Milwaukee M18 FUEL CAG125XPD User manual

Cat. No.
0&$*;3'
M18™ FUEL™ 5" GRINDER
OPERATOR'S MANUAL
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manual.

2
PERSONAL SAFETY
GENERAL POWER TOOL SAFETY WARNINGS
WORK AREA SAFETY
ELECTRICAL SAFETY
•Keepworkareacleanandwelllit. Cluttered or
dark areas invite accidents.
•Donotoperatepowertoolsinexplosiveatmos-
pheres,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 bystanders away while
operatingapowertool. Distractions can cause
you to lose control.
•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.Unmodied plugs and matching outlets will
reduce risk of electric shock.
•Avoidbodycontactwithearthedorgrounded
surfacessuchaspipes,radiators,rangesand
refrigerators.There is an increased risk of electric
shock if your body is earthed or grounded.
•Donotexposepowertoolstorainorwetcondi-
tions.Water entering a power tool will increase
the risk of electric shock.
•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.
•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.
•Ifoperatingapowertoolinadamplocation
isunavoidable,usearesidualcurrentdevice
(RCD)protectedsupply.Use of an RCD reduces
the risk of electric shock.
result in personal injury.
•Do not overreach. Keep proper footing and
balanceatalltimes. This enables better control
of the power tool in unexpected situations.
•Dressproperly.Donotwearlooseclothingor
jewellery.Keepyourhair,clothingandgloves
awayfrommovingparts. Loose clothes, jewel-
lery or long hair can be caught in moving parts.
•If devices areprovidedforthe connection of
dustextractionandcollectionfacilities,ensure
theseareconnectedandproperlyused.Use of
dust collection can reduce dust-related hazards.
WARNING READ ALL SAFETY WARNINGS AND ALL 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.
POWER TOOL USE AND CARE
•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.
•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.
•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 pre-
ventive safety measures reduce the risk of starting
the power tool accidentally.
•Storeidlepowertoolsoutofthereachofchil-
dren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.
•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.
•Keepcuttingtoolssharpandclean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
•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.
•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inuenceofdrugs,alcoholormedication.A
moment of inattention while operating power tools
may result in serious personal injury.
•Usepersonal protective equipment.Always
weareyeprotection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
•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 energising power tools
that have the switch on invites accidents.
•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
•Rechargeonlywiththechargerspeciedby
themanufacturer.A charger that is suitable for
one type of battery pack may create a risk of re
when used with another battery pack.
•Usepowertoolsonlywithspecicallydesig-
natedbatterypacks. Use of any other battery
packs may create a risk of injury and re.
•Whenbatterypackisnotinuse,keepitaway
fromother metalobjects likepaper clips,
BATTERY TOOL USE AND CARE

3
tection must be capable of stopping ying debris
generated by various operations. The dust mask
or respirator must be capable of ltrating particles
generated by your operation. Prolonged exposure
to high intensity noise may cause hearing loss.
• Keepbystanders a safe distanceaway from
work area. Anyone entering the work area
must wear personal protective equipment.
Fragments of workpiece or of a broken accessory
may y away and cause injury beyond immediate
area of operation.
• Hold the power tool by insulated gripping
surfacesonly,whenperforminganoperation
wherethecuttingaccessorymaycontacthid-
den wiring. Contact with a “live” wire will also
make exposed metal parts of the power tool “live”
and could give the operator an electric shock.
• Never lay the power tool down until the ac-
cessory has come to a complete stop. The
spinning accessory may grab the surface and
pull the power tool out of your control.
• 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.
• 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.
• Donotoperatethepowertoolnearammable
materials.Sparks could ignite these materials.
• Do not use accessories that require liquid
coolants. Using water or other liquid coolants
may result in electrocution or shock.
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 acces-
sory’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.
• 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 kick-
back forces, if proper precautions are taken.
• Neverplaceyourhandneartherotatingacces-
sory.Accessory may kickback over your hand.
• Donotpositionyourbodyintheareawhere
powertoolwillmoveifkickbackoccurs.Kick-
SPECIFIC SAFETY RULES
• Thispower toolisintendedtofunctionasa
grinder,sander,wirebrushingorcut-offtool.
Readall safety warnings,instructions, illus-
trationsandspecicationsprovidedwiththis
powertool. Failure to follow all instructions listed
below may result in electric shock, re and/or se-
rious injury.
• Operationssuchaspolishingarenot recom-
mendedtobeperformedwiththispowertool.Op-
erations for which the power tool was not designed
may create a hazard and cause personal injury.
• Donotuseaccessorieswhicharenotspeci-
callydesignedandrecommendedbythetool
manufacturer. Just because the accessory can
be attached to your power tool, it does not assure
safe operation.
• 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.
• Theoutsidediameterandthethicknessofyour
accessorymustbewithinthecapacityrating
ofyourpowertool.Incorrectly sized accesso-
ries cannot be adequately guarded or controlled.
• The arbour size of wheels, anges, backing
padsoranyotheraccessorymustproperlyt
thespindleofthepowertool.Accessories with
arbour holes that do not match the mounting hard-
ware of the power tool will run out of balance, vi-
brate excessively and may cause loss of control.
• Do not use a damaged accessory. Before
each use inspect the accessory such as
abrasivewheelsforchipsandcracks, back-
ing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equipment.Depend-
ingonapplication,usefaceshield,safetygog-
gles or safety glasses. As appropriate, wear
dust mask, hearing protectors, gloves and
workshop apron capable of stopping small
abrasiveorworkpiecefragments.The eye pro-
SERVICE
coins,keys,nails,screws,orothersmallmetal
objectsthatcanmakeaconnectionfromone
terminaltoanother.Shorting the battery terminals
together may cause burns or a re.
•Underabusiveconditions,liquidmaybeeject-
edfromthebattery;avoidcontact.Ifcontact
accidentallyoccurs,ushwithwater.Ifliquid
contactseyes,additionallyseekmedicalhelp.
Liquid ejected from the battery may cause irritation
or burns.
•Haveyourpowertoolservicedbyaqualied
repairpersonusingonlyidenticalreplacement
parts.This will ensure that the safety of the power
tool is maintained.

4
back will propel the tool in direction opposite to
the wheel’s movement at the point of snagging.
• Use special care when working corners,
sharp edges etc.Avoid bouncing and snag-
ging the accessory. 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woodcarvingblade
ortoothedsawblade.Such blades create fre-
quent kickback and loss of control.
Safety Warnings Specic for Grinding and
AbrasiveCutting-OffOperations:
• Useonlywheeltypesthatarerecommended
for your power tool and the specic guard
designed for the selected wheel. Wheels for
which the power tool was not designed cannot
be adequately guarded and are unsafe.
• Theguardmustbesecurelyattachedtothe
powertoolandpositionedformaximumsafe-
ty,sothe least amount ofwheelis exposed
towardstheoperator.The guard helps to pro-
tect operator from broken wheel fragments and
accidental contact with wheel.
• Wheels must be used only for recommend-
ed 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.
• Always use undamaged wheel anges that
are of correct size and shape for your se-
lected wheel. Proper wheel anges support
the wheel thus reducing the possibility of wheel
breakage. Flanges for cut-off wheels may be dif-
ferent from grinding wheel anges.
• 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.
AdditionalSafetyWarningsSpecicforAbra-
siveCutting-OffOperations:
• Donot“jam” thecut-offwheelorapplyexces-
sivepressure.Donotattempttomakeanex-
cessivedepthofcut.Overstressing the wheel
increases the loading and susceptibility to twist-
ing or binding of the wheel in the cut and the pos-
sibility of kickback or wheel breakage.
• Do not position your body in line with and
behindtherotatingwheel.When the wheel, at
the point of operation, is moving away from your
body, the possible kickback may propel the spin-
ning wheel and the power tool directly at you.
• Whenwheelisbindingorwheninterruptinga
cutforanyreason,switchoffthepowertool
andholdthepowertoolmotionlessuntilthe
wheel comes to a complete stop. Never at-
tempttoremovethecut-offwheelfromthecut
whilethewheelisinmotion otherwisekick-
backmayoccur.Investigate and take corrective
action to eliminate the cause of wheel binding.
• Do not restart the cutting operation in the
workpiece.Letthewheelreachfullspeedand
carefullyreenterthecut.The wheel may bind,
walk up or kickback if the power tool is restarted
in the workpiece.
• Supportpanelsoranyoversizedworkpieceto
minimizetheriskofwheelpinchingandkick-
back.Large workpieces tend to sag under their
own weight. Supports must be placed under the
workpiece near the line of cut and near the edge
of the workpiece on both sides of the wheel.
• Useextracautionwhenmakinga“pocketcut”
into existing walls or other blind areas. The
protruding wheel may cut gas or water pipes, elec-
trical wiring or objects that can cause kickback.
SafetyWarningsSpecicfor Sanding Opera-
tions:
• Do not use excessively oversized sanding
discpaper.Followmanufacturersrecommen-
dations,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arethrownbythe
brushevenduringordinaryoperation.Donot
overstress the wires by applying excessive
loadtothebrush.The wire bristles can easily
penetrate light clothing and/or skin.
·Iftheuseofaguardisrecommendedforwire
brushing, do not allow any interference of
thewirewheelorbrushwiththeguard.Wire
wheel or brush may expand in diameter due to
work load and centrifugal forces.
AdditionalSafetyWarnings
Your risk from these exposures varies, depend-
ing on how often you do this type of work. To re-
duce your exposure to these chemicals: work in
a well ventilated area, and work with approved
safety equipment, such as those dust masks that
are specially designed to lter out microscopic
particles.
•
Maintain labels and nameplates. These carry
important information. If unreadable or missing,
contact an authorised MILWAUKEE® dealer
or service centre for a replacement.
• WARNING:Some dust created by power sand-
ing, sawing, grinding, drilling, and other construc-
tion activities contains chemicals known to cause
cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
• lead from lead-based paint
• crystalline silica from bricks and cement and
other masonry products, and
• arsenic and chromium from chemically-treated
lumber.
ADDITIONAL BATTERY SAFETY RULES
warningTo reduce the risk of fire,
personal
injury , and product damage due to a
short circuit, never immerse your tool, battery
pack or charger in fluid or allow a fluid to flow
inside them. Corrosive or conductive fluids,
such as seawater , certain industrial chemicals,
and bleach or bleach-containing products, etc.,
can cause a short circuit.

5
FUNCTIONAL DESCRIPTION
ASSEMBLY
WARNING Recharge only with the
chargerspeciedforthebattery.Forspecic
charginginstructions, read the operator’s
manualsuppliedwithyourchargerandbattery.
Inserting/RemovingtheBattery
To remove the battery, push in the release buttons
and pull the battery pack away from the tool.
To insert the battery, slide the pack into the body of
the tool. Make sure it latches securely into place.
1. Spindle lock
2. Dust guard
3. Switch lock-off
4. Paddle switch
WARNING Always remove battery
packbeforechangingorremovingaccesso-
ries.Onlyuseaccessoriesspecicallyrecom-
mendedforthistool.Othersmaybehazardous.
Cat. No. 0&$*;3'
1
5
4
3
6
7
InstallingSideHandle
The side handle may be installed on either side
of the gear case. Position the side handle in the
location which offers best control and guard protec-
tion. To install, thread side handle into side handle
socket and tighten securely.
WARNING Toreducetheriskofinjury
whengrinding:
• ALWAYSusetheproperguard.
• ALWAYSproperlyinstalltheguard.
• ALWAYSholdthetoolrmlywithboth
handsusingthehandlesprovidedbefore
andduringgrinding.
• NEVERuseawheelthathasbeendropped.
• NEVERbanggrindingdiscontowork.
• NEVERgrindwithoutpropersafety
equipment.
Tab
slots
Installing,RemovingandAdjustingtheGuard
This tool is shipped with a guard. The guard must
be used when using the tool as a grinder. The guard
may be removed when using tool as a sander.
1. To remove the guard, remove the battery pack
and remove any accessories from spindle.
2. Press in the lock lever and rotate the guard to
line up the tabs on the grinder with the slots in
the guard.
3. Press in the lock lever and lift the guard straight
up and away from the tool.
Fig.1
Detent slots
4. To install the guard, remove the battery pack
and remove any accessories from the spindle.
5. Line up the tabs on the grinder with the slots in
the guard.
6. Press in the lock lever and press the guard onto
the tool.
7. To adjust the guard, press in the lock lever and
rotate the guard to one of ve detent slots.
2
5. Side handle
6. Guard
7. Guard lock lever
WARNING Toreducetheriskofinjury,
wearsafetygogglesorglasseswithsideshields.
Installing/Removing/CleaningtheDustScreen
Using the dust screen will increase the performance
and extend the life of the tool.
1. To attach the dust screen, snap the screen over
the tool’s handle.
2. Toremove the dust screen, insert a at screw-
driver into the notch at the top of the dust screen
and pry away from the tool.
3. To clean the dust screen, tap against a hard
surface, or blow clean with compressed air.
NOTE: Use only 125mm (5") grinding wheels
with 125mm (5") guards.
Cat.
No.
Volts
DC
No load
RPM
Spindle
Thread
Size
Max
Wheel
Size
Switch
Type
M18 CAG125XPD 18 8500 M14 125mm (5") Paddle
SPECIFICATIONS

6
WARNING Onlyuseaccessorieswith
MaximumSafeOperatingSpeedratedatleast
equaltothemaximumspeedmarkedonthe
powertool.Thisspeedisbasedonthestrength
ofthewheel,allowingforareasonablemea-
sureofsafety.Itisnotmeanttoimplyabestor
mostefcientoperatingspeed.Donotexceed
theMaximumSafeOperatingSpeed.
Installing/RemovingAccessories
Make sure the wheel does not extend beyond the
bottom of the guard. Threaded hub grinding wheels
may require a deeper guard (see "Accessories").
1. Remove the battery pack.
2. Properly position the guard (Fig. 2).
ControlledStart
The controlled start feature reduces the torque
reaction "jerk" when its trigger is pulled.
PaddleSwitchOperation
To start the tool, grasp the handle and side handle
rmly. Push the lock-off button forward and squeeze
the paddle switch.
To stop the tool, release the paddle switch. Make
sure the tool comes to a complete stop before lay-
ing the tool down.
GeneralOperation
1. If you have just installed an accessory or are
beginning a period of work, test it by letting it
spin for one minute before applying it to the
workpiece. Out-of-balance or damaged acces-
sories can mar workpiece, damage the tool, and
cause stress that may cause accessory failure.
2. Use a clamp, vise or other practical means to
hold your work, freeing both hands to control
the tool.
3. Hold tool securely with both hands.
4. Start the tool.
Note: If the battery is inserted when the tool
switch is in the “ON” position, the tool will not run.
Turn the tool off, then back on to begin work..
5. Allow accessory to come to full speed before
beginning work.
6. Control pressure and surface contact between
accessory and workpiece. Too much pressure
slows speed.
7. When nished, turn off the tool and make sure it
comes to a complete stop before laying it down.
OPERATION
WARNING Always remove battery
packbefore changingor removing acces-
sories.Only useaccessories specifically
recommended for this tool. Others may be
hazardous.
7. Press in the spindle lock button while turning the
ange nut clockwise. Tighten securely using a
spanner wrench.
8. Toremove wheel, remove the battery pack and
reverse the procedure.
Flangenut
positionfor
   
Fig.4
Flangenut
positionfor
Fig.2 Operator's Zones
Spindle
Flange
Wheel
Flange nut
3. Wipe the flange, flange nut and spindle to
remove dust and debris. Inspect the parts for
damage. Replace if needed.
4. Place the ange on spindle, as shown.
Fig.3
5. Place the selected wheel on the spindle and align
it with the ange.
6. Position the ange nut over the spindle according
to wheel thickness (Fig. 4).
WARNING Toreducetheriskofinjury,
wear safety goggles or glasses with side
shields.
PPWKLFNRU
PRUHZKHHOV
PPWKLFNRU
OHVVZKHHOV PP
PPPP

7
Fig.7
WARNING Toreducetheriskofinjury,
theoperatorshouldbeinstructedintheuse,
careandprotectionofgrindingwheels.
Fig.6
For best result use only this portion of disc
Hold at a
5° to 15°
angle
USING GRINDING WHEELS
Grinding and cut-off wheels should NOT be
dropped, rolled or bumped.
Discard wheels that have been dropped, rolled,
bumped, subjected to extreme changes in tempera-
ture, or come into contact with solvents or wetness.
Grinding
When grinding, hold tool at a 5oto 15oangle, using
constant pressure for a uniform nish. Too great an
angle causes concentrated pressure on small areas
which may gouge or burn work surface.
Wire Wheel Brush
Fig.8
WARNING Everyoneintheareamust
wearprotectiveclothingandsafetygoggles
orfaceshields.Fatiguedwiresandresidue
willyoffthebrushwithconsiderableforce,
causingpotentialforseriousinjury.
USING WIRE BRUSHES
Wire brushes are useful for removing rust, scale,
burrs, weld slag, etc.
Always install wire cup brushes according to the
accessory manufacturer’s instructions.
When using a wire wheel brush, install guard ac-
cording to "Installing/Removing Accessories".
WARNING Becausethewiresonwire
wheelbrushesaredirectedtowardstheop-
erator,aguardmustbeusedtoprotectthe
operatorwhenfatiguedwiresbreak.
WARNING AType"1"guardmustbe
installedwhenusingacut-offwheeltoprovide
maximumprotection forthe operatorif the
wheelshouldbreak.
WARNING UsingthefaceofaCut-Off
Wheel(asingrinding)willcausetheWheel
tocrackandbreak,resultinginseriousper-
sonalinjury.
USING CUT-OFF WHEELS
Guard
Wire Cup Brush
GrindingWheelSelection
Use grinding wheels, and accessories that are:
• correct size as written on tool’s nameplate.
• rated at or above the RPM listed on the tool’s
nameplate.
• correct accessory, wheel type and grit for the job.
Grinding is the cutting action of thousands of abra-
sive grains on the face of a grinding wheel. When
grinding metals such as steel and iron, choose an
aluminum oxide grinding wheel. Select a silicon
carbide grinding wheel for stone and concrete. Use
cotton reinforced wheels for non-ferrous metals.
CareofGrinding&Cut-OffWheels
Grinding/cut-off wheels should be protected from:
• wetness and extreme humidity
• any type of solvent
• extreme changes in temperature
• dropping and bumping
Grinding and cut-off wheels should be stored:
• in an organized way so wheels can be removed
without disturbing or damaging other wheels
• with their safety information
Type 27 Reinforced 3mm(1/8") thick or less
Cut-Off Wheels are suited for small cut-off and
shallow notching operations only. Always handle
wheels carefully to avoid damage. Before
installing any wheel, always inspect it for cracks. If
wheel is cracked, discard it to prevent others from
using it.
Fig. 5
Type "1" Cut-Off Wheels are suited for small cut-off
and shallow notching operations only.
When using a cut-off wheel, hold the tool as shown,
using only the edge of the wheel.
For a complete listing of accessories refer to your
MILWAUKEE®Electric Tool catalogue or go
online to www.milwaukeetools.com.au or
www.milwuakeetools.co.nz

8
WARNINGNever exceedMaximum
SafeOperatingSpeedofbrush.Donotuse
adamagedbrushoronethatisfunctioning
improperly(throwing wires, out-of-balance,
etc.). These conditions increase the pos-
sibilityoffurtherbrushfailureandpossible
injury.Discardandreplacedamagedbrushes
immediately.
Test wheel for balance and loose or damaged wires
by letting it spin for one minute before applying it
to the workpiece. During this time, no one should
stand in front of or in line with it.
Control pressure and surface contact between
wheel and workpiece. Too much pressure causes
over-bending of wires and heat build-up caus-
ing premature wire breaking, rapid dulling and
reduced brush life. Instead of more pressure, try
a wire wheel with more aggressive cutting action
(increased wire size, decreased wire length or dif-
ferent brush type (knot type vs. crimped wire type).
AluminumOxide
For fast cutting, general purpose discs for most
metal jobs. Best for cold-rolled steel, stainless
steel or metals requiring tough, fast cutting, long
lasting abrasives.
AluminumZirconiaBi-Cut
Unique grit pattern is arranged in clusters for fast-
er stock removal and cleaning. Ideal for removing
paint from cars, boats, etc. without clogging.
Ceramic
Lasts up to 3 times longer than Aluminum Ox-
ide Discs. For general metal working. Ideal for
tough jobs.
SandingDiscSelection
Use sanding discs and accessories that are:
• correct size as written on tool’s nameplate.
• rated at or above the RPM listed on the tool’s
nameplate.
• correct accessory, wheel type and grit for the job.
Refer to the table below to select the correct type
of sanding disc for your job. Generally, use 24 or
36 grit for heavy stock removal; 50, 60, or 80 grit
for medium stock removal and 120 grit for nishing.
Always begin with a coarse grit, using successively
ner grits to obtain the desired nish.
USING SANDING DISCS
InstallingBackingPadandSandingDiscs
1. Remove the battery pack.
2. Wipe the accessories, disc nut and spindle to
remove dust and debris. Inspect the parts for
damage. Replace if needed.
3. Slip backing pad onto spindle with at side away
from gear case.
4. Place sanding disc on backing pad and secure
assembly to spindle with disc nut.
Fig.9
Spindle
Backing
pad
Disc nut
Sanding
disc
5. To tighten, press the spindle lock button while
turning disc nut clockwise with the spanner
wrench provided.
6. To remove backing pad and sanding disc,
remove the battery pack and reverse the pro-
cedure.
Sanding
Hold tool at 5° to 15° angle to ensure proper sand-
ing pressure and control. Too great an angle will
result in too much pressure and could cause exces-
sive wear to the disc and workpiece. Too small an
angle will reduce control.
Use long, sweeping, side to side strokes, advancing
forward to produce the desired nish.
Fig.10
For best result use only this portion of disc
Hold at a
5° to 15°
angle

9
ACCESSORIES
WARNING Alwaysremovebatterypack
beforechanging or removing accessories.
Onlyuseaccessoriesspecicallyrecommend-
edfor thistool. Others may be hazardous.
Cleaning
Clean dust and debris from charger and tool vents.
Keep tool handles clean, dry and free of oil or
grease. Use only mild soap and a damp cloth to
clean the tool, battery pack and charger since certain
cleaning agents and solvents are harmful to plastics
and other insulated parts. Some of these include
gasoline, turpentine, lacquer thinner, paint thinner,
chlorinated cleaning solvents, ammonia and house-
hold detergents containing ammonia. Never use
ammable or combustible solvents around tools.
Repairs
For repairs, return the tool, battery pack and
charger to the nearest service center.
WARNING Toreducetheriskofper-
sonalinjuryanddamage,neverimmerseyour
tool,batterypackorchargerinliquidorallow
aliquidtoowinsidethem.
CrossSanding
When nishing a surface that has been prepared by
a coarse disc or wheel, sand at right angles to the
strokes made by the coarser disc. Finishing marks
left from previous sanding are easily seen and
removed for a uniform nish. Failure to cross sand
when changing from a coarse disc to a nishing disc
may result in deep scratches and circular marks.
RemovingWeldsorHammerMarks
When removing welds or hammer marks, limit
coarse sanding to the immediate area. Use suc-
cessively ner grits to smooth surface.
FinishingMetal
Constantly move across the surface. Work faster on
curved surfaces where contact areas are smaller
and pressure is greater. Flat areas may appear at
the end of the stroke when pressure is too heavy.
Ease up on pressure at end of each stroke and
when reversing strokes.
Troubleshooting
Deep scratches and circular marks can result from:
• Using too coarse a grit
• Using a partially glazed disc
• Dirt or loose metal on the workpiece
• Failure to sand across the grain when changing
from coarse to nishing discs
• Failure to use closed coated discs to reduce the
problem of grains working loose and scratching
the workpiece
Bluish discoloration of metal surface indicates:
• Excessive heat caused by circular motion in a
small area
• Excessive pressure
• Use of worn out or glazed discs
•Lubrication
•Mechanical inspection and cleaning (gears, spin-
dles, bearings, housing, etc.)
•Electrical inspection (battery pack, charger,
motor)
•Testing to assure proper mechanical and electrical
operation
If the tool does not start or operate at full power
with a fully charged battery pack, clean the contacts
on the battery pack. If the tool still does not work
properly, return the tool, charger and battery
pack, to your MILWAUKEE®dealer or service
centre.
Maintaining Tool
Keep your tool, battery pack and charger in good
repair by adopting a regular maintenance program.
After six months to one year, depending on use,
return the tool, battery pack and charger to your
authorised MILWAUKEE®dealer or service
centre for:
For a complete listing of accessories refer to your
MILWAUKEE®Electric Tool catalogue or go
online to www.milwaukeetools.com.au or
www.milwuakeetools.co.nz
symbology
Volts
Direct Current
No load Revolutions per Minute
(RPM)
MAINTENANCE
WARNING
always unplug the charger and remove the
battery pack from the charger or tool before
performing any maintenance. Never disas-
semble the tool, battery pack or charger.
Contact an authorised MILWAUKEE®
dealer or service centre for all repairs.
To reduce the risk of injury, Regulatory Compliance mark
(RCM). This product meets
applicable regulatory
requirements.

10

WARRANTY - AUSTRALIA and NEW ZEALAND
SERVICE - AUSTRALIA and NEW ZEALAND
MILWAUKEE®prides itself in producing a premium quality product that is Nothing But Heavy Duty®.
Your satisfaction with our products is very important to us! If you encounter any problems with the
operation of this tool, please contact your authorised MILWAUKEE®dealer.
For a list of MILWAUKEE®dealers, guarantee or service agents please contact MILWAUKEE®
Customer Service or visit our website.
(Australia Toll Free Telephone Number 1300 645 928)
(New Zealand Toll Free Telephone Number 0800 645 928)
or visit www.milwaukeetools.com.au / www.milwaukeetools.co.nz.
Please refer to Australian and New Zealand warranty supplied with tool. This warranty applies only to
product sold in Australia and New Zealand.
Milwaukee Electric Tool Corporation
13135 West Lisbon Road, Brookfield, Wisconsin U.S.A. 53005
Milwaukee Tool (Australia)
21 Kelletts Road, Rowville, VIC 3178
Melbourne, Australia
Milwaukee Tool (New Zealand)
274 Church Street, Penrose,
Auckland, 1061, New Zealand
Designed by Milwaukee Electric Tool Corp.
Professionally Made in China for Milwaukee Tool (Australia) / Milwaukee Tool (New Zealand)
Printed in China
961068040-02(A)