Chicago Electric Grinder 97588 User Manual

MagnesiuM Heavy Duty 7”  
angle grinDer  
97588  
set up anD Operating instructiOns  
®
Distributed exclusively by Harbor Freight tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
visit our website at: http://www.harborfreight.com  
read this material before using this product.  
Failure to do so can result in serious injury.  
save tHis Manual.  
©
®
Copyright 2008 by Harbor Freight Tools . All rights reserved. No portion of this manual or any artwork  
contained herein may be reproduced in any shape or form without the express written consent of Harbor  
FreightTools. Diagramswithinthismanualmaynotbedrawnproportionally. Duetocontinuingimprovements,  
actual product may differ slightly from the product described herein.  
For technical questions or replacement parts, please call 1-800-444-3353.  
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plugs with grounded power tools.  
Unmodified plugs and matching out-  
lets will reduce risk of electric shock.  
Safety equipment such as dust mask,  
non-skid safety shoes, hard hat, or  
hearing protection used for appropri-  
ate conditions will reduce personal  
injuries.  
b.avoid body contact with grounded  
surfaces such as pipes, radiators,  
ranges and refrigerators. There is  
an increased risk of electric shock if  
your body is grounded.  
c.prevent unintentional starting.  
ensure the switch is in the off-po-  
sition before connecting to power  
source and/or battery pack, pick-  
ing up or carrying the tool. Carry-  
ing power tools with your finger on  
the switch or energizing power tools  
that have the switch on invites acci-  
dents.  
c.Do not expose power tools to rain  
or wet conditions. Water entering  
a power tool will increase the risk of  
electric shock.  
d.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.  
d.remove any adjusting key or  
wrench before turning the power  
tool on. A wrench or a key left at-  
tached to a rotating part of the power  
tool may result in personal injury.  
e.Do not overreach. Keep proper  
footing and balance at all times.  
This enables better control of the  
power tool in unexpected situations.  
e.When operating a power tool out-  
doors, use an extension cord suit-  
able for outdoor use. Use of a cord  
suitable for outdoor use reduces the  
risk of electric shock.  
f. Dress properly. Do not wear loose  
clothing or jewelry. Keep your  
hair, clothing and gloves away  
from moving parts. Loose clothes,  
jewelry or long hair can be caught in  
moving parts.  
f. if operating a power tool in a damp  
location is unavoidable, use a  
ground Fault circuit interrupter  
(gFci) protected supply. Use of  
a GFCI reduces the risk of electric  
shock.  
g.if devices are provided for the con-  
nection of dust extraction and col-  
lection facilities, ensure these are  
connected and properly used. Use  
of these devices can reduce dust-  
related hazards.  
3. personal safety  
a.stay alert, watch what you are do-  
ing 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.  
h.Only use safety equipment that  
has been approved by an appropri-  
ate standards agency. Unapproved  
safety equipment may not provide  
adequate protection. Eye protection  
must be ANSI-approved and breath-  
ing protection must be NIOSH-ap-  
b.use personal protective equip-  
ment. always wear eye protection.  
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proved for the specific hazards in the  
work area.  
g.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 differ-  
ent from those intended could result  
in a hazardous situation.  
4. power tool use and care  
a.Do not force the power tool. use  
the correct power tool for your ap-  
plication. The correct power tool will  
do the job better and safer at the rate  
for which it was designed.  
5. service  
b.Do not use the power tool if the  
switch does not turn it on and off.  
Any power tool that cannot be con-  
trolled with the switch is dangerous  
and must be repaired.  
a.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.  
c.Disconnect the plug from the  
power source and/or the battery  
pack from the power tool before  
making any adjustments, chang-  
ing accessories, or storing power  
tools. Such preventive safety mea-  
sures reduce the risk of starting the  
power tool accidentally.  
grinding, sanding or Wire  
Brushing Operation safety  
Warnings  
1. this power tool is intended to  
function as a grinder, sander or  
wire brushing tool. read all safety  
warnings, instructions, illustra-  
tions and specifications provided  
with this power tool. Failure to fol-  
low all instructions listed below may  
result in electric shock, fire and/or  
serious injury.  
d.store idle power tools out of the  
reach of children and do not allow  
persons unfamiliar with the power  
tool or these instructions to oper-  
ate the power tool. Power tools are  
dangerous in the hands of untrained  
users.  
2. Operations such as polishing or  
cutting-off 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.  
e.Maintain power tools. check for  
misalignment or binding of moving  
parts, breakage of parts and any  
other condition that may affect the  
power tools operation. if dam-  
aged, have the power tool repaired  
before use. Many accidents are  
caused by poorly maintained power  
tools.  
3. Do not use accessories which  
are not specifically designed and  
recommended by the tool manu-  
facturer. Just because the accessory  
can be attached to your power tool, it  
does not assure safe operation.  
f. Keep cutting tools sharp and  
clean. Properly maintained cutting  
tools with sharp cutting edges are  
less likely to bind and are easier to  
control.  
4. the rated speed of the accessory  
must be at least equal to the maxi-  
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mum speed marked on the power  
tool. Accessories running faster than  
their RATED SPEED can break and  
fly apart.  
sive or work piece fragments. the  
eye protection must be capable of  
stopping flying debris generated  
by various operations. The eye pro-  
tection must be capable of stopping  
flying debris generated by various  
operations. The dust mask or respira-  
tor must be capable of filtrating par-  
ticles generated by your operation.  
Prolonged exposure to high intensity  
noise may cause hearing loss.  
5. 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.  
6. The arbor size of wheels, flanges,  
backing pads or any other acces-  
sory must properly fit the spindle  
of the power tool. Accessories with  
arbor holes that do not match the  
9. Keep bystanders a safe distance  
away from work area. anyone  
entering the work area must wear  
personal protective equipment.  
Fragments of work piece or of a  
broken accessory may fly away and  
cause injury beyond immediate area  
of operation.  
mounting hardware of the power tool  
will run out of balance, vibrate exces-  
sively and may cause loss of control.  
7. Do not use a damaged accessory.  
Before each use inspect the ac-  
cessory 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.  
10. Hold power tool by insulated grip-  
ping surfaces only, when perform-  
ing an operation where the cutting  
accessory may contact hidden  
wiring or its own cord. Cutting ac-  
cessory contacting a ″live″ wire may  
make exposed metal parts of the  
power tool ″live″ and shock the op-  
erator.  
11. position the cord clear of the spin-  
ning accessory. If you lose control,  
the cord may be cut or snagged and  
your hand or arm may be pulled into  
the spinning accessory.  
12. never lay the power tool down  
until the accessory has come to a  
complete stop. The spinning acces-  
sory may grab the surface and pull  
the power tool out of your control.  
8. Wear personal protective equip-  
ment. Depending on application,  
use face shield, safety goggles  
or safety glasses. as appropriate,  
wear dust mask, hearing protec-  
tors, gloves and workshop apron  
capable of stopping small abra-  
13. Do not run the power tool while  
carrying it at your side. Accidental  
contact with the spinning accessory  
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could snag your clothing, pulling the  
accessory into your body.  
pacemakers should:  
• Avoid operating alone.  
• Do not use with power switch locked  
on.  
• Properly maintain and inspect to  
avoid electrical shock.  
• Any power cord must be properly  
grounded. Ground Fault Circuit Inter-  
rupter (GFCI) should also be imple-  
mented – it prevents sustained elec-  
trical shock.  
14. regularly clean the power tools  
air vents. The motor’s fan will draw  
the dust inside the housing and ex-  
cessive accumulation of powdered  
metal may cause electrical hazards.  
15. Do not operate the power tool near  
flammable materials. Sparks could  
ignite these materials.  
23. Some dust created by power sand-  
ing, sawing, grinding, drilling, and  
other construction activities, contains  
chemicals known [to the State of Cali-  
fornia] to cause cancer, birth defects  
or other reproductive harm. Some  
examples of these chemicals are:  
• Lead from lead-based paints  
16. Do not use accessories that re-  
quire liquid coolants. Using water  
or other liquid coolants may result in  
electrocution or shock.  
17. Maintain labels and nameplates on  
the tool. These carry important safety  
information. If unreadable or miss-  
ing, contact Harbor Freight Tools for a  
replacement.  
• Crystalline silica from bricks and ce-  
ment or other masonry products  
• Arsenic and chromium from chemi-  
cally treated lumber  
18. Avoid unintentional starting. Prepare  
to begin work before turning on the  
tool.  
Your risk from these exposures var-  
ies, 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. (California Health & Safety  
Code § 25249.5, et seq.)  
19. Do not lay the tool down until it has  
come to a complete stop. Moving  
parts can grab the surface and pull  
the tool out of your control.  
20. Do not leave the tool unattended  
when it is plugged into an electrical  
outlet. Turn off the tool, and unplug it  
from its electrical outlet before leav-  
ing.  
24. WARNING: Handling the cord on  
this product will expose you to lead,  
a chemical known to the State of  
California to cause cancer, and birth  
defects or other reproductive harm.  
Wash hands after handling. (Califor-  
nia Health & Safety Code § 25249.5,  
et seq.)  
21. This product is not a toy. Keep it out  
of reach of children.  
22. People with pacemakers should  
consult their physician(s) before use.  
Electromagnetic fields in close prox-  
imity to heart pacemaker could cause  
pacemaker interference or pacemak-  
er failure. In addition, people with  
25. The warnings, precautions, and in-  
structions discussed in this instruction  
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manual cannot cover all possible con- 2. never place your hand near the  
ditions and situations that may occur.  
It must be understood by the operator  
that common sense and caution are  
factors which cannot be built into this  
product, but must be supplied by the  
operator.  
rotating accessory. Accessory may  
kickback over your hand.  
3. 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.  
Kickback and related Warnings  
Kickback is a sudden reaction to a  
pinched or snagged rotating wheel, back-  
ing pad, brush or any other accessory.  
Pinching or snagging causes rapid stall-  
ing of the rotating accessory which in turn  
causes the uncontrolled power tool to be  
forced in the direction opposite of the ac-  
cessory’s rotation at the point of the bind-  
ing.  
4. use special care when working  
corners, sharp edges etc. avoid  
bouncing and snagging the ac-  
cessory. Corners, sharp edges or  
bouncing have a tendency to snag  
the rotating accessory and cause loss  
of control or kickback.  
5. Do not attach a saw chain wood-  
carving blade or toothed saw  
blade. Such blades create frequent  
kickback and loss of control.  
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, depend-  
ing on direction of the wheel’s movement  
at the point of pinching. Abrasive wheels  
may also break under these conditions.  
Safety Warnings Specific for  
grinding Operations  
1. 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 de-  
signed cannot be adequately guarded  
and are unsafe.  
Kickback is the result of power tool  
misuse and/or incorrect operating proce-  
dures or conditions and can be avoided by  
taking proper precautions as given below.  
2. the guard must be securely at-  
tached to the power tool and posi-  
tioned 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 con-  
tact with wheel.  
1. Maintain a firm grip on the power  
tool and position your body and  
arm to allow you to resist kick-  
back forces. always use auxiliary  
handle, if provided, for maximum  
control over kickback or torque  
reaction during start-up. The opera-  
tor can control torque reactions or  
kickback forces, if proper precautions  
are taken.  
3. Wheels must be used only for  
recommended applications. For  
example: do not grind with the  
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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.  
wheel or brush with the guard.  
Wire wheel or brush may expand in  
diameter due to work load and cen-  
trifugal forces.  
4. 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.  
vibration safety  
This tool vibrates during use. Re-  
peated or long-term exposure to vibra-  
tion may cause temporary or permanent  
physical injury, particularly to the hands,  
arms and shoulders. To reduce the risk of  
vibration-related injury:  
5. Do not use worn down wheels  
from larger power tools. Wheel  
intended for larger power tool is not  
suitable for the higher speed of a  
smaller tool and may burst.  
1. Anyone using vibrating tools regu-  
larly or for an extended period should  
first be examined by a doctor and  
then have regular medical check-  
ups to ensure medical problems are  
not being caused or worsened from  
use. Pregnant women or people  
who have impaired blood circulation  
to the hand, past hand injuries, ner-  
vous system disorders, diabetes, or  
Raynaud’s Disease should not use  
this tool. If you feel any medical or  
physical symptoms related to vibra-  
tion (such as tingling, numbness, and  
white or blue fingers), seek medical  
advice as soon as possible.  
Safety Warnings Specific for  
sanding Operations  
1. Do not use excessively oversized  
sanding disc paper. Follow manu-  
facturers 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.  
2. Do not smoke during use. Nico-  
tine reduces the blood supply to the  
hands and fingers, increasing the risk  
of vibration-related injury.  
Safety Warnings Specific for Wire  
Brushing Operations  
1. Be aware that wire bristles are  
thrown by the brush even dur-  
ing 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.  
3. Wear suitable gloves to reduce the  
vibration effects on the user.  
4. Use tools with the lowest vibration  
when there is a choice between dif-  
ferent processes.  
5. Include vibration-free periods each  
day of work.  
2. if the use of a guard is recom-  
mended for wire brushing, do not  
allow any interference of the wire  
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6. Grip tool as lightly as possible (while  
still keeping safe control of it). Let  
the tool do the work.  
grounded tools: tools with three  
prong plugs  
7. To reduce vibration, maintain the tool  
as explained in this manual. If any  
abnormal vibration occurs, stop use  
immediately.  
save tHese  
instructiOns.  
grOunDing  
1. Tools marked with “Grounding Re-  
quired” have a three wire cord and  
three prong grounding plug. The  
plug must be connected to a properly  
grounded outlet. If the tool should  
electrically malfunction or break  
down, grounding provides a low  
resistance path to carry electricity  
away from the user, reducing the risk  
of electric shock. (see 3-prong plug  
and Outlet.)  
tO prevent  
electric sHOcK  
anD DeatH FrOM  
incOrrect grOunDing  
Wire cOnnectiOn:  
Check with a qualified  
electrician if you are in doubt  
as to whether the outlet is  
properly grounded. Do not  
modify the power cord plug  
provided with the tool. never 2. The grounding prong in the plug is  
remove the grounding prong  
from the plug. Do not use the  
tool if the power cord or plug  
is damaged. if damaged, have  
it repaired by a service facility  
before use. if the plug will not  
fit the outlet, have a proper  
outlet installed by a qualified  
electrician.  
connected through the green wire in-  
side 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. (see 3-prong plug  
and Outlet.)  
3. The 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 the  
preceding illustration. (see 3-prong  
plug and Outlet.)  
note: This is a double insulated tool. Infor-  
mation on grounded tools is provided  
for reference only.  
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ample, a 14 gauge cord can carry a  
higher current than a 16 gauge cord.  
(see table a.)  
Double insulated tools: tools  
with two prong plugs  
3. When using more than one exten-  
sion cord to make up the total length,  
make sure each cord contains at  
least the minimum wire size required.  
(see table a.)  
4. If you are using one extension cord  
for more than one tool, add the  
nameplate amperes and use the sum  
to determine the required minimum  
cord size. (see table a.)  
1. 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. (see Outlets for 2-prong  
plug.)  
5. If you are using an extension cord  
outdoors, make sure it is marked with  
the suffix “W-A” (“W” in Canada) to  
indicate it is acceptable for outdoor  
use.  
6. Make sure the extension cord is prop-  
erly wired and in good electrical con-  
dition. Always replace a damaged  
extension cord or have it repaired by  
a qualified electrician before using it.  
2. Double insulated tools may be used  
in either of the 120 volt outlets shown  
in the preceding illustration. (see  
Outlets for 2-prong plug.)  
7. Protect the extension cords from  
sharp objects, excessive heat, and  
damp or wet areas.  
extension cords  
1. Grounded tools require a three wire  
extension cord. Double Insulated  
tools can use either a two or three  
wire extension cord.  
2. As the distance from the supply outlet  
increases, you must use a heavier  
gauge extension cord. Using exten-  
sion cords with inadequately sized  
wire causes a serious drop in voltage,  
resulting in loss of power and pos-  
sible tool damage.  
(see table a.) The smaller the  
gauge number of the wire, the greater  
the capacity of the cord. For ex-  
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recOMMenDeD MiniMuM Wire  
gauge FOr eXtensiOn cOrDs*  
(120/240 vOlt)  
eXtensiOn cOrD  
naMeplate  
lengtH  
aMperes  
(at full load)  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* Based on limiting the line  
voltage drop to five volts at  
150% of the rated amperes.  
taBle a  
symbology  
Double Insulated  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
Amperes  
v~  
a
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
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tO prevent  
seriOus injury  
speciFicatiOns  
FrOM acciDental  
Electrical Requirements 120 V~ / 60 Hz / 15 A  
OperatiOn:  
Motor No Load Speed  
Wheel Diameter  
Arbor Diameter  
8000 RPM  
7 inches  
turn the power switch of the  
tool to its “OFF” position and  
unplug the tool from its  
electrical outlet before  
assembling or making any  
adjustments to the tool.  
7/8 inch  
Spindle Thread  
5/8 inch x 11 TPI  
90sM  
e194601  
note: For additional information regarding  
the parts listed in the following pages,  
refer to the Assembly Diagram near  
the end of this manual.  
unpacKing  
When unpacking, check to make sure  
that the item is intact and undamaged. If  
any parts are missing or broken, please  
call Harbor Freight Tools at the number  
shown on the cover of this manual as soon  
as possible.  
assembly  
installing the Wheel guard  
1. The Wheel Guard (7) must be in-  
stalled before installing a grinding  
wheel or other disc.  
list of contents  
Description  
Q’ty  
2. Loosen the Wheel Guard Quick Re-  
Angle Grinder  
1
1
1
1
1
1
lease (6) by pulling the lever outward.  
Grinding Wheel  
3. Slide the collar of the Wheel Guard  
(7) over the rim of the Front Cap (13).  
Quick Release Wheel Guard  
Auxiliary Handle  
Pin Wrench  
4. Rotate the position of the Wheel  
Guard as needed for the planned  
work.  
Owner’s Manual  
instructiOns FOr  
putting intO use  
5. Tighten the Wheel Guard Quick Re-  
lease by pressing the lever back in  
place. The clamping pressure of the  
Quick Release may be adjusted us-  
ing the Nut (4).  
read the entire iMpOrtant  
saFety inFOrMatiOn  
section at the beginning of this  
manual including all text under  
subheadings therein before set  
up or use of this product.  
6. Check the Wheel Guard to ensure it  
is firmly in place. Adjust if necessary  
before proceeding.  
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installing the auxiliary Handle  
tO prevent  
Operating instructiOns  
read the entire iMpOrtant  
saFety inFOrMatiOn  
section at the beginning of this  
manual including all text under  
subheadings therein before set  
up or use of this product.  
seriOus injury:  
Do not operate this tool with  
one hand only or without the  
auxiliary Handle properly  
installed.  
7. The Auxiliary Handle may be installed  
in one of three positions, on either  
side or on top of the Gear Housing  
(26). (See Photo.)  
tool set up  
tO prevent  
seriOus injury  
FrOM acciDental  
OperatiOn:  
8. Screw the threaded end of the Auxil-  
iary Handle into the selected position.  
Tighten securely before beginning  
work.  
turn the power switch of the  
tool to its “OFF” position and  
unplug the tool from its  
electrical outlet before  
performing any inspection,  
maintenance, or cleaning  
procedures.  
Functions  
Auxiliary Handle (25)  
Alternative Mounting  
Positions for Auxiliary  
Handle  
Spindle  
Lock  
installing a grinding Wheel  
Button  
(24)  
1. Before installing a grinding wheel,  
review the warnings on pages 5 - 7.  
The Grinding Wheel MUST be:  
rated to at least 8000 RPM.  
no larger than 7” in diameter.  
• fitted with a 7/8” round arbor hole.  
• 3/8” thick or less.  
Magnesium  
Alloy Cover  
a type of grinding wheel suitable for  
surface grinding, not edge grinding.  
dry and clean.  
Carbon Brush Cap (45)  
Wheel Guard (7)  
proven undamaged by inspec-  
tion and by the ring-test explained  
below.  
Quick Release Adjusting Nut (4)  
Wheel Guard Quick Release (6)  
This hand-held tool may be used for  
grinding, sanding, scaling, and other  
related operations.  
2. Press in and hold the Spindle Lock  
Button (24) to prevent the Spindle (8)  
from turning.  
3. Remove the Outer Flange (1). Keep  
the Inner Flange (3) in position on the  
Spindle.  
SKU 97588  
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4. Closely inspect the Grinding Wheel  
before mounting. Perform a ring-test  
on the wheel (unless wheel is smaller  
than 4” or is an unusual shape) as  
follows:  
with. Blotters help prevent grind-  
ing wheel damage and wheel slip-  
page, causes of wheel failure.  
6. Thread the Outer Flange Arbor Nut  
onto the Spindle. Wrench tighten  
only enough so that the wheel is se-  
curely held on the spindle.  
a. Suspend wheel using a pin or finger  
through the arbor hole.  
Warning: to prevent serious  
injury, do not overtighten flange.  
Overtightening can damage the  
wheel, causing wheel failure.  
45°  
45°  
v
e
r
t
i
c
a
l
Hang  
Wheel  
from  
pin  
installing a threaded accessory  
tO prevent  
injury:  
tap  
Wheel  
Here  
c
e
n
t
e
r
Wear heavy-duty work gloves  
when handling wire wheels  
and brushes. these  
accessories are sharp and  
can cause injury.  
45°  
45°  
1. Before installing an accessory, review  
the warnings on pages 5 - 7.  
The accessory MUST be:  
rated to at least 8000 RPM.  
no larger than 7” in diameter.  
• fitted with a threaded opening of  
5/8” x 11 TPI.  
b. Tap the flat side of the wheel with a  
light non-metallic object, such as a  
screwdriver handle, at a point 45°  
from the vertical center line on each  
side of the wheel and 1 – 2 inches  
from the edge of the wheel (see Il-  
lustration).  
undamaged.  
c. Rotate the wheel 45 degrees and  
repeat the test until the entire wheel  
has been checked.  
a sanding disc and backing pad, a  
sanding flap disc, a wire wheel or  
a wire cup brush (accessories not  
included).  
d. An undamaged wheel will give a  
clear tone. If cracked, there will be a  
dead sound and not a clear ring.  
2. Press in and hold the Spindle Lock  
Button (24) to prevent the Spindle (8)  
from turning.  
5. Slip the grinding wheel onto the Spin-  
dle with a paper gasket, or blotter,  
first. The blotter should be centered  
on the grinding wheel and the wheel  
and blotter should rest flat against the  
Inner Flange.  
3. Remove the Outer Flange Arbor Nut  
(1) and the Inner Flange (3) and keep  
in a safe place.  
4. Thread disc accessory firmly onto  
the Spindle. Wrench tighten onto the  
spindle.  
Warning: to prevent serious  
injury, blotters must be used for all  
grinding wheels they are provided  
SKU 97588  
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Work piece and Work area set up  
general Operating instructions  
1. Designate a work area that is clean  
and well-lit. The work area must not  
allow access by children or pets to  
prevent injury and distraction.  
tO prevent  
seriOus injury:  
Grip the tool firmly in both  
hands.  
2. Route the power cord along a safe  
route to reach the work area without  
creating a tripping hazard or exposing  
the power cord to possible damage.  
The power cord must reach the work  
area with enough extra length to al-  
low free movement while working.  
1. This tool has a lock-on Trigger  
Switch. Push the switch, and then  
push forward the tab to lock the  
switch for continuous running.  
2. Allow the tool to come up to full  
speed before touching the work ma-  
terial.  
3. Secure loose work pieces using a  
vise or clamps (not included) to pre-  
vent movement while working.  
3. Apply the wheel to the work mate-  
rial, allowing the tool to operate at  
full speed. If the tool bogs down, use  
lighter pressure.  
4. There must not be hazardous ob-  
jects, such as utility lines or foreign  
objects, nearby that will present a  
hazard while working.  
4. To create a smoother surface, keep  
the tool moving over the work sur-  
face.  
5. You must use personal safety equip-  
ment including, but not limited to,  
5. Release the Trigger Switch to stop  
the tool.  
ANSI-approved eye and hearing pro-  
tection, as well as heavy work gloves.  
6. Allow the tool to come to a complete  
stop before setting it down.  
6. Before beginning work, provide for  
sparks and debris that will fly off the  
work surface.  
7. To prevent accidents, turn off the tool  
and disconnect its power supply after  
use. Clean, then store the tool in-  
doors out of children’s reach.  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 15  
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3. aFter use, clean external surfaces  
of the tool with clean cloth. Never use  
solvents or harsh cleaners as they  
may damage the housing. to pre-  
vent electrical shock, do not allow  
water or other liquids to enter the  
motor vent holes in the gear Hous-  
ing (26).  
Maintenance anD  
servicing  
Procedures not specifically  
explained in this manual  
must be performed only by a  
qualified technician.  
tO prevent  
seriOus injury  
FrOM acciDental  
OperatiOn:  
turn the power switch of the  
tool to its “OFF” position and  
unplug the tool from its  
electrical outlet before  
performing any inspection,  
maintenance, or cleaning  
procedures.  
4. grinDing WHeel care:  
Handling - Do not lean grinding  
wheels against an object, or rest ob-  
jects on grinding wheels. Do not drop  
grinding wheels or roll them across  
the floor.  
storage - Store thick grinding wheels  
on appropriate racks and store thin  
grinding wheels flat on a dry surface.  
Store in a relatively constant temper-  
ature and do not expose to moisture  
or freezing temperatures.  
Warning: to prevent serious  
injury from grinding wheel failure,  
discard any wheels that have been  
improperly handled or stored.  
tO prevent seriOus  
injury FrOM tOOl  
Failure:  
Do not use damaged  
equipment. if abnormal noise  
or vibration occurs, have the  
problem corrected before  
further use.  
5. OtHer accessOry care:  
Handling - Do not drop accessories.  
Do not bend or flex accessories that  
are not intended to bend.  
cleaning, Maintenance, and  
lubrication  
storage - Store accessories in dry,  
cool area.  
1. BeFOre eacH use, inspect the  
general condition of the tool. Check  
for loose screws, misalignment or  
binding of moving parts, cracked or  
broken parts, damaged electrical wir-  
ing, and any other condition that may  
affect its safe operation.  
6. carBOn BrusH Maintenance.  
The carbon brushes may require  
maintenance when the motor perfor-  
mance of the tool decreases or stops  
working completely. To maintain the  
brushes:  
a. Remove the Screws (40) and Brush  
Caps (41 and 45) from the sides of  
the motor housing.  
2. Periodically blow dust and grit out  
of the motor vents using dry com-  
pressed air. Always wear safety  
glasses when performing this mainte-  
nance operation.  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 16  
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armature, and that the springs face  
away from the motor. Also, make  
sure the springs operate freely.  
h. Reconnect the Carbon Brush Leads.  
i. Replace the Brush Caps and  
Screws. Do not overtighten.  
note: New carbon brushes tend to spark  
when first used until they wear and  
conform to the motor’s armature.  
7.  
Warning! if the supply cord of  
this power tool is damaged, it must  
be replaced only by a qualified  
service technician.  
b. Disconnect the Carbon Brush Leads  
as shown in the illustration above.  
c. Use a small prying tool (not includ-  
ed) to hold the Spring Clips to the  
side while you remove the carbon  
brushes. Keep track of which  
orientation the old carbon brush-  
es were in to prevent needless  
wear if they will be reinstalled.  
d. If either carbon brush is worn down  
by more than 1/2, replace both car-  
bon brushes.  
e. To clean old carbon brushes before  
reusing them, rub the contact areas  
with a pencil eraser.  
f. Hold the spring clips to the side and  
reinsert the old carbon brushes in  
the same orientation to reduce wear.  
g. When installing the carbon brushes,  
make sure the carbon portions of the  
carbon brushes contact the motor  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 17  
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troubleshooting  
problem  
possible causes  
likely solutions  
Tool will not start  
1. No power at outlet.  
1. Check power at outlet.  
2. Cord not connected.  
2. Check that cord is plugged in.  
3. Carbon Brushes may be worn or  
damaged.  
3. Inspect Carbon Brushes and replace if  
necessary.  
Tool operates  
slowly or  
1. Carbon Brushes may be worn or  
damaged.  
1. Inspect Carbon Brushes and replace if  
necessary.  
erratically.  
2. Excess pressure applied to  
workpiece.  
2. Decrease pressure, allow tool to do  
the work.  
Tool does not  
grind, sand or  
brush effectively.  
1. Disc accessory may be loose on  
Spindle. Check tightness of Outer  
Flange Arbor Nut or threaded disc  
accessory on Spindle.  
1. Be sure disc accessory is of correct  
dimension and Outer Flange Arbor Nut  
is tight.  
2. Disc accessory may be damaged, 2. Check condition and type of disc  
worn or wrong type for the  
material.  
accessory. Use only proper type of  
disc accessory in good condition.  
Follow all safety precautions whenever diagnosing or servicing the  
tool. Disconnect power supply before service.  
please reaD tHe FOllOWing careFully  
THE MANUfACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLy  
DIAGRAM IN THIS MANUAL AS A REfERENCE TOOL ONLy. NEITHER THE MANUfACTURER OR  
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT  
HE OR SHE IS QUALIfIED TO MAkE ANy REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS  
QUALIfIED TO REPLACE ANy PARTS Of THE PRODUCT. IN fACT, THE MANUfACTURER AND/  
OR DISTRIBUTOR ExPRESSLy STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD  
BE UNDERTAkEN By CERTIfIED AND LICENSED TECHNICIANS, AND NOT By THE BUyER. THE  
BUyER ASSUMES ALL RISk AND LIABILITy ARISING OUT Of HIS OR HER REPAIRS TO THE  
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT Of HIS OR HER  
INSTALLATION Of REPLACEMENT PARTS THERETO.  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 18  
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parts list  
parts list  
part  
Description  
Qty.  
part  
Description  
Qty.  
1
Outer Flange Arbor Nut  
1
28 Pinion  
1
2
3
4
5
6
7
8
9
Grinding Wheel (not included)  
Inner Flange  
-
29 Bearing 6201  
1
1
1
1
1
1
1
1
1
1
1
4
1
1
2
2
1
2
1
5
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
8
1
1
1
7
7
1
1
1
1
1
1
1
1
1
1
30 Bearing Retaining Plate  
31 Rotor  
Quick Release Adjusting Nut m8  
Washer  
32 Bearing 629  
Wheel Guard Quick Release  
Wheel Guard  
33 Bearing Sleeve  
34 Baffle Ring  
Spindle  
35 Self Tapping Screw m4.2 x 71  
36 Stator  
Woodruff Key  
10 Phillips Pan Head Screw m5 x 16  
11 Spring Washer m5  
12 Flat Washer  
37 Lug  
38 Heat Shrinkable Tube  
39 Magnesium Alloy Cover  
40 Self Tapping Screw m4.2 x 14  
41 Carbon Brush Cap (left)  
42 Motor Housing  
43 Carbon Brush  
13 Front Cap  
14 Bearing 6203  
15 Bearing Retaining Plate  
16 Spring Washer m4  
17 Phillips Pan Head Screw m4 x 12  
18 Bevel Gear  
44 Carbon Brush Holder  
45 Carbon Brush Cap (right)  
46 Coil Spring  
19 Open Circlip  
20 Needle Gear  
47 Nameplate  
21 Open Circlip  
48 Self Tapping Screw  
49 Left Handle  
22 Phillips Pan Head Screw m4.8 x 28  
23 Spring  
50 Power Cable & Plug  
51 Cable Clamp  
24 Spindle Lock Button  
25 Auxiliary Handle  
26 Gear Housing  
52 Cable Sleeve  
53 Right Handle  
27 Lock Nut m8 (black)  
54 Trigger Switch  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 19  
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asseMBly DiagraM  
record products serial number Here:  
note: If product has no serial number, record month and year of purchase instead.  
note: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement parts.  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 20  
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90 Day Warranty  
Harbor Freight Tools Co. makes every effort to assure that its products meet high  
quality and durability standards, and warrants to the original purchaser that this product  
is free from defects in materials and workmanship for the period of 90 days from the date  
of purchase. This warranty does not apply to damage due directly or indirectly, to misuse,  
abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity,  
improper installation, normal wear and tear, or to lack of maintenance. We shall in no event  
be liable for death, injuries to persons or property, or for incidental, contingent, special or  
consequential damages arising from the use of our product. Some states do not allow the  
exclusion or limitation of incidental or consequential damages, so the above limitation of  
exclusion may not apply to you. This warranty is expressly in lieu of all other warranties,  
express or implied, including the warranties of merchantability and fitness.  
To take advantage of this warranty, the product or part must be returned to us with  
transportation charges prepaid. Proof of purchase date and an explanation of the complaint  
must accompany the merchandise. If our inspection verifies the defect, we will either  
repair or replace the product at our election or we may elect to refund the purchase price  
if we cannot readily and quickly provide you with a replacement. We will return repaired  
products at our expense, but if we determine there is no defect, or that the defect resulted  
from causes not within the scope of our warranty, then you must bear the cost of returning  
the product.  
This warranty gives you specific legal rights and you may also have other rights which  
vary from state to state.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
REV 11h  
SKU 97588  
For technical questions, please call 1-800-444-3353.  
Page 21  
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