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
10000
10000
10000
11000
4000-11000
11000
4000-11000
9000
Volts
120 AC/DC
120 AC/DC
120 AC/DC
120 AC/DC
120 AC/DC
120 AC
120 AC/DC
120 AC
120 AC
Spindle
Thread
Size
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
5/8"-11
Amps
8.5
8.5
8.5
8.5
12
12
12
12
11
Wheel
Size
4-1/2"
5"
4-1/2"
5"
4-1/2"
4-1/2"
5"
5"
6"
Min. Wheel
RPM Rating
12000
12000
12000
12000
12000
12000
12000
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
1000
1000
1000
1400
1400
1400
1400
1300
Mexican Approvals Marking
4
Cat. No.
6160-20
1
11
10
9
8
5
7
4
3
2
6
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'
16
16
14
12
10
75'
16
14
12
10
10
100'
14
12
10
10
--
150'
12
10
--
--
--
200'
12
--
--
--
--
Recommended Minimum Wire Gauge
for Extension Cords*
* Based on limiting the line voltage drop to five
volts at 150% of the rated amperes.
50'
16
16
14
12
10
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
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
o
to 15
o
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 MILWAUKEEs 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 laide technique,
loutillage 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 ladresse
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 dutilisation de loutil ou
pour localiser le centre de service/ventes ou le
centre dentretien 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, Brookeld, 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
0
0
0
54-38-3727
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Milwaukee 6154-20 User manual
- Category
- Power tools
- Type
- User manual
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