Porter-Cable PCB575BG User Manual

8 IN. (200 MM) VARIABLE SPEED GRINDER WITH WORKLIGHT

MEULE À VITESSE VARIABLE DE 200 MM (8 PO) AVEC BALADEUSE

AMOLADORA DE VELOCIDAD VARIABLE DE 200 MM (8 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

PCB575BG

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

16 17 18 20

PRODUCT SPECIFICATIONS

MOTOR WHEEL

Power source ........ 120 V AC, 60 HZ, 5 A Diameter .......................... 8 in. (200 mm)

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

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

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

Shaft diameter ...... 5/8 in. (15.88 mm)

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

3/4 HP Face ................................ 1 in. (25 mm)

2000 ~ 3400 RPM Hole ................................. 5/8 in. (15.88 mm)

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

ON/OFF

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, 5 AMP branch circuit and use a 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

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

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.

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.

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.

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.

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, 5 Amp circuit and use a 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 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

TOOLS NEEDED FOR ASSEMBLY

OFF

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

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

ASSEMBLY AND ADJUSTMENTS

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

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

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

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

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

CAUTION

Turn off and unplug the bench grinder. Use only grinding wheels that measure 8 inches (200 mm) in diameter. This tool has 5/8 inch (15.88 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

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

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.

7 Wood wedge

Loosen

Fig. H

REPLACING THE BULB (FIG. I)

OFF

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

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

OPERATION

OFF

REMOVE TO LOCK

OFF

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

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

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

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

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 5/8 in. (15.88 mm) center hole, 8 in. (200 mm) diameter and should be a maximum of 1 in. (25 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.

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 (888) 609-9779.

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 (888) 609-9779. 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 (888) 609-9779 - 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 (888) 609-9779.

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.

PARTS LIST

8 IN. (200 MM) VARIABLE SPEED GRINDER WITH WORKLIGHT

PARTS LIST

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

X488 PHILLIPS SCREW (WHITE) M5X16 4 X46S PLATE 1

X486 BASE COVER 1 X46R RIGHT END CAP 1

X485 PC BOARD 1 X46Q LOCK NUT M5 2

X484 PHILLIPS SCREW (WHITE) ST2.9X5 2 X46P FLAT WASHER D5 10

X483 PC BOARD COVER 1 X46K PHILLIPS SCREW M4X12 4

X482 PHILLIPS SCREW (WHITE) M8X22 2 X46J RIGHT SPARK SHIELD 1

X481 LOCK WASHER (WHITE) D8 2 X46H CARRIAGE BOLT M6X12 2

X480 RUBBER FOOT 4 X46G PHILLIPS SCREW (WHITE) M4X8 3

X47Z LOCK WASHER D5 20 X46F RIGHT SAFETY GUARD 1

X47Y CAPACITOR 1 X46E RIGHT FIXED WORK REST 1

X47X BASE 1 X46D RIGHT MOVABLE WORK REST 1

X47W CORD CLIP FIXING PLATE 1 X46C I TYPE HEX NUT (WHITE) M16 LEFT 1

X47V CORD CLIP 1 X46B LOCKING KNOB M6X17 2

X47U PHILLIPS SCREW M4X8 4 X46A BIG FLAT WASHER (WHITE) D5 4

X47T CORD & PLUG 1 X469 LEFT SAFETY GUARD COVER 1

X47S SPECIAL NUT M8 2 X468 LEFT SAFETY GUARD 1

X47R CORD BUSHING 3 X467 WHEEL 60# 1

X47Q TOOTHED LOCK WASHER D4 6 X466 LEFT FIXED WORK REST 1

X47P LOCK WASHER D4 5 X465 LEFT MOVABLE WORK REST 1

X47N HEX NUT M4 6 X461 PHILLIPS SCREW M2.5X8 2

X47M FIX PLATE 1 X460 PHILLIPS SCREW M4X6 1

X47L MOUNTING PLATE 1 X45Z FLAT WASHER D6 2

X47K PHILLIPS SCREW M4X25 2 X45Y LEFT SPARK SHIELD 1

X47J SPEED CONTROLER 1 X45X WHEEL DRESSING TOOL 1

X47H SWITCH PLATE 1 X45W WHEEL DRESSING CLIP 1

X47G PHILLIPS SCREW M5X10 14 X45U VARIABLE SPEED LABEL 1

X47F SPEED CONTROL KNOB 1 X45T DATA LABEL 1

X47E SWITCH GUARD 1 X45S ROTATION LABEL 2

X47D PHILLIPS SCREW M3X10 2 X45R INTRUCTION MANUAL 1

X47C SWITCH 1 X4BD FLAT WASHER (WHITE) D4 3

X47B COOLANT TRAY 1 X4BC BIG FLAT WASHER D5 2

X47A I TYPE HEX NUT M5 9 X4BB STANDARD SPRING WASHER (WHITE) D4 2

X479 LOCK NUT M6 2 X4BA I TYPE HEX NUT (WHITE) M5 4

X478 COOLANT TRAY CLIP 1 X4B8 RIGHT EYE SHIELD ASSEMBLY 1

X477 FLANGE 4 X4B7 LEFT EYE SHIELD ASSEMBLY 1

X476 WHEEL 36# 1 X4B6 LAMP ASSEMBLY 1

X475 CAPACITOR SUPPORT 1 X4C4 RUB COVER 1

X474 HEX NUT (WHITE) M16 1

X473 RIGHT SAFTY GUARD COVER 1

X472 CARRIAGE BOLT M5X51 2 HARDWARE BAG

X471 PHILLIPS SCREW M5X48 4 X4C7

X46T SENSOR 1 X4C6

TOOL REST & EYE SHIELD HARDWARE BAG

SPARK GUARD HARDWARE BAG

8 IN. (200 MM) VARIABLE SPEED GRINDER WITH WORKLIGHT

X488

X486

X485

X484

X483

X482

X481

X47Y

X47X

X47W

X47V

X47T

X47S

X47R

X47Q

X47N

X47M

X47L

X47K

X477

X476

X474

X473

X472

X471

X4BA

X4BB

X4BD

X46T

X46S

X46R

X45Z

X46J

X47Z

X47G

X46F

X46E

X46D

X46B

X47Z

X46Q

X469

X46C

X45Z

X466

X465

X47G

X46G

X477

X47A

X47Z

X461

X47R

X47Z

X46H

X46P

X471

X472

X4B6

X47G

X45Y

X479

X46Q

X47Z

X46B

X4BC

X4B8

X4B7

X46P

X47J

X47H

X47G

X47F

X47E

X47D

X47C

X47B

X47U

X47Q

X478

X479

X467

X468

X460

X47A

X46G

X475

X47P

X47A

X47Z

X47A

X46H

X46P

X47G

X47Z

X46P

X46A

X46P

X47U

X45W

X45U

X45T

X45S

X480

X47Q

X46P

X45X

MANUAL

INSTRUCTION

X45R

D. Hardware Bag

F. Hardware Bag

X479

X4C7

X4C4

X4C6

X45Z

X46H

X47G

X46P

X47Z

X46P

X46B

SCHEMATIC

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 (888) 609-9779. 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 (888) 609-9779 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

Power Tool Specialists, Inc.

684 Huey Road, Rock Hill, SC 29730

(888) 609-9779

www.portercable.com

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