Milwaukee 6088-31, 6089-31, 6089-30, 6088-30 User Manual

Cat. No.

No de Cat.

6088-30 6088-31 6089-30 6089-31

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

WORK AREA SAFETY

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

• 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 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.

• 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 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’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.

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, or Abrasive CuttingOff Operations:

• This power tool is intended to function as a grinder, sander, wire brushing or cut-off tool. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions

listed below may result in electric shock, fire and/ or serious injury.

• Operations such as polishing are not recommended 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 specifically 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 fly 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, flanges, backing pads or any other accessory must properly fit 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. 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 protection must be capable of stopping flying debris generated by various operations. The eye protection must

be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating 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 fly away and cause injury beyond immediate area of operation.

• Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring. Cutting accessory contacting a “live” wire

may make exposed metal parts of the power tool “live” and could give the operator an electric shock.

• 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.

• 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 flammable 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.

NOTE The above warning does not apply for power tools specifically designed for use with a liquid system.

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 firm 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 accessory. Accessory may kickback over your

hand.

• Do not position your body in the area wherepower tool will move if kickback occurs. Kick-

back 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 specific guard designed for the selected wheel. Wheels for

which the power tool was not designed cannot 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

the operator from broken wheel fragments and, accidental contact with wheel and sparks that could ignite clothing.

NOTE The above warning may be omitted for

grinders or cut-off grinders with rated capacity of less than 55 mm.

• 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 flanges that are of correct size and shape for your selected wheel. Proper wheel flanges support the wheel

thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.

• 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 Specific for Abrasive Cutting-Off Operations:

• Do not "

• Do not position your body in line with and behind

• When wheel is binding or when interrupting a

• Do not restart the cutting operation in the

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.

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.

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.

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 protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

Safety Warnings Specific 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 Specific 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.

• 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 work load and centrifugal forces.

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

15 15 15 15

Spindle

Thread

Size

5/8"-11 5/8"-11 5/8"-11 5/8"-11

Wheel

Size

7"/9" 7"/9" 7"/9" 7"/9"

Cat. No. Amps 6088-30

6088-31 6089-30 6089-31

No Load

RPM

120 120 120 120

FUNCTIONAL DESCRIPTION

1. Rear handle

2. Trigger

3. Lock-on button (select models)

4. Handle release button (select models)

5. Side handle

6. Wheel guard (select models)

7. Grinding wheel (select models)

8. Guard adjustment lock lever (select models)

9. Spindle lock button

10. Side handle socket

(on bottom)

SYMBOLOGY

Double Insulated

Amperes

Volts

Alternating Current/Direct Current No Load Revolutions

per Minute (RPM)

Underwriters Laboratories, Inc. United States and Canada

Mexican Approvals Marking

GROUNDING

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 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 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. Y our 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

Fig. A

in Figure 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

Fig. B

Fig. C

Figures B and C.

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

18 18 16 14 12 10

18 16 14 12 10

16 14 12 12

READ AND SAVE ALL

INSTRUCTIONS FOR FUTURE USE.

ASSEMBLY

WARNING T o reduce the risk of injury ,

always unplug tool before changing or removing accessories. Only use accessories speciﬁ cally recommended for this tool. 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.

1. To remove the Quik-Lok® Cord, turn the cord nut 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.

EXTENSION CORDS

Fig. 1

Installing the Side Handle

The side handle may be installed on the top of the gear case or 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 Fig.

9. To install, thread side handle into side handle socket on desired side of gear case and tighten securely.

WARNING To reduce the risk of in-

jury when grinding, ALWAYS use the proper guard. ALWAYS properly install the guard.

Installing, Adjusting, and Removing 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. To install the guard, unplug the tool and place it upside down on a level surface. Remove any accessories from the spindle.

Line up the tabs with the tab slots (Fig. 2). Then

press the guard down onto the tool.

Fig. 2

Tab slot

Guard adjustment lock lever

Press in the guard adjustment lock lever and rotate the guard to one of the detent slots. The lock lever must engage with one of the detents (Fig. 3).

Fig. 3

Guard adjustment lock lever

Tab slot

Guard

Lock lever must

engage

one of

detents

Press in the guard adjustment lock lever and ro-

tate the guard to one of the detent slots. The lock lever must engage with one of the detents (Fig. 3).

2. To adjust the guard, press in the guard adjustment lock lever and rotate the guard to one of the detents (Fig. 3).

Position the guard in the location which offers

best control and guard protection. For operating zones that provide maximum protection for the operator, see Fig. 9.

3. To remove the guard, unplug tool and place it upside down on a level surface. Remove any accessories from spindle.

Press in the guard adjustment lock lever and

rotate the guard to line up the tabs with the slots (Fig. 2). Then lift the guard straight up and away from the tool.

OPERATION

WARNING T o reduce the risk of injury ,

wear safety goggles or glasses with side shields.

Starting and Stopping the Motor

1. To start the tool, pull the trigger.

2. To stop the tool, release the trigger.

WARNING

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.

Locking the Trigger Select Models

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

Fig. 4

1. To lock the trigger on, hold the lock-on button in while pulling the trigger. Release the trigger.

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

WARNING

do not operate tool with handle release button pressed in or with handle not locked into position. If the handle does not lock securely into position, do not operate tool. Return the tool to a MILWAUKEE service facility for repair immediately.

To reduce the risk of injury

Lock-on button

To reduce the risk of injury ,

Adjusting the Rear Handle Position Select Models

This tool is equipped with an adjustable rear handle. This feature allows the user to adjust the angle of the handle to nine positions for optimum operating positions.

Fig. 5

Handle releas button (on bottom)

1. Unplug tool.

2. Press and hold the handle release button in and rotate the rear handle to one of the nine handle positions. The adjustable handle feature has detents which allow the handle to snap into position. Make sure the handle snaps ﬁ rmly into position and does not rotate.

Position the guard in the location which offers

best control and guard protection. For operating zones that provide maximum protection for the operator, see Fig. 9.

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.

Sanding Disc and Grinding Wheel Selection

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 “WARN-

ING” section on the tool's nameplate Use backing pads, adapters, and other accessories that are:

•correct size for tool and for sanding disc or grind-

ing wheel

•rated at or above the RPM listed in the “WARN-

ING” 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.

WARNING T o reduce the risk of injury ,

always unplug tool before attaching or remov-

ing accessories or making adjustments. Use

only speciﬁ cally recommended accessories.

Others may be hazardous.

USING SANDING DISCS

Installing Sanding Discs

1. Unplug tool and place it upside down on a level surface as shown. Remove any accessories from spindle.

2. Thread nylon washer onto spindle. Attach backing pad and sanding disc using Fig. 6 to determine type and order of assembly.

Fig. 6

Disc nut

Sanding disc

Backing pads

A. Polypropylene B. Spiral C. Rubber D. Phenolic

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. 7). 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. 7

Hold at a 5° to 15° angle

For best results use only this portion of disc

3. Use long, sweeping, side to side strokes, advancing 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

CDA

NOTE: When installing ﬂ ap disc without hub, position disc nut as shown.

3. To tighten, press the spindle lock button while turning disc nut clockwise.

4. T o remove sanding disc and backing pad, unplug tool and reverse procedure.

Disc nut position

Flap disk Flap disk with hub

Rubber

pad

Nylon washer

Spindle

Spindle lock button

Type 27 ﬂ ange

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 Aluminum Zirconia Bi-Cut Ceramic

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.

Unique grit pattern is arranged in clusters for faster stock removal and cleaning. Ideal for removing paint from cars, boats, etc. without clogging.

Lasts up to 3 times longer than aluminum oxide discs. For general metal working. Ideal for tough jobs.

Installing Grinding Wheels

USING GRINDING AND CUT-OFF WHEELS

1. Unplug tool and place it upside down on a level surface as shown. Remove any accessories from spindle.

2. Thread nylon washer onto spindle. Attach guard and grinding wheel using Fig. 8 to determine type and order of assembly (See Fig. 2 and 3 for attaching guard). NOTE: When installing Type 27 or Type 29 grinding wheels, position disc nut according to wheel thickness.

Position the guard in the location which offers

Fig. 8

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

Nylon washer

Spindle lock button

best control and guard protection. For operating zones that provide maximum protection for the operator, see Fig. 9. 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 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.

Disc nut position

Disc nut

1/8" thick or less wheels

Type 27 ﬂ ange

Spindle

1/4" thick

wheels

Type 11

ﬂ ange

WARNING T o reduce the risk of injury ,

the operator should be instructed in the use, care and protection of grinding wheels.

Care of Grinding & Cut-Off 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 bestored:

• 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.

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.

WARNING Only use wheels with Maxi-

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.

Selecting Wheels

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 .

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 5o to 15o angle as

shown, using constant pressure for a uniform ﬁ nish (Fig. 10). Too great an angle causes too much pressure on small areas which may gouge or burn work surface.

Fig. 10

Hold at a 5° to 15° angle

5. Control pressure and surface contact between

wheel and workpiece. T oo much pressure slows cutting speed.

WARNING To reduce the risk of injury

when grinding:

• 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.

Grinding

1. Depending on your job, position the guard to provide maximum protection for the operator (Fig. 9).

Fig. 9

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.

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.

Using Type 27 Cut-Off Wheels

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. 11).

Fig. 11

3. Control pressure and surface contact between

wheel and workpiece. T oo much pressure slows cutting speed.

WARNING A Type 1 guard must be

installed when using a Type 1 cut-off wheel to provide maximum protection for the operator if the wheel should break.

Installing and Removing Type 1 Guard Assembly and Adjusting Shoe

1. Unplug tool and place it upside down on a level

surface. Remove any accessories from spindle.

2. Loosen the guard screw and slip the 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 Fig. 9. Tighten the guard screw securely.

Fig. 12

Adjusting shoe

Carriage bolt and wingnut

Guard

Guard screw

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. 14

Wire cup brush

Spindle

3. To adjust the guard, unplug the tool, loosen the guard screw, rotate the guard to the desired position and retighten the guard screw.

4. To remove the adjusting shoe, loosen the wing nuts, slide the shoe over to the access holes and lift out. To install the adjusting shoe, insert the head of the carriage bolts into guard access holes and slide the shoe over to the far edge of slots. Adjust shoe to desired position and tighten wing nuts securely.

5. To remove the guard, unplug the tool, remove the accessories and reverse the procedure.

Using Type 1 Cut-Off Wheels

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. 13).

3. Control pressure and surface contact between wheel and workpiece. Too much pressure slows cutting speed.

Fig. 13

Nylon washer

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 nylon washer onto spindle. Attach wire cup brush onto spindle.

3. Press 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.

WARNING Because the wires on wire

wheel brushes are directed towards the operator, a Type 27 guard must be used to protect the operator when fatigued wires break.

Installing Wire Wheel Brushes

Fig. 15

Nylon washer

Wire wheel brush

Guard

WARNING T o reduce the risk of injury ,

never use a Type 1 cut-off wheel for surface grinding.

Spindle lock button

Spindle

1. Unplug tool and place it upside down on a level surface. Remove any accessories from spindle.

2. Thread nylon washer onto spindle. Attach guard and wire wheel brush onto spindle (see Fig. 2 and 3 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 Fig. 9.

3. Press 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.

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.

Using Wire Brushes

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).

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.

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.)

• T esting 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.

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