614230 - Sander MILWAUKEE - Free user manual and instructions

USER MANUAL 614230 MILWAUKEE

SAFETY WARNINGS WARNING Read all safety warnings, instruc- tions, illustrations and specica- tions provided with this power tool. Failure to follow all instructions listed below may result in electric shock, re and/or serious injury. Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-oper- ated (cordless) power tool.

Keep work area clean and well lit. Cluttered or dark areas invite accidents.

• Do not operate power tools in explosive atmo- spheres, such as in the presence of ammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

• Keep children and bystanders away while operat

ing a power tool. Distractions can cause you to lose control. ELECTRICAL SAFETY

• Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Un- modied plugs and matching outlets will reduce risk of electric shock.

• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

• Do not expose power tools to rain or wet condi- tions. Water entering a power tool will increase the risk of electric shock.

• Do not abuse the cord. Never use the cord for car- rying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.

• When operating a power tool outdoors, use an ex- tension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.

• If operating a power tool in a damp location is unavoidable, use a ground fault circuit interrupter (GFCI) protected supply. Use of an GFCI reduces the risk of electric shock. PERSONAL SAFETY

• Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the inuence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.

• Use personal protective equipment. Always wear eye protection. Protective equipment such as a dust mask, non-skid safety shoes, hard hat or hearing protection used for appropriate conditions will reduce personal injuries.

• Prevent unintentional starting. Ensure the switch is in the o󰀨-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your nger on the switch or energizing power tools that have the switch on invites accidents.

• Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury.

• Do not overreach. Keep proper footing and bal- ance at all times. This enables better control of the power tool in unexpected situations.

• Dress properly. Do not wear loose clothing or jewelry. Keep your hair and clothing away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

• If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust col- lection can reduce dust-related hazards.

• Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

POWER TOOL USE AND CARE

• Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.

• Do not use the power tool if the switch does not turn it on and o󰀨. Any power tool that cannot be controlled with the switch is dangerous and must be repaired.

• Disconnect the plug from the power source and/ or remove the battery pack, if detachable, 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.

• Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.

• Maintain power tools and accessories. Check for misalignment or binding of moving parts, break- age of parts and any other condition that may a󰀨ect the power tool’s operation. If damaged, have the power tool repaired before use. Many ac- cidents are caused by poorly maintained power tools.

• Keep cutting tools sharp and clean. Properly main- tained cutting tools with sharp cutting edges are less likely to bind and are easier to control.

• Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations di󰀨erent from those intended could result in a hazard- ous situation.

• Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations. SERVICE

• Have your power tool serviced by a qualied repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

SPECIFIC SAFETY RULES FOR

GRINDERS Safety Warnings Common for Grinding, Sanding, Wire Brushing or Cutting-O󰀨 Operations:

• This power tool is intended to function as a grinder, sander, wire brush, hole cutter or cut- o󰀨 tool. Read all safety warnings, instructions, illustrations and specications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, re and/or serious injury.3

• Operations such as polishing are not to be per- formed with this power tool. Operations for which the power tool was not designed may create a hazard and cause personal injury.

• Do not convert this power tool to operate in a way which is not speccally designed and specied by the tool manufacturer. Such a conversion may result in a loss of control and cause serious personal injury.

• Do not use accessories which are not specically designed and specied by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation.

• The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their rated speed can break and y apart.

• The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool. Incorrectly sized accessories can- not be adequately guarded or controlled.

• The dimensions of the accessory mounting must t the dimensions of the mounting hardware of the power tool. Accessories that do not match the mount- ing hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.

• Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an ac- cessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.

• Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping ying debris generated by various applica- tions. The dust mask or respirator must be capable of ltrating particles generated by the particular ap- plication. Prolonged exposure to high intensity noise may cause hearing loss.

• Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken accessory may y away and cause injury beyond immediate area of operation.

• Hold the power tool by insulated gripping sur- faces only, when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a "live" wire may also make exposed metal parts of the power tool "live" and could give the operator an electric shock.

• Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.

• Never lay the power tool down until the acces- sory has come to a complete stop. The spinning accessory may grab the surface and pull the power tool out of your control.

• Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory could snag your clothing, pulling the accessory into your body.

• Regularly clean the power tool's air vents. The motor's fan will draw the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

• Do not operate the power tool near ammable materials. Sparks could ignite these materials.

• Do not use accessories that require liquid cool

ants. Using water or other liquid coolants may result in electrocution or shock. Kickback and Related Warnings: Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other acces- sory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncon- trolled power tool to be forced in the direction opposite of the accessory's rotation at the point of the binding. For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel's movement at the point of pinching. Abrasive wheels may also break under these conditions. Kickback is the result of power tool misuse and/or in- correct operating procedures or conditions and can be avoided by taking proper precautions as given below.

• Maintain a rm grip on the power tool and posi- tion your body and arms to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up. The operator can control torque reactions or kickback forces, if proper precautions are taken.

• Never place your hand near the rotating acces- sory. Accessory may kickback over your hand.

• 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 wheel's movement at the point of snagging.

• Use special care when working corners, sharp edges, etc. Avoid bouncing and snagging the ac- cessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.

• Do not attach a saw chain woodcarving blade, segmented diamond wheel with a peripheral gap greater than 10 mm or toothed saw blade. Such blades create frequent kickback and loss of control. Safety Warnings Specic for Grinding and Cutting- O󰀨 Operations:

• Use only wheel types that are specied for your power tool and the specic guard designed for the selected wheel. Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.

• The grinding surface of centre depressed wheels must be mounted below the plane of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.

• The guard must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator. The guard helps to protect the operator from broken wheel fragments, accidental contact with wheel and sparks that could ignite clothing.

• Wheels must be used only for specied applica

tions. For example: do not grind with the side of cut-o󰀨 wheel. Abrasive cut-o󰀨 wheels are intended4 wire wheel or brush with the guard. Wire wheel or brush may expand in diameter due to work load and centrifugal forces. Additional Safety Warnings

WARNING To reduce the risk of injury when working in dusty situations, use an OSHA compliant dust extraction solution in ac- cordance with its operating instructions or wear appropriate respiratory protection.

• Do not use this tool to work on asbestos-con- taining products. Determine the composition of the workpiece before beginning work. Asbestos should only be removed by a qualified professional.

• Always operate with two hands.

• Always use common sense and be cautious when using tools. It is not possible to anticipate every situation that could result in a dangerous outcome. Do not use this tool if you do not understand these operating instructions or you feel the work is beyond your capability; contact Milwaukee Tool or a trained professional for additional information or training.

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

WARNING Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• lead from lead-based paint

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumber. Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to lter out microscopic particles. EXTENSION CORDS Grounded tools require a three wire extension cord. Double insulated tools can use either a two or three wire extension cord. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. Refer to the table shown to determine the required minimum wire size. The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord. When using more than one extension cord to make up the total length, be sure each cord contains at least the minimum wire size required. If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum wire size. Guidelines for Using Extension Cords

• If you are using an extension cord outdoors, be sure it is marked with the su󰀩x “W-A” (“W” in Canada) to indicate that it is acceptable for outdoor use.

• Be sure your extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualied person before using it.

• Protect your extension cords from sharp objects, excessive heat and damp or wet areas. for peripheral grinding, side forces applied to these wheels may cause them to shatter.

• Always use undamaged wheel anges that are of correct size and shape for your selected wheel. Proper wheel anges support the wheel thus reducing the possibility of wheel breakage. Flanges for cut-o󰀨 wheels may be di󰀨erent from grinding wheel anges.

• Do not use worn down wheels from larger power tools. A wheel intended for larger power tool is not suitable for the higher speed of a smaller tool and may burst.

• When using dual purpose wheels always use the correct guard for the application being performed. Failure to use the correct guard may not provide the desired level of guarding, which could lead to seri- ous injury. Additional Safety Warnings Specic for Cutting- O󰀨 Operations:

• Do not "jam" the cut-o󰀨 wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage.

• 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 pos- sible kickback may propel the spinning wheel and the power tool directly at you.

• When wheel is binding or when interrupting a cut for any reason, switch o󰀨 the power tool and hold it motionless until the wheel comes to a complete stop. Never attempt to remove the cut-o󰀨 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.

• Do not restart the cutting operation in the work- piece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the workpiece.

• Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.

• Use extra caution when making a "pocket cut" into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

• Do not attempt to do curved cutting. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and the possibility of kickback or wheel breakage, which can lead to serious injury. Safety Warnings Specic for Sanding Operations:

• Use proper sized sanding disc paper. Follow manufacturers recommendations, when selecting sanding paper. Larger sanding paper extending be- yond the sanding pad presents a laceration hazard and may cause snagging, tearing of the disc or kickback. Safety Warnings Specic for Wire Brushing Op- erations:

• Be aware that wire bristles are thrown by the brush even during ordinary operation. Do not overstress the wires by applying excessive load to the brush. The wire bristles can easily penetrate light clothing and/or skin.

• If the use of a guard is recommended for wire brushing, do not allow any interference of the5 Recommended Minimum Wire Gauge For Extension Cords* Nameplate Amps Extension Cord Length 25' 50' 75' 100' 150'

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

• INSTRUCTIONS FOR FUTURE USE. GROUNDING WARNING Improperly connecting the ground- ing wire can result in the risk of electric shock. Check with a qualied electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug pro- vided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the cord or plug is damaged. If damaged, have it repaired by a MILWAUKEE service facility before use. If the plug will not t the outlet, have a proper outlet installed by a qualied electrician. Grounded Tools (Three-Prong Plugs) Tools marked “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet (See Figure A). If the tool should electrically mal- function or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool's grounding system and must never be attached to an electrically “live” terminal. Your tool must be plugged into an appro- Fig. A priate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in Figure A. Double Insulated Tools (Two-Prong Plugs) Tools marked “Double Insulated” do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards Fig. BFig. C of Underwriters Laboratories, Inc., the Canadian Standard Association and the National Electrical Code. Double Insulated tools may be used in either of the 120 volt outlets shown in Figures B and C. SPECIFICATIONS Cat. No p. 6141
• -30, 6141-31, 6142-30, 6142-31 Volts p. 120
• AC Amps p. 11
• RPM p. 12
• ,000 Spindle Thread Size p. 5
• /8"-11 Max Capacity -1/2"x1/4" FUNCTIONAL DESCRIPTION p. 4

SYMBOLOGY Double Insulated Volts

Alternating Current Amps

Rated Revolutions per Minute (RPM) UL Listing for Canada and U.S. Approval Mark for Mexico ASSEMBLY WARNING To reduce the risk of injury, always unplug tool before changing or removing accessories. To reduce the risk of injury when grinding, always use properly installed guards. The guard size and type must match the wheel size and type to provide maximum protection for the operator if the wheel should break. Only use accessories specically recommended for this tool. Others may be hazardous. Removing/Installing/Adjusting the Guard This tool is shipped with a guard. Always use a guard unless otherwise indicated by these instructions.

1. WARNING! Unplug to avoid starting the tool.

3. Press in the detent tab and rotate the guard clock-

wise until the tabs on the grinder line up with the slots in the guard.

4. Lift the guard straight up and away from the tool.6

5. To install the guard, unplug the tool and remove

any accessories from the spindle. NOTE: Guard size must match wheel size. For example, use 4 1/2" guard only with 4 1/2" wheel. (Some guards available as accessories). See "Ac- cessories".

6. Line up the tabs on the grinder with the slots in

the guard. The arrows on the grinder and guard will align.

7. Press in the detent tab and press the guard onto

the tool. Rotate guard counterclockwise into rst detent slot.

8. To adjust the guard, press in the detent tab

and rotate the guard to one of ve detent slots. WARNING! Always adjust the guard to provide the operator with maximum protection while operating. Operator's Zones WARNING To reduce the risk of injury, always use a side handle when using this tool. Hold securely. Installing Side Handle The side handle may be installed on either side of the gear case. Position the side handle in the loca- tion which o󰀨ers best control and guard protection. To install, thread side handle into side handle socket and tighten securely. WARNING To reduce the risk of injury, the operator should be instructed in the use, care and protection of grinding wheels. Grinding Wheel Selection Use grinding wheels, and accessories that are:

• correct size as written on tool’s nameplate.

• rated at or above the RPM listed on the tool’s name- plate.

• correct accessory, wheel type and grit for the job. Grinding is the cutting action of thousands of abrasive grains on the face of a grinding wheel. When grinding metals such as steel and iron, choose an aluminum oxide grinding wheel. Select a silicon carbide grinding wheel for stone and concrete. Use cotton reinforced wheels for non-ferrous metals. Type 1 reinforced 1/8" thick or less cut-o󰀨 wheels are suited for small cut-o󰀨 and shallow notching operations only. Always handle wheels carefully to avoid damage. Before installing any wheel, always inspect it for cracks. If wheel is cracked, discard it to prevent others from using it. Care of Grinding & Cut-O󰀨 Wheels Grinding/cut-o󰀨 wheels should be protected from:

• wetness and extreme humidity

• extreme changes in temperature

• dropping and bumping Grinding and cut-o󰀨 wheels should be stored:

• in an organized way so wheels can be removed without disturbing or damaging other wheels

• with their safety information Grinding and cut-o󰀨 wheels should NOT be dropped, rolled or bumped. Grinding and cut-o󰀨 wheels should not be used beyond their expiration date. Discard wheels that have been dropped, rolled, bumped, subjected to extreme changes in tempera- ture, come into contact with solvents or wetness, or expired. WARNING The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Ac- cessories running faster than their rated speed can break and y apart, causing injury. Installing/Removing Grinding & Cut-O󰀨 Wheels Make sure the wheel does not extend beyond the bottom of the guard. Threaded hub grinding wheels may require a deeper guard.

1. WARNING! Unplug to avoid starting the tool.

2. Properly position the guard.

3. Wipe the ange, ange nut and spindle to remove

dust and debris. Inspect the parts for damage. Re- place if needed. Use only MILWAUKEE mounting hardware designed for the tool.

4. Place the ange on spindle, as shown. Rotate

ange until it is engaged on the spindle. NOTE: Do not install the ange or ange nut when using a threaded hub grinding wheel. When using a threaded wheel, ensure the installed height is within the height of the guard. Spindle Flange Wheel Flange nut

5. Place the selected wheel on the spindle and align

6. Position the ange nut over the spindle according

to wheel thickness. Flange nut position for 1/8" thick or less wheels 1/8" 1/4" Flange nut position for 1/4" thick or more wheels

7. Press in the spindle lock button while turning the

ange nut clockwise. Tighten securely.

8. To remove wheel, unplug the tool and reverse

the procedure. Sanding Disc Selection Use sanding discs and accessories that are:

• correct size as written on tool’s nameplate.

• rated at or above the RPM listed on the tool’s name- plate.

• correct accessory, wheel type and grit for the job. Select the correct type of sanding disc for your job. Generally, use 24 or 36 grit for heavy stock removal; 50, 60, or 80 grit for medium stock removal and 120 grit for nishing. Always begin with a coarse grit, us- ing successively ner grits to obtain the desired nish.

• Aluminum Oxide: For fast cutting, general purpose discs for most metal jobs. Best for cold-rolled steel, stainless steel or metals requiring tough, fast cutting, long lasting abrasives.

• Aluminum Zirconia Bi-Cut: Unique grit pattern is arranged in clusters for faster stock removal and cleaning. Ideal for removing paint from cars, boats, etc. without clogging.

• Ceramic: Lasts up to 3 times longer than Aluminum Oxide Discs. For general metal working. Ideal for tough jobs. Installing Backing Pad and Sanding Discs

1. WARNING! Unplug to avoid starting the tool.

2. Wipe the accessories, disc nut and spindle to

remove dust and debris. Inspect the parts for dam- age. Replace if needed. Use only MILWAUKEE mounting hardware designed for this tool.

3. Slip backing pad onto spindle with at side away

4. Place sanding disc on backing pad and secure

assembly to spindle with disc nut. Spindle Backing pad Disc nut Sanding disc

5. Press in the spindle lock button while turning disc

nut clockwise. Tighten securely.

6. To remove backing pad and sanding disc, unplug

the tool and reverse the procedure. OPERATION WARNING To reduce the risk of injury, always wear proper eye protection marked to comply with ANSI Z87.1. When working in dusty situations, use an OSHA compliant dust extraction solution in accordance with its operating instructions or wear appropriate respiratory protection. Never grind without proper safety equipment. Always hold the tool rmly with both hands using the handles provided before and during grinding. Controlled Start (some models) The controlled start feature reduces the torque reac- tion "jerk" when its trigger is pulled. Constant Speed Tachometer (some models) The constant speed tachometer keeps the tool's revolutions per minute at an almost constant speed even under load. The tachometer also helps pre- vent tool overheating. The tool switches itself o󰀨 automatically when the motor is overloaded. If this happens, release the trigger to reset. Pull the trigger and continue work. Electric Brake (some models) The electric brake engages when the switch is re- leased, causing the wheel to stop within seconds. There may be a delay between the time the switch is released and when the brake engages. Occasionally the brake may miss completely. If the brake misses frequently, have the tool serviced by an authorized MILWAUKEE service facility. Make sure the tool comes to a complete stop before laying it down. WARNING Always hold the tool rmly with both hands using the handles provided before and during grinding. Paddle Switch Operation To start the tool, grasp the handle and side handle rmly. Pull the lock-o󰀨 button back and squeeze the paddle switch. To stop the tool, release the paddle switch. Make sure the tool comes to a complete stop before laying the tool down. To lock-on the switch (some models), start the tool and push in the lock-on button. To stop the tool, squeeze and release the paddle switch. Make sure the tool comes to a complete stop before laying the tool down. General Operation

1. After installing new accessories and before starting

work, test the wheel by letting it spin for one minute before applying it to the workpiece. WARNING! Never use a grinding wheel that has been dropped. Out-of-balance or damaged accessories can mar workpiece, damage the tool, and cause stress that may cause accessory failure.

2. Use a clamp, vise or other practical means to hold

the workpiece, freeing both hands to control the tool.

3. WARNING! Hold tool securely with both hands.

4. NOTE: On some models, if the tool is plugged in

when the tool switch is in the "ON" position, the tool will not run. Turn the tool o󰀨, then back on to begin work.

5. Allow accessory to come to full speed before

6. Control pressure and surface contact between ac-

cessory and workpiece. WARNING! Never bang grinding wheel onto work. Too much pressure causes accessory failure or slows speed.

7. When nished, turn o󰀨 the tool and make sure it

comes to a complete stop before laying it down. Using Grinding Wheels WARNING The guard type must match the wheel type to provide maximum protection for the operator if the wheel should break. When grinding, hold tool at a 5

angle, using constant pressure for a uniform nish. Too great an angle causes concentrated pressure on small areas which may gouge or burn work surface. For best result use only this portion of disc Hold at a 5° to Hold at a 5° to 15° angle15° angle Using Cut-O󰀨 Wheels Cut-o󰀨 wheels are suited for small cut-o󰀨 and shallow notching operations only. WARNING The guard type must match the wheel type to provide maximum protection for the operator if the wheel should break. When using a cut-o󰀨 wheel, hold the tool as shown, using only the edge of the wheel. WARNING! Using the face of a cut-o󰀨 wheel (as in grinding) will cause the wheel to crack and break, resulting in serious personal injury. Using Wire Brushes Wire brushes are useful for removing rust, scale, burrs, weld slag, etc. WARNING Everyone in the area must wear protective clothing and safety goggles or face shields. Wire bristles are thrown by the brush even during ordinary operation. The wire bristles can easily penetrate light clothing and/or skin. 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 y apart, causing injury. Do not use a damaged accessory. Before each use inspect the accessory. Discard and replace damaged accessories. Wire wheel brushes must be used with a properly positioned Type 27 guard to provide maximum protection if wire bristles are thrown. Wire wheel brush Type 27 guard WARNING Wire cup brushes should be used without a guard, or with the guard type recommended by the wire cup brush manu- facturer. Wire cup brushes expand during use; wires bristles contacting the guard could break and be thrown, causing injury. Wire cup brush Always install wire brushes according to the acces- sory manufacturer's instructions. Only use acces- sories with threads matching the tool's spindle. Test wire brushes for balance and loose or damaged wires by letting it spin for one minute before applying it to the workpiece. During this time, no one should stand in front of or in line with it. Only allow the tip of the wire brush to contact the workpiece. Do not contact the sides of the wire brush to the workpiece. Wires will be damaged and could break and be thrown. Control pressure and surface contact between wire brushes and workpiece. Too much pressure causes over-bending of wires and heat build-up causing premature wire breaking, rapid dulling and reduced brush life. Instead of more pressure, try a wire brush with more aggressive cutting action (increased wire size, decreased wire length, or di󰀨erent brush type (knot type vs. crimped wire type). Using Sanding Discs Hold tool at 5° to 15° angle to ensure proper sanding pressure and control. Too great an angle will result in too much pressure and could cause excessive wear to the disc and workpiece. Too small an angle will reduce control. Use long, sweeping, side to side strokes, advancing forward to produce the desired nish. For best result use only this portion of disc Hold at a 5° to Hold at a 5° to 15° angle15° angle9 Cross Sanding - When nishing a surface that has been prepared by a coarse disc or wheel, sand at right angles to the strokes made by the coarser disc. Finishing marks left from previous sanding are easily seen and removed for a uniform nish. Failure to cross sand when changing from a coarse disc to a nishing disc may result in deep scratches and circular marks. Removing Welds or Hammer Marks - When remov- ing welds or hammer marks, limit coarse sanding to the immediate area. Use successively ner grits to smooth surface. Finishing Metal - Constantly move across the sur- face. Work faster on curved surfaces where contact areas are smaller and pressure is greater. Flat areas may appear at the end of the stroke when pressure is too heavy. Ease up on pressure at end of each stroke and when reversing strokes. Troubleshooting Deep scratches and circular marks can result from:

• Using too coarse a grit

• Using a partially glazed disc

• Dirt or loose metal on the workpiece

• Failure to sand across the grain when changing from coarse to nishing discs

• Failure to use closed coated discs to reduce the problem of grains working loose and scratching the workpiece Bluish discoloration of metal surface indicates:

• Excessive heat caused by circular motion in a small area

• Use of worn out or glazed discs MAINTENANCE WARNING To reduce the risk of injury, always unplug the tool before performing any maintenance. Never disassemble the tool, except as provided in these instructions. Contact a MILWAUKEE service facility for all other repairs. Maintaining Tools Keep this tool in good repair by adopting a regular maintenance program. Inspect the tool for issues such as undue noise, misalignment or binding of moving parts, breakage of parts, or any other condition that may a󰀨ect the tool operation. Return the tool to a MILWAUKEE service facility for repair. Depending on use, periodically have an authorized service facility inspect and maintain the tool to ensure proper performance. WARNING To reduce the risk of personal in- jury and damage, never immerse a tool in liquid or allow a liquid to ow inside them. Cleaning Clean dust and debris from vents. Keep handles clean, dry and free of oil or grease. Use only mild soap and a damp cloth to clean, since certain clean- ing agents and solvents are harmful to plastics and other insulated parts. Some of these include gasoline, turpentine, lacquer thinner, paint thinner, chlorinated cleaning solvents, ammonia and household deter- gents containing ammonia. Never use ammable or combustible solvents around tools. Repairs For repairs, return the tool to the nearest authorized service center. ACCESSORIES WARNING Use only recommended accesso- ries. Others may be hazardous. For a complete listing of accessories, go online to www.milwaukeetool.com or contact a distributor. Size Type 27 Type 1 Steel 4-1/2" 43-54-1200 43-54-1210

SERVICE - UNITED STATES

1-800-SAWDUST (1.800.729.3878) Monday-Friday, 7:00 AM - 6:30 PM CST or visit www.milwaukeetool.com Contact Corporate After Sales Service Technical Support with technical, service/repair, or warranty questions. Email: [e-mail] Become a Heavy Duty Club Member at www.milwaukeetool.com to receive important notications regarding your tool purchases.

Monday-Friday, 7:00 AM - 4:30 PM CST or visit www.milwaukeetool.ca LIMITED WARRANTY USA & CANADA This MILWAUKEE power tool* is warranted to the original purchaser from an authorized MILWAUKEE distributor only to be free from defects in material and workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace any part on this power tool which, after examination, is determined by MILWAUKEE to be defective in material or workmanship for a period of ve (5) years after the date of purchase unless otherwise noted. Return of the power tool to a MILWAUKEE factory Service Center location or MILWAUKEE Authorized Service Station, freight prepaid and insured, is required. A copy of the proof of purchase should be included with the return product. This warranty does not apply to damage that MILWAUKEE determines to be from repairs made or attempted by anyone other than MILWAUKEE authorized personnel, misuse, altera tions, abuse, normal wear and tear, lack of maintenance, or accidents.Normal Wear: Many power tools need periodic parts replacement and service to achieve best performance. This warranty does not cover repair when normal use has exhausted the life of a part including, but not limited to, carriage gears, chucks, brushes, cords, saw shoes, blade clamps, o-rings, seals, bumpers, driver blades, pistons, strikers, lifters, and bumper cover washers.*This warranty does not cover battery packs or all power tools. Refer to the separate and distinct warranties available for those products.The warranty period for the LED in the LED Work Light (49-24-0171) and the LED Upgrade Bulb (49-81-0090) is the lifetime of the product subject to the limitations above. If during normal use the LED or LED Upgrade Bulb fails, the part will be replaced free of charge. Warranty Registration is not necessary to obtain the applicable warranty on a MILWAUKEE power tool product. The manufacturing date of the product will be used to determine the warranty period if no proof of pur chase is provided at the time warranty service is requested.ACCEPTANCE OF THE EXCLUSIVE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN IS A CONDITION OF THE CON TRACT FOR THE PURCHASE OF EVERY MILWAUKEE PRODUCT. IF YOU DO NOT AGREE TO THIS CONDITION, YOU SHOULD NOT PURCHASE THE PRODUCT. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY INCIDENTAL, SPECIAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES, OR FOR ANY COSTS, ATTORNEY FEES, EXPENSES, LOSSES OR DELAYS ALLEGED TO BE AS A CONSE QUENCE OF ANY DAMAGE TO, FAILURE OF, OR DEFECT IN ANY PRODUCT INCLUDING, BUT NOT LIMITED TO, ANY CLAIMS FOR LOSS OF PROFITS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES, WRITTEN OR ORAL. TO THE EXTENT PERMITTED BY LAW, MILWAUKEE DISCLAIMS ANY IMPLIED WAR RANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WAR-RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE; TO THE EXTENT SUCH DISCLAIMER IS NOT PERMITTED BY LAW, SUCH IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THE APPLICABLE EXPRESS WARRANTY AS DESCRIBED ABOVE. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE10 LIMITATION MAY NOT APPLY TO YOU, THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. This warranty applies to product sold in the U.S.A. and Canada only. Please consult the ‘Service Center Search’ in the Parts & Service sec

tion of MILWAUKEE’s website www.milwaukeetool.com or call 1.800. SAWDUST (1.800.729.3878) to locate your nearest service facility for warranty and non-warranty service on a MILWAUKEE power tool.

PICTOGRAPHIE Double Isolation Volts

Monday-Friday, 7:00 AM - 4:30 PM CST www.milwaukeetool.ca