Power It! JD3103U User manual

6A ANGLE GRINDER
JD3103U
Owner’s Manual
PRODUCT SPECIFICATIONS
Rating
120V, 60Hz, AC
Amperes
6 AMP
Speed
11,000 RPM (no load)
Maximum disc diameter
4½" (115 mm)
Spindle threads
5/8" –11UNC (15.875 mm)
Minimum disc thickness
5/32" (3.9 mm)
Weight
4 lb 14 oz (2.2 kg)
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Replacement parts
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2
Product specifications ………….…………………………………………………….
1
Table of contents ……………………………………………………………………...
2
General safety warnings ……………………………………………………………..
3–4
Eye, ear & lung protection ……………………………………………………………
3–4
Electrical safety ……………………………………………………………………….
4
Power tool safety ……………………………………………………………………...
5–6
General safety rules …………………………………………………………………..
5
Work area ………………………………………………………………….…………..
5
Electrical safety ……………………………………………………………………….
5
Personal safety ………………………………………………………………………..
5–6
Power tool use and care.……………………………………………………………..
6
Service …………………………………………………………………………………
6
Specific safety rules …………………………………………………………………..
7–10
Extension cord safety ……………………………………………….………………..
10
Symbols ………………………………………………………………………………..
11
Know your angle grinder ……………………………………………………………..
12
Assembly and operating ……………………………………………………………..
13–16
Installing the auxiliary handle ………………………………………………………..
13
Installing the guard ……………………………………………………………………
13
Positioning the guard …………………………………………………………………
14
Installing a grinding disc ……………………………………………………………..
14
ON/OFF switch ……………………………………………………………………….
15
Grinding ……………………………………………………………………………….
15–16
Maintenance …………………………………………………………………………..
16–17
Exploded view …………………………………………………………………………
18
Parts list ………………………………………………………………………………..
19–20
Warranty ……………………………………………………………………….………
21
TABLE OF CONTENTS

3
EYE, EAR & LUNG PROTECTION
This instruction manual includes the following:
General Safety Rules
Specific Safety Rules and Symbols
Functional Description
Assembly
Operation
Maintenance
Accessories
!
ALWAYS WEAR EYE PROTECTION THAT CONFORMS WITH CSA
REQUIREMENTS or ANSI SAFETY STANDARD Z87.1
FLYING DEBRIS can cause permanent eye damage. Prescription
eyeglasses ARE NOT a replacement for proper eye protection.
WARNING: Non-compliant eyewear can cause serious injury if
broken during the operation of a power tool.
SAVE THESE INSTRUCTIONS FOR REFERENCE
WARNING: Use hearing protection, particularly during extended
periods of operation of the tool, or if the operation is noisy.
!
GENERAL SAFETY WARNINGS
WARNING: Before using this tool or any of its accessories, read this
manual and follow all Safety Rules and Operating Instructions. The important
precautions, safeguards and instructions appearing in this manual are not
meant to cover all possible situations. It must be understood that common
sense and caution are factors which cannot be built into the product.
!

4
ELECTRICAL SAFETY
WARNING: To avoid electrical hazards, fire hazards or damage to the
tool, use proper circuit protection.
This tool is wired at the factory for 120V AC operation. It must be connected
to a 120V AC, 15 A circuit that is protected by a time-delayed fuse or circuit
breaker. To avoid shock or fire, replace power cord immediately if it is worn,
cut or damaged in any way.
GENERAL SAFETY WARNINGS
WEAR A DUST MASK THAT IS DESIGNED TO BE USED WHEN
OPERATING A POWER TOOL IN A DUSTY ENVIRONMENT.
WARNING: Dust that is created by power sanding, sawing, grinding,
drilling, and other construction activities may contain chemicals that are
known to cause cancer, birth defects, or other genetic abnormalities. These
chemicals include:
Lead from lead-based paints
Crystalline silica from bricks, cement, and other masonry products
Arsenic and chromium from chemically treated lumber
The level of risk from exposure to these chemicals varies, according to how
often this type of work is performed. In order to reduce exposure to these
chemicals, work in a well-ventilated area, and use approved safety
equipment, such as a dust mask that is specifically designed to filter out
microscopic particles.
!
SAVE THESE INSTRUCTIONS FOR REFERENCE

5
WARNING: Read all safety warnings
and instructions. Failure to follow the warnings
and instructions may result in electric shock, fire
and/or serious injury.
Save all warnings and instructions for future
reference.
Work area safety
Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or
fumes.
Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
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. Unmodified 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
conditions. 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 a ground fault
circuit interrupter (GFCI) reduces the risk of
electric shock.
Personal safety
Stay alert, watch what you are doing and use
common sense when operating a power tool.
Do not use a power tool while you are tired
or under the influence of drugs, alcohol or
medication. A moment of inattention while
operating power tools may result in serious
personal injury.
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 finger on the
switch or energizing 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 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.
POWER TOOL SAFETY
!
SAVE THESE INSTRUCTIONS FOR REFERENCE

6
Personal safety –cont’d
Dress properly. Do not wear loose clothing
or jewellery. Keep your hair, clothing and
gloves away from moving parts. Loose
clothes, jewellery 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.
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
preventive safety measures reduce the risk of
starting the power tool accidentally.
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.
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.
Service
Have your power tool serviced by a qualified
repair person using only identical
replacement parts. This will ensure that the
safety of the power tool is maintained.
POWER TOOL SAFETYPOWER TOOL SAFETY
SAVE THESE INSTRUCTIONS FOR REFERENCE

7
WARNING: This power tool is intended
to function as a grinder or cut-off tool. Read
all safety warnings, instructions, illustrations
and specifications provided with this power
tool. Failure to follow all instructions listed below
may result in electric shock, fire and/or serious
injury.
WARNING: Operations such as sanding,
wire brushing or polishing are not
recommended to be performed with this
power tool. Operations for which the power tool
was not designed may create a hazard and
cause personal injury.
Do not use accessories which are not
specifically designed and recommended by
the tool manufacturer. Just because the
accessory can be attached to your power tool, it
does not assure safe operation.
The rated speed of the accessory must be at
least equal to the maximum speed
marked on the power tool. Accessories
running faster than their RATED SPEED can
break and fly apart.
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.
The arbor size of wheels, flanges, backing
pads or any other accessory must properly
fit the spindle of the power tool. Accessories
with arbor holes that do not match the mounting
hardware of the power tool will run out of
balance, vibrate excessively and may cause
loss of control.
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.
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
workpiece fragments.
The eye protection must be capable of stopping
flying debris generated by various operations.
The eye protection must be capable of stopping
flying debris generated by various operations.
The dust mask or respirator must be capable of
filtrating 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 fly away and cause injury
beyond immediate area of operation.
Hold power tool by insulated gripping
surfaces 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 "live" and
shock the operator.
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.
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.
SPECIFIC SAFETY RULES
SAVE THESE INSTRUCTIONS FOR REFERENCE
!
!

8
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
flammable 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.
FURTHER SAFETY INSTRUCTIONS FOR ALL
OPERATIONS
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.
Maintain a firm grip on the power tool and
position your body and arm to allow you to
resist kickback forces. Always use auxiliary
handle, if provided, for maximum control
over kickback or torque reaction during
start-up. The operator can control torque
reactions or kickback forces, if proper
precautions are taken.
Never place your hand near the rotating
accessory. Accessory may kickback over your
hand.
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.
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.
Do not attach a saw chain woodcarving
blade or toothed saw blade. Such blades
create frequent kickback and loss of control.
ADDITIONAL SAFETY INSTRUCTIONS FOR
GRINDING AND CUTTING-OFF OPERATIONS
Safety Warnings Specific for Grinding
and Abrasive Cutting-Off Operations
Use only wheel types that are recommended
for your power tool and the specific guard
designed for the selected wheel. Wheels for
which the power tool was not designed cannot
be adequately guarded and are unsafe.
SPECIFIC SAFETY RULES
SAVE THESE INSTRUCTIONS FOR REFERENCE
!
!

9
Safety Warnings Specific for Grinding and
Abrasive Cutting-Off Operations –cont’d
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.
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.
Always use undamaged wheel flanges that
are of correct size and shape for your
selected wheel. Proper wheel flanges support
the wheel thus reducing the possibility of wheel
breakage. Flanges for cut-off wheels may be
different from grinding wheel flanges.
Do not use worn down wheels from larger
power tools. Wheels intended for larger power
tool is not suitable for the higher speed of a
smaller tool and may burst.
ADDITIONAL SAFETY INSTRUCTIONS FOR
CUTTING-OFF OPERATIONS
Additional Safety Warnings Specific for
Abrasive Cutting-Off Operations
Do not "jam" the cut-off wheel or apply
excessive pressure. Do not attempt to make
an excessive depth of cut. Overstressing the
wheel increases the loading and susceptibility to
twisting or binding of the wheel in the cut and
the possibility 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
spinning 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
attempt to remove the cut-off wheel from the
cut while the wheel is in motion otherwise
kickback 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 re-enter 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
kickback. 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, electrical wiring or objects that can cause
kickback.
ADDITIONAL SAFETY INSTRUCTIONS FOR
SANDING OPERATIONS
Safety Warnings Specific for Sanding
Operations
Do not use excessively oversized sanding
disc paper. Follow manufacturer’s
recommendations, when selecting sanding
paper. Larger sanding paper extending beyond
the sanding pad presents a laceration hazard
and may cause snagging, tearing of the disc or
kickback.
SPECIFIC SAFETY RULES
!
!
SAVE THESE INSTRUCTIONS FOR REFERENCE

10
ADDITIONAL SAFETY INSTRUCTIONS FOR
POLISHING OPERATIONS
Safety Warnings Specific for
Polishing Operations
Do not allow any loose portion of the
polishing bonnet or its attachment strings to
spin freely. Tuck away or trim any loose
attachment strings. Loose and spinning
attachment strings can entangle your fingers or
snag on the workpiece.
ADDITIONAL SAFETY INSTRUCTIONS FOR
WIRE BRUSHING OPERATIONS
Safety Warnings Specific 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.
Make sure your extension cord is the proper
size. When using an extension cord, be sure to
use one heavy enough to carry the current the
tool will draw. An undersized cord will cause a
drop in line voltage resulting in loss of power
and overheating. The table on at right shows the
correct size to use according to cord length and
nameplate ampere rating. If in doubt, use the
next heavier gauge. The smaller the gauge
number the heavier the cord.
Be sure your extension cord is properly
wired and in good condition. Always replace a
damaged extension cord or have it repaired by a
qualified electrician before using it. Protect your
extension cord from sharp objects, excessive
heat and damp or wet areas.
Use a separate electrical circuit for your
power tools. This circuit must not be less than
14 gauge wire and should be protected with
either a 15A time delay fuse or circuit breaker.
Before connecting the power tool to the power
source, make sure the switch is in the OFF
position and the power source is the same as
indicated on the nameplate. Running at lower
voltage will damage the motor.
WARNING: Repair or replace damaged
or worn extension cords immediately.
Select the appropriate extension cord gauge
and length using the chart below.
When operating a power tool outdoors, use
an outdoor extension cord marked “W-A” or
“W”. These cords are rated for outdoor use and
reduce the risk of electric shock.
WARNING: Keep the extension cord
clear of the working area. Position the cord
so it will not get caught on the workpiece,
tools or any other obstructions while you are
working with the power tool.
SPECIFIC SAFETY RULES
!
!
EXTENSION CORD
SAFETY
!
MINIMUM GAUGE (AWG) EXTENSION
CORDS (120 V use only)
Ampere rating
Total length in feet
More
than
Not
more
than
7.5 m
(25')
15 m
(50')
30 m
(100')
45 m
(150')
0
6
18
16
16
14
6
10
18
16
14
12
10
12
16
16
14
12
12
16
14
12
Not Applicable
!
SAVE THESE INSTRUCTIONS FOR REFERENCE

11
This symbol designates that this tool is
listed with U.S. requirements by
ETL Testing Laboratories, Inc.
Conforms to UL Std. 60745-1 and
60745-2-3.
3042597
JD3103U
LISTED
V
Volts
A
Amperes
Hz
Hertz
W
Watts
kW
Kilowatts
Microfarads
L
Liters
kg
Kilograms
H
Hours
N/cm2
Newtons per square
centimeter
Pa
Pascals
OPM
Oscillations per minute
Min
Minutes
S
Seconds
or a.c.
Alternating current
Three-phase alternating
current
Three-phase alternating
current with neutral
Direct current
No load speed
Alternating or direct
current
Class II construction
Splash-proof
construction
Watertight construction
Protective grounding at
grounding terminal,
Class I tools
Revolutions or
reciprocations per
minute
Diameter
Off position
Directional arrow
Warning symbol
Wear your safety
glasses
Wear a dust mask
Wear hearing protection
SYMBOLS
WARNING: Some of the following symbols may appear on this tool. Study these
symbols and learn their meaning. Proper interpretation of these symbols will allow for
more efficient and safer operation of this tool.
!
SAVE THESE INSTRUCTIONS FOR REFERENCE

12
KNOW YOUR ANGLE GRINDER
Flange wrench
Auxiliary
handle
Air vents
ON/OFF switch
Guard
Spindle locking
button
Grinding disc

13
WARNING: Always disconnect your
angle grinder from the power source when
replacing grinding or cut-off discs, adjusting
the guard, cleaning the tool or when the tool
is not in use. Disconnecting the angle
grinder will prevent accidental starting that
could cause serious personal injury.
INSTALLING THE AUXILIARY HANDLE
1. Unplug the angle grinder from the power
source.
2. Install the auxiliary handle (1) by screwing
it clockwise into the left side (2) of the gear
housing (3) (Fig. 1).
NOTE: The handle can be installed in two
different positions; left side or right side of
the tool (Fig. 6 & 7).
WARNING: The auxiliary handle must
always be used to prevent loss of control and
possible injury.
3. Tighten the auxiliary handle securely.
INSTALLING THE GUARD
WARNING: The guard must be installed
before installing a grinding disc or using the
angle grinder. Failure to do so could result in
serious personal injury.
1. Turn the guard clamp screw (1) counter
clockwise using a #2 screwdriver to
allow the guard clamp (2) to expand for
installation (Fig. 2).
2. Slide the guard clamp over the spindle
housing (3) until the blade guard locating
detent (4) mate with the groove (5) in the
spindle housing.
3. Press the blade guard clamp fully onto the
spindle housing.
NOTE: Rotate the guard so it is positioned
correctly depending upon the location of
the side handle in Fig. 3 & 4.
4. Tighten the blade clamp screw by turning it
clockwise until the guard clamp firmly locks
the guard onto the spindle housing.
ASSEMBLY AND OPERATING
!
!
!
Fig. 1
Fig. 2

14
POSITIONING THE GUARD
WARNING: The guard must be
positioned correctly to protect the operator.
Guard placement depends upon which side
of the tool the auxiliary handle is used, to
afford the greatest protection for the user.
Rotate the guard to the correct position as
noted in Fig. 3 & 4 below.
INSTALLING A GRINDING DISC
WARNING: Use the correct size
grinding disc. Never use a grinding disc
thinner than 5/32" (3.9mm).
1. Make sure the disc guard is properly
positioned as shown in Fig. 3 & 4 and
securely locked in position.
2. Depress the spindle lock button (1) and
rotate the clamp nut (2) until the spindle
locks (Fig. 5).
3. Turn the clamp nut counter clockwise and
remove it from spindle.
NOTES:
a) If the clamp nut cannot be loosened by hand,
use the wrench (3) provided.
b) DO NOT remove the disc flange (4).
4. Make sure the flats on the bottom of disc
flange are engaged with the flats on the
spindle (5).
5. Place the grinding disc over the spindle
with the concave side of the disc (6) facing
outward.
NOTE: Make sure the hole in the center of
the disc is placed over the small diameter
portion of the disc flange (7).
6. Screw the clamp nut (2) onto the spindle
with the flat side of nut facing up. Fit the
raised small diameter portion of the clamp
nut into the hole in the grinding disc.
Tighten to finger tight only.
7. Depress the spindle lock button and rotate
the grinding disc clockwise until the spindle
locks.
8. Securely tighten the clamp nut with the
wrench provided.
!
Fig. 4
Fig. 3
ASSEMBLY AND OPERATION
!
Fig. 5

15
WARNING: Never attach a wood cutting
or carving blade of any type to this angle
grinder. It is designed for grinding metal
only. Use for any other purpose is not
recommended and creates a hazard which
will result in serious injury.
WARNING: Never cover the air vents.
They must always be open for proper motor
cooling.
ON/OFF SWITCH
To turn the switch ON, press the front of the
switch slider (1) into the body of the tool. While
pressing on the front of the slider, push it
forward (2) until the front part of the switch
engages the catch (Fig. 6). When the switch
“snaps” into position, the switch will remain ON
and the motor will continue running. To turn the
switch OFF, press the rear of the slider (3) into
the angle grinder body. The switch will “snap” to
the OFF position.
GRINDING
Always select and use grinding discs that are
recommended for the material to be ground.
Make sure that the maximum operating speed of
the grinding disc selected is not less than
11,000 RPM.
Secure all work before beginning the grinding
operation.
Secure small workpieces in a vice or clamp to a
workbench.
WARNING: Never use your grinder with
the guard removed. It has been designed for
use only with the guard installed. Attempting
to use the grinder with the guard removed
will result in loose particles being thrown
against the operator resulting in serious
personal injury.
WARNING: Never use your grinder
without eye protection. Following this rule
will reduce the risk of serious personal
injury.
ASSEMBLY AND OPERATING
For safety reasons, the operator must
read the sections of this Owner’s Manual
entitled "GENERAL SAFETY
WARNINGS", "POWER TOOL SAFETY",
"SPECIFIC SAFETY RULES",
"EXTENSION CORD SAFETY" and
"SYMBOLS" before using this angle
grinder.
Verify the following every time the angle
grinder is used:
1. Cord is not damaged
2. Grinding disc is correct for the type
of material being ground
3. Grinding disc is in good condition
and securely tightened onto the
spindle
4. Proper eye, hearing and breathing
protection are being worn.
Failure to adhere to these safety rules
can greatly increase the chances of
serious injury.
WARNING
!
!
!
Fig. 6
!
!

16
GRINDING –cont’d
The efficient operation of the angle grinder
begins by controlling the pressure and surface
contact between the grinding disc and the
workpiece. Flat surfaces are ground at an acute
angle, normally between 5 and 15 degrees
(Fig. 7).
For maximum control, hold the grinder in front
and away from you with both hands, keeping the
grinding disc clear of the workpiece. Start your
grinder and let the motor and grinding disc build
up to full speed. Gradually lower the grinder until
the grinding disc contacts the workpiece.
For best results keep the grinder tilted at an
angle of between 5 and 15 degrees and
continuously moving at a steady, consistent
pace. Move the grinder back and forth or up and
down over the work area. Keep the grinder
moving so that an excessive amount of material
is not removed from one area. If the grinder is
held in one spot too long, it will gouge and cut
grooves in the workpiece. If the grinder is held
at too sharp an angle, it will gouge the
workpiece because of the concentration of
pressure on a small area.
Use just enough pressure to keep the grinder
from chattering or bouncing. Heavy pressure will
decrease its speed and put a strain on the
motor. Normally, the weight of the tool alone is
adequate for most grinding jobs. Use light
pressure when grinding jagged edges or loose
bolts where there is potential for the grinder to
snag on the metal edge.
Lift the grinder away from the workpiece before
turning it OFF.
GENERAL
WARNING: When servicing, use only
identical replacement parts. The use of any
other part may create a hazard or cause
product damage.
DO NOT use solvents when cleaning plastic
parts. Plastics are susceptible to damage from
various types of commercial solvents and may
be damaged by their use. Use a clean cloth to
remove dirt, dust, oil, grease etc.
WARNING: Do not allow brake fluids,
gasoline, petroleum-based products,
penetrating oils, etc. to come into contact
with plastic parts. They contain chemicals
that can damage, weaken or destroy plastic.
DO NOT abuse power tools. Abusive practices
can damage the tool and the workpiece.
WARNING: DO NOT attempt to modify
tools or create accessories. Any such
alteration or modification is misuse and
could result in a hazardous condition leading
to possible serious injury. It will also void
the warranty.
WARNING: Always wear safety goggles
or safety glasses with side shields during all
grinding operations. It is critical that you
also wear safety goggles or safety glasses
with side shields and a dust mask while
blowing dust out of the angle grinder with an
air jet. Failure to take these safety
precautions could result in permanent eye or
lung damage.
LUBRICATION
All of the bearings in this tool are lubricated with
a sufficient amount of high-grade lubricant for
the life of the unit under normal conditions.
Therefore, no further lubrication is required.
ASSEMBLY AND
OPERATION
MAINTENANCE
!
!
!
!
Fig. 7
5° to 15°

17
REPLACING MOTOR BRUSHES
Motor brushes are a normal wear item and will
require replacing periodically depending upon
the type of material being ground. The following
information outlines the general procedure for
removal of the worn brushes and installation of
the new brushes.
WARNING: Make sure the angle grinder
is unplugged from the power source.
Removing worn brushes
1. Lay the tool on a towel or on corrugated
with the disc guard DOWN.
2. Remove the screw (1) from the motor end
cap (2) using a #2 screwdriver (Fig. 8).
3. Carefully pull the motor end cap off the
main motor housing (3).
NOTE: Pay attention to the position of the
braided copper brush wire (4). When the new
carbon brush is installed, the braided brush wire
MUST be placed in exactly the same position
(Fig. 9).
4. Use a small slot screwdriver to lift the end
of the coil spring (5) upward and place it on
top of the screw (6).
5. Use small needle nose pliers to pull the top
spade connector (7) from the spade
terminal (8).
6. Carefully grasp the braided copper brush
wire and lift the carbon brush (9) from the
brush holder (10).
Installing new brushes
7. To install the new brush, simply reverse the
above procedure.
8. When the new brush has been installed,
turn the angle grinder over on its back with
the disc guard UP.
9. Remove and replace the second motor
brush as outlined above.
10. When both motor brushes have been
replaced, reinstall the motor end cap by
reversing the procedure outlined in Fig. 9.
MAINTENANCE
!
Fig. 8
Fig. 9

18
EXPLODED VIEW
4
3
2
1
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19 20
21 22 23 24 25
26 27 28 29 30 31
32 33 34 35 36 37
38
39
40
41
42
39
43
44
45
46
47

19
WARNING: When servicing, use only original equipment replacement parts. The use of any
other parts may create a safety hazard or cause damage to the angle grinder.
Any attempt to repair or replace electrical parts on this may create a safety hazard unless repairs are
performed by a qualified technician. For more information, call the Toll-free Helpline, at
1-866-349-8665 (Monday through Friday 9am –5pm Eastern Time).
Always order by PART NUMBER, not by key number.
Key #
Part #
Part Name
Quantity
1
2040210006
Outer flange
1
2
6080010001
Grinding wheel
1
3
2040210005
Inner flange
1
4
1270030041
Grinding wheel guard
1
5
4020010107
Screw M6x16
1
6
2040040112
Output shaft
1
7
4020010108
Screw M4x12
4
8
2030170010
Dust-proof ring
1
9
2020150057
Gear box cover
1
10
4010010130
Bearing 6201-2RS
1
11
4100010005
Circlip 32mm
1
12
2030020207
Adjustment washer
1
13
2010050034
Big gear
1
14
4010020003
Needle bearing HK0810
1
15
2020050049
Gear box
1
16
4030010195
Screw ST3.9x25
4
17
2050040045
Spindle lock button spring
1
18
2040160131
Spindle locking pin
1
19
3120020099
Spindle locking pin cap
1
20
1160020046
Auxiliary handle
1
PARTS LIST
!

20
Key #
Part #
Part Name
Quantity
21
3140060038
Buffer ring
1
22
4060010018
I-type Hexagon nut
1
23
2040110024
Pinion
1
24
4010010131
Bearing 608-2RS
1
25
3150050053
Air-guiding ring
1
26
1010150036
Rotor
1
27
3150190142
Insulation ring
1
28
4010010034
Bearing 607-2Z
1
29
3140040016
Bearing sleeve
1
30
3150050055
Air baffle
1
31
1020150036
Stator
1
32
3011150024
Housing
1
33
1230010136
Carbon brush
2
34
4030010136
Screw ST2.9x9
2
35
2030070043
Brush holder
2
36
2050020001
Spiral spring
2
37
1210020057
Capacitor(not needed for N.A.)
1
38
3160010055
Back cover
1
39
4030010096
Screw ST3.9x12
3
40
1190030062
Cord set
1
41
3140010046
Cord guard
1
42
3150020003
Cord clamp
1
43
1062020058
Switch
1
44
3120110052
Switch lever
1
45
2050060159
Spring
1
46
3120120099
Switch button
1
47
6140030006
Spanner
1
PARTS LIST