Milwaukee Tool 6066-6 User Manual [en, es, fr]
Cat. No.
No de cat.
6065
6065-6
6066
6066-6
6072
6078
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
HEAVY-DUTY SANDERS AND GRINDERS
PONCEUSES-RECTIFIEUSES EXTRA ROBUSTES
LIJADORAS Y ESMERILADORAS HEAVY-DUTY
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. Save all warnings and instructions for future reference. 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.
ELECTRICAL SAFETY
WORK AREA SAFETY
• 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.
PERSONAL SAFETY
• 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 medi-
cation. 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 plugging in 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
2
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.
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.
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 pre-
ventive 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.
Any power tool that cannot be
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.
3
SPECIFIC SAFETY RULES
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-of 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,
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 acces-
sory 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 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 posi-
tion 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.
4
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 Operations:
• 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:
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.
Some dust created by power sanding,
SYMBOLOGY
Double Insulated
Amperes
Volts
Alternating Current
Alternating Current/Direct
Current
No Load Revolutions
per Minute (RPM)
Underwriters Laboratories, Inc.
United States and Canada
Mexican Approvals Marking
5
FUNCTIONAL DESCRIPTION
2
1
3
9
1. Cord
2. Back handle
3. Dial speed control (6078 only)
4. Tool rest
5. Side handle
6. Spindle
2
1
9
4
5
7
8
7
6
7. Spindle lock button
8. Guard
9. Trigger
4
SPECIFICATIONS
Cat. No. Volts Amps No Load RPM Spindle Size Wheel Size
6065
6065-6
6066
6066-6
6072
6078
120 AC/DC
120 AC/DC
120 AC/DC
120 AC/DC
120 AC/DC
120 AC
15
15
15
15
13
13
5000
5000
6000
6000
5000
0 - 6000
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
7"/9"
7"/9"
7"/9"
7"/9"
7"/9"
7"/9"
EXTENSION CORDS
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 suffi x “W-A” (“W” in Cana-
da) 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
qualifi ed person before using it.
• Protect your extension cords from sharp objects,
excessive heat and damp or wet areas.
Recommended Minimum Wire Gauge
For Extension Cords*
Nameplate
Amperes
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
* Based on limiting the line voltage drop to fi ve volts at
150% of the rated amperes.
Extension Cord Length
25' 50' 75' 100' 150'
18
18
18
18
16
14
12
10
18
18
16
14
12
10
--
18
18
18
16
14
12
READ AND SAVE ALL
INSTRUCTIONS FOR FUTURE USE.
6
18
16
14
12
10
GROUNDING
through the green wire inside the cord to the
WARNING Improperly connecting the
grounding wire can result in the risk of electric shock. Check with a qualifi ed 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
5
6
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
fi t the outlet, have a proper outlet installed by
a qualifi ed 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
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
Double Insulated Tools:
Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require
grounding. They have a special double insulation system which satisfi es 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
Fig. C
ASSEMBLY
Installing the Side Handle
WARNING To reduce the risk of injury,
always unplug tool before attaching or removing accessories or making adjustments. Use
only specifi cally recommended accessories.
Others may be hazardous.
Removing and Replacing Quik-Lok® Cords
(Select Models)
MILWAUKEE's exclusive Quik-Lok® Cords provide
instant fi eld replacement or substitution.
Fig. 1
16
14
12
12
--
--
--
--
--
1. To remove the Quik-Lok
1/4 turn to the left and pull it out.
2. T o replace the Quik-Lok® Cord, align the connector keyways and push the connector in as far as
it will go. Turn the cord nut 1/4 turn to the right
to lock.
®
Cord, turn the cord nut
The side handle may be installed on either side
of gear case for right or left handed use. Position
side handle in the location which offers best control
and guard protection. For operating zones that
provide maximum protection for the operator, see
"Grinding". To install, thread side handle into side
handle socket on desired side of gear case and
tighten securely.
Installing, Adjusting, and Removing the Guard
(Select Models)
WARNING To reduce the risk of injury
when grinding, AL WA YS use the proper guard.
ALWAYS properly install the guard.
The guard must be used when using the tool as a
grinder. The guard should be removed when using
tool as a sander.
1. Unplug the tool and place it upside down on a
level surface. Remove any accessories from the
spindle.
2. Place the grinding wheel guard over the spindle.
Position the guard in the location which offers
best control and guard protection. For operating
zones that provide maximum protection for the
operator, see "Grinding".
3. Fasten the guard to the lower half of the gear
case with screws and lock washers provided.
7
OPERATION
WARNING To reduce the risk of injury,
wear safety goggles or glasses with side
shields. Unplug the tool before changing
accessories or making adjustments.
Starting and Stopping the Motor
1. To start the tool, pull the trigger.
2. To stop the tool, release the trigger.
Locking the Trigger (Select Models)
WARNING To reduce the risk of injury
or damage to the tool, do not use the spindle
lock button to stop the spindle while the tool
is in use or is coasting after shut-off.
The lock button holds the trigger in the ON position
for continuous use.
1. To lock the trigger on, hold in the lock-on button
while pulling the trigger. Release the trigger.
2. To unlock the trigger, pull the trigger and release.
The lock-on button will pop out.
Using the Dial Speed Control (Cat. No. 6078 only)
Cat. No. 6078 has a dial speed control and variable
speed trigger switch. The maximum speed may be
preset using the speed control dial and the speed
may be varied by the trigger switch. Speed control
dial settings range from 1 to 5. Lower numbers
correspond to lower speeds and higher numbers
USING SANDING DISCS
Installing Sanding Discs
1. U
nplug tool and place it upside down on a level surface
as shown. Remove any accessories from spindle.
2. Thread fl ange and nylon washer onto spindle.
Attach backing pad and sanding disc using
Fig. 2 to determine type and order of assembly.
Fig. 2
Disc nut
Sanding
disc
BCDA
correspond to higher speeds. Use the setting that
best suits the work.
To control the speed, set the dial to the desired
number. Then, pull the trigger . Increase or decrease
pressure on the trigger to vary the speed. To stop
the tool, release the trigger.
Sanding Disc and Grinding Wheel Selection
WARNING To reduce the risk of personal
injury and damage to the tool, use ONL Y accessories rated at or above the RPM listed on the
“WARNING” section of the tool's nameplate.
Use sanding discs and grinding wheels that are:
• correct size as written on tool's nameplate
• correct wheel type and grit for the job
•rated at or above the RPM listed in the “WARNING” section on the tool's nameplate
Use backing pads, adapters, and other accessories
that are:
• correct size for tool and for sanding disc or grinding
wheel
•rated at or above the RPM listed in the “WARNING”
section on the tool's nameplate
•the proper accessory for the job
Sanding Disc and Grinding Wheel Material
Sanding discs and grinding wheels are made of
various materials and are designed for different
jobs. Be sure that you choose the proper sanding
disc or grinding wheel for the job you plan to do.
NOTE: When installing fl ap disc without hub,
position fl ap disc nut as shown.
3. To tighten, press in the spindle lock button while
turning disc nut clockwise.
4. T o remove sanding disc and backing pad, unplug
tool and reverse procedure.
Flap disc
nut position
Flap disk
without hub
Flap disk
with hub
Sanding
1. Use a clamp, vise or other practical means to
hold your work, freeing both hands to control your
tool. Firmly grasp rear handle and side handle
before starting and while tool is in operation.
Allow sanding disc to come to full speed before
beginning to sand.
2. Hold tool at 5° to 15° angle as shown to ensure
proper sanding pressure and control (Fig. 3). T oo
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.
Fig. 3
Hold at a
5° to 15°
angle
For best results, use only
this portion of the disc.
3. Use long, sweeping, side to side strokes, advanc-
ing forward to produce the desired fi nish.
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.
Cross Sanding
When finishing 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.
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
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
Selecting Sanding Discs & Grit
Refer to the table below to select the correct type
of sanding disc for your job. Generally, use 16, 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 Catalog
for a complete list of MILWAUKEE sanding discs.
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.
Backing
pads
A. Polypropylene
B. Spiral
C. Rubber
D. Phenolic
Rubber
pad
Nylon washer
Flange
Spindle
Spindle lock button
Type 27
fl ange
8
9
USING GRINDING AND CUT-OFF WHEELS
Installing Grinding Wheels
1. U
nplug tool and place it upside down on a level surface
as shown. Remove any accessories from spindle.
2. Thread fl ange and nylon washer onto spindle.
Attach guard and grinding wheel using Fig. 4
to determine type and order of assembly (See
"Installing, Adjusting, and Removing the Guard"
for attaching guard). NOTE: When installing Type
27 or Type 29 grinding wheels, position wheel
nut according to wheel thickness.
Position the guard in the location which offers
Fig. 4
Grinding wheels
A. Type 28 with hub
B. Type 27 with hub
Type 29 with hub
C. Type 27 with fl ange
Type 29 with fl ange
D. Type 11
Guard
E. Type 28
F. Type 27
G. Type 27
H. Type 11
Care of Grinding & Cut-Off Wheels
A
E
Spindle lock button
B
FG
Spindle
WARNING To reduce the risk of injury,
the operator should be instructed in the use,
care and protection of grinding wheels.
Grinding and 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
• bumped
If any wheel is dropped, rolled, bumped, subjected
to extreme changes in temperature, or has come
into contact with solvents or wetness, discard wheel
immediately.
best control and guard protection. For operating
zones that provide maximum protection for the
operator, see "Grinding". NOTE: When selecting
Type 11 grinding cup wheels, the guard’s skirt
should be adjusted so that no more than 1/8" of
the wheel extends beyond the guard.
3. To tighten, press in the spindle lock button while
turning wheel or disc nut clockwise using the
spanner wrench provided.
4. T o remove grinding wheel and guard, unplug tool
and reverse procedure.
C
Troubleshooting
Deep scratches and circular marks can result from:
• Uneven pressure
• Using a partially glazed wheel - especially on
aluminum applications
• Dirt or loose metal on the workpiece
• Failure to constantly move across surface
Bluish discoloration of metal surface indicates:
• Excessive heat caused by circular motion in a
small area
• Excessive pressure
• Use of worn out or glazed wheels
Inspecting Wheels
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.
Wheel nut
Hub
adaptor
Lock
washers
D
H
Wheel
Nylon
washer
Flange
Screws
Guard
Selecting Wheels
WARNING
mum Safe Operating Speed rated at or above
the RPM listed on the “WARNING” section of
the tool's nameplate. 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.
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" cut-off wheels are suited for
small cut-off and shallow notching operations only .
Grinding
Only use wheels with Maxi-
WARNING
• ALW A YS hold the tool fi rmly with both hands
using the handles provided; before and
during grinding
• NEVER allow the wheel to bind
• NEVER use a wheel that has been dropped
• NEVER bang grinding wheel onto work
• NEVER grind without proper safety equipment
WARNING To reduce the risk of injury
when grinding, AL WA YS use the proper guard.
ALWAYS properly install the guard.
1. Depending on your job, position the guard to provide maximum protection for the operator (Fig. 5).
Fig. 5
Operator's Zones
2. If you have just installed a grinding wheel or are
just beginning a period of work, test the wheel
by letting it spin for one minute before applying
it to the workpiece.
NOTE: Out-of-balance wheels can mar work-
piece, damage the tool, and cause stress to
wheel that may cause wheel failure.
3. Firmly grasp rear handle and side handle before
starting and while using tool. Allow wheel to come
to full speed before starting to grind.
4. When grinding, hold tool at a 5
shown, using constant pressure for a uniform
fi nish (Fig. 6). Too great an angle causes too
much pressure on small areas which may gouge
or burn work surface.
5. Control pressure and surface contact between
wheel and workpiece. T oo much pressure slows
cutting speed.
Fig. 6
Using Type 27 Cut-Off Wheels
o
to 15o angle as
Hold at a 5° to 15° angle
WARNING A Type 27 guard must be
installed when using a Type 27 cut-off wheel to
provide maximum protection for the operator
if the wheel should break.
Type 27 cut-off wheels are only suited for small
cut-off and shallow notching operations.
1. Firmly grasp rear handle and side handle before
starting and while using tool. Allow wheel to come
to full speed before starting.
2. When using a cut-off wheel, hold tool as shown,
using only the edge of the wheel (Fig. 7).
Fig. 7
3. Control pressure and surface contact between
wheel and workpiece. T oo much pressure slows
cutting speed.
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11
USING WIRE BRUSHES
Selecting Wire Brushes
Wire brushes are useful for removing rust, scale,
burrs, weld slag, etc. A wide variety of wire brushes
are available for many applications.
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 the potential for serious injuries.
Installing Wire Cup Brushes
Fig. 8
Wire cup brush
Nylon washer
Flange
Spindle
Spindle lock button
1. Unplug tool and place it upside down on a level
surface. Remove any accessories from spindle.
NOTE: Never use a guard with a wire cup brush.
2. Thread fl ange and nylon washer onto spindle.
Attach wire cup brush onto spindle.
3. Press in the spindle lock button while tightening
brush with a wrench (not provided with tool).
4. To remove wire cup brush, unplug tool and reverse procedure.
Installing Wire Wheel Brushes
WARNING
wheel brushes are directed towards the operator, a Type 27 guard must be used to protect
the operator when fatigued wires break.
Fig. 9
Nylon
washer
Flange
Because the wires on wire
Wire
wheel
brush
Guard
Spindle
1. Unplug tool and place it upside down on a level
surface. Remove any accessories from spindle.
2. Thread fl ange and nylon washer onto spindle.
Attach guard and wire wheel brush onto spindle
(see Fig. 4 for attaching guard).
Position the guard in the location which offers
best control and guard protection. For operating
zones that provide maximum protection for the
operator, see "Grinding".
3. Press in the spindle lock button while tightening
brush with a wrench (not provided with tool).
4. To remove wire wheel brush and guard, unplug
tool and reverse procedure.
Using Wire Brushes
WARNING Never exceed Maximum
Safe Operating Speed of the brush. Do not use
a damaged brush or one which 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.
1. Do not wear loose clothing when using wire
brushes. The wires may catch on loose clothing
and pull the clothing into the moving parts.
2. Firmly grasp rear handle and side handle before
starting and while using tool. Always test the wire
brush for balance and loose or damaged wires
by running tool at no load speed for at least one
minute before applying it to your work.
3. 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).
MAINTENANCE
WARNING T o 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 MILW AUKEE 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 T o reduce the risk of injury,
electric shock and damage to the tool, never
immerse your tool in liquid or allow a liquid
to fl ow 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 fl ammable or combustible
solvents around tools.
Repairs
If your tool is damaged, return the entire tool to the
nearest service center.
ACCESSORIES
WARNING To reduce the risk of injury ,
always unplug the tool before attaching or
removing accessories. Use only specifi cally
recommended accessories. Others may be
hazardous.
For a complete listing of accessories refer to your
MILWAUKEE Electric Tool catalog or go on-line
to www.milwaukeetool.com. To obtain a catalog,
contact your local distributor or a service center.
Spindle lock button
12
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