Drill Master 95578 Installation manual
4-1/2” ANGLE GRINDER
95578
SET UP AND OPERATING INSTRUCTIONS
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©2006 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.
Manual Revised 10d; 11a
SKU 95578 For technical questions, please call 1-800-444-3353. Page 2
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 3
GENERAL POWER TOOL
SAFETY WARNINGS.......................3
SAFETY WARNINGS COMMON
FOR GRINDING, SANDING, OR
WIRE BRUSHING OPERATIONS ...5
KICKBACK AND RELATED
WARNINGS......................................8
SAFETY WARNINGS SPECIFIC
FOR GRINDING OPERATIONS ......8
SAFETY WARNING SPECIFIC
FOR SANDING OPERATIONS........9
SAFETY WARNINGS SPECIFIC
FOR WIRE BRUSHING
OPERATIONS.................................. 9
VIBRATION SAFETY .........................9
GROUNDING ............................... 10
DOUBLE INSULATED TOOLS:
TOOLS WITH TWO PRONG
PLUGS ...........................................10
EXTENSION CORDS .......................10
SYMBOLOGY................................... 11
SPECIFICATIONS........................ 12
UNPACKING ................................ 12
INSTRUCTIONS FOR PUTTING
INTO USE .................................. 12
ASSEMBLY.......................................12
FUNCTIONS .....................................13
OPERATING INSTRUCTIONS .... 13
TOOL SET UP ..................................13
WORK PIECE AND WORK AREA
SET UP ..........................................14
GENERAL OPERATING
INSTRUCTIONS ............................15
MAINTENANCE AND
SERVICING ............................... 16
CLEANING, MAINTENANCE, AND
LUBRICATION ............................... 16
ACCESSORY STORAGE AND
HANDLING ....................................17
TROUBLESHOOTING......................17
PARTS LIST................................. 18
ASSEMBLY DIAGRAM................ 19
LIMITED 90 DAY WARRANTY .... 20
SKU 95578 For technical questions, please call 1-800-444-3353. Page 3
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.
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.
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.
1. Work area safety
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 ammable liquids,
gases or dust. Power tools create
sparks which may ignite the dust or
fumes.
c. Keep children and bystanders
away while operating a power tool.
SKU 95578 For technical questions, please call 1-800-444-3353. Page 4
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.
Unmodied 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 increased risk of electric shock if
your body is grounded.
c. Do not expose power tools to rain
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
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.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.
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. 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 inuence 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 dust mask,
non-skid safety shoes, 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 and/or battery pack,
picking up or carrying the tool.
Carrying power tools with your nger
on the switch or energizing power
tools that have the switch on invites
accidents.
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.
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.
g.If devices are provided for the
connection of dust extraction and
collection facilities, ensure these
are connected and properly used.
SKU 95578 For technical questions, please call 1-800-444-3353. Page 5
Use of these devices can reduce
dust-related hazards.
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 specic
hazards in the work area.
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 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. Keep cutting tools sharp and
clean. Properly maintained cutting
tools with sharp cutting edges are
less likely to bind and are easier to
control.
g.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 qualied 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, or Wire
Brushing Operations
1. This power tool is intended
to function as a grinder,
sander, or wire brush. Read all
safety warnings, instructions,
illustrations and specications
provided with this power tool.
Failure to follow all instructions listed
below may result in electric shock,
re and/or serious injury.
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.
SKU 95578 For technical questions, please call 1-800-444-3353. Page 6
3. Do not use accessories which
are not specically 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 y 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,
anges, backing pads or any
other accessory 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 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 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. 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 ying debris generated
by various operations. The eye
protection must be capable of
stopping ying debris generated by
various operations. The dust mask
or respirator must be capable of
ltering out particles generated by
your operation. Prolonged exposure
to high intensity noise may cause
hearing loss.
9. 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 y 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.
SKU 95578 For technical questions, please call 1-800-444-3353. Page 7
11. Position the cord clear of the
spinning accessory. If you lose
control, the cord may be cut or
snagged and your hand or arm may
be pulled into the spinning accessory.
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
ammable 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 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.
20. 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 and
personal injury.
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 elds 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
REV 10c
SKU 95578 For technical questions, please call 1-800-444-3353. Page 8
a well ventilated area, and work with
approved safety equipment, such as
those dust masks that are specially
designed to lter 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 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 rm 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 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.
SKU 95578 For technical questions, please call 1-800-444-3353. Page 9
Safety Warnings Specic for
Grinding Operations
1. Use only wheel types that are
recommended for your power tool
and the specic guard designed
for the selected wheel. Wheels
for which the power tool was not
designed cannot be adequately
guarded and are unsafe.
2. 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.
3. 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.
4. Always use undamaged wheel
anges that are of correct size and
shape for your selected wheel.
Proper wheel anges support the
wheel thus reducing the possibility of
wheel breakage. Flanges for cut-off
wheels may be different from grinding
wheel anges.
5. 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.
6. Dress appropriately. Wear leather
leggings and re 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 Warning Specic 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 Specic for Wire
Brushing Operations
1. 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.
2. 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
SKU 95578 For technical questions, please call 1-800-444-3353. Page 10
rst 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 not
use this tool. If you feel any medical
or physical symptoms related to
vibration (such as tingling, numbness,
and white or blue ngers), seek
medical advice as soon as possible.
2. Do not smoke during use. Nicotine
reduces the blood supply to the
hands and ngers, 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 qualied
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 qualied
electrician.
Double Insulated Tools: Tools
with Two Prong Plugs
Outlets for 2-Prong Plug
1. Tools marked “Double Insulated”
do not require grounding. They
have a special double insulation
system which satises OSHA
requirements and complies with the
applicable standards of Underwriters
Laboratories, Inc., the Canadian
Standard Association, and the
SKU 95578 For technical questions, please call 1-800-444-3353. Page 11
National Electrical Code.
(See Outlets for 2-Prong Plug.)
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.)
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 a higher current than a 16
gauge cord. (See Table A.)
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 Table A.)
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 Table A.)
6. If you are using an extension cord
outdoors, make sure it is marked with
the sufx “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 qualied electrician before using it.
8. Protect the extension cords from
sharp objects, excessive heat, and
damp or wet areas.
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
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0 xxxx/min. No Load Revolutions per Minute
(RPM)
SKU 95578 For technical questions, please call 1-800-444-3353. Page 12
SPECIFICATIONS
Electrical Input 120 V~ / 60 Hz / 4.3 A
Motor No Load Speed 11,000 RPM
Max. Accessory
Diameter 4-1/2” (114 mm)
Arbor Hole Diameter 7/8”
Spindle Thread 5/8” x 11 TPI
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.
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 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.
Assembly
Adjusting the Wheel Guard
TO PREVENT
SERIOUS INJURY:
Do not operate this tool
without the Wheel Guard
properly installed.
1. Loosen the Wheel Guard Bolt.
2. Rotate the Wheel Guard as needed
to shield you during the planned
work.
3. Tighten the Wheel Guard Bolt
securely.
4. Check the Wheel Guard to ensure it
is rmly in place. Adjust if necessary
before proceeding.
Installing the Side Handle
TO PREVENT
SERIOUS INJURY:
Do not operate this tool with
one hand only or without the
Side Handle properly
installed.
5. The Side Handle may be installed on
either side of the Gear Housing.
6. Screw the threaded end of the Side
Handle into the selected position.
Tighten securely before beginning
work.
REV 10d
SKU 95578 For technical questions, please call 1-800-444-3353. Page 13
Functions
Switch - Press the Switch forward to
turn the tool on; pull it backward to
turn the tool off.
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 off and unplug the tool
from its electrical outlet
before installing accessories.
Installing a Non-threaded Grinding
Wheel
1. The Grinding Wheel MUST be:
• rated to at least 11,000 RPM.
• no larger than 4-1/2” in diameter.
• tted with a 7/8” round arbor hole.
• from 0.08” to 1/4” thick.
• a type of grinding wheel suitable for
surface grinding, not edge grinding.
• dry and clean.
• proven undamaged by inspection
and by the ring-test explained
below.
2. Press in and hold the Spindle Lock
Button to prevent the Spindle from
turning.
3. Use the Pin Wrench to remove the
Outer Flange. Keep the Inner Flange
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:
a. Suspend wheel using a pin or nger
through the arbor hole.
b.
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
Tap the at 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).
REV 10c; 11a
Switch
Side Handle
Spindle
Lock
Wheel
Guard
Wheel
Guard
Bolt
SKU 95578 For technical questions, please call 1-800-444-3353. Page 14
c. Rotate the wheel 45 degrees 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 rst. The gasket should
be centered on the grinding wheel
and the wheel and gasket should rest
at 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.
Spindle
Inner Flange
The raised portions on the Inner
Flange must line up with the ats on
the spindle so that they lock together,
as shown above.
7. Thread the Outer Flange onto the
Spindle. Using the Pin Wrench,
tighten only enough so that the wheel
is securely 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.
1. The accessory MUST be:
• rated to at least 11,000 RPM.
• no larger than 4-1/2” in diameter.
• tted with a threaded opening of
5/8” x 11 TPI.
• undamaged.
• a sanding disc and backing pad, a
sanding ap disc, a wire wheel or
a wire cup brush (accessories not
included).
2. Press in and hold the Spindle Lock
Button to prevent the Spindle from
turning.
3. Remove the Outer Flange and the
Inner Flange and keep in a safe
place.
4. Thread disc accessory rmly onto
the Spindle. Wrench tighten onto the
spindle.
Work Piece and Work Area Set Up
1. 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.
2. 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.
SKU 95578 For technical questions, please call 1-800-444-3353. Page 15
The power cord must reach the work
area with enough extra length to
allow free movement while working.
3. Secure loose work pieces using
a vise or clamps (not included) to
prevent movement while working.
4. There must not be hazardous
objects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
5. You must use personal safety
equipment including, but not limited
to, ANSI-approved eye and hearing
protection, as well as heavy work
gloves.
6. Before beginning work, provide for
sparks and debris that will y off the
work surface.
General Operating Instructions
TO PREVENT
SERIOUS INJURY:
Grip the tool rmly in both
hands.
1. Turn the tool off. Then, plug in the
tool.
2. Press the Switch forward to turn the
tool on. Never depress the Spindle
Lock Button (22N) when starting
the grinder, or while it is running.
3. Allow the tool to come up to full
speed before touching the work
material.
4. Apply the wheel to the work material
at about a 10°-15° angle, allowing the
tool to operate at full speed. If the tool
bogs down, use lighter pressure.
5. To create a smoother surface,
keep the tool moving over the work
surface.
6. Pull the Switch backward to turn the
tool off.
7. Allow the tool to come to a complete
stop before setting it down.
8. To prevent accidents, turn off the
tool and disconnect its power supply
after use. Clean, then store the tool
indoors out of children’s reach.
Maintenance And Servicing
Procedures not specically
explained in this manual
must be performed only by a
qualied 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.
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.
REV 10b; 10d
SKU 95578 For technical questions, please call 1-800-444-3353. Page 16
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. AFTER USE, wipe external surfaces
of the tool with clean cloth.
3. Periodically blow dust and grit
out of the motor vents using dry
compressed air. Wear ANSI-
approved safety goggles and NIOSH-
approved breathing protection while
doing this.
4. CARBON BRUSH MAINTENANCE.
The carbon brushes may require
maintenance when the motor
performance of the tool decreases or
stops working completely. Carbon
brushes are internal to the Motor
Housing, and should only be checked
by a qualied service technician.
5. WARNING! If the supply cord of
this power tool is damaged, it must
be replaced only by a qualied
service technician.
Replacing Carbon Brush
1. NOTE: Only a qualied service
technician should replace Carbon
Brush.
2. Use screwdriver (not included) to
remove Screw (46N) from center of
End Cap Housing (45N). Then slide
off Housing. See photo, above.
3. Loosen screw holding Carbon Brush
Holder (41N) in place. Then remove
Carbon Brush (42N) from Holder.
4. Insert new Carbon Brush into Holder,
reinsert Holder and fasten into place
with screw.
5. Slide End Cap Housing back into
place and fasten securely with Screw.
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 or cut-off wheels
exposed to humidity or freezing
temperatures must not be used.
REV 10c; 10d
Screw
(46N)
End Cap
Housing
(45N)
Carbon
Brush
(42N)
Carbon Brush
Holder (41N)
SKU 95578 For technical questions, please call 1-800-444-3353. Page 17
Troubleshooting
Problem Possible Causes Likely Solutions
Tool will not start. 1. Cord not connected.
2. No power at outlet.
3. Tool’s thermal reset breaker tripped
(if equipped).
4. Brushes damaged.
5. Internal damage or wear.
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. Turn off tool and allow to cool. Press reset
button on tool.
4. Have a qualied service technician replace
brushes.
5. Have technician service tool.
Tool operates slowly. 1. Excess pressure applied to
workpiece.
2. Power being reduced by long or
small diameter extension cord.
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.
Performance
decreases over time.
Carbon brush worn or damaged. Have service technician replace brush.
Excessive noise or
rattling.
1. Brushes damaged.
2. Internal damage or wear.
(Bearings, for example.)
1. Have a qualied service technician replace
brushes.
2. Have technician service tool.
Overheating. 1. Forcing tool to work too fast.
2. Blocked motor housing vents.
3. Motor being strained by long or
small diameter extension cord.
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. 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.
Tool does not grind,
sand or brush
effectively.
1. Disc accessory may be loose on
Spindle. Check tightness of Outer
Flange Arbor Nut or threaded disc
accessory on Spindle.
2. Disc accessory may be damaged,
worn or wrong type for the material.
1. Be sure disc accessory is of correct
dimension and Outer Flange Arbor Nut is
tight.
2. Check condition and type of disc
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.
REV 10c
SKU 95578 For technical questions, please call 1-800-444-3353. Page 18
Part Description
1 Outer Flange Nut
3 Inner Flange
4N Wheel Guard
5N Wheel Guard Bolt
6N Wheel Guard Square Nut
7N Spindle
8N Woodruff Key
9N Screw
10N Spring Washer
12N Gearbox Bottom Cover
13 Bearing 60201
14 Locking Ring
15 Ring Gear
16 Locking Ring
17 Bearing
18N Side Handle
19N Screw
20N Keeper
21N Lock Spring
22N Spindle Lock Button
23N Gear Housing
24 Pinion Gear
25 Bearing 6018
26 Gearbox Back Cover
27N Self Tapping Screw
Part Description
28N Screw
29N Woodruff Key
30N Armature
31 Bearing 6018
32 Bearing Cover
33N Bolt
34N Stator
35N Sliding Spring
36N Wind Shield Ring
37N On/Off Switch
38N Power Switch
39N Lock Spring
40N Motor Housing
41N Carbon Brush Holder
42N Brush
43N Sliding Spring
44N Switch
45N End Cap Housing
46N Screw
47 Sheath (#115A)
48N Power Cord Bracket
49N Self Tapping Screw
50 Power Cord/Plug
51 Wrench
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
REV 10c
SKU 95578 For technical questions, please call 1-800-444-3353. 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. REV 10c
SKU 95578 For technical questions, please call 1-800-444-3353. Page 20
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 veries 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 specic 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
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