Porter-Cable 6 IN. (150 MM) VARIABLE SPEEDGRINDER WITH WORKLIGHT, PCB575BG, PCB525BG Instruction Manual

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6 IN. (150 MM) VARIABLE SPEED
GRINDER WITH WORKLIGHT

MEULE À VITESSE VARIABLE DE
150 MM (6 PO) AVEC BALADEUSE

AMOLADORA DE VELOCIDAD
VARIABLE DE 150 MM (6 PULG.)
CON LUZ DE TRABAJO

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.

CATALOG NUMBER

PCB525BG

1

TABLE OF CONTENTS

SECTION PAGE

PRODUCT SPECIFICATIONS .......................................................................................................................

CALIFORNIA PROPOSITION 65 ...................................................................................................................

SAFETY GUIDELINES - DEFINITIONS .........................................................................................................

POWER TOOL SAFETY .................................................................................................................................

BENCH GRINDER SAFETY ...........................................................................................................................

ELECTRICAL REQUIREMENTS AND SAFETY ............................................................................................

TOOLS NEEDED FOR ASSEMBLY ...............................................................................................................

CARTON CONTENTS ....................................................................................................................................

KNOW YOUR BENCH GRINDER ..................................................................................................................

ASSEMBLY AND ADJUSTMENTS .................................................................................................................

OPERATION .................................................................................................................................................. 13

MAINTENANCE ............................................................................................................................................. 15

TROUBLESHOOTING GUIDE........................................................................................................................

ACCESSORIES AND ATTACHMENTS ..........................................................................................................

PARTS LIST ...................................................................................................................................................

WARRANTY ...................................................................................................................................................

2
2
3
4
5
7
8
8
9

10

16
17
18
20

PRODUCT SPECIFICATIONS

MOTOR WHEEL

Power source ........ 120 V AC, 60 HZ, 2.5 A Diameter .......................... 6 in. (150 mm)

Horsepower ...........

Speed ....................

Type.......................

Shaft diameter ...... 1/2 in. (12.7 mm)

Switch ....................

1/3 HP

2000 ~ 3400 RPM Hole ................................. 1/2 in. (12.7 mm)

Induction LIGHT BULB (not included) 40 W (maximum)

ON/OFF

Face ................................ 3/4 in. (20 mm)

!

WARNING

To avoid electrical hazards, fire hazards or damage to the tool, use proper circuit protection. Use a separate electrical
circuit for your tools. The grinder is wired at the factory for 110-120 Volt operation. It must be connected to a 120 V,

2.5 AMP branch circuit and use a 2.5 AMP time delay fuse or circuit breaker. To avoid shock or fire, replace power cord
immediately if it is worn, cut or damaged in any way.

CALIFORNIA PROPOSITION 65

!

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:

• 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 chemical: 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.

2010/01

2

Printed in China

SAFETY GUIDELINES - DEFINITIONS

WARNING ICONS
Your power tool and its Instruction Manual may contain “WARNING ICONS” (a picture symbol intended to alert
you to, and/or instruct you how to avoid, a potentially hazardous condition). Understanding and heeding these
symbols will help you operate your tool better and safer. Shown below are some of the symbols you may see.

SAFETY ALERT: Precautions that involve your safety.

PROHIBITION

WEAR EYE PROTECTION: Always wear safety goggles or safety glasses with side shields.

READ AND UNDERSTAND INSTRUCTION MANUAL: To reduce the risk of injury, user and all bystanders

must read and understand instruction manual before using this product.

KEEP HANDS AWAY FROM BLADE: Failure to keep your hands away from the blade will result in serious
personal injury.

SUPPORT AND CLAMP WORK

!

DANGER

!

WARNING

!

CAUTION

CAUTION

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 hazardous situation which, if not avoided, may result in minor
or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.

3

POWER TOOL SAFETY

GENERAL SAFETY INSTRUCTIONS
BEFORE USING THIS POWER TOOL

Safety is a combination of common sense, staying alert
and knowing how to use your power tool.

!

WARNING

To avoid mistakes that could cause serious injury,
do not plug the tool in until you have read and
understood the following.

1. READ and become familiar with the entire
Instruction Manual. LEARN the tool’s
application, limitations and possible hazards.

2. KEEP GUARDS IN PLACE and in working order.

3. REMOVE ADJUSTING KEYS AND WRENCHES.

Form the habit of checking to see that keys and
adjusting wrenches are removed from the tool before
turning ON.

4. KEEP WORK AREA CLEAN. Cluttered areas and

benches invite accidents.

5. DO NOT USE IN DANGEROUS ENVIRONMENTS.

Do not use power tools in damp locations, or expose
them to rain or snow. Keep work area well lit.

6. KEEP CHILDREN AWAY. All visitors and bystanders

should be kept a safe distance from work area.

7. MAKE WORKSHOP CHILD PROOF with padlocks,

master switches or by removing starter keys.

8. DO NOT FORCE THE TOOL. It will do the job better

and safer at the rate for which it was designed.

9. USE THE RIGHT TOOL. Do not force the tool or an

attachment to do a job for which it was not designed.

10. USE PROPER EXTENSION CORDS. Make sure

your extension cord is in good condition. When
using an extension cord, be sure to use one heavy
enough to carry the current your product will draw.
An undersized cord will result in a drop in line
voltage and in loss of power which will cause the tool
to overheat. The table on page 7 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.

11. WEAR PROPER APPAREL. Do not wear loose

clothing, gloves, neckties, rings, bracelets or other
jewelry which may get caught in moving parts.
Nonslip footwear is recommended. Wear protective
hair covering to contain long hair.

ANSI Z87.1 could seriously injure you when they
break.

13. WEAR A FACE MASK OR DUST MASK. Sawing

operation produces dust.

14. SECURE WORK. Use clamps or a vise to

hold work when practical. It is safer than
using your hand and it frees both hands to
operate the tool.

15. DISCONNECT TOOLS FROM POWER SOURCE

before servicing, and when changing accessories
such as blades, bits and cutters.

16. REDUCE THE RISK OF UNINTENTIONAL
STARTING. Make sure switch is in the OFF position
before plugging the tool in.

17. USE RECOMMENDED ACCESSORIES.
Consult this Instruction Manual for recommended
accessories. The use of improper accessories may
cause risk of injury to yourself or others.

18. NEVER STAND ON THE TOOL. Serious injury
could occur if the tool is tipped or if the cutting tool is
unintentionally contacted.

19. CHECK FOR DAMAGED PARTS. Before further
use of the tool, a guard or other part that is damaged
should be carefully checked to determine that it will
operate properly and perform its intended function
– check for alignment of moving parts, binding of
moving parts, breakage of parts, mounting and
any other conditions that may affect its operation.
A guard or other part that is damaged should be
properly repaired or replaced.

20. NEVER LEAVE THE TOOL RUNNING
UNATTENDED. TURN THE POWER “OFF”. Do
not walk away from a running tool until the grinding
wheels come to a complete stop and the tool is
unplugged from the power source.

21. DO NOT OVERREACH. Keep proper footing and
balance at all times.

22. MAINTAIN TOOLS WITH CARE. Keep tools sharp
and clean for best and safest performance. Follow
instructions for lubricating and changing accessories.

23. DO NOT use power tool in presence of flammable
liquids or gases.

24. DO NOT operate the tool if you are under the
influence of any drugs, alcohol or medication that
could affect your ability to use the tool properly.

12. ALWAYS WEAR EYE PROTECTION. Any

power tool can throw foreign objects into
the eyes and could cause permanent eye
damage. ALWAYS wear Safety Goggles

(not glasses) that comply with ANSI Safety standard
Z87.1. Everyday eyeglasses have only impact–
resistant lenses. They ARE NOT safety glasses.
NOTE: Glasses or goggles not in compliance with

25. Dust generated from certain materials can be
hazardous to your health. Always operate tool in
well-ventilated area and provide for proper dust
removal.

26. WEAR HEARING PROTECTION to reduce the risk
of induced hearing loss.

4

BENCH GRINDER SAFETY

1. Wear eye protection that complies with ANSI
Z87.1 specifications.

2. Use grinding wheels suitable for the speeds of the

grinder.

3. Stand beside the bench grinder during start-up, not

facing directly in front.

4. Do not remove the wheel guard.

5. Do not use the grinding wheel to cut anything.

6. Do not use anything to stress the grinding wheel.

7. Use a grinding wheel dressing tool to shape or

remove glaze from grinding wheels.

8. Adjust distance between wheel and tool rest to

maintain 1/8 inch (3.2 mm) or less separation as
the diameter of the wheel decreases with use.

9. Connect to a supply circuit protected by a circuit

breaker or time-delay fuse.

10. Secure the bench grinder to its supporting surface

to prevent the grinder from tipping over, sliding, or

walking on its supporting surface.
A. Replace a cracked wheel immediately.
B. Always use the guards and eye shields.
C. Do not overtighten the wheel nut.
D. Use only flanges furnished with this grinder.

11. Always inspect grinding wheels prior to use

for cracks, missing pieces, etc. Replace wheel

immediately before use.

12. USE ONLY GRINDING WHEELS that comply with

ANSI B7.1 and rated greater than 3450 RPM.

13. GUARD AGAINST ELECTRICAL SHOCK by

preventing body contact with grounded surfaces.

For example: pipes, radiators, ranges, refrigerator

enclosures.

17. NEVER stand or have any part of your body in line

with the path of the wheel.

18. DO NOT USE TOOL IF SWITCH DOES NOT
TURN IT ON AND OFF. Have defective switches
replaced by an authorized service center.

19. DO NOT TURN THE MOTOR SWITCH ON AND
OFF RAPIDLY. This could cause the wheel to
loosen and create a hazard. Should this ever
occur, stand clear and allow the wheel to come to
a complete stop. Disconnect your grinder from the
power supply and retighten the wheel nut securely.

20. RISK OF INJURY DUE TO ACCIDENTAL
STARTING. Do not use in an area where children
may be present.

21. NEVER START THE GRINDER when the wheel is
in contact with the workpiece.

22. SECURE WORK. Always hold the workpiece firmly
against the work rest.

23. DO NOT USE THE BENCH GRINDER if the flange
nut or clamp nut is missing or if the spindle shaft is
bent.

24. FREQUENTLY clean grinding dust from beneath
the grinder.

25. DO NOT OPERATE THIS TOOL WHILE UNDER

THE INFLUENCE OF DRUGS, ALCOHOL OR
ANY MEDICATION.

26. ALWAYS STAY ALERT. Do not allow familiarity
(gained from frequent use of your grinder) to cause
a careless mistake. ALWAYS REMEMBER that a
careless fraction of a second is sufficient to inflict
severe injury.

27. STAY ALERT AND EXERCISE CONTROL. Watch
what you are doing and use common sense. Do not
operate the tool when you are tired. Do not rush.

14. DO NOT use wheels with incorrect size holes.
NEVER use wheel washers or wheel screws that
are defective or incorrect, and NEVER touch a
grinding wheel or other moving parts.

15. NEVER reach to pick up a workpiece, a piece of
scrap, or anything else that is in or near the grinding
path of the wheel.

16. AVOID AWKWARD OPERATIONS AND HAND
POSITIONS where a sudden slip could cause your
hand to move into the wheel. ALWAYS make sure
you have good balance.

28. SAVE THESE INSTRUCTIONS. Refer to them

frequently and use them to instruct other users.
If you loan someone this tool, loan them these
instructions also.

29. ALWAYS EASE THE WORKPIECE AGAINST THE
ABRASIVE WHEEL when starting to grind. A harsh
impact can break the wheel. Use light pressure
when starting to grind. Too much pressure on a cold
wheel can cause the wheel to crack.

30. USE ONLY FLANGES furnished with this bench
grinder.

5

BENCH GRINDER SAFETY

31. IF ANY PART OF THIS GRINDER IS MISSING or

should break, bend, fail in any way, or should any
electrical component fail to perform properly, shut
off the power switch, remove the machine plug from
the power surce and have damaged, missing, or
failed parts replaced before resuming operation.

32. SAFETY SHIELD AND SPARK DEFLECTOR. The

safety shields and spark deflectors are adjustable
for operator convenience. Operating the grinder
without these features attached could result in
serious injury. Do not grind with the safety shield
raised. Always wear safety glasses for personal
protection.

33. WORK REST. The work rests are independently
adjustable to compensate for wheel wear. Before
grinding, make certain the work rests are adjusted
properly. Generally, the object being ground is done
slightly above the center of the grinding wheel.

34. Lawn mower blades are usually sharpened on only
one edge and dressed up slightly on the other.
Perform this sharpening process on both cutting
ends of the blade. After sharpening, balance the
blade by removing additional material.

6

ELECTRICAL REQUIREMENTS AND SAFETY

POWER SUPPLY AND MOTOR SPECIFICATIONS

!

WARNING

To avoid electrical hazards, fire hazards, or damage
to the tool, use proper circuit protection. Use a
separate electrical circuit for your tool. Your grinder
is wired at the factory for 120 V operation. Connect
to a 120 V, 2.5 Amp circuit and use a 2.5 Amp time
delay fuse or circuit breaker. To avoid shock or fire,
if power cord is worn, cut, or damaged in any way,
have it replaced immediately.

GROUNDING INSTRUCTIONS

!

WARNING

This tool must be grounded while in use to protect
the operator from electrical shock.

IN THE EVENT OF A MALFUNCTION OR
BREAKDOWN, grounding provides a path of least

resistance for electric currents and reduces the risk of
electric shock. This tool is equipped with an electrical
cord that has an equipment-grounding conductor
and a grounding plug. The plug must be plugged
into a matching receptacle that is properly installed
and grounded in accordance with all local codes and
ordinances.

DO NOT MODIFY THE PLUG PROVIDED. If it will not
fit the receptacle, have the proper receptacle installed
by a qualified electrician.

IMPROPER CONNECTION of the equipment grounding
conductor can result in risk of electric shock. The
conductor with the green insulation (with or without
yellow stripes) is the equipment grounding conductor.
If repair or replacement of the electrical cord or plug is
necessary, do not connect the equipment grounding
conductor to a live terminal.

CHECK with a qualified electrician or service person
if you do not completely understand the grounding
instructions, or if you are not certain the tool is properly
grounded.

USE only 3-wire extension cords that have
three-pronged grounding plugs with three-pole
receptacles that accept the tool’s plug. Repair or
replace damaged or worn cords immediately.

Use a separate electrical circuit for your tool. This circuit
must not be less than #18 wire and should be protected
with a 2.5 Amp time lag fuse. Before connecting the
motor to the power line, make sure the switch is in the
off position and the electric current is rated the same as
the current stamped on the motor nameplate. Running
at a lower voltage will damage the motor.

GUIDELINES FOR EXTENSION CORDS
USE THE PROPER EXTENSION CORD. Make sure

your extension cord is in good condition. Use an
extension cord 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, overheating

and burning out of the motor. The table below 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.

Make sure your extension cord is properly wired and in
good condition. Always replace a damaged extension
cord or have it repaired by a qualified technician before
using it. Protect your extension cords from sharp
objects, excessive heat and damp or wet areas.

MINIMUM GAUGE FOR EXTENSION CORDS (AWG)

(When using 120 volts only)

Ampere Rating Total length of Cord

More Than Not More Than 25 50 100 150 ft.

0 6 18 16 16 14

6 10 18 16 14 12

10 12 16 16 14 12

12 16 14 12 Not Recommended

!

WARNING

(7.62 15.24 30.48 45.72 m)

AWG- American Wire Gauge

This tool is for indoor use only. Do not expose to rain or
use in damp locations.

This tool is intended for use on a circuit that has a
receptacle like the one illustrated in Fig. 1. Fig. 1 shows
a three-pronged electrical plug and receptacle that has a
grounding conductor. If a properly grounded receptacle
is not available, an adapter (Fig. 2) can be used to
temporarily connect this plug to a two-contact grounded
receptacle. The adapter (Fig. 2) has a rigid lug extending
from it that MUST be connected to a permanent earth
ground, such as a properly grounded receptacle box.

!

CAUTION

In all cases, make certain the receptacle is properly
grounded. If you are not sure, have a qualified
electrician check the receptacle.

Fig. 1

Three-Pronged Plug

Grounding Prong

Properly Grounded
Three-Pronged Receptacle

Fig. 2

Grounding Lug

Make sure this is
connected to a
known ground.

Two-Pronged
Receptacle

Adapter

7

TOOLS NEEDED FOR ASSEMBLY

A

B

E

G

F

C

D

H

I

ON

OFF

L

H

Not supplied

Adjustable wrench Phillips screwdriver

CARTON CONTENTS

UNPACKING AND CHECKING CONTENTS

Carefully unpack the grinder and all its parts, and
compare against the list below and the illustration to the
right. With the help of an assistant place the grinder on
a secure surface and examine it carefully.

!

WARNING

● To avoid injury from unexpected starting or electrical
shock, do not plug the power cord into a source of
power during unpacking and assembly. This cord
must remain unplugged whenever you are adjusting/
assembling the grinder.

●

The grinder is heavy and should be lifted with care.

If needed, get the assistance of someone to lift and

move the grinder.

●

If any part is missing or damaged, do not attempt
to assemble the grinder, or plug in the power cord
until the missing or damaged part is correctly
replaced.

UNPACKING YOUR BENCH GRINDER

TABLE OF LOOSE PARTS

ITEM

DESCRIPTION QUANTITY

A. Bench grinder 1
B. Tool rest mounting bracket 2
C. Tool rest 2
D. Tool rest & eye shield hardware

bag
Locking knob / flat washer
Locking nut knob / flat washer /

carriage bolt
E. Spark guards 2
F. Spark guard hardware bag

Phillips screw 4

Lock washer 4

Flat washer 4

G. Right / left eye shields 1 each

H. Coolant tray 1

I. Wheel dressing tool 1

2 each

2 each

8

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F

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KNOW YOUR BENCH GRINDER

Worklight ON/OFF switch

Worklight

Eye shield mounting bracket

Spark guard

Medium grinding
wheel (60 Grit)

Left tool rest
(V-Grooved)

Mounting hole

Eye shield

Coarse grinding
wheel (36 Grit)

Right tool rest

Variable speed control knob

Coolant tray

ON/OFF switch

9

ASSEMBLY AND ADJUSTMENTS

O

N

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F

F

L

H

O

N

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F

F

L

H

Estimated Assembly Time: 10 - 20 minutes.

!

CAUTION

To avoid injury, make sure all parts are assembled
and adjusted properly before plugging the grinder
into a power outlet and turning it ON.

INSTALLING TOOL RESTS (FIG. A, B, C )

1. Bag “D” - Insert the lock knob (1) through

the flat washer (2) and the right side tool rest (3)
to the right side tool rest mounting bracket (4) as
shown.
NOTE: The grooved tool rest mounts on the left side
of grinder.

Fig. A

4

2

3

1

2. Remove the knob (5), lock washer (6) and flat
washer (7) from the carriage bolt (8) on the lower
portion of the wheel guard.

Fig. B

Fig. C

9

5

INSTALLING THE SPARK GUARDS (FIG. D)

1. Bag “F” - Attach the right spark guard (1) to the

extended pad (2) of guard by using the bolts (3),
spring washers (4) and flat washers (5).

2. Repeat for the left side spark guard.

NOTE: As the wheel wears down, the spark guards
must be re-adjusted to maintain a 1/16 in. (1.6 mm)

distance.

Fig. D

2

5

4

3

1

8

7

6

5

3. Attach the tool rest assembly (9) to the grinder as
shown.

4. Replace the washers and the lock knob (5).

5. Repeat the procedure for the left side tool rest.
NOTE: When in use, the tool rests should be
adjusted to within 1/8 in. (3.2 mm) of the grinding
wheel or other accessory being used.

INSTALLING THE EYE SHIELDS (FIG. E)

1. Bag “D” - Attach the right eye shield (1) to the spark

guard (2) by using the locking nut knob (3), lock
washer (4) and the carriage bolt (5).

2. Repeat for left side eye shield.

NOTE: Adjust eye shields to appropriate distance
from tool rests avoiding interference when operation.

Fig. E

1

5

4

3

2

10

CHANGING GRINDING WHEELS (FIG. F, G, G-1, H)

!

CAUTION

Turn off and unplug the bench grinder. Use only
grinding wheels that measure 6 inches (150 mm) in
diameter. This tool has 1/2 inch (12.7 mm) arbors on
both sides.

1. Raise the eye shield (1) out of the way and place the

spark guard (6) in its highest setting.

2. Loosen the knob (2) and remove the tool rest

assembly (3) and carriage bolt (4).

3. Remove the two screws (5) from the left side wheel

cover and then remove the outer cover.

Fig. F

6

1

5

ON

H

L

4

3

2

OFF

4. To prevent wheel rotating, place a wood wedge (7)

(not supplied) between the wheel and the wheel
cover as shown in Fig. G.
NOTE: Using a metal object, like a screwdriver, is
not recommended as it may damage the grinding
wheel.

5. Remove the hex nut (8) (as shown in Fig. G), the

wheel flange (9) and the wheel (10). (Fig. H)

Fig. G

Fig. G-1

7
Wood wedge

8

Tighten

NOTE: The nut on the right side of the grinder has
a standard right-hand thread (turn counterclockwise
to loosen). The one on the left side has a left-hand
thread (turn clockwise to loosen). Both wheel nuts
tighten when turning toward the rear of the grinder and
loosen when turning toward the front of the grinder.

6. Inspect the wheel (10) for cracks, chips or any
other visible damage (other than normal wear) and
discard if such damage is found. Inspect the blotter/
cardboard disc for damage. If the blotter is missing
or severely damaged, replace it with a piece of thin
cardboard or blotter paper cut in the same shape.
NEVER USE A GRINDING WHEEL WITHOUT A
BLOTTER.

7. Install the new wheel or other accessory. Make sure
both wheel flanges (9) are in place with the concave
sides toward wheels. (Fig. H)

8. Place a wood wedge (7) (not supplied) between the

wheel and the wheel cover as shown in Fig. G-1.
NOTE: Do not overtighten the nut as this can crack
the grinding wheel (10).

9. Replace the wheel cover and screws.

10. Adjust the tool rest to 1/8 in. (3.2 mm) away from the
wheel and tighten securely.

11. Reattach and adjust the eye shield to a point
between your eyes and the wheel.

12. Set the spark guard 1/16 in. (1.6 mm) away from the
wheel.

8

7
Wood wedge

Loosen

11

Fig. H

10

9

9

8

REPLACING THE BULB (FIG. I)

ON

OFF

L

H

ON

OFF

L

H

NOTE: Bulb is not included.

1. Remove the light bulb (1) from lampshade (2).

2. Install the new light bulb (40 W bulb maximum) into
lampshade (2).

Fig. I

2

1

MOUNTING THE TOOL ON A WORKBENCH (FIG. K)
NOTE: We highly recommend that you bolt this bench

grinder securely to a workbench to gain maximum
stability for your machine.

1. Using the base of the bench grinder as a template,
mark the bench through the holes in the casting.

2. Bolt the bench grinder on the bench with bolts,
washers and nuts. Note that these fasteners are not
supplied with the machine.

Fig. K

!

CAUTION

• To avoid injury from an accidental start, make
sure the switch is in the OFF position and the
plug is not connected to a power outlet.

• To prevent injury resulting from heat of the
light bulb, never touch the light bulb until it has
completely cooled.

• To prevent electric shock, never touch any part
of the light bulb when the plug is connected to a
power outlet.

• It is recommended to use a vibration-resistant
light bulb for this grinder.

INSTALLING THE COOLANT TRAY (FIG. J)

1. Hang the coolant tray (1) on the clips (2).

Fig. J

Hole in casting

WHEEL DRESSING TOOL STORAGE (Fig. L)

Storage clips (1) for the wheel dressing tool (2) are
located on the rear of the grinder.

Fig. L

2 1

1

2

12

OPERATION

ON

OFF

L

H

REMOVE
TO LOCK

ON

OFF

L

H

L

H

STARTING AND STOPPING THE GRINDER (FIG. M)

The “ON / OFF” switch has a removable, black plastic
key. With the key removed from the switch, unauthorized
and hazardous use by children and others is minimized.

1. To turn the grinder “ON”, insert key (1) into the slot

of the switch (2), and move the switch to the “ON”
position.

2. To turn the grinder “OFF”, move the switch to the

“OFF” position.

3. To lock the switch in the “OFF” position, grasp the

end, of the switch key, and pull it out.

4. With the switch key removed, the switch will not

operate.

5. If the switch key is removed while the grinder

is running, it can be turned “OFF” but cannot be
restarted without inserting the switch key.

!

CAUTION

Always lock the switch “OFF” when the grinder is
not in use. Remove the key and keep it in a safe
place. In the event of a power failure, blown fuse, or
tripped circuit breaker, turn the switch “OFF” and
remove the key, preventing an accidental startup
when the power comes on.

!

CAUTION

• To avoid injury from an accidental start, make
sure the switch is in the OFF position and the
plug is not connected to a power outlet.

• To prevent injury resulted from heat of the light

bulb, never touch the light bulb until it has
completely cooled.

• To prevent electric shock, never touch any part

of the light bulb when the plug is connected to a
power outlet.

• It's recommended to use a vibration-resistant

light bulb for this grinder.

ADJUSTING THE SPEED OF GRINDER (FIG. O)

Your grinder is equipped with a variable speed control
knob. The speed of the grinder may be adjusted by
simply rotating the variable speed control knob (1).

1. To increase speed, rotate the variable speed control

knob (1) clockwise.

2. To reduce speed, rotate the variable speed control

knob (1) counterclockwise.

Fig. O

Fig. M

2

1

USING THE WORKLIGHT (FIG. N)

1. To turn the worklight "ON", rotate the worklight
switch (1) counterclockwise.

2. To turn the worklight "OFF", rotate the worklight
switch (1) clockwise.

Fig. N

1

1

pointer

COOLING WORKPIECE (FIG. P)

The coolant tray (1) allows you to cool overheated
workpieces. Simply pull upward the tray and half fill with
appropriate coolant, such as water.

!

CAUTION

Do not overfill the coolant tray.

Fig. P

1

13

GENERAL OPERATION

!

CAUTION

Keep all bystanders a safe distance away from
the tool and not in direct line, front or back of the
grinder.

1. Your bench grinder has a medium wheel (60 grit)

for medium material removal and general purpose
grinding, and a coarse wheel (36 grit) for fast material
removal.

2. To operate the bench grinder, always wear safety

glasses and turn the tool on while standing at the side
and not in front of the grinder. Allow it to reach full
speed before grinding.

3. Hold the work piece firmly against the tool rest. Hold

very small pieces with pliers or other suitable clamps.

4. Feed the work piece smoothly and evenly into the

grinding wheel.

5. Move the work piece slowly and avoid jamming the

work piece against the wheel. If the wheel tends
to slow down from excessive force, you should
occasionally release the pressure to let the wheel
return to full speed.

6. Grind only on the face of the grinding wheel and

never the side of it. (Some wheels are designed
for side grinding and will say so on their blotters/
cardboard disc.)

!

CAUTION

Prolonged grinding will cause most materials
to become hot. Use care when handling such
materials.

TWIST DRILL BITS (FIG. Q)

Drill bits are best sharpened on a sharpening jig,
available at most hardware stores, but can be “dressed
up” on your grinder. Begin on one side of the point at
the existing angle, then twist the bit while maintaining a
constant angle with grinding surface. Sharpen only the
tip. This technique requires considerable practice, so
take your time and make a few “dry runs” first with the
grinder off. Be sure to maintain the original cutting edge
angle as this is important to the efficiency of your bits.
One tool rest has a V-groove that is correctly angled for
most drill bits.

Fig. Q

LAWN MOWER BLADES

Lawn mower blades are usually sharpened on only
one side and dressed up slightly on the other. After
sharpening, be sure to balance the blade by removing
additional material from the heavy end. There are a
number of inexpensive cone balancers on the market
for this purpose. Unbalanced blades can cause serious
crank shaft damage to your lawn mower. Always remove
spark plug wires from the mower before servicing the
blades to prevent accidental starting.

SCISSORS

If possible, take the scissors apart to make the
sharpening operation easier and safer. Remove material
only from the outside surface and work from the heavy
end of the blade toward the tip.

KNIVES

Remove metal from both faces of most knives, working
from the heavy end of the blade toward the tip.

SCREWDRIVERS

The end of a properly sharpened screwdriver will be
a perfect rectangle, absolutely flat and perpendicular
to the center line of the shank. The two sides and two
faces will taper outward from the edge of the shoulder
or shank. They should be flat with intersecting faces
perpendicular. Hold each face of the screwdriver against
the wheel to true it up, then ease the end straight into
the stone to grind it true.

DRESSING A GRINDING WHEEL (FIG. R)

A wheel dressing tool is provided with the grinder. Bring
the dressing tool forward on the tool rest until it touches
the high point on the face of the wheel. Dress the wheel
by moving the dressing tool back and forth. Repeat this
operation until the face of the grinding wheel is clean
and the corner of the wheel is square. NOTE: DO NOT
use the wheel dressing tool on wire wheels.

Fig. R

14

MAINTENANCE

!

CAUTION

For your own safety, turn switch “OFF” and remove
plug from power source outlet before adjusting and
maintaining your bench grinder. If power cord is
worn, cut or damaged in any way, have it replaced
immediately.

GENERAL

1. Regularly check the tool and use a soft brush to

remove accumulated dust. Wear safety goggles to
protect your eyes while cleaning.

2. If the body of the grinder needs cleaning, wipe it

down with a soft, damp cloth. A mild detergent can
be used. Do not use alcohol, petrol or other similar
cleaning agents. Do not make contact with the
grinding wheels with any damp cloth.

3. Always make sure the eyeshields are transparent

and not blocking the view of the grinding wheel.

4. In normal use, grinding wheels may become cracked,

grooved, rounded at the edges, chipped, out of true
or loaded with foreign material. Cracked wheels
should be replaced IMMEDIATELY. While any of the
other conditions can be remedied with a dressing tool
(included), new wheels sometimes require dressing
to make them round.

5. If you must replace a wheel be sure to obtain one

with a safe rated speed at least as high as the “NO
LOAD” RPM marked on your grinder’s nameplate.
Replacement wheels must have a 1/2 in. (12.7 mm)
center hole, 6 in. (150 mm) diameter and should be
a maximum of 3/4 in. (20 mm) wide. Test new wheels
for cracks and maintain the existing sequence of
retaining hardware. Be sure the tool is unplugged
before attempting repairs.

!

CAUTION

• Never use caustic agents to clean the plastic

parts of the tool.

• Water must never come into contact with the

grinder.

• The use of any other accessories is not

recommended and may result in serious injury.

15

TROUBLESHOOTING GUIDE

!

WARNING

To avoid injury from an accidental start, turn the switch OFF and always remove the plug from the power source before
making any adjustments.

REPLACEMENT PARTS

Use only identical replacement parts. For a parts list or to order parts, visit our service website at www.portercable.
com. You can also order parts from your nearest Porter-Cable Factory Service Center or Porter-Cable Authorized
Warranty Service Center. Or, you can call our Customer Care Center at [phone].

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 Power Tool Specialists, 684 Huey Road, Rock Hill, SC 29730
[phone] - Attention: Product Service. Be sure to include all of the information shown on the nameplate of your
tool (model number, type, serial number, etc.).

PROBLEM PROBLEM CAUSE SUGGESTED CORRECTIVE ACTION

Motor will not run. 1. Not plugged into power outlet.

2. Switch and key not in ON position.

3. Motor cord cut or abraded.

4. Plug on cord is faulty.

5. Faulty motor.

6. Fuse on circuit breaks open.

Grinding wheel vibrates or
shakes.

1. Grinding wheel is not fixed properly.

2. Other.

1. Plug it into the power outlet.

2. Insert key and turn the switch ON.

3. Contact Porter-Cable Service Center
or Authorized Service Station for repair
or replacement.

4. Contact Porter-Cable Service Center
or Authorized Service Station for repair
or replacement.

5. Contact Porter-Cable Service Center
or Authorized Service Station for repair
or replacement.

6. Re-set; may be too many machines on
line.

1. Adjust grinding wheel properly.
See ADJUSTMENT section.

2. Contact Porter-Cable Service Center
or Authorized Service Station for repair
or replacement.

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

16

ACCESSORIES AND ATTACHMENTS

AVAILABLE ACCESSORIES

!

WARNING

Since accessories, other than those offered by Porter­Cable, 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 Porter­Cable Authorized Warranty Service Center. Please
visit our Web Site www.portercable.com for a catalog
or for the name of your nearest supplier.

!

WARNING

Do not use any accessory unless you have completely
read the Instruction Manual for that accessory.

17

PARTS LIST

6 IN. (150 MM) VARIABLE SPEED GRINDER WITH WORKLIGHT

PARTS LIST

I.D. DESCRIPTION SIZE QTY I.D. DESCRIPTION SIZE QTY

X4AZ LAMP ASSEMBLY 1 X49R WHEEL 36# 1

X4AT PHILLIPS SCREW (WHITE) M5X16 4 X49Q CAPACITOR SUPPORT 1

X4AR BASE COVER 1 X49P HEX NUT (WHITE) M12 1

X4AQ PC BOARD 1 X49N RIGHT SAFTY GUARD COVER 1

X4AP PHILLIPS SCREW (WHITE) ST2.9X5 2 X49M CARRIAGE BOLT M5X51 2

X4AN PC BOARD COVER 1 X49L PHILLIPS SCREW M5X48 4

X4AM PHILLIPS SCREW (WHITE) M6X18 2 X49C SENSOR 1

X4AL LOCK WASHER (WHITE) D6 2 X49B PLATE 1

X4AK RUBBER FOOT 4 X49A RIGHT END CAP 1

X4AJ LOCK WASHER D5 16 X499 LOCK NUT M5 2

X4AH CAPACITOR 1 X498 FLAT WASHER D5 10

X4AG BASE 1 X494 PHILLIPS SCREW M4x12 4

X4AF CORD CLIP FIXING PLATE 1 X493 RIGHT SPARK SHIELD 1

X4AE CORD CLIP 1 X492 CARRIAGE BOLT M6x12 2

X4AD PHILLIPS SCREW M4X8 4 X491 PHILLIPS SCREW (WHITE) M4x8 3

X4AC CORD & PLUG 1 X490 RIGHT SAFETY GUARD 1

X4AB SPECIAL NUT M6 2 X48Z RIGHT FIXED WORK REST 1

X4AA CORD BUSHING 3 X48Y RIGHT MOVABLE WORK REST 1

X4A9 TOOTHED LOCK WASHER D4 6 X48X I TYPE HEX NUT (WHITE) M12 1

X4A8 LOCK WASHER D4 9 X48W LOCKING KNOB M6x17 2

X4A7 HEX NUT M4 10 X48V BIG FLAT WASHER (WHITE) D5 4

X4A6 FIX PLATE 1 X48U LEFT SAFETY GUARD COVER 1

X4A5 MOUNTING PLATE 1 X48T LEFT SAFETY GUARD 1

X4A4 PHILLIPS SCREW M4X25 2 X48S WHEEL 60# 1

X4A3 SPEED CONTROLER 1 X48R LEFT FIXED WORK REST 1

X4A2 SWITCH PLATE 1 X48Q LEFT MOVABLE WORK REST 1

X4A1 PHILLIPS SCREW M5X10 14 X48L PHILLIPS SCREW M2.5X8 2

X4A0 SPEED CONTROL KNOB 1 X48K PHILLIPS SCREW M4x6 1

X4B5 FLAT WASHER (WHITE) D4 7 X48J FLAT WASHER D6 2

X4B4 BIG FLAT WASHER D5 2 X48H LEFT SPARK SHIELD 1

X4B3 STANDARD SPRING WASHER (WHITE) D4 2 X48G WHEEL DRESSING TOOL 1

X4B2 I TYPE HEX NUT (WHITE) M4 4 X48F WHEEL DRESSING CLIP 1

X4B1 RIGHT EYE SHIELD ASSEMBLY 1 X48D VARIABLE SPEED LABEL 1

X4B0 LEFT EYE SHIELD ASSEMBLY 1 X48C DATA LABEL 1

X4C5 RUB COVER 1 X48B ROTATION LABEL 2

X49Z SWITCH GUARD 1 X48A INSTRUCTION MANUAL 1

X49Y PHILLIPS SCREW M3X10 2

X49X SWITCH 1

X49W COOLANT TRAY 1 HARDWARE BAG

X49V I TYPE HEX NUT M5 5 X4C9

X49U LOCK NUT M6 2 X4C8

X49T COOLANT TRAY CLIP 1

X49S FLANGE 4

TOOL REST & EYE SHIELD HARDWARE BAG

SPARK GUARD HARDWARE BAG

1

1

18

6 IN. (150 MM) VARIABLE SPEED GRINDER WITH WORKLIGHT

X4AT

X4AR

X4A

Q

X4AP

X4AN

X4AM

X4AL

X4AK

X4AH

X4A

G

X4AF

X4AE

X4A

C

X4AB

X4AA

X4A9
X4B5

X4B3

X4B5

X4A7

X4A6

X4A5

X4A4

X49S

X49R

X49P

X49N

X49M

X49L

X49C

X49B

X49A

X48J

X493

X4AJ

X4A1

X490

X48Z

X48Y

X48W

X4AJ

X4B4

X499

X48U

X48X

X48J

X48R

X48Q

X4A1

X491

X49S

X49S

X49S

X4A7

X4A8

X48L

X4AA

X4B2

X4AJ

X4AJ

X492

X498

X49L

X49M

X4A1

X48H

X49U

X499

X4AJ

X48W

X4B4

X498

X4A3

X4A2

X4A1

X4A0

X49Z

X49Y

X49X

X49W

X4AD

X4A9

X49T

X49U

X48S

X48T

X48K

X49V

X491

X49Q

X4A8

X49V

X4AJ

X4AJ

X49V

X492

X498

X4A1

X4A1

X4AJ

X498

X498

X48V

X498

X4AD

X48F

X48D

X48C

X48B

X48B

X4AK

X4A9

X498

X4AZ

X48G

MANUAL

INSTRUCTION

X48A

X4B0

X4B1

D. Hardware Bag F. Hardware Bag

X49U

2

X48J

2

X492

2

X4C9 X4C8

X4C5

X4A1

4

X498

4

X4AJ

4

X498

2

X48W

2

SCHEMATIC

19

WARRANTY

THREE YEAR LIMITED WARRANTY

PORTER-CABLE will repair, without charge, any defects due to faulty materials or workmanship for three years from the date of
purchase. This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and
warranty repair information, 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 DAYS 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®, 890TM, Air America®, AIRBOSSTM, 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 & DESIGNTM, Delta Shopmaster and Design®, Delta X5®, Deltacraft®, DELTAGRAM®, Do It. Feel it.®, DUAL
LASERLOC AND DESIGN®, EASY AIR®, EASY AIR TO GOTM, ENDURADIAMOND®, Ex-Cell®, Front Bevel Lock®, Get Yours While
the Sun Shines®, Grip to Fit®, GRIPVACTM, GTF®, HICKORY WOODWORKING®, Homecraft®, HP FRAMER HIGH PRESSURE®,
IMPACT SERIESTM, Innovation That Works®, Jet-Lock®, Job Boss®, Kickstand®, LASERLOC®, LONG-LASTING WORK LIFE®, MAX
FORCETM, MAX LIFE®, Micro-Set®, Midi-Lathe®, Monsoon®, MONSTER-CARBIDETM, Network®, OLDHAM®, Omnijig®, PC EDGE®,
Performance CrewTM, Performance Gear®, Pocket Cutter®, Porta-Band®, Porta-Plane®, Porter-Cable®, Porter-Cable Professional
Power Tools®, Powerback®, POZI-STOPTM, Pressure Wave®, PRO 4000®, Proair®, Quicksand and Design®, Quickset II®, QUIET
DRIVE TECHNOLOGYTM, QUIET DRIVE TECHNOLOGY AND DESIGNTM, Quick-Change®, QUIK-TILT®, RAPID-RELEASETM,
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®, VTTM, VT RAZORTM, Water Driver®, WATER VROOM®, Waveform®, Whisper Series®, X5®, YOUR
ACHIEVEMENT. OUR TOOLS.
also be registered in other countries. Other trademarks may apply.

®

, Trademarks noted with ® are registered in the United States Patent and Trademark Office and may

PORTER-CABLE and the PORTER-CABLE logo are registered trademarks of PORTER-CABLE and are used under license. All
rights reserved.

Power Tool Specialists, Inc.

684 Huey Road, Rock Hill, SC 29730

[phone]

www.portercable.com

20