Bauer 1865E-B, 64856 - 4-1/2 in. Slide Switch Angle Grinder Manual

WARNING SYMBOLS AND DEFINITIONS
	This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
	Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
	Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
	Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
	Addresses practices not related to personal injury.

Electrical Safety

1. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with grounded power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
2. 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.
3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

Personal Safety

1. 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 you operating power tools may result in serious personal injury.
2. Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used of appropriate conditions will redice personal injuries.
3. Prevent unintentional starting. Ensure the switch/trigger is in the off-position before connecting to power source and/ or battery pack, picking up or carrying the tool.Carrying power tools with your finger on the switch or energizing power tools that have have the switch on invites accidents.

4. 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.
5. Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
6. 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.
7. If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of these devices can reduce dust-related hazards.
8. Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the work area.

Service

Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.

Safety Warnings Common for Grinding, Sanding, or Wire Brushing Operations

1. This power tool is intended to function as a grinder, sander, or wire brush. Read all safety warnings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
2. Operations such as polishing or cuttingoff 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.
3. Do not use accessories which are not specifically designed and recommended by the tool manufacturer. Just because the accessory can be attached to your power tool, it does not assure safe operation
4. The rated speed of the accessory must be at least equal to the maximum speed marked on the power tool. Accessories running faster than their RATED SPEED can break and fly apart.
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 accessory must properly fit the spindle of the power tool. Accessories with arbor holes that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
7. Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, backing pad for cracks, tear or excess wear, wire brush for loose or cracked wires. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.
8. Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping flying debris generated by various operations.
9. Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken accessory may fly away and cause injury beyond immediate area of operation.
10. Hold power tool by insulated gripping surfaces only, when performing an operation where the accessory may contact hidden wiring or its own cord. An accessory contacting a "live" wire make make exposed metal parts of the power tool 'live' and shock the operator.
11. Position the cord clear of the spinning accessory. If you lose control, the cord may be cut or snagged and your hand or arm may be pulled into the spinning accessory.
12. Never lay the power tool down until the accessory has come to a complete stop.
13. Do not run the power tool while carrying it at your side. Accidental contact with the spinning accessory may grab the surface and pull the power tool out of your control.
14. Regularly clean the power tool's air vents. The motor's fan will draw the dust inside the housing and excessive accumulation of powered metal may cause electrical hazards.
15. Do not operate the power tool near flammable materials.
16. Do not use accessories that require 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 missing, contact Harbor Freight Tools for a replacement.
18. Avoid unintentional starting. Prepare to begin work before turning on the tool.
19. Do not depress the spindle lock when starting or during operation.
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 leaving.
21. Use clamps (not included) or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control and personal injury.
22. This product is not a toy. Keep it out of reach of children.
23. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

In addition, people with pacemakers should:

• Avoid operating alone.
• Do not use with power switch locked on.
• Properly maintain and inspect to avoid electrical shock.
• Properly ground power cord. Ground Fault Circuit Interrupter (GFCI) should also be implemented – it prevents sustained electrical shock.

24. The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions 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.

Kickback and Related Warnings

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or any other accessory. Pinching or snagging causes rapid stalling of the rotating accessory which in turn causes the uncontrolled power tool to be forced in the direction opposite of the accessory's rotation at the point of the binding.

For example, if an abrasive wheel is snagged or pinched by the workpiece, the edge of the wheel that is entering into the pinch point can dig into the surface of the material causing the wheel to climb out or kick out. The wheel may either jump toward or away from the operator, depending on direction of the wheel's movement at the point of pinching. Abrasive wheels may also break under these conditions. Kickback is the result of power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

1. Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start-up.
2. Never place your hand near the 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.
4. Use special care when working corners, sharp edges etc. Avoid bouncing and snagging the accessory. Corners, sharp edges or bouncing have a tendency to snag the rotating accessory and cause loss of control or kickback.
5. Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.

Safety Warnings Specific for Grinding and Abrasive Cutting-off Operations

1. Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel.
2. The guard must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator.
3. Wheels must be used only for recommended applications. For example: do not grind with the side of cut-off wheel.

4. Always use undamaged wheel flanges that are of correct size and shape for your selected wheel.
5. Do not use worn down wheels from larger power tools.
6. Dress appropriately.

Safety Warnings Specific for Sanding Operations

Do not use excessively oversized sanding disc paper. Follow manufacturer's recommendations when selecting sanding paper. Larger sanding paper extending beyond the sanding pad presents a larceration hazard and may cause snagging, tearing of the disc or kickback.

Safety Warnings Specific for Wire Brushing Operations

2. If the use of a guard is recommended for wire brushing, do not allow any interference of the wire wheel or brush with the guard.

Vibration Safety

This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury:

1. Anyone using vibrating tools regularly 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, nervous system disorders, diabetes, or Raynaud's Disease should not use this tool. If you feel any medical or physical symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible.
2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury.
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 different processes.
5. Include vibration-free periods each day of work.
6. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work.
7. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately.

SAVE THESE INSTRUCTIONS.

Symbology

	Double Insulated
V	Volts
~	Alternating Current
A	Amperes
n0 xxxx/min.	No Load Revolutions per Minute (RPM)
	WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields.
	Read the manual before set-up and/or use.
	WARNING marking concerning Risk of Fire. Do not cover ventilation ducts. Keep flammable objects away.
	WARNING marking concerning Risk of Electric Shock. Properly connect power cord to appropriate outlet.

Specifications

Setup - Before use

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.

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Make sure that the Power Switch is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section.

Note:For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual.

ASSEMBLY

Installing the Wheel Guard

TO PREVENT SERIOUS INJURY: Do not operate this tool without the Wheel Guard properly installed.

1. Pull the Clamp Handle open to loosen the Wheel Guard.
2. Slide the collar of the Wheel Guard over the rim of the Gear Housing.
3. Rotate the Wheel Guard as needed to shield you during the planned work.
4. Once in place, push to close the Clamp Handle to secure the Wheel Guard.
5. Check the Wheel Guard to ensure necessary before proceeding.

Installing the Auxiliary Handle

TO PREVENT SERIOUS INJURY: Do not operate this tool with one hand only or without the Auxiliary Handle properly installed.

1. The Auxiliary Handle may be installed on either side of the Gear Housing.
2. Screw the threaded end of the Auxiliary Handle into the selected position. Tighten securely before beginning work.
   

Functions

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.

Tool Set Up

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Make sure that the Power Switch is in the off-position and unplug the tool from its electrical outlet before performing any procedure in this section.

Installing a Non-threaded Grinding Wheel

1. The Grinding Wheel MUST be:

• rated to at least 11,000 RPM.
• no larger than 4-1/2' (115 mm) in diameter.
• fitted with a 5/8 - 11 UNC round arbor hole.
• 1/4" (6mm) thick or less.
• suitable for surface grinding, not edge grinding.
• dry and clean.
• proven undamaged by inspection

2. Press in and hold the Spindle Lock Button Flange to prevent the Spindle from turning.
3. Remove the Outer Flange. Keep the Inner Flange in position on the Spindle.

4. Thread the Outer Flange onto the Spindle. Wrench tighten only enough so that the wheel is securely held on the spindle.
   
   To prevent serious injury, do not overtighten flange. Overtightening can damage the wheel, causing wheel failure.

Installing a Threaded Accessory

TO PREVENT INJURY: Wear heavy-duty work gloves when handling wire wheels and brushes. These accessories are sharp and can cause injury.

1. The accessory MUST be:

• rated to at least 11,000 RPM.
• no larger than 4-1/2' (115 mm) in diameter.
• fitted with a threaded opening of 5/8 - 11 UNC.
• undamaged.
• a sanding disc and backing pad, or
  a sanding flap disc; a wire wheel, or
  a wire cup brush; (accessories not included).

2. Press in and hold the Spindle Lock Button to prevent the Spindle from turning.
3. Remove the Outer Flange and Inner Flange, and keep in a safe place.
4. Thread disc accessory onto the Spindle. Wrench tighten onto the Spindle.

Workpiece and Work Area Set Up

1. Designate a work area that is clean and well-lit. The work area must not allow access by children or pets to prevent distraction and injury.
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 allow free movement while working.
3. Secure loose workpieces using a vise or clamps (not included) to prevent movement while working.
4. There must not be hazardous objects, such as utility lines or foreign objects, nearby that will present a hazard while working.
5. You must use personal safety equipment including, but not limited to, ANSI-approved eye and hearing protection, as well as heavy-duty work gloves.
6. Before beginning work, provide for sparks and debris that will fly off the work surface.

Grinding, and Wire Brushing Instructions

TO PREVENT SERIOUS INJURY: Grip the tool firmly in both hands.

1. Make sure that the Power Switch is in the off-position, then plug in the tool.
2. Place one hand on the motor housing the other on the side handle before starting the tool.
3. Start the tool by pressing the Power Switch forward until it locks in place.
4. Allow the tool to come up to full speed before touching the work material.

5. Apply the wheel to the work material at a 10° – 15° angle, allowing the tool to operate at full speed. If the tool bogs down, use lighter pressure.
6. To create a smoother surface, keep the tool moving over the work surface.
7. TO PREVENT ACCIDENTS, AFTER USE: Turn off the tool by pushing the Power Switch backward.

Allow the tool to come to a complete stop before setting it down. Unplug the tool. Clean, then store the tool indoors out of children's reach.

Sanding Instructions

TO PREVENT SERIOUS INJURY: Grip the tool firmly in both hands.

1. Wipe the work surface clean of all dirt and debris, especially that of previous coarser sanding sessions, which will scratch the surface of a finer grit sanding session.
2. Attach the desired grit Sanding Disk (sold separately) onto the Spindle.
3. Make sure that the Power Switch the off-position, then plug in the tool.
4. Start the tool by pressing the Power Switch forward until it locks in place.
5. Wait until the tool has reached full speed, then gently contact the surface.
6. Keep heavy pressure off of the tool when operating. Allow the tool to do the work.
7. Move the tool in a uniform pattern up and down or side to side while sanding to ensure even sanding.
8. Periodically, stop the tool and check for disc wear. Replace worn sanding discs as needed.
9. TO PREVENT ACCIDENTS, AFTER USE: Turn off the tool by pushing the Power Switch backward.

Allow the tool to come to a complete stop before setting it down. Unplug the tool. Clean, then store the tool indoors out of children's reach.

2. AFTER USE, wipe external surfaces of the tool with clean cloth. Carefully clean the dust collection chute and the area around the Lower Blade Guard. Check that the Lower Blade Guard moves smoothly through its entire range of movement, without sticking.
3. Periodically, wear ANSI-approved safety goggles and NIOSH-approved breathing protection and blow dust out of the motor vents using dry compressed air.

If the supply cord of this power tool is damaged, it must be replaced only by a qualified service technician.

Accessory Storage and Handling

1. Handle accessories carefully to prevent dropping or bumping. Do not use wheels that have been dropped or bumped.

Troubleshooting

Problem	Possible Causes	Likely Solutions
Tool will not start	Cord not connected. No power at outlet. Tool's thermal reset breaker tripped (if equipped). Internal damage or wear. (Carbon brushes or power switch, for example.)	Check that cord is plugged in. Check power at outlet. If outlet is unpowered, turn off tool and check circuit breaker. If breaker is tripped, make sure circuit is right capacity for tool and circuit has no other loads. Turn off tool and allow to cool. Press reset button on tool. Have technician service tool.
Tool operates slowly	Excess pressure applied to workpiece. Power being reduced by long or small diameter extension cord.	Decrease pressure, allow tool to do the work. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See ([WHQVLRQ Cords in GROUNDING section.
Performance decreases over time	Carbon brushes worn or damaged.	Have qualified technician replace brushes.
Excessive noise or rattling	Internal damage or wear. (Carbon brushes or bearings, for example.)	Have technician service tool.
Overheating	Forcing tool to work too fast. Blocked motor housing vents. Motor being strained by long or small diameter extension cord.	Allow tool to work at its own rate. Wear ANSI-approved safety goggles and NIOSH-approved dust mask/ respirator while blowing dust out of motor using compressed air. Eliminate use of extension cord. If an extension cord is needed, use one with the proper diameter for its length and load. See ([WHQVLRQ Cords in GROUNDING section.
Tool does not grind, sand or brush effectively	Accessory loose. Accessory damaged, worn or wrong type for the material.	Confirm accessory arbor is correct and Outer Flange/Arbor Nut is tight. Check condition and type of disc 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.