Chicago Electric 67648 Operating instructions

7” Angle Grinder
Model 67648
Set up and Operating Instructions
(Grinding Wheel Sold Separately)
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
Save this manual.
Copyright© 2010 by Harbor Freight Tools®. All rights 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. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements,
actual product may differ slightly from the product described herein.
For technical questions or replacement parts, please call 1-800-444-3353.
Contents
Important SAFETY
Information���������������������������������3
General Power Tool Safety
Warnings������������������������������������������� 3
Safety Warnings Common
for Grinding, Sanding, and
Wirebrushing Operations��������� 5
Maintenance And Servicing���16
Cleaning, Maintenance, and
Lubrication������������������������������������ 16
Carbon Brush (40)
Replacement��������������������������������� 17
Accessory Storage and
Handling����������������������������������������� 17
Troubleshooting��������������������������� 18
Kickback and Related Warnings7
Parts List��������������������������������������19
Safety Warnings Specific for
Grinding Operations�������������������� 8
ASSEMBLY DIAGRAM���������������������20
Safety Warnings Specific for
Sanding Operations��������������������� 9
LIMITED 90 DAY WARRANTY���������21
Safety Warnings Specific for
Wire Brushing Operations�������� 9
Vibration Safety������������������������������ 9
Grounding��������������������������������������9
Grounded Tools: Tools with
Three Prong Plugs��������������������� 10
Double Insulated Tools:
Tools with Two Prong Plugs� 10
Extension Cords���������������������������� 10
Symbology ����������������������������������������11
Specifications�����������������������������12
Unpacking�������������������������������������12
Components������������������������������������� 12
Instructions for putting
into use���������������������������������������12
Assembly������������������������������������������� 13
Operating Instructions���������14
Tool Set Up��������������������������������������� 14
Work Piece and Work Area
Set Up����������������������������������������������� 15
General Operating
Instructions��������������������������������� 15
Page 2
For technical questions, please call 1-800-444-3353.
SKU 67648
NOTICE is used to
address practices not
related to personal injury.
Save This Manual
Keep this manual for the safety warnings
and precautions, assembly, operating,
inspection, maintenance and cleaning
procedures. Write the product’s serial number
in the back of the manual near the assembly
diagram (or month and year of purchase if
product has no number). Keep this manual
and the receipt in a safe and dry place for
future reference.
CAUTION, without the
safety alert symbol, is
used to address practices not
related to personal injury.
General Power Tool Safety Warnings
WARNING Read all safety warnings
and instructions. Failure to follow the
warnings and instructions may result
in electric shock, fire and/or serious
injury.
Save all warnings and instructions
for future reference.
The term ″power tool″ in the warnings
refers to your mains-operated (corded)
power tool.
Important SAFETY
Information
In this manual, on the labeling, and
all other information provided with
this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that follow
this symbol to avoid possible
injury or death.
1.
a.Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
b.Do not operate power tools in
explosive atmospheres, such as in the
presence of flammable liquids, gases
or dust. Power tools create sparks
which may ignite the dust or fumes.
DANGER indicates a
hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING indicates a
hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION, used with
the safety alert
symbol, indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
SKU 67648
Work area safety
c.Keep children and bystanders
away while operating a power tool.
Distractions can cause you to lose
control.
2.
Electrical safety
a.Power tool plugs must match the
outlet. Never modify the plug in
any way. Do not use any adapter
plugs with grounded power tools.
Unmodified plugs and matching outlets
will reduce risk of electric shock.
b.Avoid body contact with grounded
surfaces such as pipes, radiators,
ranges and refrigerators. There is an
For technical questions, please call 1-800-444-3353.
Page 3
increased risk of electric shock if your
body is grounded.
energizing power tools that have the
switch on invites accidents.
c.Do not expose power tools to rain or
wet conditions. Water entering a power
tool will increase the risk of electric
shock.
d.Remove any adjusting key or wrench
before turning the power tool on.
A wrench or a key left attached to a
rotating part of the power tool may result
in personal injury.
d.Do not abuse the cord. Never use
the cord for carrying, pulling or
unplugging the power tool. Keep cord
away from heat, oil, sharp edges or
moving parts. Damaged or entangled
cords increase the risk of electric shock.
e.Do not overreach. Keep proper
footing and balance at all times. This
enables better control of the power tool
in unexpected situations.
f. Dress properly. Do not wear loose
clothing or jewelry. Keep your hair,
clothing and gloves away from
moving parts. Loose clothes, jewelry or
long hair can be caught in moving parts.
e.When operating a power tool
outdoors, use an extension cord
suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the risk
of electric shock.
g.If devices are provided for the
connection of dust extraction and
collection facilities, ensure these are
connected and properly used. Use of
these devices can reduce dust-related
hazards.
f. If operating a power tool in a damp
location is unavoidable, use a Ground
Fault Circuit Interrupter (GFCI)
protected supply. Use of a GFCI
reduces the risk of electric shock.
3.
h.Only use safety equipment that has
been approved by an appropriate
standards agency. Unapproved safety
equipment may not provide adequate
protection. Eye protection must be
ANSI-approved and breathing protection
must be NIOSH-approved for the specific
hazards in the work area.
Personal safety
a.Stay alert, watch what you are
doing and use common sense when
operating a power tool. Do not use
a power tool while you are tired or
under the influence of drugs, alcohol
or medication. A moment of inattention
while operating power tools may result in
serious personal injury.
b.Use safety equipment. Always wear
eye protection. Safety equipment such
as a dust mask, non-skid safety shoes,
a hard hat, or hearing protection used
for appropriate conditions will reduce
personal injuries.
c.Prevent unintentional starting. Ensure
the switch is in the off-position before
connecting to power source, picking
up or carrying the tool. Carrying power
tools with your finger on the switch or
Page 4
4.
Power tool use and care
a.Do not force the power tool. Use
the correct power tool for your
application. The correct power tool will
do the job better and safer at the rate for
which it was designed.
b.Do not use the power tool if the
switch does not turn it on and off.
Any power tool that cannot be controlled
with the switch is dangerous and must
be repaired.
c.Disconnect the plug from the power
source and/or the battery pack from
For technical questions, please call 1-800-444-3353.
SKU 67648
the power tool before making any
adjustments, changing accessories,
or storing power tools. Such
preventive safety measures reduce
the risk of starting the power tool
accidentally.
d.Store idle power tools out of the reach
of children and do not allow persons
unfamiliar with the power tool or
these instructions to operate the
power tool. Power tools are dangerous
in the hands of untrained users.
e.Maintain power tools. Check for
misalignment or binding of moving
parts, breakage of parts and any other
condition that may affect the power
tool’s operation. If damaged, have
the power tool repaired before use.
Many accidents are caused by poorly
maintained power tools.
f. Use the power tool, accessories and
tool bits etc. in accordance with these
instructions, taking into account the
working conditions and the work to
be performed. Use of the power tool for
operations different from those intended
could result in a hazardous situation.
5.
Service
a.Have your power tool serviced by a
qualified repair person using only
identical replacement parts. This will
ensure that the safety of the power tool
is maintained.
Safety Warnings Common
for Grinding, Sanding, and
Wirebrushing Operations
1.
This power tool is intended to
function as a grinder, sander, or
wire brushing tool. Read all safety
warnings, instructions, illustrations
and specifications provided with
this power tool. Failure to follow all
SKU 67648
instructions listed below may result in
electric shock, fire and/or serious injury.
2.
Operations such as polishing or
cutting off are not recommended to
be performed with this power tool.
Operations for which the power tool was
not designed may create a hazard and
cause personal injury.
3.
Do not use accessories which
are not specifically designed
and recommended by the tool
manufacturer. Just because the
accessory can be attached to your power
tool, it does not assure safe operation.
4.
The rated speed of the accessory
must be at least equal to the
maximum speed marked on the power
tool. Accessories running faster than
their RATED SPEED can break and fly
apart.
5.
The outside diameter and the
thickness of your accessory must
be within the capacity rating of
your power tool. Incorrectly sized
accessories cannot be adequately
guarded or controlled.
6.
The arbor size of wheels, flanges,
backing pads or any other accessory
must properly fit the spindle of the
power tool. Accessories with arbor
holes that do not match the mounting
hardware of the power tool will run out
of balance, vibrate excessively and may
cause loss of control.
7.
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
For technical questions, please call 1-800-444-3353.
Page 5
install an undamaged accessory.
After inspecting and installing an
accessory, position yourself and
bystanders away from the plane of
the rotating accessory and run the
power tool at maximum no-load speed
for one minute. Damaged accessories
will normally break apart during this test
time.
8.
9.
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 work piece
fragments. The eye protection must
be capable of stopping flying debris
generated by various operations.
The eye protection must be capable
of stopping flying debris generated by
various operations. The dust mask or
respirator must be capable of filtering out
particles generated by your operation.
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
work piece or of a broken accessory
may fly away and cause injury beyond
immediate area of operation.
10. Hold power tool by insulated gripping
surfaces only, when performing an
operation where the accessory may
contact hidden wiring or its own cord.
An accessory contacting a ″live″ wire
may make exposed metal parts of the
power tool ″live″ and shock the operator.
11. Position the cord clear of the spinning
accessory. If you lose control, the cord
may be cut or snagged and your hand
Page 6
or arm may be pulled into the spinning
accessory.
12. Never lay the power tool down until
the accessory has come to a complete
stop. The spinning accessory may grab
the surface and pull the power tool out of
your control.
13. 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.
14. 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.
15. Do not operate the power tool near
flammable materials. Sparks could
ignite these materials.
16. Do not use accessories that require
liquid coolants. Using water or other
liquid coolants may result in electrocution
or shock.
17. Maintain labels and nameplates on
the tool. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
18. Avoid unintentional starting. Prepare to
begin work before turning on the tool.
19. Do not lay the tool down until it has come
to a complete stop. Moving parts can
grab the surface and pull the tool out of
your control.
20. Do not leave the tool unattended when
it is plugged into an electrical outlet.
Turn off the tool, and unplug it from its
electrical outlet before leaving.
For technical questions, please call 1-800-444-3353.
SKU 67648
21. This product is not a toy. Keep it out of
reach of children.
22. People with pacemakers should
consult their physician(s) before use.
Electromagnetic fields in close proximity
to heart pacemaker could cause
pacemaker interference or pacemaker
failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked
on.
• Properly maintain and inspect to avoid
electrical shock.
• Any power cord must be properly
grounded. Ground Fault Circuit
Interrupter (GFCI) should also be
implemented – it prevents sustained
electrical shock.
23. 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 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 your exposure to
these chemicals: work in a well ventilated
area, and work with approved safety
equipment, such as those dust masks
that are specially designed to filter out
microscopic particles. (California Health
& Safety Code § 25249.5, et seq.)
24. WARNING: Handling the cord on this
product will expose you to lead, a
chemical known to the State of California
to cause cancer, and birth defects or
SKU 67648
other reproductive harm. Wash hands
after handling. (California Health &
Safety Code § 25249.5, et seq.)
25. The warnings, precautions, and
instructions discussed in this instruction
manual cannot cover all possible
conditions and situations that may occur.
It must be understood by the operator
that common sense and caution are
factors which cannot be built into this
product, but must be supplied by the
operator.
Kickback and Related Warnings
Kickback is a sudden reaction to a
pinched or snagged rotating wheel, backing
pad, brush or any other accessory. Pinching
or snagging causes rapid stalling of the
rotating accessory which in turn causes the
uncontrolled power tool to be forced in the
direction opposite of the 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 incorrect operating procedures
or conditions and can be avoided by taking
proper precautions as given below.
1.
Maintain a firm grip on the power
tool and position your body and
arm to allow you to resist kickback
forces. Always use auxiliary handle, if
provided, for maximum control over
kickback or torque reaction during
start-up. The operator can control
For technical questions, please call 1-800-444-3353.
Page 7
torque reactions or kickback forces, if
proper precautions are taken.
2.
Never place your hand near the
rotating accessory. Accessory may
kickback over your hand.
3.
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.
4.
Use special care when working
corners, sharp edges etc. Avoid
bouncing and snagging the
accessory. Corners, sharp edges or
bouncing have a tendency to snag the
rotating accessory and cause loss of
control or kickback.
5.
Do not attach a saw chain
woodcarving blade or toothed saw
blade. Such blades create frequent
kickback and loss of control.
4.
Use only wheel types that are
recommended for your power tool
and the specific guard designed for
the selected wheel. Wheels for which
the power tool was not designed cannot
be adequately guarded and are unsafe.
5.
The guard must be securely attached
to the power tool and positioned for
maximum safety, so the least amount
of wheel is exposed towards the
operator. The guard helps to protect
operator from broken wheel fragments
and accidental contact with wheel.
6.
Wheels must be used only for
recommended applications. For
example: do not grind with the side of
cut-off wheel. Abrasive cut-off wheels
are intended for peripheral grinding,
side forces applied to these wheels may
cause them to shatter.
7.
Always use undamaged wheel flanges
that are of correct size and shape for
your selected wheel. Proper wheel
flanges support the wheel thus reducing
the possibility of wheel breakage.
Flanges for cut-off wheels may be
different from grinding wheel flanges.
8.
Do not use worn down wheels from
larger power tools. Wheel intended for
larger power tool is not suitable for the
higher speed of a smaller tool and may
burst.
9.
Dress appropriately. Wear leather
leggings and fire resistant footwear
during use. Do not wear pants with cuffs,
shirts with open pockets, or any clothing
that can catch and hold molten metal or
sparks.
Safety Warnings Specific for
Grinding Operations
1.
Always use proper guard with
grinding wheel. A guard protects
operator from broken wheel fragments.
2.
Accessories must be rated for at
least the speed recommended on the
tool warning label. Wheels and other
accessories running over rated speed
can fly apart and cause injury.
3.
Hold tool by insulated gripping
surfaces when performing an
operation where the tool may contact
hidden wiring or its own cord. Contact
with a “live” wire will make exposed
metal parts of the tool “live” and shock
the operator.
Page 8
For technical questions, please call 1-800-444-3353.
SKU 67648
not use this tool. If you feel any medical
or physical symptoms related to vibration
(such as tingling, numbness, and white
or blue fingers), seek medical advice as
soon as possible.
Safety Warnings Specific for
Sanding Operations
Do not use excessively oversized
sanding disc paper. Follow
manufacturer’s recommendations
when selecting sanding paper. Larger
sanding paper extending beyond the
sanding pad presents a laceration
hazard and may cause snagging, tearing
of the disc or kickback.
Safety Warnings Specific for Wire
Brushing Operations
1.
2.
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 the wire wheel or
brush with the guard. Wire wheel or
brush may expand in diameter due to
work load and centrifugal forces.
Vibration Safety
This tool vibrates during use. Repeated
or long-term exposure to vibration may cause
temporary or permanent physical injury,
particularly to the hands, arms and shoulders.
To reduce the risk of vibration-related injury:
1.
Anyone using vibrating tools regularly
or for an extended period should first
be examined by a doctor and then have
regular medical check-ups to ensure
medical problems are not being caused
or worsened from use. Pregnant
women or people who have impaired
blood circulation to the hand, past hand
injuries, nervous system disorders,
diabetes, or Raynaud’s Disease should
SKU 67648
2.
Do not smoke during use. Nicotine
reduces the blood supply to the hands
and fingers, increasing the risk of
vibration-related injury.
3.
Wear suitable gloves to reduce the
vibration effects on the user.
4.
Use tools with the lowest vibration when
there is a choice between different
processes.
5.
Include vibration-free periods each day
of work.
6.
Grip tool as lightly as possible (while still
keeping safe control of it). Let the tool
do the work.
7.
To reduce vibration, maintain the tool
as explained in this manual. If any
abnormal vibration occurs, stop use
immediately.
Save these
instructions.
Grounding
To prevent
electric shock
and death from incorrect
grounding wire
connection:
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
For technical questions, please call 1-800-444-3353.
Page 9
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.
illustration. (See 3-Prong Plug and
Outlet.)
Double Insulated Tools: Tools with
Two Prong Plugs
Grounded Tools: Tools with Three
Prong Plugs
Outlets for 2-Prong Plug
1.
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.
2.
Double insulated tools may be used in
either of the 120 volt outlets shown in the
preceding illustration. (See Outlets for
2-Prong Plug.)
3-Prong Plug and Outlet
1.
2.
3.
Tools marked with “Grounding Required”
have a three wire cord and three prong
grounding 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
electric shock. (See 3-Prong Plug and
Outlet.)
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.
(See 3-Prong Plug and Outlet.)
The 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 preceding
Page 10
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 Table A.)
3.
The smaller the gauge number of the
wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry
For technical questions, please call 1-800-444-3353.
SKU 67648
4.
5.
a higher current than a 16 gauge cord.
(See Table A.)
Symbology
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 Table
A.)
Double Insulated
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
Table A.)
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.
7.
Make sure the 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.
8.
Protect the extension cords from sharp
objects, excessive heat, and damp or
wet areas.
Canadian Standards Association
Underwriters Laboratories, Inc.
V~
A
Volts Alternating Current
Amperes
No Load Revolutions per Minute
n0 xxxx/min. (RPM)
RECOMMENDED MINIMUM WIRE GAUGE
FOR EXTENSION CORDS* (120/240 VOLT)
EXTENSION CORD
NAMEPLATE
LENGTH
AMPERES
(at full load)
25’ 50’ 75’ 100’ 150’
0 – 2.0
18
18
18
18
16
2.1 – 3.4
18
18
18
16
14
3.5 – 5.0
18
18
16
14
12
5.1 – 7.0
18
16
14
12
12
7.1 – 12.0
18
14
12
10
-
12.1 – 16.0
14
12
10
-
-
16.1 – 20.0
12
10
-
-
-
TABLE A
SKU 67648
* Based on limiting the line
voltage drop to five volts at 150%
of the rated amperes.
For technical questions, please call 1-800-444-3353.
Page 11
Specifications
Electrical Input
120 V~ / 60 Hz / 11 A
Motor No Load Speed
7,800 RPM
Max. Accessory
Diameter
7”
Arbor Hole Diameter
7/8”
Spindle Thread
5/8” x 11 TPI
Instructions for putting
into use
Read the entire Important
Safety Information
section at the beginning of this
manual including all text under
subheadings therein before set up
or use of this product.
95GA
E194601
This angle grinder can be used for
grinding steel, stone or ceramic
workpieces such as pipe, iron steel
bar, household bricks and tiles. Do not
attempt to grind wood or a soft metal
such as lead. The material will quickly fill
the disc and render it useless.
Unpacking
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor
Freight Tools at 1-800-444-3353 as soon as
possible.
To prevent
serious injury
from accidental
operation:
Turn the Power Switch of the tool
off and unplug the tool from its
electrical outlet before
assembling or making any
adjustments to the tool.
Note: For additional information regarding the
parts listed in the following pages, refer
to the Assembly Diagram near the end of
this manual.
Components
Spindle Lock
Button (21)
Lock-on
Grinding Wheel
Carbon Brush Switch (46)
(Sold Separately)
Cap (41)
Trigger
(47)
Wheel Guard (3)
Figure 1
Page 12
Handle
(43)
Hex Wrench
(55)
Spanner (53)
Auxiliary Handle (23)
For technical questions, please call 1-800-444-3353.
SKU 67648
Installing the Auxiliary Handle
Assembly
TO PREVENT
SERIOUS INJURY:
Do not operate this tool with one
hand only or without the
Auxiliary Handle properly
installed.
Installing the Wheel Guard
TO PREVENT
SERIOUS INJURY:
Do not operate this tool without
the Wheel Guard properly
installed.
Auxiliary Handle locations
1
Wheel Guard (3)
2
Figure 2
3
Gear Housing Rim
The Auxiliary Handle (23) may be
installed in one of three positions,
on either side or on top of the Gear
Housing.
2.
Screw the threaded end of the Auxiliary
Handle into the selected position.
Tighten securely before beginning work.
Hex Wrench Socket Head
Bolt (4)
(55)
Figure 2
1.
Using the Hex Wrench (55), loosen the
Socket Head Bolt (4) and slide the collar
of the Wheel Guard (3) over the rim of
the Gear Housing.
2.
Rotate the Wheel Guard as needed to
shield you during the planned work.
3.
Use the Hex Wrench (55) to tighten
the Socket Head Bolt securely. Check
the Wheel Guard to ensure it is firmly
in place. Adjust if necessary before
proceeding.
SKU 67648
1.
For technical questions, please call 1-800-444-3353.
Page 13
Operating Instructions
Read the entire Important
Safety Information
section at the beginning of this
manual including all text under
subheadings therein before set up
or use of this product.
2.
Press in and hold the Spindle Lock
Button (21) to prevent the Spindle (6)
from turning.
3.
Remove the Outer Flange (1). Keep
the Inner Flange (2) in position on the
Spindle.
4.
Closely inspect the Grinding Wheel
before mounting. Perform a ring-test on
the wheel (unless wheel is smaller than
4” or is an unusual shape) as follows:
Tool Set Up
To prevent
serious injury
from accidental
operation:
Turn the Power Switch of the tool
off and unplug the tool from its
electrical outlet before installing
accessories.
a.Suspend wheel using a pin or finger
through the arbor hole.
45°
Hang
Wheel
from
Pin
Do not install a circular saw
blade, a wood carving blade,
carving disc with saw chain
cutters, or a cutting-carving disc
on this tool.
The Grinding Wheel (Sold separately)
MUST be:
• rated to at least 8,000 RPM.
• no larger than 7” in diameter.
• fitted with a 7/8” round arbor hole.
• 1/4” thick or less.
• suitable for surface grinding, not edge
grinding.
• dry and clean.
• proven undamaged by inspection and
by the ring-test explained following.
Page 14
C
E
N
T
E
R
45°
45°
b.Tap the flat side of the wheel with a
light non-metallic object, such as a
screwdriver handle, at a point 45° from
the vertical center line on each side of
the wheel and 1 – 2 inches from the
edge of the wheel (see Illustration).
Installing the Grinding Wheel
1.
V
E
R
T
I
C
A
L
Tap
Wheel
Here
Each accessory must have the
correct arbor size and must fit
properly on the shoulder
bushing. Make sure accessories
are tightened down securely.
45°
c. Rotate the wheel 90° and repeat the
test until the entire wheel has been
checked.
d.An undamaged wheel will give a clear
tone. If cracked, there will be a dead
sound and not a clear ring.
5.
For wheels with paper gaskets (blotters)
or metal gaskets: Slip the grinding wheel
onto the Spindle with the gasket first.
The gasket should be centered on the
grinding wheel and the wheel and gasket
For technical questions, please call 1-800-444-3353.
SKU 67648
should rest flat against the Inner Flange.
WARNING: To prevent serious
injury, gaskets must be used for all
grinding wheels they are provided
with. Gaskets help prevent grinding
wheel damage and wheel slippage,
causes of wheel failure.
6.
Plug the Cord (52) into the electrical
outlet.
Hold the Handle (43) with one hand
and the Auxiliary Handle (23) with your
other hand. Always use two hands when
operating this tool.
Route the power cord along a safe
route to reach the work area without
creating a tripping hazard or exposing
the power cord to possible damage. The
power cord must reach the work area
with enough extra length to allow free
movement while working.
5.
Allow the tool to come up to full speed
before touching the work material.
6.
Apply the wheel to the work material at
a 10° – 15° angle, allowing the tool to
operate at full speed. If the tool bogs
down, use lighter pressure.
Secure loose work pieces using a vise
or clamps (Sold separately) to prevent
movement while working.
7.
To create a smoother surface, keep the
tool moving over the work surface.
8.
To stop the tool, press and release the
Trigger.
9.
Allow the tool to come to a complete stop
before setting it down.
2.
6.
Press and release the Trigger to make
sure the Trigger is not locked in the on
position.
To start the motor, press and hold the
Trigger (47), then press and hold the
Lock-on Switch (46). Release the Trigger
then the Lock-on Switch. The motor will
be locked on.
Designate a work area that is clean and
well-lit. The work area must not allow
access by children or pets to prevent
distraction and injury.
5.
1.
4.
1.
4.
To prevent
serious injury:
Grip the tool firmly in both
hands.
Thread the Outer Flange clockwise onto
the Spindle. Using the Spanner (53)
tighten only enough so that the wheel is
2.
securely held on the spindle.
WARNING: To prevent serious
injury, do not overtighten flange.
3.
Overtightening can damage the wheel,
causing wheel failure.
Work Piece and Work Area Set Up
3.
General Operating Instructions
There must not be hazardous objects,
such as utility lines or foreign objects,
nearby that will present a hazard while
working.
You must use personal safety equipment
including, but not limited to, ANSIapproved eye and hearing protection, as
well as heavy work gloves.
Before beginning work, provide for
sparks and debris that will fly off the work
surface.
SKU 67648
10. To prevent accidents, unplug the tool
after use. Clean, then store the tool
indoors out of children’s reach.
Note: Do not cover the vents when the tool is
in use. This may cause damage to the
motor and reduce the efficiency of the
tool.
For technical questions, please call 1-800-444-3353.
Page 15
may damage the housing. To prevent
electrical shock, do not allow water or
other liquids to enter the motor vent
holes.
Maintenance And
Servicing
Procedures not specifically
explained in this manual must
be performed only by a qualified
technician.
To prevent
serious injury
from accidental
operation:
Turn the Power Switch of the tool
off and unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
4.
The grease in the gearbox will require
replacement after extensive use of the
grinder. Have the tool serviced by a
qualified technician for this procedure.
5.
WARNING! If the supply cord of
this power tool is damaged, it must be
replaced only by a qualified service
technician.
To prevent serious injury
from tool failure:
Do not use damaged equipment.
If abnormal noise or vibration
occurs, have the problem
corrected before further use.
Cleaning, Maintenance, and
Lubrication
1.
BEFORE EACH USE, inspect the
general condition of the tool. Check for
loose screws, misalignment or binding of
moving parts, cracked or broken parts,
damaged electrical wiring, and any
other condition that may affect its safe
operation.
2.
Periodically blow dust and grit out of
the motor vents using dry compressed
air. Always wear ANSI-approved safety
goggles and NIOSH-approved breathing
protection when performing this
maintenance operation.
3.
After Use, wipe external surfaces
of the tool with a clean cloth. Do not
use solvents or harsh cleaners as they
Page 16
For technical questions, please call 1-800-444-3353.
SKU 67648
Carbon Brush (40) Replacement
The Carbon Brushes (40) may
require maintenance when the motor
performance of the tool decreases or
stops working completely. To maintain
the brushes:
Side of Housing (36)
Brush Holder (39)
7.
Replace the Brush Caps. Do not
overtighten.
Accessory Storage and Handling
1.
Handle accessories carefully to prevent
dropping or bumping. Do not use wheels
that have been dropped or bumped.
2.
Store accessories in shelves, racks,
boxes, or drawers. Storage area must
be kept dry, and above freezing. Any
grinding wheels exposed to humidity or
freezing temperatures must not be used.
Carbon Brush (40)
Figure 5
Carbon Brush Cap (41)
1.
Unscrew the Brush Holder Cap (41)
using a flat head screwdriver (Sold
separately).
2.
Pull the Brush from the Housing (36),
noting the orientation of the old carbon
brushes to prevent needless wear if they
will be reinstalled.
3.
The Carbon Brushes (41) are
approximately 1/2” long. If either carbon
brush is worn down by more than 1/3,
replace both carbon brushes.
4.
To clean old carbon brushes before
reusing them, rub the contact areas with
a pencil eraser.
5.
Hold the spring clips to the side and
carefully, without forcing them, reinsert
the old carbon brushes in the same
orientation to reduce wear.
6.
When installing the carbon brushes,
make sure the carbon portions of the
carbon brushes contact the motor
armature and that the springs operate
freely.
SKU 67648
For technical questions, please call 1-800-444-3353.
Page 17
Troubleshooting
Problem
Tool will not start.
Possible Causes
1. Cord not connected.
2. No power at outlet.
3. Internal damage or wear. (Carbon
brushes or switch, for example.)
Tool operates slowly. 1. Excess pressure applied to workpiece.
2. Power being reduced by long or small
diameter extension cord.
Performance
decreases over time.
Excessive noise or
rattling.
Overheating.
Tool does not grind,
sand or wire brush
effectively.
Carbon brushes worn or damaged.
Internal damage or wear. (Carbon
brushes or bearings, for example.)
1. Forcing tool to work too fast.
2. Blocked motor housing vents.
Likely Solutions
1. Check that cord is plugged in.
2. Check power at outlet. If outlet is
unpowered, turn off tool and check circuit
breaker. If breaker is tripped, make sure
circuit is right capacity for tool and circuit
has no other loads.
3. Have technician service tool.
1. Decrease pressure, allow tool to do the
work.
2. Eliminate use of extension cord. If an
extension cord is needed, use one with
the proper diameter for its length and load.
See Extension Cords in GROUNDING
section.
Have qualified technician replace brushes.
Have qualified technician service tool.
1. Allow tool to work at its own rate.
2. Wear ANSI-approved safety goggles and
NIOSH-approved dust mask/respirator
while blowing dust out of motor using
compressed air.
3. Motor being strained by long or small
3. Eliminate use of extension cord. If an
diameter extension cord.
extension cord is needed, use one with
the proper diameter for its length and load.
See Extension Cords in GROUNDING
section.
1. Disc accessory may be loose on
1. Check tightness of Outer Flange Arbor Nut
Spindle.
or threaded disc accessory on Spindle. Be
sure disc accessory is of correct dimension
and Outer Flange Arbor Nut is tight.
2. Disc accessory may be damaged, worn 2. Check condition and type of disc
or wrong type for the material.
accessory. Use only proper type of disc
accessory in good condition.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect power supply before service.
Page 18
For technical questions, please call 1-800-444-3353.
SKU 67648
PLEASE READ THE FOLLOWING CAREFULLY
The manufacturer and/or distributor has provided the parts list and assembly
diagram in this manual as a reference tool only. Neither the manufacturer or
distributor makes any representation or warranty of any kind to the buyer that he
or she is qualified to make any repairs to the product, or that he or she is qualified
to replace any parts of the product. In fact, the manufacturer and/or distributor
expressly states that all repairs and parts replacements should be undertaken by
certified and licensed technicians, and not by the buyer. The buyer assumes all risk
and liability arising out of his or her repairs to the original product or replacement
parts thereto, or arising out of his or her installation of replacement parts thereto.
Parts List
Part
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Description
Outer Flange
Inner Flange
Wheel Guard Ø 180
Socket Head Bolt M8 x 1.25 x 25mm
Wheel Guard Nut M8
Spindle
Key M4 x 5 x 13
Pan Head Screw M5 x 16
Spring Lock Washer Ø 5
Gear Box Cover
Ball Bearing 6002.RS
Bearing Cover
Spring Lock Washer Ø 4
Pan Head Screw M 4 x 10
Gear
Circlip Ø 14
Friction Bearing
E-Clip Ø 6
Gear Box
Tapping Screw ST5 x 45C
Spindle Lock Button
Spindle Lock Spring
Auxiliary Handle
Heck Nut M8
Pinion
Ball Bearing 6201.2RS
SKU 67648
Qty
1
1
1
1
1
1
1
4
4
1
1
1
6
6
1
1
1
1
1
4
1
1
1
2
1
1
Part
27
28
29
30
31
32
33
36
38
39
40
41
42
43
44
46
47
48
49
50
51
52
53
54
55
Description
Bearing Cover
Armature
Ball Bearing 608.2Z
Bearing Bushing
Baffle
Tapping Screw ST4 X 75C
Stator
Housing
Ring Terminal
Brush Holder
Carbon Brush
Brush Holder Cap
Plastic Plate
Handle
Cord Clamp
Switch
Trigger
Handle Cover
Tapping Screw ST4 x 16C
Tapping Screw ST4 x 14F
Cord Sleeve
Cord
Spanner
Rubber Cap
Hex Wrench
For technical questions, please call 1-800-444-3353.
Qty
1
1
1
1
1
2
1
1
2
2
2
2
1
1
1
1
1
1
6
1
1
1
1
3
1
Page 19
ASSEMBLY DIAGRAM
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and are not available
individually as replacement parts.
Page 20
For technical questions, please call 1-800-444-3353.
SKU 67648
LIMITED 90 DAY WARRANTY
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 90 days from the date of purchase. This
warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or
accidents, repairs or alterations outside our facilities, criminal activity, improper installation,
normal wear and tear, or to lack of maintenance. We shall in no event be liable for death,
injuries to persons or property, 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 the warranties of merchantability and fitness.
To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the complaint
must accompany the merchandise. If our inspection verifies the defect, we will either repair or
replace the product at our election or we may elect to refund the purchase price if we cannot
readily and quickly provide you with a replacement. We will return repaired products at our
expense, but if we determine there is no defect, or that the defect resulted from causes not
within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which
vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
SKU 67648
For technical questions, please call 1-800-444-3353.
Page 21