Milwaukee 6148 User manual

OPERATOR'S MANUAL

MANUEL de L'UTILISATEUR

MANUAL del OPERADOR

TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND OPERATOR'S MANUAL.

AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE ET BIEN COMPRENDRE LE

MANUEL DE L'UTILISATEUR.

PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER Y ENTENDER EL MANUAL DEL

OPERADOR.

HEAVY-DUTY SANDERS/GRINDERS

EXTRA ROBUSTE PONCEUSE-RECTIFIEUSE

LIJADORAS/ESMERILADORAS HEAVY-DUTY

Cat. No.

No de Cat.

Cat. No.

6148

6149-20

6151

6152-20

6153-20

6154-20

6155-20

6156-20

6160-20

page 2

page 3

GENERAL SAFETY RULES  FOR ALL POWER TOOLS

WORK AREA SAFETY

ELECTRICAL SAFETY

PERSONAL SAFETY

POWER TOOL USE AND CARE

SERVICE

4. 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.

5. 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.

6. Do not expose power tools to rain or wet conditions. Water

entering a power tool will increase the risk of electric shock.

7. 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.

8. 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.

WARNING!

READ ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term "power tool" in

all of the warnings listed below refers to your mains-operated (corded) power tool or battery-opearted (cordless) power tool.

SAVE THESE INSTRUCTIONS

16. 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.

17. 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.

18. Disconnect the plug from the power source and/or the bat-

tery pack from the power tool before making any adjust-

ments, changing accessories, or storing power tools. Such

preventive safety measures reduce the risk of starting the tool acci-

dentally.

19. Store idle power tools out of the reach of children and do

not allow persons unfamiliar with the power tools or these

instructions to operate power tools. Power tools are danger-

ous in the hands of untrained users.

20. 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.

21. Keep cutting tools sharp and clean. Properly maintained cutting

tools with sharp cutting edges are less likely to bind and are easier

to control.

22. Use the power tool, accessories and tool bits etc., in accor-

dance with these instructions and in the manner intended

for the particular type of power tool, 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.

23. 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.

1. Keep work area clean and well lit. Cluttered or dark areas invite

accidents.

2. 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.

3. Keep children and bystanders away while operating a power

tool. Distractions can cause you to lose control.

9. 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.

10. 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 per-

sonal injuries.

11. Avoid accidental starting. Ensure the switch is in the off-

position before plugging in. Carrying tools with your finger on

the switch or plugging in power tools that have the switch on invites

accidents.

12. 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.

13. Do not overreach. Keep proper footing and balance at all

times. This enables better control of the power tool in unexpected

situations.

14. 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.

15. If devices are provided for the connection of dust extrac-

tion and collection facilities, ensure these are connected

and properly used. Use of these devices can reduce dust-re-

lated hazards.

page 4

1. Side handle

2. Guard clamp

3. Grinding wheel

4. Lock lever

5. Wheel guard

6. Spindle lock button

7. Side handle sockets

8. Lock-off button

9. Paddle trigger (under body of tool)

10. Lock-on button (Cat. No. 6148,

6149-20, 6154-20, & 6156-20 only)

11. Speed control dial (Cat. No. 6154-20 &

6156-20 only)

FUNCTIONAL DESCRIPTION

Symbology

Volts Alternating Current/

Direct Current

No Load Revolutions per Minute (RPM)

Amps

Canadian Standards Association

Underwriters Laboratories, Inc.

Double Insulated

Specifications

Cat.

No.

6148

6149-20

6151

6152-20

6153-20

6154-20

6155-20

6156-20

6160-20

No Load

RPM

10000

11000

4000-11000

11000

4000-11000

9000

Volts

120 AC/DC

120 AC

120 AC/DC

120 AC

Spindle

Thread

Size

5/8"-11

Amps

8.5

Wheel

Size

4-1/2"

Min. Wheel

RPM Rating

12000

10000

SPECIFIC SAFETY RULES  SANDERS AND GRINDERS

1. Always use proper guard with grinding wheel. A guard protects operator from broken wheel fragments.

2. Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running

over rated speed can fly apart and cause injury.

3. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden

wiring or its own cord. Contact with a live wire will make exposed metal parts of the tool live and shock the operator.

4. Keep hands away from all cutting edges and moving parts.

5. Maintain labels and nameplates. These carry important information. If unreadable or missing, contact a MILWAUKEE service facility for a free

replacement.

6. WARNING! Some dust created by power sanding, sawing, grinding, drilling, and other construction 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.

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

a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic

particles.

Input

Watts

1000

1400

1300

Mexican Approvals Marking

Cat. No.

6160-20

page 5

Grounded tools require a three wire extension cord. Double insulated

tools can use either a two or three wire extension cord. As the distance

from the supply outlet increases, you must use a heavier gauge exten-

sion cord. Using extension cords with inadequately sized wire causes a

serious drop in voltage, resulting in loss of power and possible tool

damage. Refer to the table shown to determine the required minimum

wire size.

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. When using more than one extension cord to make up the

total length, be sure each cord contains at least the minimum wire size

required. If you are using one extension cord for more than one tool, add

the nameplate amperes and use the sum to determine the required mini-

mum wire size.

Guidelines for Using Extension Cords

 If you are using an extension cord outdoors, be sure it is marked

with the suffix W-A (W in Canada) to indicate that it is acceptable

for outdoor use.

 Be sure your extension cord is properly wired and in good electrical

condition. Always replace a damaged extension cord or have it

repaired by a qualified person before using it.

 Protect your extension cords from sharp objects, excessive heat

and damp or wet areas.

GROUNDING EXTENSION CORDS

Grounded Tools:

Tools with Three Prong Plugs

Tools marked Grounding Required

have a three wire cord and three

prong grounding plug. The plug must

be connected to a properly grounded

outlet (See Figure A). If the tool should

electrically malfunction or break

down, grounding provides a low re-

sistance path to carry electricity

away from the user, reducing the risk

of electric shock.

Improperly connecting the grounding wire can result in the

risk of electric shock. Check with a qualified electrician if you

are in doubt as to whether the outlet is properly grounded.

Do not modify the plug provided 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 repaired by a

MILWAUKEE service facility before use. If the plug will not fit

the outlet, have a proper outlet installed by a qualified

electrician.

Nameplate

Amperes

0 - 5

5.1 - 8

8.1 - 12

12.1 - 15

15.1 - 20

Extension Cord Length

25'

75'

100'

150'

200'

Recommended Minimum Wire Gauge

for Extension Cords*

* Based on limiting the line voltage drop to five

volts at 150% of the rated amperes.

50'

READ AND SAVE ALL INSTRUCTIONS

FOR FUTURE USE.

The grounding prong in the plug is connected through the green wire

inside the cord to the grounding system in the tool. The green wire in the

cord must be the only wire connected to the tool's grounding system and

must never be attached to an electrically live terminal.

Your tool must be plugged into an appropriate outlet, properly installed

and grounded in accordance with all codes and ordinances. The plug

and outlet should look like those in Figure A.

Double Insulated Tools:

Tools with Two Prong Plugs

Tools marked Double Insulated do

not require grounding. They have a

special double insulation system

which satisfies OSHA requirements

and complies with the applicable

standards of Underwriters Labora-

tories, Inc., the Canadian Standard

Association and the National Electri-

cal Code. Double Insulated tools may

be used in either of the 120 volt out-

lets shown in Figures B and C.

WARNING!

Fig. A

Fig. B

Fig. C

page 6

TOOL ASSEMBLY

Installing Side Handle

The side handle may be installed on the top of the gear case or on either

side of gear case for right or left handed use. Position side handle in the

location which offers best control and guard protection. To install, thread

side handle into side handle socket on desired side of gear case and

tighten securely.

Wear safety goggles or glasses with side shields. Always

unplug tool before attaching or removing accessories. Only

use accessories specifically recommended for these tools.

Others may be hazardous. Protect others in work area from

debris such as chips and sparks. Provide barriers or shields

as needed.

WARNING!

Removing and Replacing Quik-Lok

Cords (Fig. 1)

MILWAUKEE's exclusive Quik-Lok

Cords provide instant field replace-

ment or substitution.

1. To remove the Quik-Lok

Cord, turn the cord nut 1/4 turn to the left

and pull it out.

2. To replace the Quik-Lok

Cord, align the connector keyways and

push the connector in as far as it will go. Turn the cord nut 1/4 turn

to the right to lock.

OPERATION

Fig. 1

To reduce the risk of injury, wear safety goggles or glasses

with side shields. Unplug the tool before changing accesso-

ries or making adjustments.

WARNING!

Controlled Start (Cat. No. 6154-20, 6156-20, and 6160-20)

When used on 120 Volts AC, the controlled start feature reduces the

torque reaction "jerk" when its trigger is pulled. The controlled start

feature works only with AC.

Speed Control Dial (Cat. No. 6154-20 and 6156-20)

The speed control dial controls the sander/grinder's maximum rotations

per minute. Dial settings range from numbers 1 through 5. Lower num-

bers correspond to lower speeds and higher numbers correspond to

higher speeds. Use the setting that best suits your job.

1. To control the speed, set the dial to the desired number.

2. Pull the trigger.

3. To stop the tool, release the trigger.

Constant Speed Tachometer (Cat. No. 6160-20)

The constant speed tachometer, which keeps the tool's revolutions per

minute (9000 RPM) at an almost constant speed even under load. The

tachometer also helps prevent tool overheating. The tool switches itself

off automatically when the motor is overloaded. It can be restarted by

squeezing the paddle trigger again.

Lock-off button

Lock-on button

Fig. 2

Use sanding discs and grinding wheels that are:

 correct size as written on tool's nameplate.

 correct wheel type and grit for the job.

 rated at or above the RPM listed in the "WARNING" section on the

tool's nameplate.

1. Plug in the tool.

2. To start the tool, flip the lock-off button and simultaneously squeeze

the paddle trigger.

3. Release paddle trigger to stop tool.

Lock-On Button (Fig. 2) (Cat. No. 6148, 6149-20, 6154-20 & 6156-20)

The lock-on button holds the trigger in the ON position for continuous full

speed use.

1. To lock the paddle trigger, hold in the lock-on button after pulling the

paddle trigger. Then release the paddle trigger.

2. To unlock the paddle trigger. Pull the paddle trigger and release. The

lock-on button will pop out.

Sanding Disc and Grinding Wheel Selection

To reduce the risk of personal injury and damage to the tool,

use ONLY accessories rated at or above the RPM listed on the

"WARNING" section of the tool's nameplate.

WARNING!

Starting and Stopping the Motor (Fig. 2)

page 7

Ceramic

Aluminum

Zirconia Bi-Cut

Aluminum

Oxide

For fast cutting, gen-

eral purpose discs

for most metal jobs.

Best for cold-rolled

steel, stainless steel

or metals requiring

tough, fast cutting,

long lasting abra-

sives.

Lasts up to 3 times

longer than Aluminum

Oxide Discs. For

general metal work-

ing. Ideal for tough

jobs.

Unique grit pattern is

arranged in clusters

for faster stock re-

moval and cleaning.

Ideal for removing

paint from cars,

boats, etc. without

clogging.

Installing Backing Pad and Sanding Discs (Fig. 3)

Sanding (Fig. 4)

1. Use a clamp, vise or other practical means to hold your work, free-

ing both hands to control your tool. Firmly grasp body of tool and

side handle before starting and while tool is in operation. Allow

sanding disc to come to full speed before beginning to sand.

2. Hold sander/grinder at 5° to 15° angle (Fig. 4) to ensure proper

sanding pressure and control. Too great an angle will result in too

much pressure and could cause excessive wear to the disc and

workpiece. Too small an angle will reduce control.

3. Use long, sweeping, side to side strokes, advancing forward to

produce the desired finish.

Removing Welds or Hammer Marks

When removing welds or hammer marks, limit coarse sanding to the

immediate area. Use successively finer grits to smooth surface.

Cross Sanding

When finishing 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 finish. Failure to cross sand when changing from a coarse

disc to a finishing disc may result in deep scratches and circular marks.

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

finishing 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

Fig. 3

Gear case

Spindle

Backing pad

Disc nut

Sanding disc

1. Unplug tool and place it upside down on a level surface. Remove

any accessories from spindle.

2. Slip backing pad onto spindle with flat side away from gear case.

3. Place sanding disc on backing pad and secure assembly to spindle

with disc nut.

4. To tighten, press the spindle lock button while turning disc nut clock-

wise with the spanner wrench provided.

5. To remove backing pad and sanding disc, unplug tool and reverse

procedure.

Fig. 4

For best result use

only this portion of disc

Hold at a 5° to 15° angle

Use backing pads, adapters, and other accessories that are:

 correct size for tool and for sanding disc or grinding wheel.

 rated at or above the RPM listed in the "WARNING" section on the

tool's nameplate.

 the proper accessory for the job.

Sanding Disc and Grinding Wheel Material

Sanding discs and grinding wheels are made of various materials and

are designed for different jobs. Be sure that you choose the proper

sanding disc or grinding wheel for the job you plan to do.

Selecting Sanding Discs & Grit

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 finishing. Always begin

with a coarse grit, using successively finer grits to obtain the desired

finish. See your MILWAUKEE Electric Tool Catalog for a complete list of

sanding discs.

page 8

Installing, Removing and Adjusting the Guard (Fig. 5 & 6) Cat. No.

6148, 6149-20, 6151, 6152-20, 6153-20, 6154-20, 6155-20, 6156-20

1. To remove the guard, unplug tool and place it upside down on a

level surface. Remove any accessories from spindle.

2. Press in the lock lever and rotate the guard to line up the four tabs

with the four slots (Fig. 6).

Lock lever

Fig. 6

This tool is shipped with the guard installed. The guard must be used

when using the tool as a grinder. The guard should be removed when

using tool as a sander.

3. Lift the guard straight up and away from the tool.

4. To install the guard, unplug the tool and place it upside down on a

level surface. Remove any accessories from the spindle.

5. Line up the four tabs with the four slots (Fig. 6).

6. Press down the guard onto the tool.

7. Press in the lock lever and rotate the guard to one of the five detent

slots. The lock lever must engage with one of the detent slots.

8.To adjust the guard, press in the lock lever and rotate the guard to

one of the five detent slots.

To reduce the risk of injury, the operator should be in-

structed in the use, care and protection of grinding wheels.

WARNING!

Care of Grinding & Cut-Off Wheels

Grinding and 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

Grinding and cut-off wheels should NOT be:

 dropped

 rolled

 bumped

If any wheel is dropped, rolled, bumped, subjected to extreme changes

in temperature, or has come into contact with solvents or wetness,

discard wheel immediately.

Only use wheels with Maximum Safe Operating Speed rated

at or above the RPM listed on the WARNING section of the

tool's nameplate. This speed is based on the strength of the

wheel, allowing for a reasonable measure of safety. It is not

meant to imply a best or most efficient operating speed. Do not

exceed the Maximum Safe Operating Speed.

WARNING!

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.

WARNING!

To reduce the risk of injury when grinding:

 ALWAYS use the proper guard.

 ALWAYS properly install the guard.

 ALWAYS hold the tool firmly 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.

Grinding and Cut-off Wheels

Fig. 5

Lock lever

Guard

Lock lever must

engage one of five

detents

Tab slots

page 9

Selecting Wheels

Grinding is the cutting action of thousands of abrasive 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.

1. When guard is properly positioned, place flange on spindle with

flange facing away from tool.

2. Place selected wheel on spindle and align with flange. Position flange

nut according to wheel thickness (Fig. 9, 10 and 11).

3. Press the spindle lock button while turning flange nut clockwise.

Tighten securely with the spanner wrench provided.

4. To remove wheel, unplug tool and reverse procedure.

To reduce the risk of injury, do not use the spindle lock

button to stop the spindle while the tool is in use or is

coasting after shut-off. This will result in tool damage.

WARNING!

Fig. 12

Operator's Zones

WARNING!

To reduce the risk of injury when grinding:

 ALWAYS use the proper guard.

 ALWAYS properly install the guard.

 ALWAYS hold the tool firmly 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.

Installing, Removing and Adjusting the Guard (Cat. No. 6160-20)

(Fig. 7 & 8)

1. To remove the guard, unplug tool and place it upside down on a

level surface. Remove any accessories from spindle.

2. Press in the lock lever and rotate the guard to line up the tabs with

the slots, as shown (Fig. 8).

Fig. 7

Lock lever

Guard

Lock lever must

engage one of

five detents

This tool is shipped without the guard installed. The guard must be used

when using the tool as a grinder. The guard should be removed when

using tool as a sander.

3. Press in the lock lever and lift the guard straight up and away from

the tool.

4. To install the guard, unplug the tool and place it upside down on a

level surface. Remove any accessories from the spindle.

5. Line up the tabs with the slots, as shown (Fig. 8).

6. Press in the lock lever and press the guard down onto the tool.

7. Press in the lock lever and rotate the guard clockwise to one of the

five detent slots. The lock lever must engage with one of the detent

slots.

8.To adjust the guard, press in the lock lever and rotate the guard to

one of the five detent slots (Fig. 8).

Fig. 8

Type 27 Reinforced 1/8" thick or less Cut-Off Wheels are suited for small

cut-off and shallow notching operations only.

Installing Grinding Wheels (Fig. 9, 10, 11 & 12)

Lock lever

Ta b

slots

Detent

slots

Flange nut position for 1/8" thick or less wheels

Fig. 10

Boss

Flange nut

Spindle

Grinding wheel

Flange

Flange nut position for 1/4" thick wheels

Fig. 9

Flange nut

Boss

Spindle

Grinding wheel

Flange

Type 27 Grinding Wheel

Fig. 11

Spindle

Grinding wheel

Flange

page 10

Grinding (Fig. 13)

1. If you have just installed a grinding wheel or are just beginning a

period of work, test wheel by letting it spin for one minute before

applying it to the workpiece.

NOTE: Out-of-balance wheels can mar workpiece, damage the tool,

and cause stress to wheel that may cause wheel failure.

2. Firmly grasp body of tool and side handle before starting and while

using tool. Allow wheel to come to full speed before starting to grind.

3. When grinding, hold sander/grinder at a 5

to 15

angle, using con-

stant pressure for a uniform finish. Too great an angle causes con-

centrated pressure on small areas which may gouge or burn work

surface.

4. Control pressure and surface contact between disc and workpiece.

Too much pressure slows cutting speed.

Using Cut-Off Wheels (Fig. 14)

Type 1 Cut-Off Wheels are suited for small cut-off and shallow notch-

ing operations only.

1. Firmly grasp body of tool and side handle before starting and while

using tool. Allow wheel to come to full speed before starting.

2. When using a cut-off wheel, hold Sander/Grinder as shown, using

only the edge of the wheel.

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!

Fig. 14

3. Control pressure and surface contact between disc and workpiece.

Too much pressure slows cutting speed.

Fig. 13

Hold at a 5° to 15° angle

Everyone in the area must wear protective clothing and

safety goggles or face shields. Fatigued wires and residue

will fly off the brush with considerable force, causing

potential for serious injury.

WARNING!

Installing Wire Cup Brushes (Fig. 15)

2. To install, thread wire cup brush onto spindle. Press the spindle lock

button while tightening brush with a 7/8" open end wrench (not

provided with tool).

3. To remove wire cup brush, unplug tool and reverse procedure.

Using Wire Wheel Brushes (Fig. 16)

1. Unplug tool and place it upside down on a level surface as shown.

Remove any accessories from spindle.

Fig. 15

Wire Cup Brush

Wire Wheel Brush

Fig. 16

Guard

Wire wheel brushes are useful for removing rust, scale, burrs, weld

slag, etc. A wide variety of wire brushes are available for many

applications.

Test wire wheel brush for balance and loose or damaged wires by

running tool at no load speed for at least one minute before applying it to

your work. During this time, no one should stand in front of or in line with

it. When applying brush to work, avoid using too much pressure. This

causes over-bending of wires and heat build-up resulting in premature

wire breakage, rapid dulling and reduced brush life. Instead of using

more pressure, try a wire wheel brush with more aggressive cutting

action (increased wire size, decreased wire length or different brush

type, i.e. knot type instead of crimped wire type).

Because the wires on wire wheel brushes are directed

towards the operator, a guard must be used to protect the

operator when fatigued wires break.

WARNING!

Using the face of a Cut-Off Wheel (as in grinding) will cause

the Wheel to crack and break, resulting in serious personal

injury.

WARNING!

Never exceed Maximum Safe Operating Speed of brush. Do

not use a damaged brush or one which is functioning

improperly (throwing wires, out-of balance, etc.). these

conditions increase the possibility of further brush failure

and possible injury. Discard and replace damaged brushes

immediately.

WARNING!

page 11

Maintaining Tools

Keep your tool in good repair by adopting a regular maintenance pro-

gram. Before use, examine the general condition of your tool. Inspect

guards, switches, tool cord set and extension cord for damage. Check

for loose screws, misalignment, binding of moving parts, improper mount-

ing, broken parts and any other condition that may affect its safe opera-

tion. If abnormal noise or vibration occurs, turn the tool off immediately

and have the problem corrected before further use. Do not use a dam-

aged tool. Tag damaged tools DO NOT USE until repaired

(see Repairs).

Under normal conditions, relubrication is not necessary until the motor

brushes need to be replaced. After six months to one year, depending on

use, return your tool to the nearest MILWAUKEE service facility for the

following:

 Lubrication

 Brush inspection and replacement

 Mechanical inspection and cleaning (gears, spindles, bearings,

housing, etc.)

 Electrical inspection (switch, cord, armature, etc.)

 Testing to assure proper mechanical and electrical operation

MAINTENANCE

Cleaning

Clean dust and debris from vents. Keep the tool handles clean, dry and

free of oil or grease. Use only mild soap and a damp cloth to clean your

tool 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 household detergents containing ammonia. Never use flammable or

combustible solvents around tools.

Repairs

If your tool is damaged, return the entire tool to the nearest service

center.

WARNING!

To reduce the risk of injury, always unplug your tool before

performing any maintenance. Never disassemble the tool or

try to do any rewiring on the tool's electrical system. Contact

a MILWAUKEE service facility for ALL repairs.

WARNING!

To reduce the risk of injury, electric shock and damage to the

tool, never immerse your tool in liquid or allow a liquid to flow

inside the tool.

ACCESSORIES

To reduce the risk of injury, always unplug the tool before

attaching or removing accessories. Use only specifically

recommended accessories. Others may be hazardous.

WARNING!

FIVE YEAR TOOL LIMITED WARRANTY

Every MILWAUKEE tool is tested before leaving the factory and is war-

ranted to be free from defects in material and workmanship. MILWAUKEE

will repair or replace (at MILWAUKEEs discretion), without charge, any

tool (including battery chargers) which examination proves to be defec-

tive in material or workmanship from five (5) years after the date of

purchase. Return the tool and a copy of the purchase receipt or other

proof of purchase to a MILWAUKEE Factory Service/Sales Support

Branch location or MILWAUKEE Authorized Service Station, freight pre-

paid and insured. This warranty does not cover damage from repairs

made or attempted by other than MILWAUKEE authorized personnel,

abuse, normal wear and tear, lack of maintenance, or accidents.

Battery Packs, Flashlights, and Radios are warranted for one (1) year

from the date of purchase.

THE REPAIR AND REPLACEMENT REMEDIES DESCRIBED HEREIN ARE

EXCLUSIVE. IN NO EVENT SHALL MILWAUKEE BE LIABLE FOR ANY

INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES, INCLUDING

LOSS OF PROFITS.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRAN-

TIES, OR CONDITIONS, WRITTEN OR ORAL, EXPRESSED OR IMPLIED FOR

MERCHANTABLILITY OR FITNESS FOR PARTICULAR USE OR PURPOSE.

This warranty gives you specific legal rights. You may also have other

rights that vary from state to state and province to province. In those

states that do not allow the exclusion of implied warranties or limitation

of incidental or consequential damages, the above limitations or exclu-

sions may not apply to you. This warranty applies to the United States,

Canada, and Mexico only.

For a complete listing of accessories refer to your MILWAUKEE Electric

Tool catalog or go on-line to www.milwaukeetool.com. To obtain a

catalog, contact your local distributor or a service center.

58-14-6201d8 11/04 Printed in USA

MILWAUKEE ELECTRIC TOOL CORPORATION

13135 West Lisbon Road  Brookfield, Wisconsin, U.S.A. 53005

UNITED STATES

MILWAUKEE Service

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, or you would like to

locate the factory Service/Sales Support Branch

or authorized service station nearest you,

please call...

1-800-SAWDUST

(1.800.729.3878)

NATIONWIDE TOLL FREE

Monday-Friday  8:00 AM - 4:30 PM  Central Time

or visit our website at

www.milwaukeetool.com

For service information, use the 'Service Center

Search' icon found in the 'Parts & Service' section.

Additionally, we have a nationwide network of

authorized Distributors ready to assist you with your

tool and accessory needs. Check your Yellow Pages

phone directory under Tools-Electric for the names

& addresses of those nearest you or see the

'Where To Buy' section of our website.

Corporate After Sales Service - Technical Support

Brookfield, Wisconsin USA

Technical Questions Service/Repair Questions Warranty

1-800-SAWDUST

(1.800.729.3878)

fax:1.800.638.9582

email: [email protected]

Monday-Friday  8:00 AM - 4:30 PM  Central Time

CANADA

Service MILWAUKEE

MEXICO

Servicios de MILWAUKEE

Milwaukee Electric Tool

Blvd. Abraham Lincoln no. 13

Colonia Los Reyes Zona Industrial

Tlalnepantla, Edo. México C.P. 54073

Tel. 55 5565-1414 Fax: 55 5565-6874

Adicionalmente, tenemos una red nacional de

distribuidores autorizados listos para ayudarle con

su herramienta y sus accesorios. Por favor, llame

al 55 5565-1414 para obtener los nombres y

direcciones de los más cercanos a usted, o consulte

la sección Where to buy (Dónde comprar) de

nuestro sitio web en

www.milwaukeetool.com

Notre réseau national de distributeurs agréés se tient

à votre disposition pour fournir laide technique,

loutillage et les accessoires nécessaires. Composez

le 416.439.4181 pour obtenir les noms et adresses

des revendeurs les plus proches ou bien consultez

la section «Où acheter» sur notre site web à ladresse

www.milwaukeetool.com

MILWAUKEE est fier de proposer un produit de

première qualité N

OTHING BUT HEAVY DUTY

. Votre

satisfaction est ce qui compte le plus!

En cas de problèmes dutilisation de loutil ou

pour localiser le centre de service/ventes ou le

centre dentretien le plus proche, appelez le...

416.439.4181

fax: 416.439.6210

Milwaukee Electric Tool (Canada) Ltd

755 Progress Avenue

Scarborough, Ontario M1H 2W7

MILWAUKEE ELECTRIC TOOL CORPORATION

13135 W. Lisbon Road, Brookeld, WI 53005

Drwg. 4

FIG. PART NO. DESCRIPTION OF PART NO. REQ.

1 49-05-0110 Flange Nut (1)

2 49-05-0125 Flange (1)

3 44-20-0325 Lock Lever (1)

4 45-36-1551 Spacer (1)

5 02-04-1745 Ball Bearing (1)

6 34-80-2960 Retaining Ring - Internal (1)

7 28-52-0222 Spindle Hub (1)

8 14-20-0910 Module Assembly (1)

9 32-05-1310 P.M. Gear (1)

10 28-14-0705 Gear Case Assembly (1)

11 02-50-2423 Needle Bearing (1)

12 38-50-5212 Spindle (1)

13 22-56-0890 Blade Housing Assembly (1)

14 32-60-1310 Pinion Gear (1)

15 02-04-0852 Ball Bearing (1)

16 44-66-5345 Bearing Retainer Plate (1)

17 42-14-0400 Bafﬂe (1)

18 16-10-2007 Armature (1)

19 18-10-2005 Field (1)

20 31-50-1125 Motor Housing (1)

21 31-44-0660 Right Cover (1)

22 23-16-0101 Commutator Insulator (1)

23 02-04-2080 Ball Bearing (1)

24 23-66-2401 Switch (1)

25 06-82-7271 6-19 x 7/8" Pan Hd. Plastite T-15 (4)

26 12-20-6207 Service Nameplate Kit (1)

27 10-98-7091 Warning Label (1)

28 23-74-1206 Brush Terminal (2)

29 06-82-7421 6-19 x 3-1/4" Pan Hd. Slt. Plast. T-15 (2)

30 22-20-1010 Brush Holder Assy. (Incl. Carbon Brush) (2)

31 23-74-1201 Switch Terminal (1)

32 48-76-5010 Quik-Lok Cord Set (1)

33 06-82-7326 8-16 x 1" Pan Hd. Slt. Plast. T-20 (4)

34 31-12-0205 Cap (1)

35 40-50-8650 Compression Spring (1)

36 34-40-4300 O-Ring (1)

37 44-60-0845 Lock Pin (1)

38 06-82-5316 8-32 x 1/2" Pan Hd. Slt. Tapt. T-20 (4)

39 42-42-0030 Lock On Button (1)

40 31-92-0320 Paddle Assembly (1)

41 06-65-1915 Pin (1)

42 42-42-0390 Lock-Off Button (1)

43 40-50-8750 Torsion Spring (1)

FIG. PART NO. DESCRIPTION OF PART NO. REQ.

44 28-41-1020 Hood (1)

45 06-82-7251 8-16 x 3/8" Pan Hd. Slt. Plast. T-20 (3)

46 31-44-0665 Left Cover (1)

47 49-15-0310 Side Handle (1)

48 49-12-0365 Guard Assembly (1)

49 --------------- 4-1/2" Disc - Select From Catalog (1)

50 45-14-0280 Pinion Shim (1)

51 06-55-3850 10-32 Hex Nut (1)

52 22-84-0960 Fan Assembly (1)

55 40-50-0921 Lock On Spring (1)

56 43-44-1080 Gasket (1)

49-96-7205 Spanner Wrench (1)

FIG. LUBRICATION:

9,14 Type "Y" Grease, No. 49-08-5270, Must Be Applied

To All Gear Teeth.

10 9-12 Grams Type "Y" Grease, No. 49-08-5270.

FIG. NOTES:

7 Position The Spindle Hub With The Side That Has The

Word "Back" Orientated Toward The Rear Of The Tool.

8 Connect Terminals Flagged "A" & "B" On Module Assembly

To The Corresponding Terminals Flagged On The Switch.

Connect The Terminal Flagged "C" On The Module To The

Terminal Flagged "C" On The Field.

11 Press .09" Below Casting Surface With Lettering Readable

After Assembly.

13 Blade Hsg. Leads Are Interchangeable On Switch

Connections.

39,55,46 Assemble Lock On Button And Spring Into The Left Cover.

51 Torque To 25-35 In./Lbs.

6154-20

54-38-3728

907D

4-1/2" DIAL SPEED SUPER MAG GRINDER

EXAMPLE:

Component Parts (Small #) Are

Included When Ordering The

Assembly (Large #).

REVISED BULLETIN

DATE

Nov. 2005

SERVICE PARTS LIST

BULLETIN NO.

WIRING INSTRUCTION

See Below

CATALOG NO.

SPECIFY CATALOG NO. AND SERIAL NO. WHEN ORDERING PARTS

STARTING

SERIAL NUMBER



54-38-3727



Milwaukee 6148, 6149-20, 6151, 6152-20, 6153-20, 6154-20, 6155-20, 6156-20, 6160-20 User manual

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