Porter-Cable PC60TAG, PC60TCTAG Instruction Manual

4-1/2 inch (114mm)
Angle Grinder

Instruction manual

Manuel d'instructions
Manual de'instrucciones

www.portercable.com

INSTRUCTIVO DE OPERACIÓN,
CENTROS DE SERVICIO Y PÓLIZA DE
GARANTÍA.

ADVERTENCIA: LÉASE ESTE

INSTRUCTIVO ANTES DE USAR EL
PRODUCTO.

Meuleuse d’angle de
4-1/2 po. (114mm)

Esmeriladora angular
de 114mm (4-1/2 pulg.)

CATALOG NUMBERS

PC60TAG

PC60TCTAG

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 1

2 3

General Power Tool Safety Warnings

Read all safety warnings and instructions. Failure to follow the warnings and

instructions may result in electric shock, fire 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.

1) Work area safety
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) 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.

c) Keep children and bystanders away while operating a power tool. Distractions

can cause you to lose control

2) Electrical safety
a) 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

b) 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.

c) Do not expose power tools to rain or wet conditions. Water entering a power

tool will increase the risk of electric shock

d) 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.

e) 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.

f) If operating a power tool in a damp location is unavoidable, use a ground fault

circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of

electric shock.

3) Personal safety
a) 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.

b) 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.

c) 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 finger on the switch or energizing power tools

that have the switch on invites accidents.

d) 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.

e) Do not overreach. Keep proper footing and balance at all times. This enables

better control of the power tool in unexpected situations.

f) 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.

g) 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.

4) Power tool use and care
a) 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.

b) 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.

c) Disconnect the plug from the power source and/or the battery pack from the

power tool before making any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the power

tool accidentally.

d) 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.

e) 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.

f) Keep tools sharp and clean. Properly maintained tools with sharp

edges are less likely to bind and are easier to control.

g) 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.

5) Service
a) 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.

SAFETY INSTRUCTIONS FOR ALL OPERATIONS

Safety Warnings Common for Grinding, Sanding, Wire Brushing or Abrasive
Cutting-Off Operations

a) This power tool is intended to function as a grinder, wire brush, sander 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.

b) 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.

c) 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.

d) 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.

e) The arbor size of wheels, flanges, backing pads or any other accessory

must properly fit the spindle of the power tool. Accessories with arbor 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.

f) Do not use a damaged accessory. Before each use inspect the accessory

such as abrasive wheel 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.

g) Wear personal protective equipment. Depending 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 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.

h) 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.

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 2

4

5

i) 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.

j) 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.

k) 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.

l) 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.

m)Regularly clean the power tool’s air vents. The motorʼs fan will draw the dust

inside the housing and excessive accumulation of powdered metal may cause
electrical hazards.

n) Do not operate the power tool near flammable materials. Sparks could ignite

these materials.

o) Do not use accessories that require liquid coolants. Using water or other

liquid coolants may result in electrocution or shock.

p) Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate

accessories can result in injury.

q) Always use side handle. Tighten the handle securely. The side handle should

always be used to maintain control of the tool at all times.

r) Use clamps or another practical way to secure and support the work piece to

a stable platform. Holding the work by hand or against your body leaves it

unstable and may lead to loss of control.

Further safety instructions for all operations

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 accessoryʼs 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 wheelʼs
movement at the point of pinching. Abrasive wheels may also break under these
conditions.
Kickback is the result of tool misuse and/or incorrect operating procedures or
conditions and can be avoided by taking proper precautions as given below:

a) 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 reaction or kickback forces, if proper precautions are taken.

b) Never place your hand near the rotating accessory. Accessory may kickback

over your hand.

c) 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

wheelʼs movement at the point of snagging.

d) 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.

e) 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

a) 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.

b) 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.

c) 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.

d) 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.

e) 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 Operation

a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt

to make an excessive depth of cut. Over stressing 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.

b) 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.

c) 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.

d) 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.

e) 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.

f) 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

a) 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

a) 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.

b) 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 and centrifugal forces.

Additional Safety Information

• Do not use Type 1 flat abrasive or diamond wheels without proper Type 1 guard.

WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety

glasses. Also use face or dust mask if operation is dusty. ALWAYS WEAR CERTIFIED
SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),

• ANSI S12.6 (S3.19) hearing protection,

• NIOSH/OSHA/MSHA respiratory protection.

WARNING: Some dust created by power sanding, sawing, grinding, drilling,

and other construction activities contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm. Some

examples of these chemicals are:

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 4

6 7

• lead from lead-based paints,

• 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.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,

and other construction activities. Wear protective clothing and wash exposed
areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the

skin may promote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disperse dust, which may

cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA

approved respiratory protection appropriate for the dust exposure. Direct particles away
from face and body.

WARNING: Always wear proper personal hearing protection that conforms to

ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from

this product may contribute to hearing loss.

WARNING: Always use eye protection. All users and bystanders must wear eye

protection that conforms to ANSI Z87.1.

WARNING: When not in use, place grinder on a stable surface where it will not

move inadvertently, roll or cause a tripping or falling hazard.

CAUTION: To reduce the risk of personal injury, use extra care when working into

a corner or edge because a sudden, sharp movement of the tool may be experienced
when the wheel or other accessory contacts a secondary surface or a surface edge.

SAFETY GUIDELINES - DEFINITIONS

It is important for you to read and understand this manual.
The information it contains relates to protecting YOUR SAFETY and PREVENTING
PROBLEMS. The symbols below are used to help you recognize this information.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION: Indicates a potentially haz ard ous situation which, if not avoided, may

result in minor or mod er ate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous

situation which, if not avoided, may result in property damage

SYMBOLS

• The label on your tool may include the following symbols. The symbols and their
definitions are as follows:

V..................volts A ..................amperes

Hz................hertz W..................watts

min ..............minutes ................alternating current

............direct current

n

o ................rated speed

................Class I Construction ..............earthing terminal

(grounded) ................safety alert symbol

................Class II Construction .../min or rpm ....revolutions or reciprocation

(double insulated) per minute

• When using an extension cord, be sure to use one heavy enough to carry the current
your product will draw. An undersized cord will cause a drop in line voltage resulting in
loss of power and overheating. The following table shows the correct size to use
depending on cord length and nameplate ampere rating. If in doubt, use the next
heavier gauge. The smaller the gauge number, the heavier the cord.

Assembly

WARNING: To prevent accidental operation, turn off and unplug tool before

performing the following operations. Failure to do this could result in serious

personal injury.

AUXILIARY HANDLE

An auxiliary 3 position handle is furnished with your grinder. It can be screwed into
either side or the top of the gear case housing. WARNING:This handle SHOULD
BE USED AT ALL TIMES to maintain complete control of the tool.

Accessories

It is important to choose the correct guards, backing pads and flanges to use with
grinder accessories. See page 9 for information on choosing the correct accessories.

CAUTION: Accessories must be rated for at least the speed recom mended on the
tool warning label. Wheels and other accessories running over their rated accessory
speed may fly apart and cause injury. Threaded accessories must have a 5/8 inch-11
hub. Every unthreaded accessory must have a 7/8 inch (22mm) arbor hole. If it does not,
it may have been designed for a circular saw. Use only the accessories shown on page
9 of this manual. Accessory ratings must always be above tool speed as shown on tool
nameplate.

Minimum Gauge for Cord Sets

Volts Total Length of Cord in Feet

120V 0-25 26-50 51-100 101-150

(0-7,6m) (7,6-15,2m) (15,2-30,4m) (30,4-45,7m)

240V 0-50 51-100 101-200 201-300

(0-15,2m) (15,2-30,4m) (30,4-60,9m) (60,9-91,4m)

Ampere Rating

More Not more American Wire Gauge
Than Than
0-6 18 16 16 14
6 - 10 18 16 14 12
10 - 12 16 16 14 12
12 - 16 14 12 Not Recommended

1

4

5

3

2

6

A

FUNCTIONAL DESCRIPTION

1. Slider switch

2. Cord

3. Tool free guard

4. Body grip

5. Side handle (3 positions)

6. Spindle lock button

Guard (Type 27 or Type 1 if
so equipped)

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 6

8

9

MOUNTING GUARD (FIGURES B & C)

CAUTION: Guards must be used with all grinding wheels, sanding flap discs,

wire brushes cut-off wheels and wire wheels. The tool may be used without a guard

only when sanding with conventional sanding discs. The PC60TCTAG is provided with a
guard intended for use with depressed center wheels (Type 27) and hubbed grinding
wheels (Type 27). The same guard is designed for use with sanding flap discs (Type 27
and 29) and wire cup brushes. Grinding and cutting with wheels other than Type 27 and
29 require different accessory guards. A Type 1 guard is provided for use with a Type 1

wheel. PC60TAG is provided with a Type 27 grinding guard only. A Type 1 guard for use
with cut off wheels is available separately at additional cost.

Both Type 27 and Type 1 guards attach and are removed in the same way as
described below.

1. Figure B - Open the guard latch (7), and align the
lugs on the guard (8) with the slots on the gear
case cover (9).

2. Push the guard down until the guard lugs engage
and rotate freely in the groove on the gear case
hub.

3. With the guard latch open, rotate the guard into the
desired working position. The guard body should
be positioned between the spindle and the
operator to provide maximum operator protection.

4. Figure C - Close the guard latch (7) to secure the
guard on the gear case. You should not be able to
rotate the guard by hand when the latch is closed.
Do not operate the grinder with a loose guard or
the guard latch in open position.

5. To remove the guard, open the guard latch, rotate
the guard so that the lugs and slots are aligned
and pull up on the guard.

ADJUSTING THE GUARD (FIGURE D)

Note: The guard is pre-adjusted to the diameter of the gear
case hub at the factory. If, after a period of time, the guard
becomes loose, tighten the adjusting screw (10) with latch in
the closed position and guard installed on the tool.

CAUTION: Do not tighten the adjusting screw with the
latch in the open position. Undetectable damage to the
guard or the mounting hub may result.

CAUTION: If the guard cannot be tightened by the guard
latch, do not use the tool and take the tool and guard to a
service center to repair or replace the guard.

Note: Edge grinding and cutting can be performed with Type
27 wheels designed and specified for this purpose; 1/4 inch (6mm) thick wheels are
designed for surface grinding while 1/8 inch (3mm) wheels are designed for edge
grinding. Cutting can also be performed by using a Type 1 wheel and a Type 1 guard.

C

7

10

D

Type 27 guard

4-1/2 inch (115mm) Grinding Wheels

unthreaded

backing flange

threaded clamp nut

Type 27 hubbed wheel

Type 27 guard

Type 27 depressed

center wheel

Wire Wheels

3 inch wire

cup brush

Type 27 guard

Type 27 guard

rubber backing pad

sanding disc

threaded clamp nut

Sanding Discs

4 inch wire

cup brush

B

9

8

7

4-1/2 inch (115mm)
Sanding Flap Discs

hubbed sanding

flap disc

unthreaded backing

flange

non-hubbed sanding

flap disc

threaded clamp nut

Type 27 guard

Type 27 guard

4-1/2 inch (115mm) Cutting Wheels

Type 1 guard

backing flange

abrasive cutting wheel

clamp nut

Type 1 guard

backing flange

diamond cutting wheel

clamp nut

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 8

11

10

MOUNTING NON-HUBBED WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before
performing the following operations. Failure to do this could result in serious

personal injury.
Depressed center Type 27 grinding wheels must be used with included flanges. See

pages 9 and 10 of this manual for more information.

1. Figure F - Install the unthreaded backing flange
(11) on spindle (12) with the raised section (pilot)
against the wheel.

2. Place wheel against the backing flange, centering
the wheel on the raised section (pilot) of the
backing flange.

3. Figure G - While depressing the spindle lock
button, thread the threaded clamp nut (13) on
spindle.

• Figure H - If the wheel you are installing is more than 1/8 inch
(3mm) thick, place the threaded clamp nut on the spindle so
that the raised section (pilot) fits into the center of the wheel.

• Figure I - If the wheel you are installing is 1/8 inch (3mm)
thick or less, place the threaded clamp nut on the spindle so
that the raised section (pilot) is not against the wheel.

4. While depressing the spindle lock button (6), tighten the
threaded clamp nut with included wrench.

5. To remove the wheel, depress the spindle lock button and
loosen the threaded clamp nut with included wrench.

NOTE: If the wheel spins after the threaded clamp nut is tightened, check the orientation
of the threaded clamp nut. If a thin wheel is installed with the pilot on the clamp nut against
the wheel, it will spin because the height of the pilot prevents the clamp nut from holding
the wheel.

SURFACE GRINDING WITH GRINDING WHEELS

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply minimum pressure to the work surface, allowing the tool to operate at high
speed. Grinding rate is greatest when the tool operates at high speed.

3. Figure J - Maintain a 20˚ to 30˚ angle between the tool and work surface.

OPERATION

SWITCH

To start the grinder, push the slider switch (1) forward. For continuous operation, push
the slider switch forward and push the front down until it locates in the lock position. To
turn the tool off, press the rear of the slider switch. Spring action returns the switch to
the off position.

CAUTION: Hold the side handle (5) and body of the tool (4) firmly to maintain control
of the tool at start up and during use and until the wheel or accessory stops rotating.
Make sure the wheel has come to a complete stop be fore laying the tool down.

CAUTION: Allow the tool to reach full speed before touching tool to the work surface.
Lift the tool from the work surface before turning the tool off.

ROTATING THE GEAR CASE (FIG. E)

Turn off and unplug tool before making any
adjustments or removing or installing accessories.
Before reconnecting the tool, depress and release the
trigger switch to ensure that the tool is off.

1. Remove guard and flanges from tool.

2. Remove the four corner screws attaching the gear
case to motor housing.

3. Separating the gear case from motor housing not
more than 1/4 in., rotate the gear case head to
desired position.

NOTE: If the gear case and motor housing become separated by more than 1/4 in., the
tool must be serviced and re-assembled by a Porter Cable service center. Failure to
have the tool serviced may cause brush, motor and bearing failure.

4. Re-install screws to attach the gear case to the motor housing.

Tighten screws to 18 in./lbs. torque. Overtightening could cause screws to strip.

SPINDLE LOCK

The spindle lock button (6) is provided to prevent the spindle from rotating when installing
or removing wheels. Operate the spindle lock only when the tool is turned off and the
wheel has come to a complete stop.

WARNING: Do not engage the spindle lock while
the tool is operating. Damage to the tool will result
and attached accessory may spin off possibly
resulting in injury.

To engage the lock, depress the spindle lock button
shown in figure E1 and rotate the spindle until you are
unable to rotate the spindle further.

MOUNTING AND USING DEPRESSED CENTER
GRINDING WHEELS AND SANDING FLAP DISCS

Mounting and Removing Hubbed Wheels

WARNING: To prevent accidental operation, turn off and unplug tool before
performing the following operations. Failure to do this could result in serious

personal injury.
Hubbed wheels install directly on the 5/8 in.-11 threaded spindle.

1. Thread the wheel on the spindle by hand.

2. Depress the spindle lock button and use a wrench (figure E1) to tighten the hub of the
wheel.

3. Reverse the above procedure to remove the wheel.

CAUTION: Failure to properly seat the wheel before turning the tool on may result in

damage to the tool or the wheel.

F

11

12

G

13

E

90

∘

90

∘

E1

1/4 inch WHEELS

Backing Flange

Threaded Clamp Nut

1/8 inch WHEELS

Backing Flange

Threaded Clamp Nut

I

H

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 10

13

yield slower material removal and a smoother finish.
Begin with coarse grit discs for fast, rough material removal. Move to a medium grit
paper and finish with a fine grit disc for optimal finish.

Coarse 16 - 30 grit
Medium 36 - 80 grit
Fine Finishing 100 - 120 grit
Very Fine Finishing 150 - 180 grit

1. Allow the tool to reach full speed before touching tool to the work surface.

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed.
Sanding rate is greatest when the tool operates at high speed.

3. Figure M - Maintain a 5˚ to 15˚ angle between the tool and work surface. The san ­ding disc should contact approximately one inch (25mm) of work surface.

4. Move the tool constantly in a straight line to prevent burning and
swirling of work surface. Allowing the tool to rest on the work
surface without moving, or moving the tool in a circular motion
causes burning and swirling marks on the work surface.

5. Remove the tool from work surface before turning tool off. Allow
the tool to stop rotating before laying it down.

PRECAUTIONS TO TAKE WHEN SANDING PAINT

1. Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of
controlling the contaminated dust. The greatest danger of lead poisoning is to children
and pregnant women.

2. Since it is difficult to identify whether or not a paint contains lead without a chemical
analysis, we recommend the following precautions when sanding any paint:

PERSONAL SAFETY

1. No children or pregnant women should enter the work area where the paint sanding
is being done until all clean up is completed.

2. A dust mask or respirator should be worn by all persons entering the work area. The
filter should be replaced daily or whenever the wearer has difficulty breathing.
NOTE: Only those dust masks suitable for working with lead paint dust and fumes
should be used. Ordinary painting masks do not offer this protection. See your local
hardware dealer for the proper N.I.O.S.H. approved mask.

3. NO EATING, DRINKING or SMOKING should be done in the work area to prevent
ingesting contaminated paint particles. Workers should wash and clean up BEFORE
eating, drinking or smoking. Articles of food, drink, or smoking should not be left in the
work area where dust would settle on them.

ENVIRONMENTAL SAFETY

1. Paint should be removed in such a manner as to minimize the amount of dust
generated.

2. Areas where paint removal is occurring should be sealed with plastic sheeting of
4 mils thickness.

3. Sanding should be done in a manner to reduce tracking of paint dust outside the
work area.

CLEANING AND DISPOSAL

1. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for
the duration of the sanding project. Vacuum filter bags should be changed frequently.

2. Plastic drop cloths should be gathered up and disposed of along with any dust chips
or other removal debris. They should be placed in sealed refuse receptacles and
disposed of through regular trash pick-up procedures.
During clean up, children and pregnant women should be kept away from the
immediate work area.

3. All toys, washable furniture and utensils used by children should be washed
thoroughly before being used again.

M

5˚-15˚

12

4. Continuously move the tool in a forward and back motion to avoid
creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow
the tool to stop rotating before laying it down.

EDGE GRINDING WITH GRINDING WHEELS

CAUTION: Wheels used for edge grinding may break or kick back if they bend or twist
while the tool is being used to do cut-off work. To reduce the risk of serious injury, limit
the use of these wheels with a standard Type 27 guard to shallow cutting and notching
(less than 1/2 inch (13mm) in depth). The open side of the guard must be positioned
away from the operator. For deeper cutting with a Type 1 cut-off wheel, use a closed
Type 1 guard. See pages 9 and 10 for more information.

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply minimum pressure to the work surface, allowing the tool to operate at high
speed. Grinding rate is greatest when the tool operates at high speed.

3. Position yourself so that the open-underside of the wheel is facing away from you.

4. Once a cut is begun and a notch is established in the workpiece, do not change the
angle of the cut. Changing the angle will cause the wheel to bend and may cause
wheel breakage. Edge grinding wheels are not designed to withstand side pressures
caused by bending.

5. Remove the tool from the work surface before turning the tool off. Allow the tool to
stop rotating before laying it down.

CAUTION: Do not use edge grinding wheels / cutting wheels for surface grinding
applications because these wheels are not designed for side pressures encountered with
surface grinding. Wheel breakage and injury may result.

SURFACE FINISHING WITH SANDING FLAP DISCS

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed.
Sanding rate is greatest when the tool operates at high speed.

3. Figure K - Maintain a 5˚ to 10˚ angle between the tool and work surface.

4. Continuously move the tool in a forward and back motion to avoid
creating gouges in the work surface.

5. Remove the tool from work surface before turning tool off. Allow the
tool to stop rotating before laying it down.

MOUNTING SANDING BACKING PADS

WARNING: To prevent accidental operation, turn off and

unplug tool before performing the following operations. Failure to

do this could result in serious personal injury.
NOTE: Guard may be removed when using sanding backing pads. WARNING: Proper

guard must be reinstalled for grinding wheel, sanding flap disc, cutting wheel, wire brush or
wire wheel applications after sanding applications are complete.

1. Figure L - Place or appropriately thread backing pad (14) on the spindle.

2. Place the sanding disc (15) on the backing pad (14).

3. While depressing spindle lock, thread clamp nut (13) on
spindle, piloting the raised hub on the clamp nut into the
center of san ding disc and backing pad.

4. Tighten the clamp nut by hand, then depress the spindle
lock button while turning the sanding disc until the sanding
disc and clamp nut are snug.

5. To remove the wheel, grasp and turn the backing pad and
sanding pad while depressing the spindle lock button.

USING SANDING BACKING PADS

Choose the proper grit sanding discs for your application.
Sanding discs are available in various grits. Coarse grits yield
faster material removal rates and a rougher finish. Finer grits

J

20˚-30˚

K

5˚-10˚

13

14

15

L

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 12

15

2. Push the guard down until the guard lug engages and rotates freely in the groove on
the gear case hub.

3. Rotate guard (9) into desired working position. The guard body should be positioned
between the spindle and the operator to provide maximum operator protection.

4. Close the guard latch to secure the guard on the gear case cover. You should be
unable to rotate the guard by hand when the latch is in closed position. Do not
operate grinder with a loose guard or clamp lever in open position.

5. To remove the guard, open the guard latch, rotate the guard so that the arrows are
aligned and pull up on the guard.

NOTE: The guard is pre-adjusted to the dia met er of the gear case hub at the factory. If,
after a period of time, the guard becomes loose, tighten the adjusting screw (12) with the
clamp lever in the closed position with guard installed on the tool.

CAUTION: Do not tighten adjusting screw with clamp lever in open position.

Undetectable damage to guard or mounting hub may result.

MOUNTING CUTTING WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before

performing the following operations. Failure to do this could result in serious

personal injury.

CAUTION: Matching diameter threaded backing flange and clamp nut (included with

tool) must be used for cutting wheels.

1. Place the unthreaded backing flange on spindle with the raised section (pilot) facing
up. The raised section (pilot) on the backing flange will be against the wheel when
the wheel is installed.

2. Place the wheel on the backing flange, centering the wheel on the raised section
(pilot).

3. Install the threaded clamp nut with the raised section (pilot) facing away from the
wheel.

4. Depress the spindle lock button and tighten clamp nut with included wrench.

5. To remove the wheel, grasp and turn the wheel while depressing the spindle lock button.

USING CUTTING WHEELS

WARNING: Do not use edge grinding/cutting wheels for surface grinding applications
because these wheels are not designed for side pressures encountered with surface
grinding. Wheel breakage and injury may result.

1. Allow tool to reach full speed before touching tool to work surface.

2. Apply minimum pressure to work surface, allowing tool to operate at high speed.
Cutting rate is greatest when the tool operates at high speed.

3. Once a cut is begun and a notch is established in the workpiece, do not change the
angle of the cut. Changing the angle will cause the wheel to bend and may cause
wheel breakage.

4. Remove the tool from work surface before turning tool off. Allow the tool to stop
rotating before setting it down.

Maintenance

CLEANING

WARNING: Blowing dust and grit out of the motor housing using compressed air is a
necessary maintenance procedure. Dust and grit from metal grinding often accumulate
on interior surfaces and could create an electrical shock hazard if not cleaned out.

WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety
glasses. Also use face or dust mask if operation is dusty. ALWAYS WEAR CERTIFIED

SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),

• ANSI S12.6 (S3.19) hearing protection,

• NIOSH/OSHA/MSHA respiratory protection.

Use only mild soap and a damp cloth to clean the tool. Never let any liquid get inside the
tool; never immerse any part of the tool into a liquid.

14

MOUNTING AND USING WIRE BRUSHES AND WIRE WHEELS

Wire cup brushes or wire wheels screw directly on the grinder spindle without the use of
flanges. Use only wire brushes or wheels provided with a 5/8 inch-11 threaded hub. A
Type 27 guard is required when using wire brushes and wheels.

CAUTION: Wear work gloves when handling wire brushes and wheels. They can

become sharp.

CAUTION: Wheel or brush must not touch guard when mounted or while in use.
Undetectable damage could occur to the accessory, causing wires to fragment from accessory
wheel or cup.

MOUNTING WIRE CUP BRUSHES AND WIRE WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before
performing the following operations. Failure to do this could result in serious

personal injury.

1. Thread the wheel on the spindle by hand.

2. Depress spindle lock button and use a wrench on the hub of the wire wheel or brush
to tighten the wheel.

3. To remove the wheel, reverse the above procedure.

CAUTION: Failure to properly seat the wheel hub before turning the tool on may result

in damage to tool or wheel.

USING WIRE CUP BRUSHES AND WIRE WHEELS

Wire wheels and brushes can be used for removing rust, scale and paint, and for
smoothing irregular surfaces.

NOTE: The same precautions should be taken when wire brushing paint as when
sanding paint (see pages 12 and 13).

1. Allow the tool to reach full speed before touching the tool to the work surface.

2. Apply minimum pressure to work surface, allowing the tool to operate at high speed.
Material removal rate is greatest when the tool operates at high speed.

3. Figure N - Maintain a 5˚ to 10˚ angle between the tool and work
surface for wire cup brushes.

4. Maintain contact between the edge of the wheel and the work
surface with wire wheels.

5. Continuously move the tool in a forward and back motion to avoid
creating gouges in the work surface. Allowing the tool to rest on the
work surface without moving, or moving the tool in a circular motion causes burning
and swirling marks on the work surface.

6. Remove the tool from the work surface before turning the tool off. Allow the tool to
stop rotating before setting it down.

CAUTION: Use extra care when working over an edge, as a sudden sharp

movement of grinder may be experienced.

MOUNTING AND USING CUTTING (TYPE 1) WHEELS

Cutting wheels include diamond wheels and abrasive discs. Abrasive cutting wheels for
metal and concrete use are available. Diamond blades for concrete cutting can also be
used.

WARNING: A closed, 2-sided cutting wheel guard is re quired when using cutting
wheels. Fail ure to use proper flange and guard can re sult in injury resulting from wheel
breakage and wheel contact. See page 9 for more information.

MOUNTING CLOSED (TYPE 1) GUARD

WARNING: To prevent accidental operation, turn off and unplug tool before
performing the following operations. Failure to do this could result in serious

personal injury.

1. Open the guard latch (10), and align the arrow on the guard (9) with the arrow on the
hub (11). This will align the lugs with slots on the gear case cover. Position the guard
facing backward.

N

5˚-10˚

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 14

17

visit www.portercable.com or call [phone]. This warranty does not apply to
accessories or damage caused where repairs have been made or attempted by
others. This warranty gives you specific legal rights and you may have other rights
which vary in certain states or provinces.

In addition to the warranty, PORTER CABLE tools are covered by our:
1 YEAR FREE SERVICE: PORTER CABLE will maintain the tool and replace worn

parts caused by normal use, for free, any time during the first year after purchase.
90 DAY MONEY BACK GUARANTEE: If you are not completely satisfied with the

performance of your PORTER CABLE Power Tool for any reason, you can return it
within 90 days from the date of purchase with a receipt for a full refund – no questions asked.

LATIN AMERICA: This warranty does not apply to products sold in Latin America. For
products sold in Latin America, see country specific warranty information contained in
the packaging, call the local company or see website for warranty information.

To register your tool for warranty service visit our website at www.portercable.com

.

WARNING LABEL REPLACEMENT

If your warning labels become illegible or are missing, call [phone] for a free
replacement.

The following are PORTER CABLE trademarks for one or more power tools and accessories: a
gray and black color scheme; a “four point star” design; and three contrasting/outlined longitudinal
stripes. The following are also trademarks for one or more Porter Cable and Delta products: 2 BY
4®, 890™, Air America®, AIRBOSS™, Auto-Set®, B.O.S.S.®, Bammer®, Biesemeyer®, Builders
Saw®, Charge Air®, Charge Air Pro®, CONTRACTOR SUPERDUTY®, Contractor's Saw®,
Delta®, DELTA®, Delta Industrial®, DELTA MACHINERY & DESIGN™, Delta Shopmaster and
Design®, Delta X5®, Deltacraft®, DELTAGRAM®, Do It. Feel It.®, DUAL LASERLOC AND
DESIGN®, EASY AIR®, EASY AIR TO GO™, ENDURADIAMOND®, Ex-Cell®, Front Bevel
Lock®, Get Yours While the Sun Shines®, Grip to Fit®, GRIPVAC™, GTF®, HICKORY
WOODWORKING®, Homecraft®, HP FRAMER HIGH PRESSURE®, IMPACT SERIES™,
Innovation That Works®, Jet-Lock®, Job Boss®, Kickstand®, LASERLOC®, LONG-LASTING
WORK LIFE®, MAX FORCE™, MAX LIFE®, Micro-Set®, Midi-Lathe®, Monsoon®, MONSTER­CARBIDE™, Network®, OLDHAM®, Omnijig®, PC EDGE®, Performance Crew™, Performance
Gear®, Pocket Cutter®, Porta-Band®, Porta-Plane®, Porter Cable®, Porter Cable Professional
Power Tools®, Powerback®, POZI-STOP™, Pressure Wave®, PRO 4000®, Proair®, Quicksand
and Design®, Quickset II®, QUIET DRIVE TECHNOLOGY™, QUIET DRIVE TECHNOLOGY
AND DESIGN™, Quik-Change®, QUIK-TILT®, RAPID-RELEASE™, RAZOR®, Redefining
Performance®, Riptide®, Safe Guard II®, Sand Trap and Design®, Sanding Center®, Saw
Boss®, Shop Boss®, Sidekick®, Site Boss®, Speed-Bloc®, Speedmatic®, Stair Ease®, Steel
Driver Series®, SUPERDUTY®, T4 & DESIGN®, THE AMERICAN WOODSHOP®, THE
PROFESSIONAL EDGE®, Thin-Line®, Tiger Saw®, TIGERCLAW®, TIGERCLAW AND
DESIGN®, Torq-Buster®, TRU-MATCH®, T-Square®, Twinlaser®, Unifence®, Uniguard®,
UNIRIP®, UNISAW®, UNITED STATES SAW®, Veri-Set®, Versa-Feeder®, VIPER®, VT™, VT
RAZOR™, Water Driver®, WATER VROOM®, Waveform®, Whisper Series®, X5®, YOUR
ACHIEVEMENT. OUR TOOLS.®

Trademarks noted with ® are registered in the United States Patent and Trademark Office and may
also be registered in other countries. Other trademarks may apply.

4825 Highway 45 North

Jackson, TN 38305

[phone]

www.portercable.com

16

IMPORTANT: To assure product SAFETY and RELIABILITY, repairs, maintenance and
adjustment (other than those listed in this manual) should be performed by authorized
service centers or other qualified service personnel, always using identical replacement
parts.

LUBRICATION

Porter Cable tools are properly lubricated at the factory and are ready for use. Tools
should be lubricated regularly every year depending on usage. (Tools used on heavy
duty jobs and tools exposed to heat may require more frequent lubrication.) This
lubrication should be attempted only by trained power tool repair person such as those
at Porter Cable service centers or in other qualified service personnel.

SERVICE AND REPAIRS

All quality tools will eventually require servicing and/or replacement of parts. For information about
Porter Cable, its factory service centers or authorized warranty service centers, visit our website at
www.portercable.com or call our Customer Care Center at [phone]. All repairs made by our
service centers are fully guaranteed against defective material and workmanship. We cannot
guarantee repairs made or attempted by others.
You can also write to us for information at PORTER CABLE, 4825 Highway 45 North, Jackson,
Tennessee 38305 - Attention: Product Service. Be sure to include all of the information shown on
the nameplate of your tool (model number, type, serial number, etc.).

ACCESSORIES

WARNING: Since accessories, other than those offered by Porter Cable, have not

been tested with this product, use of such accessories with this tool could be
hazardous. To reduce the risk of injury, only Porter Cable recommended accessories
should be used with this product.

A complete line of accessories is available from your Porter Cable Factory Service
Center or a Porter Cable Authorized Warranty Service Center. Please visit our Web
Site www.portercable.com for a catalog or for the name of your nearest supplier.

THREE YEAR LIMITED WARRANTY

PORTER CABLE will repair or replace, without charge, any defects due to faulty
materials or workmanship for three years from the date of purchase for tools (two
years for batteries). This warranty does not cover part failure due to normal wear or
tool abuse. For further detail of warranty coverage and warranty repair information,

TROUBLESHOOTING

Problem Possible Cause Possible Solution

• Unit will not start. • Cord not plugged in. • Plug tool into a working outlet.

• Circuit fuse is blown. • Replace circuit fuse. (If the
product repeatedly causes the
circuit fuse to blow, discontinue
use immediately and have it
serviced at a Porter Cable
service center or authorized
servicer.)

• Circuit breaker is tripped. • Reset circuit breaker. (If the
product repeatedly causes the
circuit breaker to trip,
discontinue use immediately
and have it serviced at a Porter
Cable service center or
authorized servicer.)

• Cord or switch is damaged. • Have cord or switch replaced
at a Porter Cable Service
Center or Authorized Servicer

For assistance with your product, vis it our website at www.portercable.com for a list of
service centers, or call the PorterCable Customer Care Center at [phone].

90566170 PC60TCTAG PC60TAG Angle Grinder w-Cut-Off.qxd:??????-00 Cir Saw book 7/20/10 1:28 PM Page 16