Milwaukee 5192 User manual
2
GENERAL POWER TOOL
SAFETY WARNINGS
WARNING
Read all safety warnings, instruc-
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tions provided with this power tool. Failure to
follow all instructions listed below may result in
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warnings and instructions for future reference.
The term "power tool" in the warnings refers to your
mains-operated (corded) power tool or battery-oper-
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WORK AREA SAFETY
•Keep work area clean and well lit. Cluttered or dark
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•Do not operate power tools in explosive atmo-
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OLTXLGV JDVHV RU GXVW Power tools create sparks
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a power tool. 'LVWUDFWLRQVFDQFDXVH\RXWRORVHFRQWURO
ELECTRICAL SAFETY
•Power tool plugs must match the outlet. Never
modify the plug in any way. Do not use any adapter
plugs with earthed (grounded) power tools. Un-
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surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric
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•Do not expose power tools to rain or wet condi-
tions. Water entering a power tool will increase the
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rying, pulling or unplugging the power tool. Keep
cord away from heat, oil, sharp edges or moving
parts. Damaged or entangled cords increase the risk
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•When operating a power tool outdoors, use an ex-
WHQVLRQFRUGVXLWDEOHIRURXWGRRUXVHUse of a cord
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•If operating a power tool in a damp location is
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(GFCI) protected supply. Use of an GFCI reduces
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PERSONAL SAFETY
•Stay alert, watch what you are doing and use com-
mon sense when operating a power tool. Do not
use a power tool while you are tired or under the
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of inattention while operating power tools may result
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eye protection. Protective equipment such as a dust
mask, non-skid safety shoes, hard hat or hearing
protection used for appropriate conditions will reduce
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•Prevent unintentional starting. Ensure the switch
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the tool. &DUU\LQJSRZHUWRROVZLWK\RXU¿QJHURQWKH
switch or energizing power tools that have the switch
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the power tool on.Awrench or a key left attached to a ro-
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at all times. This enables better control of the power
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•Dress properly. Do not wear loose clothing or
jewelry. Keep your hair and clothing away from
moving parts. /RRVHFORWKHVMHZHOU\RUORQJKDLUFDQ
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•If devices are provided for the connection of dust
extraction and collection facilities, ensure these
are connected and properly used. Use of dust col-
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tool safety principles. A careless action can cause
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POWER TOOL USE AND CARE
•Dono
t force the power tool. Use the correct power tool
for your application. The correct power tool will do the
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•Do not use the power tool if the switch does not turn
it on and off. Any power tool that cannot be controlled
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•Disconnect the plug from the power source and/
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changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting
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•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. Pow-
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•Maintain power tools and accessories. Check for
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of parts and any other condition that may affect the
power tool’s operation. If damaged, have the power
WRROUHSDLUHGEHIRUHXVHMany accidents are caused
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•Keep cutting tools sharp and clean. Properly main-
tained cutting tools with sharp cutting edges are less
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in accordance with these instructions, taking into
account the working conditions and the work to
EHSHUIRUPHGUse of the power tool for operations
different from those intended could result in a hazard-
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•Keep handles and grasping surfaces dry, clean
and free from oil and grease. Slippery handles and
grasping surfaces do not allow for safe handling and
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SERVICE
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person using only identical replacement parts. This
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SPECIFIC SAFETY RULES FOR
DIE GRINDERS
Safety Warnings Common for Grinding, Sanding,
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Cutting-Off Operations:
•This power tool is intended to function as a grinder,
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Just because the accessory can be attached to
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tool. Accessories running faster than their rated speed
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•The outside diameter and the thickness of your
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your power tool. Incorrectly sized accessories cannot
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collet of the power tool. Accessories that do not
match the mounting hardware of the power tool will
run out of balance, vibrate excessively and may cause
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•Mandrel mounted wheels, sanding drums, cutters
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collet or chuck. ,IWKHPDQGUHOLVLQVXI¿FLHQWO\KHOGDQG
or the overhang of the wheel is too long, the mounted
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•Do not use a damaged accessory. Before each use
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chips and cracks, sanding drum for cracks, tear or
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If power tool or accessory is dropped, inspect for
damage or install an undamaged accessory. After
inspecting and installing an accessory, position
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rotating accessory and run the power tool at maxi-
mum no-load speed for one minute. Damaged ac-
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on application, use face shield, safety goggles or
safety glasses. As appropriate, wear dust mask,
hearing protectors, gloves and workshop apron
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fragments. The eye protection must be capable of
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area. Anyone entering the work area must wear
SHUVRQDOSURWHFWLYHHTXLSPHQWFragments of work-
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only, when performing an operation where the
cutting accessory may contact hidden wiring or
its own cord. Cutting accessory contacting a "live"
wire may make exposed metal parts of the power tool
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the start-up. The reaction torque of the motor, as it
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•Use clamps to support workpiece whenever practi-
cal. Never hold a small workpiece in one hand and
the tool in the other hand while in use. Clamping
a small workpiece allows you to use your hand(s) to
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pipes or tubing have a tendency to roll while being cut,
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•Position the cord clear of the spinning accessory. If
you lose control, the cord may be cut or snagged and your
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•Never lay the power tool down until the accessory
has come to a complete stop. The spinning acces-
sory may grab the surface and pull the power tool out
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make sure the collet nut, chuck or any other adjust-
ment devices are securely tightened. /RRVHDGMXVW-
ment devices can unexpectedly shift, causing loss of
control, loose rotating components will be violently
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•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
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•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
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materials. 6SDUNVFRXOGLJQLWHWKHVHPDWHULDOV
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ants. Using water or other liquid coolants may result
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Kickback is a sudden reaction to a pinched or snagged
rotating wheel, sanding band, brush or any other acces-
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rotating accessory which in turn causes the uncontrolled
power tool to be forced in the direction opposite of the
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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
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from the operator, depending on direction of the wheel’s
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procedures or conditions and can be avoided by taking
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forces. The operator can control kickback forces, if
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•Use special care when working corners, sharp
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cessory. Corners, sharp edges or bouncing have a
tendency to snag the rotating accessory and cause
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'RQRWDWWDFKD WRRWKHG VDZ EODGHSuch blades
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direction as the cutting edge is exiting from the
material (which is the same direction as the chips
are thrown). Feeding the tool in the wrong direction
causes the cutting edge of the bit to climb out of the
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the work securely clamped. These wheels will grab
if they become slightly canted in the groove, and can
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Cutting-Off Operations:
•
Use only wheel types that are recommended for
your power tool and only for recommended appli-
cations. For example: do not grind with the side of
a cut-off wheel. Abrasive cut-off wheels are intended
for peripheral grinding, side forces applied to these
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undamaged wheel mandrels with an unrelieved
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•Do not “jam” a cut-off wheel or apply excessive pres-
sure. Do not attempt to make an excessive depth of
cut. Overstressing the wheel increases the loading and
susceptibility to twisting or snagging of the wheel in the
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4
EXTENSION CORDS
Grounded tools require a three wire extension
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the supply outlet increases, you must use a heavier
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inadequately sized wire causes a serious drop in
voltage, resulting in loss of power and possible tool
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The smaller the gauge number of the wire, the greater
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When using more than one extension cord to make
up the total length, be sure each cord contains at
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one extension cord for more than one tool, add the
nameplate amperes and use the sum to determine
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Guidelines for Using Extension Cords
•If you are using an extension cord outdoors, be sure
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LQGLFDWHWKDWLWLVDFFHSWDEOHIRURXWGRRUXVH
•Be sure your extension cord is properly wired and in
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H[WHQVLRQ FRUG RU KDYH LW UHSDLUHG E\ D TXDOL¿HG
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Recommended Minimum Wire Gauge
For Extension Cords*
Nameplate Amps
Extension Cord Length
25' 50' 75'
--
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GROUNDING
WARNING
Improperly connecting the ground-
ing wire can result in the risk of
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properly grounded. Do not modify the plug pro-
vided with the tool. Never remove the grounding
prong from the plug. Do not use the tool if the
cord or plug is damaged. If damaged, have it
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XVH,IWKHSOXJZLOOQRW¿WWKH RXWOHW KDYH D
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Grounded Tools (Three-Prong Plugs)
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must be connected to a properly grounded outlet
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function or break down, grounding provides a low
resistance path to carry electricity away from the
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The grounding prong in the plug is connected through
the green wire inside the cord to the grounding
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be the only wire connected to the tool's grounding
system and must never be attached to an electrically
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the rotating wheel. When the wheel, at the point of
operation, is moving away from your hand, the possible
kickback may propel the spinning wheel and the power
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any reason, switch off the power tool and hold the
power tool motionless until the wheel comes to a
complete stop. Never attempt to remove the cut-off
wheel from the cut while the wheel is in motion oth-
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•Do not restart the cutting operation in the work-
piece. Let the wheel reach full speed and carefully
reenter the cut. The wheel may bind, walk up or
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Supports must be placed under the workpiece near
the line of cut and near the edge of the workpiece on
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•Use extra caution when making a “pocket cut” into
H[LVWLQJZDOOVRURWKHUEOLQGDUHDVThe protruding
wheel may cut gas or water pipes, electrical wiring or
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Safety
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•Be aw
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even during ordinary operation. Do not overstress the
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$OORZEUXVKHVWRUXQDWRSHUDWLQJVSHHGIRUDWOHDVW
RQHPLQXWHEHIRUHXVLQJWKHP'XULQJWKLVWLPHQR
RQHLVWRVWDQGLQIURQWRULQOLQHZLWKWKHEUXVKLoose
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away from you. Small particles and tiny wire fragments
may be discharged at high velocity during the use of
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Additional Safety Warnings
•0DLQWDLQODEHOVDQGQDPHSODWHVThese carry im-
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•
WARNING
Some dust created by power sanding,
sawing, grinding, drilling, and other
construction activities contains chemicals known to
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Some examples of these chemicals are:
•lead from lead-based paint
•crystalline silica from bricks and cement and other
masonry products, and
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Your risk from these exposures varies, depending on
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exposure to these chemicals: work in a well ventilated
area, and work with approved safety equipment, such
as those dust masks that are specially designed to
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SYMBOLOGY
Double Insulated
Volts
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Amps
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Your tool must be plugged into an appro-
Fig. A
priate outlet, properly installed and
grounded in accordance with all codes
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system which satisfies OSHA requirements and
complies with the applicable standards
Fig. B Fig. C
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Canadian Standard Association and
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Insulated tools may be used in either
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SPECIFICATIONS
Volts$&'&
Max Wheel Ø 2"
Cat. No..................................................5192, 5194
Amps
5DWHG530
Cat. No............................................................5196
Amps
5DWHG530
FUNCTIONAL DESCRIPTION
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ASSEMBLY
WARNING
To reduce the risk of injury, always
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removing accessories. Only use accessories
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PD\EHKD]DUGRXV
Care of Mounted Points, Grinding Wheels
& Cut-Off Wheels
Points, grinding wheels and cut-off wheels should
be protected from:
•wetness and extreme humidity
•any type of solvent
•extreme changes in temperature
•dropping and bumping
Points, grinding wheels and cut-off wheels should
be stored:
•in an organized way so points or wheels can be
removed without disturbing or damaging other points
or wheels
•with their safety information
Points, grinding wheels and cut-off wheels should
127EHGURSSHGUROOHGRUEXPSHG
Discard points or wheels that have been dropped,
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SHUDWXUHRUFRPHLQWRFRQWDFWZLWKVROYHQWVRUZHWQHVV
Installing Collets
MILWAUKEE Die Grinders feature a special collet
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collet nut before installing the collet asembly to the
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the mounted wheel mandrel you will use, otherwise
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downward pressure onto assembly with the palm
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one hand and press the collet to one side with the
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6
Installing Accessories
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Insert mandrel
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Accessory
Mandrel
Collet
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wrench and securely tighten the collet nut with an
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WARNING
To reduce the risk of injury, always
securely tighten the collet to the
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them into the collet. Otherwise the high-speed
rotation of the tool could force the accessory to
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OPERATION
WARNING
To reduce the risk of injury, always
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removing accessories or making adjustments.
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To reduce the risk of injury, wear safety goggles
or glasses with side shields.
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the motor and check to see if the accessory is dull.
Dull accessorieVZLOOFDXVHWKHWRROWRYLEUDWHDQG
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replace or sharpen dull accessories.
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use points, grinding wheels and cut-off wheels for
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General Operation
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beginning a period of work, test it by letting it spin
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WARNING! Never use an accessory that has been
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can mar workpiece, damage the tool, and cause
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8VHDFODPSYLVHRURWKHUSUDFWLFDOPHDQVWRKROG
\RXUZRUNIUHHLQJERWKKDQGVWRFRQWUROWKHWRRO
WARNING!+ROGWRROVHFXUHO\ZLWKERWKKDQGV
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To start the tool:
turn the toggle switch ON ( I )
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FHVVRU\DQGZRUNSLHFHWARNING! Never bang
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7Rstop the tool:
turn the toggle switch OFF (O)
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Make sure the tool comes to a complete stop
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7R loc
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MAINTENANCE
WARNING
To reduce the risk of injury, always
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DQ\PDLQWHQDQFH1HYHUGLVDVVHPEOHWKHWRRO
Contact a MILWAUKEE service facility for ALL
repairs. Maintaining Tools
Keep your tool in good repair by adopting a regular
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such as undue noise, misalignment or binding of
moving parts, breakage of parts, or any other condi-
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WRD0,/:$8.((VHUYLFHIDFLOLW\IRUUHSDLU$IWHUVL[
months to one year, depending on use, return the
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WARNING
To reduce the risk of personal in-
jury, electric shock and damage,
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Cleaning
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soap and a damp cloth to clean, since certain clean-
ing agents and solvents are harmful to plastics and
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turpentine, lacquer thinner, paint thinner, chlorinated
cleaning solvents, ammonia and household deter-
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Repairs
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ACCESSORIES
WARNING
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Use only recommended accesso-
Learn more about power grinders and rotary tools we have.
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