metals such as steel and iron, choose an
aluminum oxide grinding wheel. Select a silicon
carbide grinding wheel for stone and concrete. Use
cotton reinforced wheels for non-ferrous metals.
Type 27 Reinforced 1/8" thick or less Cut-Off
Wheels are suited for small cut-off and shallow
notching operations only. Always handle 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.
Fig. 6
WARNING A Type "1" guard must be
installed when using a cut-off wheel to provide
maximum protection for the operator if the
wheel should break.
WARNING Using the face of a Cut-Off
Wheel (as in grinding) will cause the Wheel
to crack and break, resulting in serious personal injury.
USING CUT-OFF WHEELS
Type "1" Cut-Off Wheels are suited for small cut-off
and shallow notching operations only.
When using a cut-off wheel, hold the tool as shown,
using only the edge of the wheel.
Fig. 7
Wire Cup Brush
Aluminum Oxide
For fast cutting, general purpose discs for most
metal jobs. Best for cold-rolled steel, stainless
steel or metals requiring tough, fast cutting, long
lasting abrasives.
Aluminum Zirconia Bi-Cut
Unique grit pattern is arranged in clusters for faster stock removal and cleaning. Ideal for removing
paint from cars, boats, etc. without clogging.
Ceramic
Lasts up to 3 times longer than Aluminum Oxide Discs. For general metal working. Ideal for
tough jobs.
WARNING Everyone in the area must
wear protective clothing and safety goggles
or face shields. Fatigued wires and residue
will fl y off the brush with considerable force,
causing potential for serious injury.
WARNING Never exceed Maximum
Safe Operating Speed of brush. Do not use
a damaged brush or one that is functioning
improperly (throwing wires, out-of-balance,
etc.). These conditions increase the possibility of further brush failure and possible
injury. Discard and replace damaged brushes
immediately.
Sanding Disc Selection
Use sanding discs and accessories that are:
• correct size as written on tool’s nameplate.
• rated at or above the RPM listed on the tool’s
nameplate.
• correct accessory, wheel type and grit for the job.
Refer to the table below to select the correct type
of sanding disc for your job. Generally, use 24 or
36 grit for heavy stock removal; 50, 60, or 80 grit
for medium stock removal and 120 grit for fi nishing.
Always begin with a coarse grit, using successively
fi ner grits to obtain the desired fi nish. See your
MILWAUKEE Electric Tool Catalog for a complete
list of sanding discs.
USING WIRE BRUSHES USING SANDING DISCS
Wire brushes are useful for removing rust, scale,
burrs, weld slag, etc.
Always install wire cup brushes according to the
accessory manufacterer’s instructions.
T est wheel for balance and loose or damaged wires
by letting it spin for one minute before applying it
to the workpiece. During this time, no one should
stand in front of or in line with it.
Control pressure and surface contact between
wheel and workpiece. Too much pressure causes
over-bending of wires and heat build-up causing
premature wire breaking, rapid dulling and reduced
brush life. Instead of more pressure, try a wire wheel
with more aggressive cutting action (increased wire
size, decreased wire length or different brush type
(knot type vs.crimped wire type).
Installing Backing Pad and Sanding Discs
1. Remove the battery pack.
2. Wipe the accessories, disc nut and spindle to
remove dust and debris. Inspect the parts for
damage. Replace if needed.
3. Slip backing pad onto spindle with fl at side away
from gear case.
Fig. 9
Spindle
Backing
pad
Disc nut
Sanding
disc
When using a wire wheel brush, install guard according to "Installing/Removing Accessories".
4. Place sanding disc on backing pad and secure
assembly to spindle with disc nut.
WARNING Because the wires on wire
wheel brushes are directed towards the operator, a guard must be used to protect the
operator when fatigued wires break.
10
11
5. To tighten, press the spindle lock button while
turning disc nut clockwise with the spanner
wrench provided.
6. To remove backing pad and sanding disc, remove
the battery pack and reverse the procedure.
Sanding
Hold tool at 5° to 15° angle to ensure proper sanding
pressure and control. Too great an angle will result
in too much pressure and could cause excessive
wear to the disc and workpiece. T oo small an angle
will reduce control.
Use long, sweeping, side to side strokes, advancing
forward to produce the desired fi nish.
Cross Sanding
When fi nishing a surface that has been prepared by
a coarse disc or wheel, sand at right angles to the
strokes made by the coarser disc. Finishing marks
left from previous sanding are easily seen and
removed for a uniform fi nish. Failure to cross sand
when changing from a coarse disc to a fi nishing disc
may result in deep scratches and circular marks.
Removing Welds or Hammer Marks
When removing welds or hammer marks, limit
coarse sanding to the immediate area. Use successively fi ner grits to smooth surface.
Finishing Metal
Constantly move across the surface. Work faster on
curved surfaces where contact areas are smaller
and pressure is greater. Flat areas may appear at
the end of the stroke when pressure is too heavy.
Ease up on pressure at end of each stroke and
when reversing strokes.
Troubleshooting
Deep scratches and circular marks can result
from:
• Using too coarse a grit
• Using a partially glazed disc
• Dirt or loose metal on the workpiece
• Failure to sand across the grain when changing
from coarse to fi nishing discs
• Failure to use closed coated discs to reduce
the problem of grains working loose and
scratching the workpiece
Bluish discoloration of metal surface indicates:
• Excessive heat caused by circular motion in a
small area
• Excessive pressure
• Use of worn out or glazed discs
Fig. 10
For best result use only this portion of disc
Hold at a
Hold at a
5° to 15°
5° to 15°
angle
angle
• 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.
ACCESSORIES
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 a service center listed
on the back cover of this operator’s manual.
WARNING Always remove battery
pack before changing or removing accessories. Only use accessories specifically
recommended for this tool. Others may be
hazardous.
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.)
MAINTENANCE
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.
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.
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 flammable or combustible solvents
around tools.
Repairs
For repairs, return the tool, battery pack and charger to the nearest service center listed on the back
cover of this operator's manual.
FIVE YEAR TOOL LIMITED WARRANTY
Every MILWAUKEE electric power tool (including battery charger) is warranted to the original purchaser only to be free
from defects in material and workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace any part
on a electric power tool which, after examination, is determined by MILWAUKEE to be defective in material or workmanship for a period of fi ve (5) years* after the date of purchase. Return the electric power tool and a copy of proof of
purchase to a MILWAUKEE factory Service/Sales Support Branch location or MILWAUKEE Authorized Service Station,
freight prepaid and insured, are requested for this warranty to be effective. This warranty does not apply to damage
that MILWAUKEE determines to be from repairs made or attempted by anyone other than MILWAUKEE authorized
personnel, misuse, alterations, abuse, normal wear and tear, lack of maintenance, or accidents.
* The warranty period for Hoists (lever, hand chain, & electric chain hoists), all Ni-CD battery packs, Work Lights (cordless fl ashlights), Job Site Radios, and Trade Titan™ Industrial Work Carts is one (1) year from the date of purchase.
*The warranty period for Li-Ion battery packs that do not contain V™-technology – 4.0 volts through 18.0 volts - is two
(2) years from the date of purchase.
*There is a separate warranty for V™-technology Li-Ion Battery Packs V™18 volts and above that accompany V™technology cordless power tools:
*Every MILWAUKEE V™-technology Li-Ion Battery Pack 18 volts or above is covered by an initial 1000 Charges/2
Years free replacement warranty. This means that for the earlier of the fi rst 1000 charges or two (2) years from the
date of purchase/fi rst charge, a replacement battery will be provided to the customer for any defective battery free
of charge. Thereafter, customers will also receive an additional warranty on a pro rata basis up to the earlier of the
fi rst 2000 charges or fi ve (5) Years from the date of purchase/fi rst charge. This means that every customer gets an
additional 1000 charges or three (3) years of pro rata warranty on the V™-technology Li-Ion Battery Pack 18 volts or
above depending upon the amount of use. During this additional warranty period, the customer pays for only the useable service received over and above the fi rst 1000 Charges/2 years, based on the date of fi rst charge and number of
charges found on the battery pack via Milwaukee’s V™-technology Service Reader.
Warranty Registration is not necessary to obtain the applicable warranty on a MILWAUKEE product. The manufacturing date of the product will be used to determine the warranty period if no proof of purchase is provided at the time
warranty service is requested.
ACCEPTANCE OF THE EXCLUSIVE REP AIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN IS A CONDITION OF THE CONTRACT FOR THE PURCHASE OF EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE
TO THIS CONDITION, YOU SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE
LIABLE FOR ANY INCIDENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR FOR ANY COSTS,
ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED T O BE AS A CONSEQUENCE OF ANY DAMAGE
TO, FAILURE OF, OR DEFECT IN ANY PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS
OF PROFITS. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS,
WRITTEN OR ORAL, EXPRESSED OR IMPLIED. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING,
MILWAUKEE DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
USE OR PURPOSE, AND ALL OTHER WARRANTIES.
This warranty applies to product sold in the U.S.A., Canada and Mexico only.
Please consult the ‘Service Center Search’ in the Parts & Service section of MILWAUKEE’s web-site www .milwaukeetool.
com or call 1.800.SAWDUST (1.800.729.3878) to locate your nearest service facility for warranty and non-warranty
service on a MILWAUKEE electric power tool.
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