Milwaukee 5196, 5194, 5192 User Manual

Catalog No.

No de Cat.

Catálogo No.

5192
5194
5196

OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR

HEAVY-DUTY DIE GRINDERS
EXTRA ROBUSTE RECTIFIEUSES POUR MATRICES
HEAVY DUTY RECTIFICADOR DE MATRICES

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 SAFETY RULES — FOR ALL POWER TOOLS

WARNING!

Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term "power tool" in
all of the warnings listed below refers to your mains-operated (corded) power tool or battery-opearted (cordless) power tool.

SAVE THESE INSTRUCTIONS

READ ALL INSTRUCTIONS

WORK AREA SAFETY

1. Keep work area clean and well lit. Cluttered or dark areas invite
accidents.

2. Do not operate power tools in explosive atmospheres, such

as in the presence of flammable liquids, gases, or dust.

Power tools create sparks which may ignite the dust or fumes.

3. Keep children and bystanders away while operating a power
tool. Distractions can cause you to lose control.

ELECTRICAL SAFETY

4. 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. Unmodified plugs and matching outlets

will reduce risk of electric shock.

5. 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.

6. Do not expose power tools to rain or wet conditions. Water
entering a power tool will increase the risk of electric shock.

7. 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.

8. 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.

PERSONAL SAFETY

16. 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.

17. 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.

18. Disconnect the plug from the power source and/or the bat-

tery 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 tool acci­dentally.

19. Store idle power tools out of the reach of children and do

not allow persons unfamiliar with the power tools or these
instructions to operate power tools. Power tools are danger-

ous in the hands of untrained users.

20. 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 before use. Many accidents are caused

by poorly maintained power tools.

21. Keep cutting tools sharp and clean. Properly maintained cutting
tools with sharp cutting edges are less likely to bind and are easier
to control.

22. Use the power tool, accessories and tool bits etc., in accor-

dance with these instructions and in the manner intended
for the particular type of power tool, 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.

POWER TOOL USE AND CARE

SERVICE

9. 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 influence of drugs, alcohol or
medication. A moment of inattention while operating power tools

may result in serious personal injury.

10. Use safety equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions will reduce per­sonal injuries.

11. Avoid accidental starting. Ensure the switch is in the off-
position before plugging in. Carrying tools with your finger on
the switch or plugging in power tools that have the switch on invites
accidents.

12. 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.

13. Do not overreach. Keep proper footing and balance at all
times. This enables better control of the power tool in unexpected
situations.

14. Dress properly. Do not wear loose clothing or jewellery.

Keep your hair, clothing and gloves away from moving parts.

Loose clothes, jewellery, or long hair can be caught in moving parts.

15. If devices are provided for the connection of dust extrac-

tion and collection facilities, ensure these are connected
and properly used. Use of these devices can reduce dust-re-

lated hazards.

page 2

23. Have your power tool serviced by a qualified repair person
using only identical replacement parts. This will ensure that

the safety of the power tool is maintained.

SPECIFIC SAFETY RULES

1. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden
wiring or its own cord. Contact with a "live" wire will make exposed metal parts of the tool "live" and shock the operator.

2. Maintain labels and nameplates. These carry important information. If unreadable or missing, contact a MILWAUKEE service facility for a free
replacement.

3. 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 specifically designed to filter out
microscopic particles.

1. Cord

2. Collet nut

3. Collet flange

4. Toggle switch

5. Paddle switch

6. Trigger switch

Symbology

Double Insulated

Canadian Standards
Association

Underwriters
Laboratories, Inc.

Volts Alternating Current/
Direct Currenty

No Load Revolutions
per Minute (RPM)

Amperes

FUNCTIONAL DESCRIPTION

1

Specifications

Cat.

No.

5192
5194
5196

1

Volts

AC/DC

120
120
120

Amps

4.5

4.5
11

No Load

RPM

21,000
21,000
14,500

4

1

5

Cat. No. 5194

2

6

3

2

Cat. No. 5196

Cat. No. 5192

2

page 3

GROUNDING EXTENSION CORDS

WARNING!

Improperly connecting the grounding wire can
result in the risk of electric shock. Check with a
qualified electrician if you are in doubt as to
whether the outlet is properly grounded. Do not
modify the plug provided with the tool. Never
remove the grounding prong from the plug. Do
not use the tool if the cord or plug is damaged. If
damaged, have it repaired by a MILWAUKEE
service facility before use. If the plug will not fit
the outlet, have a proper outlet installed by a
qualified electrician.

Grounded Tools:
Tools with Three Prong Plugs

Tools marked “Grounding Required”
have a three wire cord and three
prong grounding plug. The plug must
be connected to a properly grounded
outlet (See Figure A). If the tool should
electrically malfunction or break
down, grounding provides a low re­sistance path to carry electricity
away from the user, reducing the risk
of electric shock.

The grounding prong in the plug is connected through the green wire
inside the cord to the grounding system in the tool. The green wire in the
cord must be the only wire connected to the tool's grounding system and
must never be attached to an electrically “live” terminal.

Your tool must be plugged into an appropriate outlet, properly installed
and grounded in accordance with all codes and ordinances. The plug
and outlet should look like those in Figure A.

Fig. A

Grounded tools require a three wire extension cord. Double insulated
tools can use either a two or three wire extension cord. As the distance
from the supply outlet increases, you must use a heavier gauge exten­sion cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool
damage. Refer to the table shown to determine the required minimum
wire size.

The smaller the gauge number of the wire, the greater the capacity of the
cord. For example, a 14 gauge cord can carry a higher current than a 16
gauge cord. When using more than one extension cord to make up the
total length, be sure each cord contains at least the minimum wire size
required. If you are using one extension cord for more than one tool, add
the nameplate amperes and use the sum to determine the required mini­mum wire size.

Guidelines for Using Extension Cords

• If you are using an extension cord outdoors, be sure it is marked
with the suffix “W-A” (“W” in Canada) to indicate that it is acceptable
for outdoor use.

• Be sure your extension cord is properly wired and in good electrical
condition. Always replace a damaged extension cord or have it
repaired by a qualified person before using it.

• Protect your extension cords from sharp objects, excessive heat
and damp or wet areas.

Recommended Minimum Wire Gauge

Nameplate

Amperes

8.1 - 12

12.1 - 15

15.1 - 20

for Extension Cords*

25'

0 - 5

5.1 - 8

16
16
14
12
10

Extension Cord Length

100'

14
12
10
10

150'

12
10

--

--

--

--

50'

16
16
14
12
10

75'

16
14
12
10
10

200'

12

--

--

--

--

Double Insulated Tools:
Tools with Two Prong Plugs

Tools marked “Double Insulated” do
not require grounding. They have a
special double insulation system
which satisfies OSHA requirements
and complies with the applicable
standards of Underwriters Labora­tories, Inc., the Canadian Standard
Association and the National Electri­cal Code. Double Insulated tools may
be used in either of the 120 volt out­lets shown in Figures B and C.

Fig. B

* Based on limiting the line voltage drop to five
volts at 150% of the rated amperes.

READ AND SA VE ALL INSTRUCTIONS

FOR FUTURE USE.

Fig. C

page 4

TOOL ASSEMBLY

WARNING!

To reduce the risk of injury, always unplug
tool before attaching or removing accessories
or making adjustments. Use only specifically
recommended accessories. Others may be
hazardous.

Installing Collets

MILWAUKEE Die Grinders feature a special collet and collet nut. The
collet must be attached to the collet nut before installing the collet asembly
to the tool. Be sure that the collet size matches the size of the mounted
wheel mandrel you will use, otherwise the collet may break.

1. To assemble, place collet on an even surface, take nut and place
over collet (Fig. 1).

Fig. 1

4. To disassemble collet from nut, hold nut firmly with one hand and
press the collet to one side with the other hand (Fig. 4).

Fig. 4

Installing Grinding Points (Fig. 5)

MILWAUKEE offers a complete line of grinding points for finish grinding,
beveling, sharpening and de-burring (see "Accessories").

Fig. 5

Insert mandrel a minimum
of 3/4" inside the collet

Overhang about 1/2"

2. Position nut squarely over collet (Fig. 2).

Fig. 2

3. Snap nut and collet together by firmly applying downward pressure
onto assembly with the palm of hand (Fig. 3).

Fig. 3

Collet

1. Remove dust and debris from the collet body before inserting grind­ing points.

2. Insert the collet with the collet nut attached into the collet body.
Thread the collet nut onto the spindle but do not tighten it yet.

3. Clean the grinding point mandrel, then insert it a minimum of
3/4" into the collet. The mandrel will overhang the collet and the
grinding point about 1/2".

4. Hold the spindle shaft steady with a 1/2" open end wrench and
securely tighten the collet nut with an 11/16" open end wrench.

5. Reverse the procedure when removing the grinding point.

Mandrel

Grinding point

WARNING!

To reduce the risk of injury, always securely
tighten the collet to the grinders and clean man­drels before inserting them into the collet. Other­wise the high-speed rotation of the tool could
force the grinding point to fly out of the collet.

page 5

OPERATION

MAINTENANCE

WARNING!

To reduce the risk of injury, wear safety goggles
or glasses with side shields. Unplug the tool
before changing accessories or making
adjustments.

WARNING!

If the grinder begins vibrating, immediately stop
the motor and check to see if the grinding point
is dull. Dull grinding points will cause the tool to
vibrate and could force the collet to fly off the
tool. Always replace or sharpen dull grinding
points.

Grinding

Always hold the grinder firmly before starting the motor. To start the
motor for Cat. No. 5192, turn the toggle switch ON. T o start Cat. No. 5194,
press the paddle switch. For Cat. No. 5196, pull the trigger.

Using the Trigger Lock Mechanism (Cat. No. 5196)

The lock button holds the trigger in the ON position for continuous full
speed use.

1. To lock the trigger, hold the lock button in while pulling the trigger,
then release the trigger.

2. To unlock the trigger , pull the trigger and release. The lock button will
pop out.

Allow the motor to reach full speed and then place the grinding point on
the work surface. The tool is designed to work most efficiently with only
light pressure. Excessive pressure will burn the work surface, damage
the grinding point, bend the mandrel, and cause slow grinding.

When a grinding point becomes dull, the grinder may start to vibrate.
When this happens immediately stop using the grinding point. Vibra­tion could loosen the collet, causing the grinding point to fly off the tool.
Replace a dull grinding point with a new one or use a dressing stone to
sharpen the dull point. Handle grinding points carefully. Dropping them or
dropping the grinder could cause the point to shatter. Do not operate the
grinder carelessly because it may cause the grinding point to explode at
high speeds.

WARNING!

To reduce the risk of injury, always unplug
your tool before performing any maintenance.
Never disassemble the tool or try to do any
rewiring on the tool's electrical system. Contact
a MILWAUKEE service facility for ALL repairs.

Maintaining Tools

Keep your tool in good repair by adopting a regular maintenance pro­gram. Before use, examine the general condition of your tool. Inspect
guards, switches, tool cord set and extension cord for damage. Check
for loose screws, misalignment, binding of moving parts, improper mount­ing, broken parts and any other condition that may affect its safe opera­tion. If abnormal noise or vibration occurs, turn the tool off immediately
and have the problem corrected before further use. Do not use a dam­aged tool. Tag damaged tools “DO NOT USE” until repaired
(see “Repairs”).

Under normal conditions, relubrication is not necessary until the motor
brushes need to be replaced. After six months to one year, depending on
use, return your tool to the nearest MILWAUKEE service facility for the
following:

• Lubrication

• Brush inspection and replacement

• Mechanical inspection and cleaning (gears, spindles, bearings,
housing, etc.)

• Electrical inspection (switch, cord, armature, etc.)

• Testing to assure proper mechanical and electrical operation

WARNING!

To reduce the risk of injury, electric shock and
damage to the tool, never immerse your tool in
liquid or allow a liquid to flow inside the tool.

Cleaning

Clean dust and debris from vents. Keep the tool handles clean, dry and
free of oil or grease. Use only mild soap and a damp cloth to clean your
tool 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.

page 6

Repairs

If your tool is damaged, return the entire tool to the nearest service
center.