Harbor Freight Tools 95578 Grinder User Manual
Contents
1. RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 VOLT NAMEPLATE EXTENSION CORD LENGTH AMPERES At Full Load Fesi Fesi Feet Feet Feet 2 5 1 7 ee ee E a XET 12 1 16 0 f N oo anh Ja Based on limiting the line voltage drop FIGURE C to five volts at 150 of the rated amperes SKU 95578 For technical questions please call 1 800 444 3353 PAGE 9 SYMBOLOGY fay Double Insulated Canadian Standards Association Underwriters Laboratories Inc olts Alternating Current No Load Revolutions FIGURE D Oxxxx min per Minute RPM UNPACKING When unpacking check to make sure all the parts shown on the Parts List on page 14 are included If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible ASSEMBLY INSTRUCTIONS NOTE For additional information regarding the parts listed in the following pages refer to the Assembly Diagram on page 14 CAUTION Always make sure the PowerSwitch 41 for the Angle Grinder is in its OFF position and the tool is unplugged from its electrical outlet prior to assembling the tool adding any accessories or making adjustments to the tool To Install A Grinding Wheel 1 Unscrew and remove the Outer Flange Nut 1 from the Spindle 7 See Figure E next page 2 Insert the Grinding Wheel not included onto the Spindle 7 making sure to SK2. THIS PRODUCT USES A an if oy i 2 PRONG PLUG Pi ft 120 VOLT 3 1 i 0 f J y WEF GROUNDED ELECTRICAL OUTLETS FIGURE B SKU 95578 For technical questions please call 1 800 444 3353 PAGE 8 EXTENSION CORDS 1 Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord 2 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 See Figures C 3 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 See Figures C 4 When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required See Figures C 5 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 cord size See Figures C 6 If you are using an extension cord outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use T Make sure your extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified electrician before using it
3. away from the user Double insulated tools are equipped with a polarized plug one blade is wider than the other This plug will fit in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation O eliminates the need for the three wire grounded power cord and grounded power supply system Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock Do not abuse the Power Cord Never use the Power Cord to carry the tools or pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immedi ately Damaged Power Cords increase the risk of electric shock When operating a power tool outside use an outdoor extension cord marked W A or W These extension cords are rated for outdoor use and reduce the risk of electric shock PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when oper ating a power tool Do not use a power tool while tired or under the influ ence of drugs alcohol or medication A moment of inattention while operat
4. invoice number on the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference GENERAL SAFETY RULES WARNING J READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA 1 Keep your work area clean and well lit Cluttered benches and dark areas invite accidents 2 Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes 3 Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed Children should not be allowed in the work area SKU 95578 For technical questions please call 1 800 444 3353 PAGE 2 10 11 12 ELECTRICAL SAFETY Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Ifthe tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity
5. 53 PAGE 15
6. DRILL L MASTER 4 1 2 ANGLE GRINDER ASSEMBLY AND OPERATING INSTRUCTIONS _ pm z s E on a e Due to continuing improvements actual product may differ slightly from the product described herein Distributed Exclusively by HARBOR FREIGHT _4 TOOLS um 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 2006 by Harbor Freight Tools All right reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools For technical questions please call 1 800 444 3353 PRODUCT SPECIFICATIONS Electrical 120 VAC 60 Hz 4 2 Amps 11 000 RPM Requirements Power Cord Type 18 AWG x 2C Long Power Plug Type 2 Prong Polarized Power Switch Type Toggle ON OFF Spindle Size 5 8 11 TPI with 7 8 Arbor Adapter Required 4 1 2 Diameter Grinding Wheel Size 1 4 Thick Not Included 7 8 Spindle Hole Dimensions 10 1 8 Long x 8 Wide x 3 3 4 High Dimensions with Side Handle 3 5 Pounds Cs Net Weight 3 5 Pounds SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and as sembly diagram Keep your invoice with this manual Write the
7. For technical questions please call 1 800 444 3353 PAGE 12 4 To clean or replace the Carbon Brushes 38 It may become necessary to clean or replace the two Carbon Brushes when the Motor performance de creases or stops working completely The Carbon Brushes are located on each side of the Motor Housing 40 To do so remove the two Brush Holder Covers 37 Then remove the two Carbon Brushes from the Brush Holders 39 If the Carbon Brushes are worn down more than 1 2 replace both Carbon Brushes If however the Carbon Brushes are just dirty they may be cleaned by rubbing them with a pencil eraser if only cleaning is required clean and place brushes in the same position as they were orginally in When installing the Car bon Brushes make sure the carbon portion of the Carbon Brushes contact the Motor Armature 30 and the springs face away from the Motor Also make sure the springs operate freely After cleaning or replacement replace the Brush Holder Covers NOTE New Carbon Brushes tend to arc or spark when first used until they wear and conform to the Motor s Armature See Assy Diagram 5 To clean the exterior parts of the Angle Grinder use only a clean cloth and mild detergent Then dry Do not immerse any electrical part of the tool in any liquids 6 Make sure to store the Angle Grinder in a clean dry safe location out of reach of children and other unauthorized people A CAUTION All maintenance service or repai
8. U 95578 For technical questions please call 1 800 444 3353 PAGE 10 install the convex rounded outward side of the Grinding Wheel toward the Spindle 7 See Figure E 3 Screw the Outer Flange Nut 1 onto the Spindle 7 Depress and hold the Lock Pin 22 to keep the Spindle from turning Then use the provided Wrench 51 to firmly tighten the Outer Flange Nut onto the Spindle See Figure E 5 r t ji B ji A l a q 7 j N i hii i GRINDING SPINDLE 7 OUTER FLANGE NUT 1 FIGURE E To Attach The Side Handle 1 The Side Handle 18 may be attached to either the eft or right side of the Angle Grinder See Figure F 2 To attach the Side Handle 18 to the Angle Grinder screw the Handle firmly into the threaded mounting hole located on either the left or right side of the Shell Head 23 See Figure F OPERATING INSTRUCTIONS WARNING Make sure the Power Switch 41 of the Angle Grinder is in its OFF position before connecting the Power Cord Plug 50 to a 120 volt grounded electrical outlet SKU 95578 For technical questions please call 1 800 444 3353 PAGE 11 2 Grip the Angle Grinder firmly with both hands Then turn the Power Switch 41 to its ON position to start the Grinder See Figure G 3 Hold the Angle Grinder at an angle of 10 to 15 to the work surface When only the outer edge of the grinding wheel is used a rough cut surface will resul
9. erty or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING E lt THE WARRANTIES OF MERCHANTABILITY AND FITNESS A Totake advantage of this warranty the product or part must be returned to us with transportation charges prepaid S A Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection p JN verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase ZN price if we cannot readily and quickly provide you with a replacement We will return repaired products at our RAS expense but if we determine there is no defect or that the defect resulted from causes not within the scope of Y sq our warranty then you must bear the cost of returning the product aw D This warranty gives you specific legal rights and you may also have other rights which vary from state to state UA SY 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 D D gt Sayre SS SE a S a E O E O es gt CANN NCA IAC ASN IC IRS ACARI ONK AINK ONINI y y y A J A ANY SANON NANANA NANANA NSIN SKU 95578 For technical questions please call 1 800 444 33
10. for at least 6 11 0 000 RPM Grinding wheels and other accessories running over the rated 11 000 RPM speed can fly apart and cause injury T When using a hand held power tool always maintain a firm grip on the tool with both hands to resist starting torque SKU 95578 For technical questions please call 1 800 444 3353 PAGE 5 10 11 12 13 14 15 16 17 18 19 20 Use only 4 1 2 diameter grinding wheels not included having a 7 8 center spindle hole Never disable or modify the Wheel Guard 4 Avoid unintentional starting Make sure you are prepared to begin work before turning on the Angle Grinder Do not force the Angle Grinder This tool will do the work better and safer at the speed and capacity for which it was designed Do not force the rotating grinding wheel not included into the object being ground Apply moderate pressure allowing the grinding wheel to rotate freely without being forced for use on this tool Never install a wood carving blade carving disc with saw chain cutters or a cutting carving disc on this tool A WARNING Never install a carbide tipped or steel circular saw blade For safest operation it is recommended that only these accessories be used with this tool Abrasive cut off discs and wheels flap wheels wire brushes and wire wheel brushes Never lay this tool down until the rotating grinding wheel has come to a complete stop The rotating gri
11. ich it is designed Do not use the power tool if the Power Switch does not turn it on or off Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users Maintain tools with care Keep cutting tools sharp and clean Properly maintained tools with a sharp cutting edge are less likely to bind and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly main tained tools Use only accessories that are recommended by the manufacturer for your SKU 95578 For technical questions please call 1 800 444 3353 PAGE 4 model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE 24 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 25 When servicing a tool use only iden
12. ing power tools may result in serious personal injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Avoid accidental starting Be sure the Power Switch is off before plugging SKU 95578 For technical questions please call 1 800 444 3353 PAGE 3 13 14 15 16 17 18 19 20 21 22 23 in Carrying power tools with your finger on the Power Switch or plugging in power tools with the Power Switch on invites accidents Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations Use safety equipment Always wear eye protection Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions TOOL USE AND CARE Use clamps not included or other practical ways to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for wh
13. nding wheel can grab the surface and pull the tool out of your control Never leave the Angle Grinder unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from the electrical outlet before leaving Always unplug this tool from its electrical outlet before performing inspec tion maintenance or cleaning procedures A _ WARNING Keep hands and fingers away from cutting area and rotat ing grinding wheel Before using the Angle Grinder always check to make sure the grinding wheel not included is properly mounted and is not cracked or dull Industrial applications must follow OSHA guidelines The grinding wheel not included will become hot while cutting Allow the grinding wheel to completely cool before handling To avoid accidental injury always wear heavy duty work gloves when changing the grinding wheel WARNING Some dust created by power sanding sawing grinding drilling SKU 95578 For technical questions please call 1 800 444 3353 PAGE 6 and other construction activities contain chemicals known to the State of Cali fornia to cause cancer birth defects or other reproductive harm Some ex amples of these chemicals are lead from lead based paints crystalline silica from bricks and cement or other masonry products 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 you
14. ng plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of elec tric shock See Figure A next page 2 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 SKU 95578 For technical questions please call 1 800 444 3353 PAGE 7 to an electrically live terminal See Figure A 3 Your tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See Figure A THIS PRODUCT 120 VOLT DOES NOT i GROUNDED USE A ELECTRICAL OUTLET 3 PRONG PLUG Y i as FIGURE A DOUBLE INSULATED TOOLS TOOLS WITH TWO PRONG PLUGS 4 Tools marked Double Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories Inc the Canadian Standard Association and the National Electrical Code See Figure B J Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration See Figure B
15. r exposure to these chemicals work in a well ventilated area and work with approved safety equipment such as those dust masks that are specially designed to filter out microscopic particles California Health amp Safety Code 25249 5 et seq 22 A WARNING People with pacemakers should consult their physician s before using this product Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker 23 AN WARNING The warnings and cautions discussed in this manual cannot cover all possible conditions and situations that may occur It must be under stood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator SAVE THESE INSTRUCTIONS J N WARNING Improperly connecting the grounding wire can result in the risk of electric shock Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool if the power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician GROUNDED TOOLS TOOLS WITH THREE PRONG PLUGS 1 Tools marked with Grounding Required have a three wire cord and three prong groundi
16. rs not mentioned in this manual must only be performed by a qualified service technician TROUBLESHOOTING Possible Solution Angle Grinder will not turn on 1 Make sure tool is plugged into a working 120 volt grounded electrical outlet 2 Make sure the Power Switch is in its ON position 3 Unplug tool from its electrical outlet Check both Carbon Brushes for excessive wear or excessive dirt and debris If necessary replace or clean both Carbon Brushes 4 Have a qualified service technician check out the tool Angle Grinder runs but a rough 1 Make sure to hold the tool at an angle of 10 to 15 degrees to the work cut surface results when grinding surface the workpiece 2 Check the grinding wheel for dullness cracks and other damage If necessary replace the grinding wheel action is irregular or bumpy and surface the tool is difficult to control The Power Switch does not turn 1 Immediately disconnect the Power Cord Plug from its electrical outlet and the Angle Grinder off discontinue using the tool Then have a qualified service technician check out the tool SKU 95578 For technical questions please call 1 800 444 3353 PAGE 13 PARTS LIST AND ASSEMBLY DIAGRAM Part Description Part Description Part Description Brush Holder Cover Carbon Brush 100 Qty 2 Brush Holder 100 6 Nut 23 ShellHead 40 Motor Housing 7 Spinde 24 Pinion Gear_ 41 Power Switch 8 Woodruff Ke
17. t If the grinding wheel is pressed flat against the workpiece the grinding action will be irregular or bumpy and the tool will be difficult to control See Figure G 4 Do not force the rotating grinding wheel into the workpiece Apply moderate pressure allowing the grinding wheel to rotate freely without being forced Do not attempt to exceed the maximum RPM of 11 000 See Figure G 5 After the grinding job is completed turn the Power Switch 41 to its OFF position Then unplug the Power Cord Plug 50 from its electrical outlet 6 Make sure to store the Angle Grinder in a clean dry safe location out of reach of children and other unauthorized people POWER SWITCH 41 FIGURE G INSPECTION MAINTENANCE AND CLEANING WARNING Always unplug this tool from its electrical outlet before performing inspection maintenance or cleaning procedures 2 Before each use inspect the general condition of the Angle Grinder Check for misalignment or binding of moving parts cracked or broken parts damaged electrical wiring and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 3 Before each use inspect the Grinding Wheel Using a dull Wheel will cause excessive wear on the Motor of the Grinder and will not produce a satisfactory cut Replace with a new Grinding Wheel when needed SKU 95578
18. tical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create arisk of electric shock or injury SPECIFIC SAFETY RULES 1 Always use the Wheel Guard 4 with the Angle Grinder The Guard protects the operator from broken grinding wheel fragments 2 Hold the tool by its insulated gripping surfaces when performing an opera tion where the cutting tool may contact hidden wiring or its own cord Con tact with a live wire will make exposed metal parts of the tool live and shock the operator 3 Maintain labels and nameplates on the Angle Grinder These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Always wear ANSl approved safety impact eye goggles and heavy work gloves when using the Angle Grinder Using personal safety devices reduce the risk for injury Safety impact eye goggles and heavy work gloves are available from Harbor Freight Tools 5 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Always keep the work area free of obstructions grease oil trash and other debris Do not use a power tool in areas near flammable chemicals dusts and vapors Do not use this product in a damp or wet location WARNING All accessories for this tool must be rated
19. y 25 Bearing 6018 42 Switch Mount 9 Screw 26 Gearbox Back Cover 43 10 Spring Washer 27 SpringWasher 44 11 FlatWasher_ 28 Screw 45 End Cap Housing 12 Gearbox Bottom Cover 29 Woodruff Key 46 Screw 13 Bearing 60201 30 Armature 47 Sheath 115A Power Cord Bracket Self Tapping Screw Power Cord Plug Wrench ed Sree Ki iz manmanan aa 41 32 16 ___ _ j i i 34 ee en 14 LF EN 35 7 5 ai 4 wa gt sf ow Nee Fd i gt SR Ba KX E fer nS s Peg ie araoa E haas aan ead NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 95578 For technical questions please call 1 800 444 3353 PAGE 14 IMPORTANT WARRANTY INFORMATION YNN lt J RAINY AS XY Y S D LIMITED 90 DAY WARRANTY TN Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of ninety days from the date of purchase This warranty does not apply to damage due directly or NNS indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities or to lack of 3 maintenance We shall in no event be liable for death injuries to persons or prop
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