Milwaukee 6089-20, 6086-20, 6080-20, 6088-20, 6081-20 User Manual

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Catalog No.

No de Cat.

Número de Catálogo

6080-20 6081-20 6082-20 6086-20 6088-20

OPERATOR'S MANUAL MANUEL DE L'UTILISATEUR MANUAL DEL OPERADOR

6089-20

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 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 - SANDERS AND GRINDERS

1. Always use proper guard with grinding wheel. A guard protects operator from broken wheel fragments.

2. Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running

over rated speed can fly apart and cause injury.

3. Make sure all wheel flanges and other mounting hardware are in good condition and are always used properly. Defective or

missing parts may damage the wheels and other accessories. Always use mounting hardware supplied with the tool.

4. 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.

5. Keep hands away from all cutting edges and moving parts.

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

7. 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 filter out microscopic particles.

Symbology

Double Insulated

Volts Alternating Current/ Direct Current

Amps

No Load Revolutions per Minute (RPM)

Underwriters Laboratories, Inc.

Canadian Standards Association

Mexican Safety Standards

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

Cat. No.

Sanders

6080-20 6081-20 6082-20

Grinders

6086-20 6088-20 6089-20

* Double Insulated

Volts

AC/DC

120 120 120

D.I.* or

Grounded

D.I.

Grounded

D.I.

D.I. D.I. D.I.

FUNCTIONAL DESCRIPTION

Specifications

No Load

15 15 15

RPM

6000 6000 6000

(on bottom)

Amps

Spindle

Thread

5/8"-11

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

5/8"-11

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

Size

Wheel

Size

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

9" 7" 9"

Min. Wheel

RPM Rating

6500 6500 6500

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.

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. A

Fig. B

Fig. 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 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

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

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'

READ AND SAVE ALL INSTRUCTIONS

FOR FUTURE USE.

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.

Removing and Replacing Quik-Lok® Cords (Fig. 1) Select Models

MILWAUKEE's exclusive Quik-Lok® Cords provide instant field replacement or substitution.

Fig. 1

1. To remove the Quik-Lok® Cord, turn the cord nut 1/4 turn to the left and pull it out.

2. To 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.

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.

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

WARNING!

To reduce the risk of injury when grinding, ALWAYS use the proper guard. ALWAYS properly install the guard.

Installing, Adjusting, and Removing the Guard (Fig. 2 & 3) Select Models

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.

Lock lever

must engage one

of detents

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.

page 5

OPERATION

WARNING!

To 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!

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.

Locking the Trigger (Fig. 4) Select Models

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

Fig. 4

Fig. 5

Handle release 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 firmly 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 ONLY accessories rated at or above the RPM listed on the WARNING section of the tool's nameplate.

Lock-on button

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!

To reduce the risk of injury, 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.

Adjusting the Rear Handle Position (Fig. 5) 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.

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 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.

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.

page 6

USING SANDING DISCS

Installing Sanding Discs (Fig. 6)

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.

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

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

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

Fig. 6

Disc nut

Sanding disc

Backing pads

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

BCDA

Rubber

pad

Nylon washer

Spindle

Spindle lock button

Disc nut position

Flap disk

Type 27 flange

Flap disk

with hub

Sanding (Fig. 7)

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). Too great an angle will result in too much pressure and could cause excessive wear to the disc and workpiece. Too 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 finish.

Removing Welds or Hammer Marks

When removing welds or hammer marks, limit coarse sanding to the immediate area. Use successively finer 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 finish. Failure to cross sand when changing from a coarse disc to a finishing 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

finishing 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 finishing. Always begin with a coarse grit, using successively finer grits to obtain the desired finish. 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.

page 7

USING GRINDING AND CUT-OFF WHEELS

Installing Grinding Wheels (Fig. 8)

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 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. To remove grinding wheel and guard, unplug tool and reverse procedure.

Fig. 8

Grinding wheels A. Type 28 with hub B. Type 27 with hub

Type 29 with hub

C. Type 27 with flange

Type 29 with flange

D. Type 11

Guard E. Type 28 F. Type 27 G. Type 27 H. Type 11

Disc nut position

Disc nut

Nylon washer

FG HE

Spindle lock button

1/8" thick or less wheels

Type 27 flange

Spindle

1/4" thick

wheels

Type 11 flange

WARNING!

To 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 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.

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 Maximum 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 efficient operating speed. Do not exceed the Maximum Safe Operating Speed.

page 8

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.

Fig. 10

WARNING!

To reduce the risk of injury when grinding:  ALWAYS hold the tool firmly 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, ALWAYS use the proper guard. ALWAYS properly install the guard.

Grinding (Fig. 9 & 10)

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

Fig. 9

1 Operator's Zones

Hold at a 5° to 15° angle

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

WARNING!

A Type 27 guard must be installed when using a Type 27 cutoff wheel to provide maximum protection for the operator if the wheel should break.

Using Type 27 Cut-Off Wheels (Fig. 11)

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

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 workpiece, 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 5o to 15o angle as shown, using constant pressure for a uniform finish (Fig. 10). Too great an angle causes too much pressure on small areas which may gouge or burn work surface.

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

page 9

WARNING!

A Type 1 guard must be installed when using a Type 1 cutoff wheel to provide maximum protection for the operator if the wheel should break.

Installing and Removing Type 1 Guard Assembly and Adjusting Shoe (Fig. 12)

Fig. 12

Adjusting shoe

Carriage bolt and wingnut

Guard

Guard screw

Spindle

Using Type 1 Cut-Off Wheels (Fig. 13)

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).

Fig. 13

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

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.

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.

WARNING!

To reduce the risk of injury, never use a Type 1 cut-off wheel for surface grinding.

page 10

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 fly off the brush with considerable force, causing the potential for serious injuries.

Installing Wire Cup Brushes (Fig. 14)

Fig. 14

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.

Wire cup brush

Nylon washer

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)

Fig. 15

Wire wheel brush

Guard

Nylon washer

Spindle lock button

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.

Spindle

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).

page 11

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