Chicago Electric 97588 Installation manual

MAGNESIUM HEAVY DUTY 7”
ANGLE GRINDER
97588
SET UP AND OPERATING INSTRUCTIONS
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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©2008 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.
REV 11h

SKU 97588 For technical questions, please call 1-800-444-3353. Page 2
SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information provid-
ed 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.
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.
NOTICE is used to
address practices
not related to personal injury.
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, 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-operated (cordless) power
tool.
Work area safety1.
Keep work area clean and well lit.a.
Cluttered or dark areas invite acci-
dents.
Do not operate power tools inb.
explosive atmospheres, 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 bystandersc.
away while operating a power tool.
Distractions can cause you to lose
control.
Electrical safety2.
Power tool plugs must match thea.
outlet. Never modify the plug in
any way. Do not use any adapter

SKU 97588 For technical questions, please call 1-800-444-3353. Page 3
plugs with grounded power tools.
Unmodied plugs and matching out-
lets will reduce risk of electric shock.
Avoid body contact with groundedb.
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 rainc.
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
Do not abuse the cord. Never used.
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.
When operating a power tool out-e.
doors, use an extension cord suit-
able for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
If operating a power tool in a dampf.
location is unavoidable, use a
Ground Fault Circuit Interrupter
(GFCI) protected supply. Use of
a GFCI reduces the risk of electric
shock.
Personal safety3.
Stay alert, watch what you are do-a.
ing and use common sense when
operating a power tool. Do not use
a power tool while you are tired
or under the inuence of drugs,
alcohol or medication. A moment
of inattention while operating power
tools may result in serious personal
injury.
Use personal protective equip-b.
ment. Always wear eye protection.
Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or
hearing protection used for appropri-
ate conditions will reduce personal
injuries.
Prevent unintentional starting.c.
Ensure the switch is in the off-po-
sition before connecting to power
source and/or battery pack, pick-
ing up or carrying the tool. Carry-
ing power tools with your nger on
the switch or energizing power tools
that have the switch on invites acci-
dents.
Remove any adjusting key ord.
wrench before turning the power
tool on. A wrench or a key left at-
tached to a rotating part of the power
tool may result in personal injury.
Do not overreach. Keep propere.
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
Dress properly. Do not wear loosef.
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.
If devices are provided for the con-g.
nection of dust extraction and col-
lection facilities, ensure these are
connected and properly used. Use
of these devices can reduce dust-
related hazards.
Only use safety equipment thath.
has been approved by an appropri-
ate standards agency. Unapproved
safety equipment may not provide
adequate protection. Eye protection
must be ANSI-approved and breath-
ing protection must be NIOSH-ap-

SKU 97588 For technical questions, please call 1-800-444-3353. Page 4
proved for the specic hazards in the
work area.
Power tool use and care4.
Do not force the power tool. Usea.
the correct power tool for your ap-
plication. 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 theb.
switch does not turn it on and off.
Any power tool that cannot be con-
trolled with the switch is dangerous
and must be repaired.
Disconnect the plug from thec.
power source and/or the battery
pack from the power tool before
making any adjustments, chang-
ing accessories, or storing power
tools. Such preventive safety mea-
sures reduce the risk of starting the
power tool accidentally.
Store idle power tools out of thed.
reach of children and do not allow
persons unfamiliar with the power
tool or these instructions to oper-
ate the power tool. Power tools are
dangerous in the hands of untrained
users.
Maintain power tools. Check fore.
misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect the
power tool’s operation. If dam-
aged, have the power tool repaired
before use. Many accidents are
caused by poorly maintained power
tools.
Keep cutting tools sharp andf.
clean. Properly maintained cutting
tools with sharp cutting edges are
less likely to bind and are easier to
control.
Use the power tool, accessoriesg.
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 differ-
ent from those intended could result
in a hazardous situation.
Service5.
Have your power tool serviced bya.
a qualied repair person using
only identical replacement parts.
This will ensure that the safety of the
power tool is maintained.
Grinding, Sanding or Wire
Brushing Operation Safety
Warnings
This power tool is intended to1.
function as a grinder, sander or
wire brushing tool. Read all safety
warnings, instructions, illustra-
tions and specications provided
with this power tool. Failure to fol-
low all instructions listed below may

serious injury.
Operations such as polishing or2.
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.
Do not use accessories which3.
are not specically designed and
recommended by the tool manu-
facturer. Just because the accessory
can be attached to your power tool, it
does not assure safe operation.
The rated speed of the accessory4.
must be at least equal to the maxi-

SKU 97588 For technical questions, please call 1-800-444-3353. Page 5
mum speed marked on the power
tool. Accessories running faster than
their RATED SPEED can break and

The outside diameter and the5.
thickness of your accessory must
be within the capacity rating of
your power tool. Incorrectly sized
accessories cannot be adequately
guarded or controlled.
The arbor size of wheels, anges, 6.
backing pads or any other acces-
sory must properly t 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 exces-
sively and may cause loss of control.
Do not use a damaged accessory.7.
Before each use inspect the ac-
cessory 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
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.
Wear personal protective equip-8.
ment. Depending on application,
use face shield, safety goggles
or safety glasses. As appropriate,
wear dust mask, hearing protec-
tors, gloves and workshop apron
capable of stopping small abra-
sive or work piece fragments. The
eye protection must be capable of
stopping ying debris generated
by various operations. The eye pro-
tection must be capable of stopping

operations. The dust mask or respira-
-
ticles generated by your operation.
Prolonged exposure to high intensity
noise may cause hearing loss.
Keep bystanders a safe distance9.
away from work area. Anyone
entering the work area must wear
personal protective equipment.
Fragments of work piece or of a

cause injury beyond immediate area
of operation.
Hold power tool by insulated grip-10.
ping surfaces only, when perform-
ing an operation where the cutting
accessory may contact hidden
wiring or its own cord. Cutting ac-

make exposed metal parts of the
-
erator.
Position the cord clear of the spin-11.
ning 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 down12.
until the accessory has come to a
complete stop. The spinning acces-
sory may grab the surface and pull
the power tool out of your control.
Do not run the power tool while13.
carrying it at your side. Accidental
contact with the spinning accessory

SKU 97588 For technical questions, please call 1-800-444-3353. Page 6
could snag your clothing, pulling the
accessory into your body.
Regularly clean the power tool’s14.
air vents. The motor’s fan will draw
the dust inside the housing and ex-
cessive accumulation of powdered
metal may cause electrical hazards.
Do not operate the power tool near15.
ammable materials. Sparks could
ignite these materials.
Do not use accessories that re-16.
quire liquid coolants. Using water
or other liquid coolants may result in
electrocution or shock.
Maintain labels and nameplates on17.
the tool. These carry important safety
information. If unreadable or miss-
ing, contact Harbor Freight Tools for a
replacement.
Avoid unintentional starting. Prepare18.
to begin work before turning on the
tool.
Do not lay the tool down until it has19.
come to a complete stop. Moving
parts can grab the surface and pull
the tool out of your control.
Do not leave the tool unattended20.
when it is plugged into an electrical
outlet. Turn off the tool, and unplug it
from its electrical outlet before leav-
ing.
This product is not a toy. Keep it out21.
of reach of children.
People with pacemakers should22.
consult their physician(s) before use.
-
imity to heart pacemaker could cause
pacemaker interference or pacemak-
er failure. In addition, people with
pacemakers should:


on.

avoid electrical shock.

grounded. Ground Fault Circuit Inter-
rupter (GFCI) should also be imple-
mented – it prevents sustained elec-
trical shock.
Some dust created by power sand-23.
ing, sawing, grinding, drilling, and
other construction activities, contains
chemicals known [to the State of Cali-
fornia] to cause cancer, birth defects
or other reproductive harm. Some
examples of these chemicals are:

-
ment or other masonry products
-
cally treated lumber
Your risk from these exposures var-
ies, 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

particles. (California Health & Safety
Code § 25249.5, et seq.)
WARNING: Handling the cord on24.
this product will expose you to lead,
a chemical known to the State of
California to cause cancer, and birth
defects or other reproductive harm.
Wash hands after handling. (Califor-
nia Health & Safety Code § 25249.5,
et seq.)
The warnings, precautions, and in-25.
structions discussed in this instruction

SKU 97588 For technical questions, please call 1-800-444-3353. Page 7
manual cannot cover all possible con-
ditions 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, back-
ing pad, brush or any other accessory.
Pinching or snagging causes rapid stall-
ing of the rotating accessory which in turn
causes the uncontrolled power tool to be
forced in the direction opposite of the ac-
cessory’s rotation at the point of the bind-
ing.
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, depend-
ing 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
-
dures or conditions and can be avoided by
taking proper precautions as given below.
Maintain a rm grip on the power 1.
tool and position your body and
arm to allow you to resist kick-
back forces. Always use auxiliary
handle, if provided, for maximum
control over kickback or torque
reaction during start-up. The opera-
tor can control torque reactions or
kickback forces, if proper precautions
are taken.
Never place your hand near the2.
rotating accessory. Accessory may
kickback over your hand.
Do not position your body in the3.
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 working4.
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 wood-5.
carving blade or toothed saw
blade. Such blades create frequent
kickback and loss of control.
Safety Warnings Specic for
Grinding Operations
Use only wheel types that are1.
recommended for your power tool
and the specic guard designed
for the selected wheel. Wheels for
which the power tool was not de-
signed cannot be adequately guarded
and are unsafe.
The guard must be securely at-2.
tached to the power tool and posi-
tioned 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 con-
tact with wheel.
Wheels must be used only for3.
recommended applications. For
example: do not grind with the

SKU 97588 For technical questions, please call 1-800-444-3353. Page 8
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.
Always use undamaged wheel4.
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-off
wheels may be different from grinding
wheel anges.
Do not use worn down wheels5.
from larger power tools. Wheel
intended for larger power tool is not
suitable for the higher speed of a
smaller tool and may burst.
Safety Warnings Specic for
Sanding Operations
Do not use excessively oversized1.
sanding disc paper. Follow manu-
facturer’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 Specic for Wire
Brushing Operations
Be aware that wire bristles are1.
thrown by the brush even dur-
ing 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 recom-2.
mended 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 cen-
trifugal forces.
Vibration Safety
This tool vibrates during use. Re-
peated or long-term exposure to vibra-
tion may cause temporary or permanent
physical injury, particularly to the hands,
arms and shoulders. To reduce the risk of
vibration-related injury:
Anyone using vibrating tools regu-1.
larly or for an extended period should

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, ner-
vous system disorders, diabetes, or
Raynaud’s Disease should not use
this tool. If you feel any medical or
physical symptoms related to vibra-
tion (such as tingling, numbness, and

advice as soon as possible.
Do not smoke during use. Nico-2.
tine reduces the blood supply to the

of vibration-related injury.
Wear suitable gloves to reduce the3.
vibration effects on the user.
Use tools with the lowest vibration4.
when there is a choice between dif-
ferent processes.
Include vibration-free periods each5.
day of work.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 9
Grip tool as lightly as possible (while6.

the tool do the work.
To reduce vibration, maintain the tool7.
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 qualied
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
t the outlet, have a proper
outlet installed by a qualied
electrician.
Note: This is a double insulated tool. Infor-
mation on grounded tools is provided
for reference only.
Grounded Tools: Tools with Three
Prong Plugs
Tools marked with “Grounding Re-1.
quired” 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 is2.
connected through the green wire in-
side 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 an3.
appropriate outlet, properly installed
and grounded in accordance with all
codes and ordinances. The plug and
outlet should look like those in the
preceding illustration. (See 3-Prong
Plug and Outlet.)

SKU 97588 For technical questions, please call 1-800-444-3353. Page 10
Double Insulated Tools: Tools
with Two Prong Plugs
Tools marked “Double Insulated” do1.
not require grounding. They have
a special double insulation system

and complies with the applicable
-
tories, Inc., the Canadian Standard
Association, and the National Electri-
cal Code. (See Outlets for 2-Prong
Plug.)
Double insulated tools may be used2.
in either of the 120 volt outlets shown
in the preceding illustration. (See
Outlets for 2-Prong Plug.)
Extension Cords
Grounded1. 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 outlet2.
increases, you must use a heavier
gauge extension cord. Using exten-
sion cords with inadequately sized
wire causes a serious drop in voltage,
resulting in loss of power and pos-
sible tool damage.
(See Table A.) The smaller the
gauge number of the wire, the greater
the capacity of the cord. For ex-
ample, a 14 gauge cord can carry a
higher current than a 16 gauge cord.
(See Table A.)
When using more than one exten-3.
sion cord to make up the total length,
make sure each cord contains at
least the minimum wire size required.
(See Table A.)
If you are using one extension cord4.
for more than one tool, add the
nameplate amperes and use the sum
to determine the required minimum
cord size. (See Table A.)
If you are using an extension cord5.
outdoors, make sure it is marked with

indicate it is acceptable for outdoor
use.
Make sure the extension cord is prop-6.
erly wired and in good electrical con-
dition. Always replace a damaged
extension cord or have it repaired by

Protect the extension cords from7.
sharp objects, excessive heat, and
damp or wet areas.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 11
RECOMMENDED MINIMUM WIRE
GAUGE FOR EXTENSION CORDS*
(120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD
LENGTH
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
* Based on limiting the line
voltage drop to ve volts at
150% of the rated amperes.
Symbology
Double Insulated
Canadian Standards Association

V~ Volts Alternating Current
AAmperes
n0 
(RPM)

SKU 97588 For technical questions, please call 1-800-444-3353. Page 12
SPECIFICATIONS
Electrical Requirements 
 8000 RPM
Wheel Diameter 7 inches
Arbor Diameter 
Spindle Thread 
E194601
90SM
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. 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.
List of contents
Description Q’ty
Angle Grinder 1
Grinding Wheel 1
Quick Release Wheel Guard 1
Auxiliary Handle 1
Pin Wrench 1
Owner’s Manual 1
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.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position 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.
Assembly
Installing the Wheel Guard
The Wheel Guard (7) must be in-1.
stalled before installing a grinding
wheel or other disc.
-2.
lease (6) by pulling the lever outward.
Slide the collar of the Wheel Guard3.
(7) over the rim of the Front Cap (13).
Rotate the position of the Wheel4.
Guard as needed for the planned
work.
Tighten the Wheel Guard Quick Re-5.
lease by pressing the lever back in
place. The clamping pressure of the
Quick Release may be adjusted us-
ing the Nut (4).
Check the Wheel Guard to ensure it6.

before proceeding.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 13
Installing the Auxiliary Handle
TO PREVENT
SERIOUS INJURY:
Do not operate this tool with
one hand only or without the
Auxiliary Handle properly
installed.
The Auxiliary Handle may be installed7.
in one of three positions, on either
side or on top of the Gear Housing
(26). (See Photo.)
Screw the threaded end of the Auxil-8.
iary Handle into the selected position.
Tighten securely before beginning
work.
Functions
Magnesium
Alloy Cover
Auxiliary Handle (25)
Alternative Mounting
Positions for Auxiliary
Handle
Carbon Brush Cap (45)
Wheel Guard (7)
Wheel Guard Quick Release (6)
Spindle
Lock
Button
(24)
Quick Release Adjusting Nut (4)
This hand-held tool may be used for
grinding, sanding, scaling, and other
related operations.
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.
Tool Set Up
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
Installing a Grinding Wheel
Before installing a grinding wheel,1.
review the warnings on pages 5 - 7.
The Grinding Wheel MUST be:
rated to at least 8000 RPM.
no larger than 7” in diameter.


a type of grinding wheel suitable for
surface grinding, not edge grinding.
dry and clean.
proven undamaged by inspec-
tion and by the ring-test explained
below.
2.
Button (24) to prevent the Spindle (8)
from turning.
Remove the Outer Flange (1). Keep3.
the Inner Flange (3) in position on the
Spindle.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 14
Closely inspect the Grinding Wheel4.
before mounting. Perform a ring-test
on the wheel (unless wheel is smaller
than 4” or is an unusual shape) as
follows:
a.
through the arbor hole.
Tap
Wheel
Here
45° 45°
45° 45°
Hang
Wheel
from
Pin
V
E
R
T
I
C
A
L
C
E
N
T
E
R
b. 
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 Il-
lustration).
Rotate the wheel 45 degrees andc.
repeat the test until the entire wheel
has been checked.
An undamaged wheel will give ad.
clear tone. If cracked, there will be a
dead sound and not a clear ring.
Slip the grinding wheel onto the Spin-5.
dle with a paper gasket, or blotter,

on the grinding wheel and the wheel

Inner Flange.
WARNING: To prevent serious
injury, blotters must be used for all
grinding wheels they are provided
with. Blotters help prevent grind-
ing wheel damage and wheel slip-
page, causes of wheel failure.
Thread the Outer Flange Arbor Nut6.
onto the Spindle. Wrench tighten
only enough so that the wheel is se-
curely held on the spindle.
WARNING: To prevent serious
injury, do not overtighten ange.
Overtightening can damage the
wheel, causing wheel failure.
Installing a Threaded Accessory
TO PREVENT
INJURY:
Wear heavy-duty work gloves
when handling wire wheels
and brushes. These
accessories are sharp and
can cause injury.
Before installing an accessory, review1.
the warnings on pages 5 - 7.
The accessory MUST be:
rated to at least 8000 RPM.
no larger than 7” in diameter.


undamaged.
a sanding disc and backing pad, a

a wire cup brush (accessories not
included).
2.
Button (24) to prevent the Spindle (8)
from turning.
Remove the Outer Flange Arbor Nut3.
(1) and the Inner Flange (3) and keep
in a safe place.
4.
the Spindle. Wrench tighten onto the
spindle.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 15
Work Piece and Work Area Set Up
Designate a work area that is clean1.
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
Route the power cord along a safe2.
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 al-
low free movement while working.
Secure loose work pieces using a3.
vise or clamps (not included) to pre-
vent movement while working.
There must not be hazardous ob-4.
jects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
You must use personal safety equip-5.
ment including, but not limited to,
ANSI-approved eye and hearing pro-
tection, as well as heavy work gloves.
Before beginning work, provide for6.

work surface.
General Operating Instructions
TO PREVENT
SERIOUS INJURY:
Grip the tool rmly in both
hands.
This tool has a lock-on Trigger1.
Switch. Push the switch, and then
push forward the tab to lock the
switch for continuous running.
Allow the tool to come up to full2.
speed before touching the work ma-
terial.
Apply the wheel to the work mate-3.
rial, allowing the tool to operate at
full speed. If the tool bogs down, use
lighter pressure.
To create a smoother surface, keep4.
the tool moving over the work sur-
face.
Release the Trigger Switch to stop5.
the tool.
Allow the tool to come to a complete6.
stop before setting it down.
To prevent accidents, turn off the tool7.
and disconnect its power supply after
use. Clean, then store the tool in-
doors out of children’s reach.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 16
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual
must be performed only by a
qualied technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
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
BEFORE EACH USE,1. inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical wir-
ing, and any other condition that may
affect its safe operation.
Periodically blow dust and grit out2.
of the motor vents using dry com-
pressed air. Always wear safety
glasses when performing this mainte-
nance operation.
AFTER USE,3. clean external surfaces
of the tool with clean cloth. Never use
solvents or harsh cleaners as they
may damage the housing. To pre-
vent electrical shock, do not allow
water or other liquids to enter the
motor vent holes in the Gear Hous-
ing (26).
GRINDING WHEEL CARE:4.
Handling - Do not lean grinding
wheels against an object, or rest ob-
jects on grinding wheels. Do not drop
grinding wheels or roll them across

Storage - Store thick grinding wheels
on appropriate racks and store thin

Store in a relatively constant temper-
ature and do not expose to moisture
or freezing temperatures.
WARNING: To prevent serious
injury from grinding wheel failure,
discard any wheels that have been
improperly handled or stored.
OTHER ACCESSORY CARE:5.
Handling - Do not drop accessories.

are not intended to bend.
Storage - Store accessories in dry,
cool area.
CARBON BRUSH MAINTENANCE.6.
The carbon brushes may require
maintenance when the motor perfor-
mance of the tool decreases or stops
working completely. To maintain the
brushes:
Remove the Screws (40) and Brusha.
Caps (41 and 45) from the sides of
the motor housing.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 17
b. 
as shown in the illustration above.
c. Use a small prying tool (not includ-
ed) to hold the Spring Clips to the
side while you remove the carbon
brushes. Keep track of which
orientation the old carbon brush-
es were in to prevent needless
wear if they will be reinstalled.
If either carbon brush is worn downd.
both car-
bon brushes.
To clean old carbon brushes beforee.
reusing them, rub the contact areas
with a pencil eraser.
Hold the spring clips to the side andf.
reinsert the old carbon brushes in
the same orientation to reduce wear.
When installing the carbon brushes,g.
make sure the carbon portions of the
carbon brushes contact the motor
armature, and that the springs face
away from the motor. Also, make
sure the springs operate freely.
h.
Replace the Brush Caps andi.
Screws. Do not overtighten.
Note: New carbon brushes tend to spark

conform to the motor’s armature.
7. WARNING! If the supply cord of
this power tool is damaged, it must
be replaced only by a qualied
service technician.

SKU 97588 For technical questions, please call 1-800-444-3353. Page 18
Troubleshooting
Problem Possible Causes Likely Solutions
Tool will not start No power at outlet.1.
Cord not connected.2.
Carbon Brushes may be worn or3.
damaged.
Check power at outlet.1.
Check that cord is plugged in.2.
Inspect Carbon Brushes and replace if3.
necessary.
Tool operates
slowly or
erratically.
Carbon Brushes may be worn or1.
damaged.
Excess pressure applied to2.
workpiece.
Inspect Carbon Brushes and replace if1.
necessary.
Decrease pressure, allow tool to do2.
the work.
Tool does not
grind, sand or
brush effectively.
Disc accessory may be loose on1.
Spindle. Check tightness of Outer
Flange Arbor Nut or threaded disc
accessory on Spindle.
Disc accessory may be damaged,2.
worn or wrong type for the
material.
Be sure disc accessory is of correct1.
dimension and Outer Flange Arbor Nut
is tight.
Check condition and type of disc2.
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.
PLEASE READ THE FOLLOWING CAREFULLY


DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT

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
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



SKU 97588 For technical questions, please call 1-800-444-3353. Page 19
PARTS LIST
Part Description Qty.
1 Outer Flange Arbor Nut 1
2 Grinding Wheel (not included) -
3 Inner Flange 1
4 Quick Release Adjusting Nut m8 1
5 Washer 1
6 Wheel Guard Quick Release 1
7 Wheel Guard 1
8 Spindle 1
9 Woodruff Key 1
10 Phillips Pan Head Screw m5 x 16 4
11 Spring Washer m5 4
12 Flat Washer 8
13 Front Cap 1
14 Bearing 6203 1
15 Bearing Retaining Plate 1
16 Spring Washer m4 7
17 Phillips Pan Head Screw m4 x 12 7
18 Bevel Gear 1
19 Open Circlip 1
20 Needle Gear 1
21 Open Circlip 1
22 Phillips Pan Head Screw m4.8 x 28 1
23 Spring 1
24  1
25 Auxiliary Handle 1
26 Gear Housing 1
27  1
PARTS LIST
Part Description Qty.
28 Pinion 1
29 Bearing 6201 1
30 Bearing Retaining Plate 1
31 Rotor 1
32 Bearing 629 1
33 Bearing Sleeve 1
34  1
35 Self Tapping Screw m4.2 x 71 1
36 Stator 1
37  1
38 Heat Shrinkable Tube 1
39 Magnesium Alloy Cover 1
40 Self Tapping Screw m4.2 x 14 4
41 Carbon Brush Cap (left) 1
42 Motor Housing 1
43 Carbon Brush 2
44 Carbon Brush Holder 2
45 Carbon Brush Cap (right) 1
46 Coil Spring 2
47 Nameplate 1
48 Self Tapping Screw 5
49  1
50 Power Cable & Plug 1
51 Cable Clamp 1
52 Cable Sleeve 1
53 Right Handle 1
54 Trigger Switch 1

SKU 97588 For technical questions, please call 1-800-444-3353. Page 20
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 avail-
able individually as replacement parts.